Chilton's General Motors Cavalier/Sunbird/Skyhawk/Firenza 1982-94 Repair Manual 0801989566, 9780801991134

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coiiPEsisEomimx)!^ ATURN II w #««# ^99^.93 REPAIR MANUAL Covers all U.S. and Canadian nnodels of Saturn SC, SC1, SC2, SL, SL1, SL2, SW1 and SW2

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SATURN mmimmmKsm 1991-98 REPAIR MANUAL

Covers

all

U.S.

and Canadian models of SW1 and SW2

Saturn SC, SC1, SC2, SL, SL1, SL2,

by Matthew

E. Frederick, as.e., s.a

e.

Automot/ve

Books PUBLISHED BY HAYNES NORTH AMERICA.

Inc.

^m^^K Manufactured

©

in

MEMBER

USA

1998 Haynes North America,

Inc.

ISBN 0-8019-8956-6 Library of

Congress Catalog Card No. 97-781 16

7890123456 9876543210

Haynes Publishing Group Sparkford Nr Yeovil

Somerset BA22 7JJ England

Haynes North America,

Inc

861 Lawrence Drive

Newbury Park 91320 USA

California

Chilton

Is

a registered trademark of W.G. Nichols,

Inc.,

and has been licensed to Haynes North America,

Inc.

Contents 1-2

Contents 7-2

MANUAL TRANSAXLE

7-11

CLUTCH

8-2

WHEELS

8-5

FRONT SUSPENSION

7-16

AUTOMATIC TRANSAXLE

8-17 8-22

REAR SUSPENSION STEERING

SUSPENSION

AND STEERING

9-2

BRAKE OPERATING SYSTEM

9-7

DISC BRAKES

9-1 6

DRUM BRAKES

10-2

EXTERIOR

9-23 9-26

ANTI-LOCK BRAKE SYSTEM

10-1 4

INTERIOR

PARKING BRAKE

BODY AND TRIM

10-39 GLOSSARY

GLOSSARY

1

0-43

MASTER INDEX

SAFETY NOTICE

Proper service and repair procedures are

vital to

forming repairs This manual outlines procedures

all motor vehicles, as well as the personal safety of those perand repairing vehicles using safe, effective methods The procedures contain many

the sale, reliable operation of

for servicing

NOTES, CAUTIONS and WARNINGS which should be followed, along with standard procedures improper service which could damage the vehicle or compromise its safety

to eliminate the possibility of personal iniury or

important to note that repair procedures and techniques, tools and parts for servicing motor vehicles, as well as the skill and experience of It is not possible to anticipate all of the conceivable ways or conditions under which vehicles may be serviced, or to provide cautions as to all possible hazards that nfiay result Standard and accepted safety precautions and equipment should be It

is

the individual performing the work vary widely

used when handling toxic or flammable

fluids,

and

safety goggles or other protection should be

used during

cutting, grinding, chiseling, prying.

or any other process that can cause material removal or projectiles.

Some

procedures require the use of tools specially designed

completely satisfied that neither your personal

Although information

in this

manual

is

safety,

for a specific

purpose Before substituting another tool or procedure, you must be will be endangered

nor the perlormance of the vehicle

based on industry sources and

is

complete as possible

at the

time of publication, the possibility exists

some car manufacturers made later changes which could not be included here. While stnving tor total accuracy, cannot assume responsibility for any errors, changes or omissions that may occur in the compilation of this data. that

the authors or publishers

PART NUMBERS

Part

ences

numbers

that

listed in this

reference are not recommendations by Haynes North America,

can be used with interchange manuals and aftennarket supplier catalogs

to locate

Inc. for

any product brand name. They are

each brand

supplier's discrete part

refer-

number.

SPECIAL TOOLS

Special tools are

recommended by

the vehicle nianufacturer to perform their specific |ob

absolutely necessary, they are referred to in the text by the part priate part let.

number

of the tool

Use has been kept

for the

minimum, but where

distributor, or an equivalent tool can be purchased locally from a one recommended, read the SAFETY NOTICE at the top of this page.

number, from your local dealer or regional

Before substituting any tool

to a

manufacturer These tools can be purchased, under the approtool supplier or parts out-

ACKNOWLEDGMENTS Portions of materials contained herein have

All

nghts reserved.

No

part of this

ing photocopying, recording or

been

reprinted with the permission of General Motors Corporation, Service Technology Group.

book may be reproduced

or transmitted

by any information storage or

is made to ensure that the damage or injury caused by any

While every attempt

information

lishers for loss,

errors

in.

retrieval

in this

in

any form or by any means, electronic or mechanical, includin writing from the copynght holder

system, without permission

manual

is

correct,

no

liability

can be accepted by the authors or pub-

or omissions from, the information given.

f-

HOW TO USE THIS BOOK WHERE TO BEGIN 1-2

FLUIDS AND LUBRICANTS 1-46

1-2

FLUID DISPOSAL 1-46

FUEL AND ENGINE OIL RECOMMENDATIONS 1-46

AVOIDING TROUBLE 1-2 MAINTENANCE OR REPAIR? 1-2

COMMON

AVOIDING THE MOST

TOOLS AND EQUIPMENT

MISTAKES 1-2

1-3

SPECIAL TOOLS 1-7

SERVICING YOUR VEHICLE SAFELY 1-7 DO'S 1-7

D0N7S

1-8

FASTENERS, MEASUREMENTS AND

CONVERSIONS BOLTS,

1-8

NUTS AND OTHER THREADED

TORQUE 1-9 TORQUE WRENCHES 1-9 TORQUE ANGLE METERS 1-12 STANDARD AND METRIC MEASUREMENTS 1-13 SERIAL NUMBER IDENTIFICATION 1-14 VEHICLE 1-14

ENGINE 1-14

TRANSAXLE 1-14

ROUTINE MAINTENANCE AND TUNE-UP 1-16 CLEANER 1-17 REMOVAL & INSTALLATION 1-17

FUEL FILTER 1-18 REMOVAL & INSTALLATION 1-18

PCV VALVE 1-21 REMOVAL & INSTALLATION

1-21

SERVICING 1-21

FLUID 1-23

CABLES 1-24 CHARGING 1-26 REPLACEMENT 1-26 INSPECTION 1-26

REMOVAL & INSTALLATION 1-28 TIMING CHAIN 1-29 INSPECTION 1-29

REMOVAL & INSTALLATION CV-BOOTS 1-31

1-56

TRANSAXLE 1-57 HANDLING A TRAILER 1-57 TOWING THE VEHICLE 1-57

JUMP STARTING A DEAD BAHERY STARTING PROCEDURE 1-58

JACKING 1-59

HOW TO

UNDERHOOD MAINTENANCE COMPONENT 1-31

TESTING 1-36

REMOVAL & INSTALLATION

1-36

IGNITION TIMING 1-37

GENERAL INFORMATION 1-37 VALVE LASH 1-37 IDLE SPEED AND MIXTURE ADJUSTMENTS 1-37 IDLE SPEED 1-37 IDLE MIXTURE 1-38 AIR CONDITIONING SYSTEM 1-39 SYSTEM SERVICE & REPAIR 1-39 PREVENTIVE MAINTENANCE 1-39 SYSTEM INSPECTION 1-40 WINDSHIELD WIPERS 1-40 ELEMENT (REFILL) CARE AND REPLACEMENT 1-40 1-42

TIRE ROTATION 1-42

TIRE DESIGN 1-43

STORAGE

1-58

1-58

COMPONENT LOCATIONS

REMOVAL & INSTALLATION 1-32 INSPECTION & GAPPING 1-33 SPARK PLUG WIRES 1-36

AND WHEELS

1-56

JACKING PRECAUTIONS 1-60

1-31

SPARK PLUG HEAT RANGE

TIRE

TRAILER TOWING 1-56 GENERAL RECOMMENDATIONS TRAILER WEIGHT 1-56 HITCH (TONGUE) WEIGHT 1-56 COOLING 1-57

JU*,1P

1-30

INSPECTION 1-31

TIRES

GENERAL

CHASSIS GREASING 1-56

JUMP STARTING PRECAUTIONS

1-29

SPARKPLUGS

1-53

ENGINE 1-57

SERPENTINE DRIVE BELT 1-26

HOSES

1-49

RECOMMENDATIONS 1-49 LEVEL CHECK 1-50 FLUID & FILTER CHANGE 1-50 COOLING SYSTEM 1-52 FLUID RECOMMENDATIONS 1-52 LEVEL CHECK 1-52 DRAIN & REFILL 1-53 FLUSHING & CLEANING THE SYSTEM BRAKE MASTER CYLINDER 1-53 FLUID RECOMMENDATIONS 1-53 LEVEL CHECK 1-53 CLUTCH MASTER CYLINDER 1-54 FLUID RECOMMENDATIONS 1-54 LEVEL CHECK 1-54 POWER STEERING PUMP 1-55 FLUID RECOMMENDATIONS 1-55 LEVEL CHECK 1-55

REPACKING 1-56

1-22

PRECAUTIONS 1-22 GENERAL MAINTENANCE 1-22

BAHERY

AUTOMATIC TRANSAXLE

1-48

BODY LUBRICATION AND MAINTENANCE WHEEL BEARINGS 1-56

EVAPORATIVE CANISTER 1-21

BAHERY

OIL & FILTER CHANGE 1-47 MANUAL TRANSAXLE 1-48 FLUID RECOMMENDATIONS LEVEL CHECK 1-48 DRAINS REFILL 1-49

FLUID

RETAINERS 1-8

AIR

ENGINE 1-46 OIL LEVEL CHECK 1-46

1-44

INFLATION & INSPECTION 1-44

CARE OF SPECIAL WHEELS 1-46 MAINTENANCE LIGHT 1-46 RESEHING 1-46

LOCATIONS 1-16 SPECIFICATIONS CHARTS VEHICLE IDENTIFICATION CHART 1-14

1-2 1-3

1-7

FASTENERS, MEASUREMENTS SERIAL

AND CONVERSIONS NUMBER IDENTIFICATION

1-8

1-14

ROUTINE MAINTENANCE

ENGINE IDENTIFICATION 1-15

GENERAL ENGINE SPECIFICATIONS 1-15 GASOLINE ENGINE TUNE-UP SPECIFICATIONS 1-38

SATURN MAINTENANCE SCHEDULE SATURN MAINTENANCE SCHEDULE

USE THIS BOOK TOOLS AND EQUIPMENT SERVICING YOUR VEHICLE SAFELY

I

II

1-60 1-60

CAPACITIES 1-61

ENGLISH TO METRIC CONVERSIONS 1-62

AND TUNE-UP

1-16

FLUIDS AND LUBRICANTS 1-46 TRAILER TOWING 1-56 TOWING THE VEHICLE 1-57 JUMP STARTING A DEAD BAHERY 1-58

JACKING 1-59

GENERAL INFORMATION AND MAINTENANCE

1-2

HOW TO USE THIS BOOK Chiltons Total Car Care manual

(or the

SL and

Saturn SC,

SW

Two basic mechanic's

is

intended to help you learn more about the inner workings ol your vehicle

money on

while saving you

The t)eginning where you

is

ol the

its

book

the

upkeep and operation. be referred

will likely

more complex systems

systems from engine through brakes are covered

Salety

SAFELY and

explain such things as rebuilding a differential, lor the simple reason that

make

the expertise required

and the investment

uneconomical.

however, give you detailed instructions to help you

will,

in special tools

always the most important

is

gers involved

means

to specify the

the passenger's

Constantly be aware of the dan-

rule.

working on an automobile and take the proper precautions.

in

See the information

not

will

whenever

First,

meant

is

wise, and tightened by turnino clockwise.

to the extent that the aver-

age do-it-yourselfer becomes mechanically involved. This book

It

it

Second, most screws and bolts are removed by turning counterclock-

side.

your vehicle. Operating

of

referred to,

is

driver's side. Conversely, the right side ol the vehicle

to the most, since that

information for maintenance and tune-up. The other

will find

sections deal with the

mentioned here.

rules should be

side of the vehicle or engine

left

in this

SERVICING YOUR VEHICLE

section regarding

SAFETY NOTICE on

the

acknowledgment page

the

this task

Common

Avoiding the Most

Mistakes

change your own brake pads and shoes, replace spark plugs, and perform

many more

Pay attention

jobs that can save you money, give you personal satislaction

and help you avoid expensive problems.

A secondary purpose understand at all are

their vehicle

ol this

book

is

in

who want

a reference for owners

and/or their mechanics

better. In this

case,

to

no tools

Incorrect order of assembly, disassembly or adjustment.

1.

ing something apart or putting

Read the

Where

to

thing

Begin

Before removing any bolts, read through the entire procedure. This

in

Monday

nothing more frustrating than having to walk to the bus stop on

morning because you were short one

bolt

on Sunday afternoon. So read

ahead and plan ahead. Each operation should be approached all

sections contain adjustments, maintenance, removal and installation

procedures, and

in

some

cases, repair or overhaul procedures.

repair is not considered practical,

then

how

to install the

new

we

tell

you how

or rebuilt replacement. In this way,

save the labor costs. Backyard repair of

When

remove the

to

some components

any

you

is just

at least

not

We

book require you

remember where everything

goes— you

luel lines incorrectly, the vehicle will

electrical wiring incorrectly,

won't.

II

run poorly,

you may

."

and disconnect

to "label

.

.

you can

il

at all.

II

you hook up

instantly learn a very expensive les-

don't need to

A

know

the official or engineering

name

piece of masking tape on the hose and a piece on

for

a torque figure

If

is

is

own label such as the letter A or a short name. As long as you remember your own code, the lines can be reconnected by matching similar letters or names. Do remember that tape will dissolve in gasoline or other fluids;

another method

if

a

component

ol identification.

is to

you

A permanent felt-lipped marker can be Remove any tape or paper labels after

can be seen

in the

fail

repair.

compensates broken or

is

for

which show signs

A need

relilling the

that

to

remember

that

if

you are using

ol

most threads

is

so slight

be multiplied

spark plug installation, especially

an aluminum cylinder head. Too

into

ol the

aluminum

many times in A good example ol how critical

will

ol

little

combustion gases

much

plug and engine parts. Too

torque

changing the spark gap.

distort the plug,

tight

enough

is Loctite*).

II

you're worried about getting something together

to hold, but loose

enough

assembly, one ol these products might

make sure

to avoid

the product

is

mechanical damage during

offer substantial insurance.

label

Before

on the package and

compatible with the materials,

fluids, etc.

involved.

when

Crossthreading. This occurs

occur

access

if

a part such as a bolt

wrong angle and

is difticult.

It

is

screwed

forced. Crossthreading is

MAINTENANCE

unscrew the

that

many

part

etc.

and

with your lingers

start

over again

parts, especially spark plugs,

angle, but only

wrench on the

specilic

dolhis can ruin the transaxle, requiring very

breaking or wearing out, a general rule can be stated:

spark plug,

more

helps to clean and lubricate lasteners.

at

If

in.

you encounter

a difterent angle until

much

effort

Keep

have tapered threads, so

in

it

mind

that gentle

turning will automatically bring the part you're threading to the proper

ol

automatic transmission at

start the bolt,

resistance,

expensive repairs While no maintenance program can prevent items Irom

CHEAPER THAN REPAIR.

ol

with

a torque wrench in

utilize

can be inserted and turned several times without

something has

caused by lack

maintenance recommended by the manulacturer

mileage intervals Failure

case

for over-

if

brand

Then,

normal wear Maintenance

lor repair is otien

maintenance. Example draining and lluid is

of

wear or deterioration. Repair implies

not working.

more common

allow a fastener to vibrate

then to start threading with the part to be installed positioned straight

mention the dilterence between maintenance and

of parts

is

it

many commercial products available for ensuring that fastencome loose, even they are not torqued just right (a very com-

mon

likely to

Maintenance includes routine inspections, adjustments, and

replacement

cannot be changed by

There are

3.

to

it

crush the gasket, causing leakage

to

into a nut or casting at the

Maintenance or Repair?

looks

probably not have to strain your-

enough. The pitch

you put on the wrench

and consequent overheating

assembly

necessary

will

choosing a threadlocking compound, read the

be washed or cleaned, use

very handy for marking metal parts.

Its

when

and

not available,

where you are putting the plug

ers won't

allow you to assign your

only

on what you are tightening.

actual lorce

each hose or

its fitting will

made

is

to torque specifications

can damage the threads or

You line.

it

proper order; often,

in the

when dealing

pay attention

torque can

son.

how

get everything

and you cannot expect even satisfactory

loose causing serious damage. Especially

torque

you hook up vacuum or

a picture ol

make sure you

may

sell to get a lastener tight

in this

you

if

supply exploded views whenever pos-

will

aftects another,

that the tension

Many procedures

draw

to

you should, even

adjustments, perlorm them

the right tool to perlorm the job,

a group ol lines, hoses or wires. Don't be lulled into thinking

break something

you're taking apart something

Overtorquing (or undertorquing). While

assembly.

Avoiding Trouble

When

torquing to cause damage, undertorquing

parts,

practical

CAN

it

tak-

wrong

other.

2.

and

part

it.

order to

in

results unless each adjustment

procedures thoroughly understood before attempting any work. All

When making

one adjustment

for

you might want

one point

at

proper position.

in its

sible.

and

logically

when assembled back

When

together, performing steps in the

the order in which the instructions say

that is very intricate,

will

give you the overall view of what tools and supplies will be required. There

mistakes

procedure before beginning disassembly. Perform every-

entire

immediately see a reason

can't

is

it

order usually just costs you extra time; however,

required

common

There are 3

to the instructions provided.

mechanical work:

IS

il

you don't lorce

part until

it's

it

or resist a

been lightened

change

in

angle. Don't put a

a couple of turns by hand.

suddenly encounter resistance, and the part has not seated it.

Pull

it

back out to

mke

sure

Always take your time and be

it's

lully,

II

you

don't lorce

clean and threading properly.

patient;

once you have some experience,

working on your vehicle may well becqme an enjoyable hobby.

GENERAL INFORMATION AND MAINTENANCE

1-3

TOOLS AND EQUIPMENT iSee Figures

15

1 thru

and equipment

Naturally, without the proper fools

properly service your vehicle.

would also be

It

log every tool that

you would need

book. Of course,

would be unwise

expensive set

them

at

some

It

to

on the theory

of tools

perform

for the

that

impossible to

is

it

virtually

impossible

to cata-

of the

operations

in this

all

amateur

he/she

to rush out

may need one

and buy an

or

more

of

time.

The best approach

is to

proceed slowly gathering a good quality set of

those tools that are used most frequently Don't be misled by the low cost of bargain tools.

It

is far

better to

spend a

more

little

Forged wrenches, 6 or 12-point sockets and

for better quality.

fine tooth ratchets are

by

.

far

As any good mechanic can

preferable to their less expensive counterparts.

you, there are few worse experiences than trying to work on a vehicle

tell

with bad tools. Your monetary savings will be far outweighed by frustration

and mangled knuckles. Begin accumulating those tools that are used most frequently: those associated with routine maintenance and tune-up.

assortment •

of

In

addition to the normal

screwdrivers and pliers, you should have the following tools:

Wrenches/sockets and combination open end/box end wrenches

sizes from

Vs-^A

or

in.

3mm-19mm

in

(depending on whether your vehicle

uses standard or metric fasteners) and a W^e

in.

or

%

in.

Fig. 2 In addition to ratchets, a

keys

will

good set

of

wrenches and hex

be necessary

spark plug socket

(depending on plug type).

^If possible, buy various length socket drive extensions. Universaljoint and wobble extensions can be extremely useful, but be careful

when using them, as they can change

the

amount

of

torque applied

to the socl(et. •

Jackstands for support.

•

Oil filter

•

Spout or funnel

•

Grease gun

wrench. for

pouring

fluids.

chassis lubrication (unless your vehicle

for

equipped with any grease fittings— for

on Fluids and Lubricants found •

Hydrometer

for

details,

is

not

please refer to information

later in this section).

checking the battery (unless equipped with a sealed,

maintenance-free battery). •

A

•

Rags

In

addition to the above items there are several others that are not

container for draining for

oil

and other

fluids.

wiping up the inevitable mess.

absolutely necessary, but handy to have around. These include Oil Dry® (or

an equivalent

oil

absorbent gravel— such as cat

of lubricants, antifreeze

and

needed. This

list

is

a basic

fluids,

litter)

and the usual supply

although these can be purchased as

for routine

maintenance, but only your personal

needs and desire can accurately determine your

list

of tools.

Fig. 3

A

hydraulic floor jack and a set of jackstands are essen-

tial for lifting

and supporting the vehicle

.»«*"i*«

Fig. 1 All but the

ment

of ratchets

most basic procedures and sockets

will require

an assort-

Fig.

4 An assortment

handy

of pliers, grippers

for old rusted parts

and cutters

and stripped bolt heads

will

be

GENERAL INFORMATION AND MAINTENANCE

1-4

•

Fig. 5

have

Various drivers, chisels and prybars are great tools to

in

Fig. 6

Many

repairs will require the use of a torque

Fig. 8

A few inexpensive lubrication tools

will

make mainte-

nance easier

your toolbox

wrench

to

assure the components are properly fastened

Fig. 9 Various pullers, for

many

larger,

clamps and separator tools are needed

more complicated repairs

sL.*- See Figures 20, 21, 22 and 23 Although there are a great variety truck, the

most commonly used

bolts, screws, studs, etc) that they are not

damaged

of fasteners

in

the

modern

car or

retainer is the threaded fastener (nuts,

may be reused, provided during the repair. Some retainers (such nuts) are designed to deform when

Most threaded in

found

use or

as stretch bolts or torgue prevailing

retainers

tightened or in use and should not be reinstalled.

Whenever

possible,

we

will

of a retainer

age Check

when all

it

is

note any special retainers which should be

removed and replace any

that

show signs

of

dam-

threads for rust or corrosion which can increase the torgue

necessary to achieve the desired clamp load

for

may become

driver to catch in only

one direction

tener

may be

which

that fastener

was

installed

or other

In

many

should

If

component ever need

you must replace

ALWAYS

be sure

same

some

of these occurrences, a fas-

line

must

In

and tightened, but the driver would not be able

and loosen the fastener again (This could lead that

damage

only partially rounded, allowing the

grip

retainer of the

replaced during a procedure But you should always inspect the condition

compromised by rounding

cases a driver surface

to

a fastener, whether to

to frustration

to

down

the

be disassembled again)

due

to

design or damage, you

use the proper replacement

In all

cases, a

design, material and strength should be used Mark-

ings on the heads of most bolts will help determine the proper strength of the fastener.

The same

material, thread

and

pitch

must be selected

to

assure

proper installation and safe operation ol the vehicle afterwards

Thread gauges are available to help measure a bolt or stud's thread.

Most automotive and hardware

stores keep gauges available to help

you

GENERAL INFORMATION AND MAINTENANCE

K~z) POZIORIVt

PHILLIPS RECESS

INDENTED HEXAGON

TORx"

CLUTCH RECESS

HEXAGON WASHER HEAD

HEXAGON TRIUMEO

TCCS1037

Fig.

20 Here are a few

of tlie

most common screw/bolt driver

styles

I

021

LOCKWASHERS

^ Fig. 21 Ttiere are

found on vetiicles

many

(9)

different types of tlireaded retainers

1-9

1-10

GENERAL INFORMATION AND MAINTENANCE a fastener.

for

A

torque wrench can also be used

general guidelines there

is

in

the

if

you are following the

accompanying charts Keep

no worldwide standardization

in

mind

that t)ecause

of fasteners, the charts are a general

guideline and should be used with caution. Again, the general rule of

you are using the

right tool lor the job,

you should not have

"if

to strain to

tighten a fastener" applies here.

Beam Type I See Figure 27

The beam type torque wrench

RIGID CASE. DIAL INDICATOR

^

sists of a pointer attached to the

one

of the

that

most popular

types.

It

con-

runs the length of the flexible

beam (shaft) to a scale located near the handle. As the wrench is beam bends and the pointer indicates the torque using the scale.

sw

D]o

is

head

pulled, the

Click (Breakaway) Type CLICK TYPE

I See Figure 28

ICCS1015

Another popular design of torque wrench Fig. at

24 Various styles

of

torque wrenches are usually available

type wrench you pre-adjust

your local automotive supply store

the

wrench has a

of the

Marie

4T

head

5T

boll

Bolt '

head No

to a

reflex signaling feature that

the click type. To use the click is

reached,

causes a momentary breakaway

Ctoas

Marii

Stud

is

torque setting. Once the torque

torque wrench body, sending an impulse to the operator's hand

Class

Hexagon

it

bolt

6T 7T

8T 9T

10T IIT

Hexagon flange bolt

Grooved

w/ washer hexagon bolt

Hexagon head

bolt

Hexagon

Two

flange bolt

protruding

w/ washer hexagon bolt

lines

Hexagon head

bolt

:^^5^

1^

^.|1

Three protruding lines

Hexagon head

bolt

ll^

N^s.

in

1991-97 models

the right front of

GENERAL INFORMATION AND MAINTENANCE When it

is

the battery

is

1-23

eventually removed for replacement or other reason,

a good idea and opportunity to check the condition of the battery tray

Clear

it

any debris, and check

of

it

for

soundness

can be

(the battery tray

cleaned with a baking soda and water solution).

BAHERY FLUID Check

the battery electrolyte level at least once a month, or

hot weather or during periods of extended vehicle operation.

batteries or by

removing the

trolyte level in

each

If

or the line

the level

checked and

cell

cell

is

low,

add only

Each

cell is

If

distilled water

filled individually. Distilled

and could

water

is

filled to

in

in

through the opening

until the

water should be used, because the

most drinking water are harmful

significantly shorten

added

the split ring inside each

of the case.

separate from the others, so each must be

chemicals and minerals found battery

caps on opaque-cased types. The elec-

should be kept

marked on the outside

level is correct

often in

can be checked either through the case on translucent

batteries, the level

cell,

more

On non-sealed

to the

its life.

freezing weather, the vehicle should be driven several

miles to allow the water to mix with the electrolyte. Otherwise, the battery

could freeze.

Although some maintenance-free batteries have removable access

to the electrolyte, the electrolyte

condition and level on

caps for

cell all

sealed

maintenance-free batteries must be checked using the built-in hydrometer "eye."

The exact type

of

eye varies between battery manufacturers, but most

apply a sticker to the battery in

itself

explaining the possible readings.

When

doubt, refer to the battery manufacturer's instructions to interpret battery

condition using the built-in hydrometer.

«» Although the readings from built-in hydrometers found batteries

may

charged battery with sufficient

fluid level.

A dark eye

is

indicator of a battery with sufficient fluid, but one which in

in

sealed

vary, a green eye usually indicates a properly

charge. And a light or yellow eye

is

normally an

may be low

usually an indication that

dropped below the necessary level

electrolyte supply has

(and hydrometer) operation.

In this last

for battery

case, sealed batteries with

an insufficient electrolyte level must usually be discarded.

Checking the Specific Gravity I See Figures 60, 61

A hydrometer

is

,

are not maintenance-free. cific gravity is

62 and 63

required to check the specific gravity on

On

all

batteries that

batteries that are maintenance-free, the spe-

checked by observing the

built-in

hydrometer "eye" on the

top of the battery case. Check with your battery's manufacturer for proper interpretation of

Fig.

59 After cleaning the tray thoroughly, wash

it

off

with

its

built-in

hydrometer readings.

some

water

vehicle if

is to

present,

nected

is

be stored for

at the

Remember tery

life.

6-8 weeks

in

a secure area and the alarm system,

not necessary, the negative battery cable should be discon-

onset of storage to protect the battery charge.

that constantly discharging and recharging m\\ shorten batTake care not to allow a battery to be needlessly discharged.

Fig.

60 On non-maintenance-free batteries, the

fluid level

be checked through the case on translucent models; the

caps must be removed on other models

can

cell

GENERAL INFORMATION AND MAINTENANCE

1-24

CAUTION

:|":c

Battery electrolyte contains sulfuric acid.

on your skin or clear water.

The

many

If you should splash any your eyes, flush the affected area with plenty of

in

lands in your eyes, get medical help immediately.

If it

fluid (sulfuric acid solution)

be kept submerged below the fluid level is is

contained

the battery cells will

in

things about the condition of the battery. Because the

order to operate, maintaining the

can be an aid

of electrical charge, testing the fluid

the battery

if

you

must

extremely important. And. because the specific gravity of the acid

an indication

mining

fluid level in

fell

cell plates

must be replaced. A

in deter-

battery in a vehicle with a properly

operating charging system should require

maintenance, but careful, peri-

little

odic inspection should reveal problems before they leave you stranded.

As

stated earlier, the specific gravity of a battery's electrolyte level can be

used as an indication

ity

ttie

If

the fluid level

opening

is

low, add only distilled water througti

should be between

1

1

check the spe-

.26

on the grav-

variety of inexpensive battery to test

the specific gravity in each cell.

The battery testing hydrometer has a squeeze bulb

until the level is correct

year,

and

.20

These can be used on any non-sealed battery

testing hydrometers.

Fig. 61

It

Most auto supply stores carry a

scale.

once a

of battery charge. At least

the battery.

cific gravity of

zle at the other. Battery electrolyte is float is lifted

from

position of the

seat

its

float.

If

sucked

The specific gravity

gravity

low

is

in

varies

if

after

until the

cells, the battery if

come

the gravity has

charging, the specific gravity between any two cells

more than 50 points

no longer produce

see

to

one end and a noz-

then read by noting the

one or more

should be slowly charged and checked again up. Generally,

is

at

hydrometer

into the

should be replaced, as

(0.50), the battery

it

can

sufficient voltage to guarantee proper operation.

CABLES I See Figures 64 thru 69

Once

a year (or as necessary), the battery terminals

and

the cable

clamps

should be cleaned. Loosen the clamps and remove the cables, negative cable first.

On

purpose

batteries with posts is

on

top, the

use

of a puller specially

recommended. These are inexpensive and

made

available in

for this

most auto

parts stores. Side terminal battery cables are secured with a small bolt.

Clean the cable clamps and the battery terminal with a wire brush, corrosion, grease,

etc., is

removed and

tant to clean the inside of the

the metal

is

shiny.

clamp thoroughly (an old

It

knife

is is

until all

especially imporuseful here),

since a small deposit of foreign material or oxidation there will prevent a sound electrical

Fig.

62 Check the specific gravity

of the battery's electrolyte

with a hydrometer

connection and

inhibit either starting or charging. Special tools are

available for cleaning these parts,

and another type dielectric

for

one type

side terminal batteries.

grease to the terminal, as this

for It

conventional top pes! batteries is

also a

will aid in

good

idea to apply

BUILT-IN

HYOPOMETER

BATTIRY TOP

DVrTHORECN DOT

MAT

»l

BATTEBY TOP

NO

omeN ooT

JUMP STAITfO

BATTERY TOP

UOKT YELLOW OR BRiGKT INOCATOR l*0 GREEN OOT DO NOT JUMP START

ir>vj

Location of Irtdlcatof on

Fig.

63 A typical sealed (maintenance-free) battery with a

manufacturers: always refer

of the charga Indicator on top of tha batlary bafora attampling a jump atari. If Ha not graan or dark, do not |ump atari tha car

Chach tha appaaranca il«d battery

to the battery's label

built-in

hydrometer

—NOTE

that the

some

the prevention of corrosion

hydrometer eye may vary between battery

GENERAL INFORMATION AND MAINTENANCE

1-25

fcS/

Fig. Fig.

64 Loosen the battery cable retaining nut

.

.

.

67 The wire brush can also be used

sion or

dirt

to

remove any corro-

from the battery terminal

^ Fig.

68 The battery terminal can also be cleaned using a solu-

tion of baking

Fig.

66 A wire brush may be used

eign material from the cable

to

clean any corrosion or for-

Fig.

soda and water

69 Before connecting the cables,

the terminals with a small

amount

it's

a

good idea

of dielectric

grease

to coat

GENERAL INFORMATION AND MAINTENANCE

1-26 After the

cable

last;

clamps and terminals are

DO NOT

tiammer

clamps securely, but do not

clean, reinstall

clamps onto

ttie

distort them.

ttie

cables, negative

battery posts. Tigtiten the

Give the clamps and terminals a

thin external coating ol grease alter installation, to retard corrosion.

Check the cables cable insulation

is

same time

at the

that the'terminals are cleaned.

cracked or broken, or

should be replaced with a new cable

if

of the

ends are

the

same

If

the

frayed, the cable

length and gauge.

CHARGING

:•"•:

CAUTION

The chemical reaction which takes place in all batteries generates explosive hydrogen gas. A spark can cause the battery to explode and splash acid. To avoid serious personal injury, be sure there is proper ventilation and take appropriate tire safety

when connecting, disconnecting,

precautions tery

A

or charging a bat-

and when using jumper cables. battery should be charged at a slow rate to keep the plates inside from

some maintenance-free batteries are allowed to almost "dead," they may have to be charged at a

getting too hot

However,

discharge

they are

until

high rate to bring them back to turer's instructions

Fig. 71

An example

of a

healthy drive belt

if

"life."

on charging the

Always follow the charger manufac-

battery.

REPLACEMENT When

it

amperage

becomes necessary

to replace the battery, select

one with an

rating equal to or greater than the battery originally installed.

Deterioration and just plain aging of the battery cables, starter motor,

associated wires makes the battery's job harder

slow increase

new

in electrical

resistance over time

in

and

successive years. The

makes

it

prudent to

install a

battery with a greater capacity than the old.

Serpentine Drive Belt IN5l»fbTI0N I See Figures 70, 71, 72, 73 and 74 Inspect the belt for signs of glazing or cracking. perfectly

smooth from slippage, while

of fabric visible.

Cracks

will

run outward. All worn or

a

good

A

glazed belt

belt will

will

be

have a slight texture

usually start at the inner edge of the belt and

damaged

drive belts should be replaced

Fig.

72 Deep cracks

in this belt will

cause

(lex, building

up heat

that will eventually lead to belt (allure

immedi-

CONVENTIONAL

V

Fig.

70 There are typically 3 types

(ound on vehicles today

o(

niBBCO BELT

accessory drive belts

Fig.

73 The cover

o( this belt is

forcing cords to excessive

wear

worn, exposing the

critical rein-

GENERAL INFORMATION AND MAINTENANCE

74

Fig.

Installing too

wide a

belt

can result

in

serious belt

wear

is

It

best to replace the drive bell as a preventive maintenance

mea-

Using tool SA9181-NE or an equivalent calibrated

5.

gauge, measure and note the tension readings

sure, during this service operation.

trally

Belt Tension

between 2

the engine

suspected or unusual

belt

dure should be used to determine 1.

Start the

ature with

all

engine and allow

the tensioner or belt

to

warm up

the vehicle

If

turn the steering wheel to the

make sure

it

if

a proper load

is

left

and

is

Turn the engine and accessories OFF.

Using a 1'4mm or ^/e

apply tension to the

normal operating temper-

belt.

Do

ON;

should take

this

the illustration.

50-65

during warm-up to

until the belt

the tensioner to return to position

and

not allow the tensioner to snap against the

belt.

If

the

marks on

outside the operating range, the drive belt must be replaced.

mum

14mm

75 Use

arm

until the belt

a

Belt

or

%

in.

lines

depending on

equipped.

is

(22.7-29.2 kg)

belts.

If

for

new

belts or a

The readings should be

minimum

the readings are out of this range or

and the drive

belt

passed the

test in

Step

4,

of

45

lbs.

(20.4 kg)

do not meet the mini-

the drive belt tensioner-

wrench

to

Alignment

fvleasure the distance from the front

1.

machined surface

of the cylin-

der block to the inboard edge of the belt at the location as shown. 2.

The distance should be 1.102-1.220

3.

If

the distance

does not

fall

Check

that the belt

•

Check

the drive belt for wear at the

is

in.

(28-31mm).

within the specification, check the following;

•

worn

mount removed.

becomes loose

and accessories with which your vehicle

The dotted

follow,

must be replaced.

•

Fig.

lbs.

used

p»lnspection of the belt using a tension gauge must be performed with the upper engine

may

> See Figure 77

Inspect the markings located on the tensioner arm. fall

in

calculate the average result for each test location.

for

is at fault.

wrench, depress the tensionsf arm

becomes loosened, then slowly allow

belt

belt.

3.

arm

shown

belt tension

2 points located cen-

equipped with power steering,

2.

4.

to

right several times

placed on the

in.

If

noises occurs, the following proce-

accessories (such as the A/C) turned

approximately 10 minutes.

the

using a spring loaded tensioner.

belt is automatically adjusted is

as

at the

Repeat the measurements from the previous step 2 more times, then

6.

The

belt pulleys

represent other possible paths which your belt

I See Figures 75 and 76

slippage

belt tension at 2 points centrally located

between the indicated pulleys

and/or breakage

ately.

76 Read the

Fig.

1-27

properly located within the pulley grooves.

edges and,

if

necessary, replace a

belt.

fvlake

sure the belt pulleys are not bent or damaged.

depress the tensioner Fig.

77 Measuring serpentine drive belt alignment

GENERAL INFORMATION AND MAINTENANCE

1-28 •

Make

sure the accessory assemblies have proper shaft and bearing

•

6.

If

the tensioner idler pulley retaining bolt

and apply Loctite* 242 or equivalent

end-play.

Check

the pulley

hubs

for

proper installation on their shafts.

tighten to

REMOVAL & INSTALLATION

22

lbs.

ft.

is

remove

loose,

the bolt

to the bolt threads. Install the bolt

and

(30 Nm).

Belt Tensioner

I

See Figures 80 and 81

Belt

On 1992 and

1.

I See Figures 78 and 79 1

Loosen the drive

belt

tem, position a

by depressing the tensioner arm using a

14mm

Remove

and cradle

in

later

X

1

2

X

long

in.

mount sys-

the torque axis

wooden block between

the torque

upper mount without the necessity

of lifting or jack-

ing the powertrain. the belt from the idler or air conditioning compressor, as

On 1992 and

2.

later

applicable.

3

Remove

To

install:

4.

Install the belt

models, remove the 3 engine mount-lo-front

cover nuts and the 2 mount-to-midrail bracket nuts, then remove the.upper

the drive belt from the vehicle.

mount. This tioned

air

models equipped with

in.

order to support the mount. This will allow removal and

installation of the right

orcein, wrench. 2.

strut

in.

1

around the pulleys, except

for the front

allow the powertrain to rest on the

will

wooden block

posi-

earlier.

cover idler or 3.

Remove

4.

Check the position

the serpentine drive belt.

conditioning compressor. 5.

Depress the tensioner arm and

ditioning

compressor

pulley.

slip the belt over the idler or air

Make sure

to the right side midrails;

it

may be

possible to remove the tensioner without removing the power steering

pump.

on the pulleys

engine

of the

con-

the belt ribs are properly aligned

If

the right

5

If

this is preferable, raise tire it

and support the vehicle

safely,

then remove

and splash shield.

was determined

that tensioner

removal

necessary, remove the

is

power steering pump and bracket from the engine.

Remove

6.

the upper

and lower fasteners attaching the tensioner

to the

engine. 7.

engine

Remove the tensioner assembly from the vehicle. may be moved slightly toward the driver's side by

motor mount and frame accessories or

To 8.

Do

rail.

damage may

not pry against the

If

necessary, the

prying on the

aluminum engine and

occur.

install: Install the

tensioner using the upper and lower fasteners, then

tighten the fasteners to

22

ft.

lbs.

(30 Nm).

power steering pump assembly.

9.

If

removed,

install the

10.

If

removed,

install the right tire

and splash

shield, then

remove the

support and lower the vehicle. 1

Install the

accessory drive

belt,

making sure

it

is

properly aligned on

the pulleys.

12

On 1992 and

later

vehicles equipped with the torque axis

system, position the upper mount and

install the

mount

3 mount to front cover

nuts. Install the 2 mount-to-midrail bracket nuts, then tighten the 5

fasteners slowly

Fig.

78 The accessory

belt routing label is located

under the

hood

SOHC (LKO)

Fig.

79 Proper drive bell routing

DOHC (LLO)

and evenly

to

block from the engine cradle.

52

ft.

lbs.

mount

(70 Nm). Remove the wooden

GENERAL INFORMATION AND MAINTENANCE

1-29

WOOD BLOCK

Fig. 81

Place a wooden block between the torque strut and

engine cradle

to

support the

mount— 1992 and

later

models

Fig.

83 A hose clamp that

is

too tight can cause older hoses to

separate and tear on either side of the clamp

Timing Chain All

Saturn models

freewheeling engine.

head may

utilize If

a timing chain driven, interference-type, non-

the timing chain breaks, the valves in the cylinder

strike the pistons,

causing potentially serious (also time-con-

suming and expensive) engine damage. Refer

to Section 3 for information

on servicing the timing chain. potential for serious engine damage, the manufacdoes not give a recommendation for timing chain replacement as a preventive measure. Such replacement, however, may be prudent on high mileage engines.

^Despite the turer

INSPECTION » See Figures 82, 83, 84 and 85 Upper and lower radiator hoses, along with the heater hoses, should be checked

for deterioration, leaks

15,000 miles (24,000 km).

Fig.

It

is

and loose hose clamps

at least

every

84 A

soft

spongy hose

(identifiable by the swollen section)

and should be replaced

also wise to check the hoses periodically

82 The cracks developing along this hose are a result of

age-related hardening

Fig.

will eventually burst

Fig.

85 Hoses are

cooling system

is

likely to deteriorate

from the inside

not periodically flushed

if

the

GENERAL INFORMATION AND MAINTENANCE

1-30

spring and

in early

forming

ottier

weakened

the beginning of

at

maintenance.

A

fall

you are per-

or winter, wfien

fiose wfiicti migfit tiave

left

you stranded

if

it

fiad

remained

When

unrepaired.

draining the coolant, keep

in

mind

Wtienever you are checking the hoses, make sure the engine and cooling for cracking, rotting or

collapsed hoses,

and replace as necessary. Run your hand along the length or swollen spot

is

of the hose.

If

a

noted when squeezing the hose wall, the hose

should be replaced.

REMOVAL & INSTALLATION

3.

I See Figures 86 and 87

Loosen the hose clamps

damps

pliers to

at

each end

o( the

squeeze the tabs and loosen) or

screw tension type (which

of the

4.

Disconnect the negative battery cable or Ian motor wiring harness connector before replacing any radiator/heater hose. The

may come ON, under is

Remove

clamps back on the hose

away from the connection.

CAUTION

the ignition

hose requiring replace-

are usually either of the spring tension type (which require

require screw or hex drivers to loosen). Pull the

1

and dogs

likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

ment,

fan

that cats

are attracted by ethylene glycol antifreeze, and are quite

system are cold. Visually inspect

weak

CAUTION

•:

quick visual inspection could discover a

Twist, pull

damage

slide the

hose

off

the fitting, taking care not to

component from which

hose

the

is

being

removed

certain circumstances, even though p»lf the

OFF.

and

the neck of the

hose

is

stuck at the connection, do not try to insert a screw-

driver or other sharp tool under the hose

end

an

in

effort to free

it,

may become damaged. Heater connections especially may be easily damaged by such a procedure. If the hose is to be replaced, use a single-edged razor blade to make as the connection and/or hose

the surge tank pressure cap.

CAUTION

a slice along the portion of the hose which

Never remove the pressure cap while the engine is running or personal injury from scalding hot coolant or steam may result. If possible, wait until the engine has cooled to remove the pressure cap. If this is not possible, wrap a thick cloth around the pressure cap and turn it slowly to the first stop. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, press down on the cap with the cloth, then turn the cap and remove it.

perpendicular

tion,

to the

end

of the

is

stuck on the connec-

hose. Oo not cut deep, so as to

prevent damaging the connection. The hose can then be peeled

from the connection and discarded. 5.

Clean both hose mounting connections. Inspect the condition of the

hose clamps and replace them,

To

if

necessary.

install:

Dip the ends of the new hose info clean engine coolant to ease

6

installation. 7.

^It removing

just the

upper radiator hose, only a

little

coolant must

be drained. To remove hoses positioned lower on the engine, such as a lower radiator hose, the entire cooling system must be emptied.

drain the coolant by opening the radiator drain and removing the engine drain plug. ratchet

The engine drain plug

and socket

or wrench. To

is

a bolt which can be

open the

8.

ends

of the hose.

and turn counterclockwise

until

removed with a

radiator drain, grasp the plug

9.

Make

to prevent plug or radiator

cw^^^

0.12

in.

(3mm) from

the

Close the radiator or engine drains and properly

refill

the cooling of ethyl-

ene glycol coolant and water. If

available, install a pressure tester

sure tester sure the plug

damage.

is fully

is

and check

for leaks.

If

a pres-

not available, run the engine until normal operating tempera-

loosture is reached (allowing the leaks.

cooiwi ntttux

at least

sure they are located beyond the raised bead of the

loosened, then use a small prybar to

dislodge the plug and large rubber gasket.

ened before prying

Make

system with the clean drained engine coolant or a suitable mixture

10. firmly

into position.

Position and secure the clamps

connector.

Position a suitable container under the radiator and block, then

2.

Slide the hose clamps over the replacement hose and slide the hose

ends over the connections

system

to naturally pressurize), then

check

lor

GENERAL INFORMATION AND MAINTENANCE Thoroughly check the boots

CAUTION

:•::•:

damaged,

you are checking for leaks with the system at normal operatBE EXTREIVIELY CAREFUL not to touch any moving or hot engine parts. Once operating temperature has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections which were removed earlier.

it

for

missing clamps and

should be replaced immediately. Please

tears.

If

refer to

1-31 the boot

is

Section 7 for

procedures.

If

ing temperature,

Spark Plugs I See Figure 90

A

CV-Boots

typical spark plug consists of a metal shell

A

insulator

and protrudes a small distance. Located

metal electrode extends

downward through

attached to the side of the outer metal shell

INSPECTION

electrode bends

a 90" angle so that

in at

the tip of the center electrode.

I See Figures 88 and 89

surrounding a ceramic

insulator.

(measured

in

thousandths

of

is

at

the center of the

the end of the plug and

the side electrode.

its tip is

just past

and

The side

parallel to

The distance between these two electrodes

an inch or hundredths

of a millimeter) is

called the spark plug gap.

The CV (Constant Velocity) boots should be checked time the

oil is

changed and any other time the vehicle

These boots keep

water, grime, dirt

ing the CV-joints.

Any

is

for

damage each

raised for service.

The spark plug does not produce a spark, but instead provides a gap across which the current can

and other damaging matter from enterto

can be expensive front wheel(s)

of these

to repair

and

could cause early CV-joint

failure, vi/hich

Heavy grease thrown around the inside

of the

on the brake caliper can be an indication of a torn boot.

50,000

volts

arc.

The

coil

produces anywhere from 20,000

(depending on the type and application) which travels

through the wires to the spark plugs. The current passes along the center electrode and

jumps

the air/fuel mixture

the

in

gap

the

to the side electrode,

and

In

doing so, ignites

combustion chamber

PORCELAIN INSULATOR INSULATOR CRACKS OFTEN OCCUR HERE

SHELL

ADJUST FOR

PROPER GAP SIDE ELECTRODE

CENTER ELECTRODE:

(BEND TO ADJUST GAP)

FILE FLAT WHEN ADJUSTING GAP;

DO NOT BEND Fig.

'

88 CV-boots must be inspected periodically for damage

^^VW--

Fig.

90 Cross-section

of a

spark plug

TCCS1045

GENERAL INFORMATION AND MAINTENANCE

1-32

Q f=\

f=\}

I

I

I

I

I

THE SHORTER THE PATH THE FASTER THE HEAT IS OISSIPATED AND THE COOLER

L^HE PLUG

J

4

)>

HEAVY LOADS. HIGH SPEEDS

SHORT Insulator Tip Fasi Heal Transfer

LOWER

Heal Range

COLO PLUG THE LONGER THE PATH THE SLOWER THE

HEAT IS OIS SIPATED AND THE HOTTER THE PLUG

SHORT TRIP STOP-AND-GO

LONG

Insulator Tip

Slow Heal Transfer HIGHER Heat Range

HOT PLUG Fig. 91

,ccsio«

Spark plug heat range

REMOVAL & INSTALLATION I See Figures 92, 93 and 94

A

set of spark plug's usually requires replacement after

about

20,000-30,000 miles (32,000-48,000 km), depending on your ving. In normal operation, plug for

gap increases about 0.001

every 2500 miles (4000 km).

requirement also increases.

gap and about two speeds

tems,

as mucti voltage to

The improved

will often

Itie

of

025mm)

.

plug's voltage

jump

fire ttie

air/fuel ratio control of

style of dri-

(0

ttie

plug

modern

modern

wider

at tiigti

fuel

ignition sys-

allow an engine to run significantly longer on a set of stan-

widens (along with

fuel

in

mind

that efficiency will

economy and

may become mixed

all at

drop as the gap

power).

you're removing spark plugs, work

removing the plug wires they

gap increases,

combined with the higher voltage output

dard spark plugs, but keep

When

ttie

requires a greater voltage to

to ttiree times

tfian at idle

injection,

It

^

in.

on one

at a

time Don't start by

once, because, unless you

up. Take a minute before

number them,

you begin and number

the wires with tape 1.

Disconnect the negative battery cable and,

recently, allow the

2

if

the vehicle has been run

engine to thoroughly cool

Carefully twist the spark plug wire boot to loosen

and remove the boot from the plug. Be sure

to pull

it,

then pull upward

on the boot and not on

Fig.

92 Carefully twist the spark plug wire boot

pull

upward and remove the boot from the plug

to

loosen

it,

then

GENERAL INFORMATION AND MAINTENANCE the wire, otherwise the connector located inside the boot

1-33

may become sep-

arated.

Using compressed

3.

when

bustion chamber

blow any water or debris from the spark plug

air,

no harmful contaminants are allowed

well to assure that

the spark plug

is

removed.

com-

to enter the

compressed

If

not

air is

available, use a rag or a brush to clean the area.

i» to

Remove the spark plugs when the engine is cold, if possible, damage to the threads. If removal of the plugs is diffi-

prevent

apply a few drops

cult,

of

penetrating

oil

or silicone spray to the

area around the base of the plug, and allow

few minutes

a

it

to

work. Using a spark plug socket

4.

that is

equipped with a rubber

insert to

properly hold the plug, turn the spark plug counterclockwise to loosen and

remove the spark plug from the bore.

WARNING Be sure not

use a flexible extension on the socket. Use of a may allow a shear force to be applied to the

to

flexible extension

plug.

A shear

force could break the plug off in the cylinder

head, leading to costly and frustrating repairs. To

install:

5.

Inspect the spark plug boot for tears or damage.

If

damaged boot

a

is

found, the spark plug wire must be replaced.

Using a wire

6.

When

feeler

gauge, check and adjust the spark plug gap.

using a gauge, the proper size should pass between the electrodes

The next

with a slight drag.

larger size

should not be able

to

pass while the

next smaller size should pass freely. 7.

Carefully thread the plug into the bore by hand.

before the plug

is

threading again.

In

twist the

end

resistance

is felt

small, hard to reach areas, an old spark plug wire

boot could be used as a threading tool. The boot

you

If

almost completely threaded, back the plug out and begin

and the wire

of the wire

would allow the plug

is

will

and

Fig.

95 A normally worn spark plug should have

deposits on the firing

light tan or

gray

tip

hold the plug while

supple enough

to twist before

it

to crossthread.

WARNING Do not use the spark plug socket to thread the plugs. Always hand or using an old plug wire to prevent the possibility of crossthreading and damaging the cylinder head bore. carefully thread the plug by

8.

Carefully tighten the spark plug.

If

the plug you are installing

is

equipped with a crush washer, seat the plug, then tighten about Va turn to

crush the washer.

If

you are

installing a tapered seat plug, tighten

the plug to specifications provided by the vehicle or plug manufacturer. 9.

Apply a small amount

compound

of silicone dielectric

end

to the

of

the spark plug lead or inside the spark plug boot to prevent sticking, then install the

click

boot to the spark plug and push

may be

felt

until

or heard, then gently pull back

it

clicks into place.

on the boot

to

The

assure

proper contact.

INSPECTION & GAPPING I See Figures 95 thru 105 Check the plugs

for

deposits and wear.

replaced, clean the plugs thoroughly. will

If

they are not going to be

Remember

that

any kind

plug cleaning machine, which can sometimes be found or

you can do an acceptable job

of cleaning with a

are cleaned, the electrodes

must be

an emery board or the

which

be

of deposit

decrease the efficiency of the plug. Plugs can be cleaned on a spark

filed perfectly flat

plug voltage by as

like,

filed flat.

stiff

Use an

will leave deposits.

in

service stations,

brush.

If

the plugs

ignition points

file,

with sharp edges; rounded edges reduce the spark

much

as

installation.

Fig.

96 A carbon fouled plug, identified by

deposits,

50%.

Check spark plug gap before

not

The electrodes must

The ground electrode

(the

may

soft, sooty,

black

indicate an improperly tuned vehicle. Check the

air cleaner, ignition

components and engine

control

system

1-34

GENERAL INFORMATION AND MAINTENANCE

L-shaped one connected

to the

body

of the plug)

must be

Up

Specifications chart for details)

Always check the gap on new plugs, as they are not always

parallel to the

center electrode and the specified size wire gauge (please refer to the Tune-

must pass between the electrodes with a

at

the factory.

not use a

flat

feeler

is

the best

way

to

check the gap. The correct gauge should pass

through the electrode gap with a slight drag

»»NEVER adjust the gap on a used platinum type spark plug.

set correctly

gauge when measuring the gap on a

used plug, because the reading may be inaccurate. A round-wire type gapping tool

slight drag

Do

If

you're in doubt, try

one

size

*j'"1

%'

Oictk o(f vrrvnf pcrfomir.) m tofTrswndmi (>o> Otty h..>r> nw«i llul no irtvKC ii ncrtrt « lh« milnjc

iritr>«l

make sure

it

is

firmly sup-

GENERAL INFORMATION AND MAINTENANCE CAPACITIES

1-61

GENERAL INFORMATION AND MAINTENANCE

1-62

ENGLISH TO METRIC CONVERSION: MASS (WEIGHT) Current mass measurement is expressed m pounds and ounces (lbs & 02s ). The metric unit of mass (or weight) is the kilogram (kg) Even although this table does not show conversion of masses (weights) larger than 15 lbs. it is easy to calculate larger units by following the data immediately below.

To convert ounces (oz ) to grams (g): multiply th number of 02s. by 28 To convert grams (g) to ounces (oz): multiply the numt>er of grams by .035 To convert pounds (lbs ) to kilograms (kg): multiply the number of lbs. by .45 To convert kilograms (kg) to pounds (lbs): multiply the number of kilograms by 2.2 lbs

GENERAL INFORMATION AND MAINTENANCE ENGLISH TO METRIC CONVERSION: LENGTH To convert inches

(ins

)

to millimeters

To convert millimeters (mm)

(mm): multiply number

to inches (ins): multiply

number

of inches

by 25.4

of millimeters by .04

1-63

1-64

GENERAL INFORMATION AND MAINTENANCE ENGLISH TO METRIC CONVERSION: TORQUE

GENERAL INFORMATION AND MAINTENANCE

1-65

ENGLISH TO METRIC CONVERSION: FORCE Force IS presently measured in pounds (lbs). This type of measurement is used to measure spring pressure, specifically how many pounds it takes to compress a spring. Our present force unit (the pound) will be replaced m SI metric measurements by the Newton (N). This term will eventually see use in specifications for electric motor brush spring pressures, valve spring pressures, etc.

To convert pounds

1-66

GENERAL INFORMATION AND MAINTENANCE ENGLISH TO METRIC CONVERSION: LIQUID CAPACITY

Liquid or fluid capacity is presently expressed as pints, quarts or gallons, or a combination of all of these. In the metric system the liter (I) will t>ecome the basic unit. Fractions of a liter would be expressed as deciliters, centiliters, or most frequently (and commonly) as milliliters.

To convert pints (pts.) to liters (I): multiply the number of pints by .47 To convert liters (I) to pints (pts ): multiply the numt)er of liters by 2.1 To convert quarts (qts ) to liters (I): multiply the number of quarts by .95

To convert liters (I) to quarts (qts ): multiply the number of liters by 1 .06 To convert gallons (gals ) to liters (I): multiply the number of gallons by 3.8 To convert liters (I) to gallons (gals ): multiply the number of liters by 26

Ph

GENERAL INFORMATION AND MAINTENANCE

1-67

ENGLISH TO METRIC CONVERSION: PRESSURE unit of pressure measurement used today is expressed as pounds per square inch (psi). The metric unit for be the kilopascal (kPa). This will apply to either fluid pressure or air pressure, and will be frequently seen in tire pressure readings, oil pressure specifications, fuel pump pressure, etc.

The basic will

To convert pounds per square inch Pti

(psi) to kilopascals (kPa): multiply the

number

of psi by

6.89

psi

1-68

GENERAL INFORMATION AND MAINTENANCE ENGLISH TO METRIC CONVERSION: PRESSURE

unit of pressure measurement used today is expressed as pounds per square inch (psi). The metric unit for psi be the kilopascal (kPa) This will apply to either fluid pressure or air pressure, and will be frequently seen in tire pressure readings, oil pressure specifications, fuel pump pressure, etc.

The basic will

To convert pounds per square inch fsi

(psi) to kilopascals (kPa); multiply the

number

of psi by

6.89

DISTRIBUTORLESS IGNITION

SYSTEM

2-2

GENERAL INFORMATION 2-2 DIAGNOSIS AND TESTING 2-2 SECONDARY SPARK TEST 2-2

NO SPARK TEST 2-2 ADJUSTMENTS 2-3 IGNITION MODULE AND COIL PACKS 2-3 TESTING 2-3 REMOVAL & INSTALLATION 2-4 CRANKSHAFT POSITION 2-4

SENSOR (CPS)

ORDERS 2-5 CHARGING SYSTEM 2-5 FIRING

GENERAL INFORMATION 2-5 ALTERNATOR PRECAUTIONS 2-5 ALTERNATOR 2-5 TESTING 2-5

REMOVAL & INSTALLATION REGULATOR

2-6

2-8

REMOVAL & INSTALLATION STARTING SYSTEM 2-8 GENERAL INFORMATION 2-8

2-8

STARTER 2-8 TESTING 2-8 REMOVAL & INSTALLATION 2-9 STARTER SOLENOID

REPLACEMENT 2-11 SENDING UNITS 2-11 FUEL LEVEL SENDER 2-11

ELECTRICAL DISTRIBUTORLESS IGNITION

SYSTEM ORDERS CHARGING SYSTEM STARTING SYSTEM FIRING

OPERATION 2-11 TESTING 2-12

REMOVAL & INSTALLATION 2-12 COOLANT TEMPERATURE SENDER 2-12

SENDING UNITS

2-2 2-5 2-5

2-8 2-11

TESTING 2-12 OIL

REMOVAL & INSTALLATION PRESSURE SENDER 2-14

2-13

TESTING 2-14

REMOVAL &

INSTALLATION 2-14

TROUBLESHOOTING CHARTS

^^

1209U4S "X le ^* TO CNCME INLINC

J^f.

13M .33

OK oin/Wht

COOUNT TEMP

GAUGE SENDER

Fig.

34 Schematic

for the coolant

, ' I

temperature sender

circuit

2-13

2-14

ENGINE ELECTRICAL

Pressure Sender

Oil

TESTING

To

1

cal

normally closed

test the

oil

pressure sender, disengage the electri-

connector and measure the resistance between the switch terminal

(ter-

minal for the wire to the warning lamp) and the metal housing. The

ohmmeter should read To

2.

ohms.

sending

test the

unit,

measure the resistance between the sender

terminal and the metal housing. The

ohmmeter should read an open

circuit

(infinite resistance)

3

Start the engine.

Once

4.

open

again, test each terminal against the metal housing.

The

a.

oil

circuit,

pressure switch terminal-to-housing circuit should read an if

there

is oil

pressure present.

The sending unit-lo-housing

b.

ohms, depending on

circuit

should read between 15-80

the engine speed, oil temperature

and

oil

viscosity. 5.

ohms

To

test the oil

ohms) as rpm 6.

If

the

oil

pressure sender

located on the rear of the

Is

engine block, between the alternator and the knock sensor

15-80

increases.

above results were not obtained, replace the sending 3.

unit/switch with a

REIVIOVAL

37 The

Fig.

pressure sender only, rev the engine and watch the

reading, which should fluctuate slightly (within the range of

new

one.

Using a 3 inch long wobble drive extension and a V* inch (19mm)

crow's loot, carefully loosen and remove the sender from the engine block

& INSTALLATION

p»

If It

is

too difficult to access the sender from the engine compart-

ment, raise and support the vehicle safely, then loosen and remove the sender from underneath the vehicle.

I See Figure 37 The

oil

pressure sender

the firewall.

The sender

is

is

located in the rear center of the block, facing

slightly

below and toward the passenger's side

the vehicle from the knock sensor

of ft.

To

install:

4.

Install the oil

lbs.

pressure sender

in

the engine block

1

Disconnect the negative battery cable.

5.

Attach the

2.

Detach the sender

6.

If

7.

Connect the negative battery cable.

electrical connector.

and tighten

(35 Nm).

raised,

oil

pressure sender's electrical connector,

remove the supports and

carefully lower the vehicle.

to

26

ENGINE ELECTRICAL

2-15

Troubleshooting Basic Starting System Problems Cause

Problem Starter

motor rotates engine slowly

Battery charge low or battery

Solution

Charge or replace

battery

defective

Defective

and

Low

circuit

starter

between battery

motor

load current

High load current

Clean and

tighten, or replace cables Bench-test starter motor Inspect for worn brushes and weak

brush spnngs. Bench-test starter motor Check engine for friction, drag or coolant in cylinders.

Check

ring gear-to-

pinion gear clearance. Starter

motor

will

not rotate engine

Battery charge low or battery

Charge or replace

battery

defective

Faulty solenoid

Check solenoid ground. Repair

or

replace as necessary.

Damaged ring

drive pinion gear or

Replace damaged gear(s)

gear

Starter motor

engagement weak

Starter motor rotates slowly with

high load current

Bench-test starter motor Inspect drive yoke pull-down and point gap,

check

for

worn end

bushings, check ring gear clear-

ance

2-16

ENGINE MECHANICAL 3-6

DISASSEMBLY 3-54

ENGINE 3-6

INSPECTION 3-57 REFINISHING & REPAIRING 3-59

REMOVAL & INSTALLATION 3-6 ROCKER ARM (CAMSHAFT/VALVE) COVER 3-10 REMOVAL & INSTALLATION 3-10 ROCKER ARMS/SHAFTS 3-12 REMOVAL & INSTALLATION 3-12 THERMOSTAT 3-13 REMOVAL & INSTALLATION 3-13 INTAKE MANIFOLD 3-14 REMOVAL & INSTALLATION 3-14 EXHAUST MANIFOLD 3-19 REMOVAL & INSTALLATION 3-19 REMOVAL & INSTALLATION

3-21

REMOVAL & INSTALLATION 3-25 TESTING 3-26 WATER PUMP 3-27 REMOVAL & INSTALLATION 3-27 CYLINDER HEAD 3-28 REMOVAL & INSTALLATION 3-28

ASSEMBLY

3-64

ENGINE START-UP AND BREAK-IN 3-67 STARTING THE ENGINE 3-67 BREAKING IT IN 3-67 KEEP IT MAINTAINED 3-67 ENGINE SPECIFICATIONS 3-2

TROUBLESHOOTING CHARTS USING A VACUUM GAUGE 3-70 ENGINE MECHANICAL

PROBLEMS

3-71

ENGINE PERFORMANCE 3-74

n

3-31

REMOVAL & INSTALLATION OIL

3-61

INSPECTION 3-62 REFINISHING 3-64

TORQUE SPECIFICATIONS 3-68

ELECTRIC COOLING FAN 3-25

PAN

DISASSEMBLY

SPECIFICATIONS CHARTS

RADIATOR 3-21

OIL

ASSEMBLY 3-60 ENGINE BLOCK 3-61 GENERAL INFORMATION 3-61

PUMP

3-31

3-32

REMOVAL

3-32

INSPECTION 3-32 INSTALLATION 3-33

CRANKSHAFT DAMPER/PULLEY 3-33 REMOVAL & INSTALLATION 3-33 TIMING CHAIN COVER 3-33 REMOVAL & INSTALLATION 3-33 TIMING CHAIN COVER OIL SEAL 3-38 REPLACEMENT 3-38 TIMING CHAIN AND SPROCKETS 3-39 REMOVAL & INSTALLATION 3-39 CAMSHAFT 3-42 REMOVAL & INSTALLATION 3-42 INSPECTION 3-44 REAR MAIN SEAL 3-45 REMOVAL & INSTALLATION 3-45 FLYWHEEL/FLEXPLATE 3-46

REMOVAL & INSTALLATION

3-46

EXHAUST SYSTEM 3-46 INSPECTION 3-46

REPLACEMENT 3-48 ENGINE RECONDITIONING 3-50 DETERMINING ENGINE CONDITION 3-50 COMPRESSION TEST 3-50 OIL PRESSURE TEST 3-50 BUY OR REBUILD? 3-51 ENGINE OVERHAUL TIPS 3-51

TOOLS 3-51 OVERHAUL TIPS CLEANING 3-51 REPAIRING

3-51

DAMAGED

THREADS 3-52 ENGINE PREPARATION 3-53 CYLINDER HEAD 3-54

ffi

ENGINE MECHANICAL 3-6

EXHAUST SYSTEM 3-46 ENGINE RECONDITIONING 3-50

3-2

ENGINE AND ENGINE OVERHAUL

1.9L

Description

SOHC (1901CC) ENGINE SPECIRCATIONS

ENGINE AND ENGINE OVERHAUL 1.9L

Description Cylinder

Head

(cont.)

SOHC (1901CC) ENGINE SPECIFICATIONS English

Metric

Specifications

Specifications

3-3

3-4

ENGINE AND ENGINE OVERHAUL 1.9L

Description

OOHC (1901CC) ENGINE SPECIFICATIONS

ENGINE AND ENGINE OVERHAUL 1.9L

Description Cylinder

Head

English

Metric

Specifications

Specifications

(cont.)

Valve spring free-length Piston

DOHC (1901CC) ENGINE SPECIFICATIONS

1.61

40.84mm

in.

and Connecting Rod 81 .956-81

.984mm

3.2266-3.2277

in.

0.0002-0.0028

in.

0.0006-0.0028

in.

0.016-0.070mm

Pis ton pin diameter

0.7676-0.7677

in.

19.496-1 9.500mm

Pis ton pin-to-piston clearance

0.0001-0.0004

in.

0.002-0.01

0.0016-0.0035

in.

0.040^.090mm

0.0012-0.0031

in.

0.030-0.080mm

Top

0.0098-0.0236

in.

0.25-0.60mm

Second

0.0098-0.0236

in.

0.25-0.60mm

Piston diameter Piston-to-bore clearance

No

.

1,2

and 3

No. 4

Ri ng

0.006-0.070mm

1mm

groove clearance

Top

ring

Second

ring

Ring end-gap (1991-94)

Oil control

3-5

ENGINE AND ENGINE OVERHAUL

3-6

ENGINE MECHANICAL

lines,

REMOVAL & INSTALLATION In the

Disconnect and label the following

5.

Engine

process

removing the engine, you

of

steps which call for the removal of a separate

will

come across

component

a

number

or system,

of

such

electrical

plugs and vacuum

as applicable: a.

The coolant temperature sensor(s).

b.

Oxygen sensor and

c.

Idle Air

d.

The

e.

Throttle Position

clip at the transaxle front

mount

bracket.

Control (lAC) valve.

module

ignition coil

coT)nector(s).

Sensor (TPS).

f.

Manifold Absolute Pressure (MAP) sensor

instances, a detailed removal procedure can be found elsewhere in this

g.

Exhaust Gas Recirculation (EGR) solenoid.

manual.

h.

Brake booster vacuum hose from the booster or intake manifold,

i.

Disconnect the 2 ground connectors from the transaxle attachment

as "disconnect the exhaust system" or "remove the radiator."

is

II

impossible to

virtually

list

In

most

each individual wire and hose which must

be disconnected, simply because so many

different

model and engine com-

common

binations have been manufactured. Careful observation and

studs

sense

are the best possible approaches to any repair procedure.

Removal and

if

you follow

If

•

you have

to drain

any

use a suitable container.

of the fluids,

Always tag any wires or hoses and,

came from

connectors.

if

components they

possible, the

before disconnecting them.

Because there are so many bolts and fasteners involved, store and

•

access

If

wait until the vehicle

is difficult,

electrical

and

safely raised

is

supported, then unplug the connections from underneath the vehicle:

these basic points: •

the rear side of the cylinder block,

Disconnect the following automatic or manual transaxle

6.

engine can be made easier

installation of the

at

Fuel injector electrical connectors.

j.

a.

The 3

b.

Valve body actuator connection.

c.

Turbine speed sensor

d.

Temperature sensor.

e.

For manual transaxles only, the reverse

neutral safety switch connectors.

"

labe< the retainers

from components separately

in

muffin pans, jars or cof-

fee cans. This will prevent confusion during installation. •

make sure

After unbolting the transaxle, always

it

properly sup-

ported. •

If

is

it

necessary to disconnect the

air

conditioning system, have this

service performed by a qualified technician using a recovery/recycling station.

and

the system does not have to be disconnected, unbolt the compressor

II

set

When

•

unbolting the engine mounts, always

When

properly supported.

any

lifting

that

if

make sure

devices are properly attached to the engine.

your engine

is

supplied with

lifting

hooks, your

It

the engine

make sure

removing/installing the engine,

apparatus be

Remove

the engine from

its

compartment

hoses, wires or other components are •

After the

Separate the fuel supply and return lines utilize fuel line

may be

tied to the

engine

is

clear of the

still

slowly, checking that

no

connected.

9.

of the

it

on an engine

On

connectors.

SA9157E

or

The

fuel spillage

lines

and

to

way

Disconnect the upper radiator hose and the cylinder head outlet and

the de-aeration hose at the engine. 10.

Remove

the serpentine drive belt

conditioning compressor from

«»lt is not

necessary

to

its

and

if

equipped, remove the

air

brackets and with the hoses attached. front

crossbar

discharge the A/C compressor during engine

removal, but be careful not

compartment, place

at their

disconnect service tool

master cylinder lines to help prevent

Support the compressor from the

attached to them. •

8.

equivalent. Plug the lines to prevent fuel contamination or loss.

recommended

is

lifting

switch) connectors.

Disconnect the accelerator cable assembly

1991-94 models,

is

that

(PRNDL

shift

7.

keep them out

aside.

it

The 2 gear

f.

is

light switch.

to kink,

damage

or rupture the refriger-

ant lines.

stand or workbench. •

After the

engine has been removed, you can perform a

teardown of the engine using the procedures outlined

partial or full

manual.

in this

1 1

If

equipped, disconnect the automatic transaxle cooler lines

back on the

Factory

Recommended Procedure

I See Figures

lines.

12.

Disconnect the automatic transaxle

shifter cables

»»The manufacturer recommends

removed as

that the engine

the

and transaxle be

a complete assembly. Disconnect the cradle and lower

the entire powertrain assembly, instead of lifting

Both the

cle.

Plug the openings to prevent

contamina-

fluid loss or

tion.

4 and 5

1. 2. 3.

at the

transaxle by pinching the plastic connector tabs and carefully pulling

SOHC and DOHC engines

are

It

out of the vehi-

removed

or installed in

same manner.

13.

If

shifter cable or the

manual

from the transaxle.

equipped with a manual transaxle, remove the 2 hydraulic slave

cylinder retaining nuts from the clutch housing studs, then slide the cylin-

der and bracket assembly from the studs. Rotate the clutch actuator V4 turn

counterclockwise while pushing toward the housing net connector

and remove

il

to

disengage the bayo-

from the clutch housing. Support the clutch

hydraulic system to the battery tray; being sure not to kink or pinch the 1.

Properly disable the SIR system,

if

equipped. Disconnect the negahydraulic lines.

tive

and then the positive 2.

battery cable.

14

Drain the engine coolant from the radiator and engine block into a

Using a length

of

an appropriate wire,

fan to the front crossbar. Route the wire

tie

the radiator,

condenser and

around the 2 fan shroud supports

suitable clean container

and the crossbar :•-::

When

CAUTION mind that cats and dogs are antifreeze, and are quite likely to

draining the coolant, keep

attracted by ethylene glycol

drink any that

is left in

in

an uncovered container or

the ground. This will prove fatal

in

it

is

Always

in sufficient quantity.

drain the coolant into a sealable container. Coolant

reused unless

puddles on

contaminated or several years

may be

old.

15

Raise and support the front end of the vehicle safely.

16

Remove

this

Pfopeny

relieve

Ifie luei

system pressure as directed

m

Section 5 of

17

4

Remove

Remove

the brake caliper bracket attaching bolts (2 on each side)

Do

not hang the assembly by the brake hose or

hydraulic system

may occur The

body when the powertrain

the complete air cleaner/intake duct assembly, as applicable.

is

damage

springs and shocks

wire.

to the brake

will

remain with the

lowered

Disconnect the struts from the knuckles on each side

(2 bolts per side)

This will allow the knuckle and

with the powertrain cradle

manual.

and remove the fasteners connecting the

and hang the caliper assemblies from the shock tower springs using

18 3

the front wheels

side and front fender shields to the cradle.

when lowered The

of the vehicle

hub assembly

stabilizer bar will

attached to the cradle and the lower control arms

to

remain

remain

ENGINE AND ENGINE OVERHAUL Using a suitable hose clamp

19.

tool,

3-7

disconnect the lower radiator and

heater return hoses from the engine. Disconnect the heater inlet hose at the

dash or the engine.

front of the

Disconnect the steering shaft and pressure switch connectors

20.

at

the

gear, as applicable.

Disconnect the front exhaust pipe

21

and powertrain

at the

manifold, catalytic converter

stiffening bracket.

For 1991 vehicles, remove the powertrain stiffening bracket bolts,

22.

except the 3 bolts holding the torque resistor bracket to the transaxle.

24.

Remove Remove

25.

Label and disconnect

23.

the flywheel cover

and

the alternator

all

and torque converter

bolts,

if

equipped.

starter shields.

and vacuum con-

the remaining electrical

nectors from the following components: a.

Unplug the connectors from the

b.

The alternator

c.

Oil

d.

Knock sensor.

e.

Crankshaft position sensor.

f.

If

field

starter

solenoid and the battery feed.

and battery feed connectors.

pressure sensor.

equipped, the

EVO

Fig.

solenoid.

h.

Canister purge solenoid.

i.

Powertrain Control IVIodule

j.

If

equipped, the

ABS

3 For 1991 vehicles, remove the powertrain stiffening

remove the 3

bracket, but do not

g. Vehicle speed sensor.

bolts attaching the torque

restrictor bracket to the transaxle

(PCM) and Oxygen

sensor.

wheel sensor connector grounds.

26.

Unclip the brake lines from the rear side of the cradle.

27.

Carefully

remove the

harness from the engine and

electrical

on top

transaxle, then lay the electrical harness

of the

underhood junction

block and battery cover. 28.

X

1

in.

For

1992-98

X 2

in.

vehicles with a torque axis

wood between

long block of

ease removal and installation

and cradle

Remove

torque engine mount.

of the

upper engine torque axis

right side

mount system, place

the torque strut

to front

wood under

1

in.

to

the 3

cover nuts and the 2 mount to

wood.

midrail bracket nuts, allowing the powertrain to rest on the block of

p»Placing a block of

a

the torque axis

mount

prior to

removing the upper mount will allow the engine to rest on the wood, thus preventing the engine from shifting. If the engine is not to be removed from the cradle, this will allow you to install the engine and the upper mount without jacking or raising the engine. 29. in.

Place a powertrain support dolly under the cradle. Use two 4

X 36 30.

pieces of

in.

Remove

wood

x 4

in.

support the cradle on the dolly.

to

the 2 right side front engine

mount torque

strut bracket-to-

cradle nuts.

Remove

31

plete powertrain

Fig. 1

Unfasten the ground connectors from

ttie

transaxle attach-

the

4 cradle attaching bolts and

carefully lower the

assembly from the vehicle. Verify

that

com-

necessary com-

all

ponents are disconnected and free before complete removal.

ment studs

32. cradle.

Attach the 2 washers, located between the cradle and

They must be repositioned and

33.

Disconnect the spark plug wires

34.

If

remove

applicable,

the

body

to the

installed during cradle installation. at

the ignition module.

power steering pump and

bracket. Support

the assembly, in an upright position, from the cradle or the steering gear.

a suitable engine

35.

Install

36.

Remove

the front

restrictor bracket,

37.

Place a V2

remove the

DOHC

starter

if

device to the service support brackets. the motion

applicable.

in.

x

1

x 3

in.

in,

support bracket

block of

wood under

bolt, intake

the axle shaft

and

manifold support brace (on

engines), and 3 axle shaft bracket support bolts. Allow the bracket to

rotate rearward. Lift the

38.

lifting

mount assembly and disconnect

engine slightly

as necessary.

for clearance,

For 1991 vehicles, remove the front engine

mount assembly and

disconnect the motion restrictor cable used with the

DOHC

engine and a

manual transaxle. 39.

X 4

in.

40. strut

For

1992-98

X 6

in.

For

1992-98

from the front

necessary Fig. 2

Remove

the 2 caliper bracket bolts and the 2 strut-to-

Icnuckle attaching bolts in order to free the knuckle

assembly

and hub

41

for

vehicles with a torque axis

long block of

wood under

vehicles,

of the

remove the engine

engine as an assembly

strut bracket

the 4 transaxle attaching bolts/studs

(100mm) forward

in

in.

and torque

the engine slightly as

Lift

removal.

Remove

assembly f^anual transaxles in.

mount system, place a 4

the transaxle housing for support.

will require the

engine

and separate the to

be

moved about 4

the cradle to disengage the input shaft.

3-8

ENGINE AND ENGINE OVERHAUL

n\

ENGINE AND ENGINE OVERHAUL Disconnect the front exhaust pipe

16.

Alternative Procedure

and powertrain

do not remove the 3 bolts holding the torque

engine should be removed following the factory recommended procedure.

transaxle.

may be

*»lt

Remove

18.

similar manner, but the engine will most

19.

Remove Remove

20.

Label and disconnect

in a

likely not clear the input shaft of the transaxle: in this case, the

complete engine/transaxle assembly must be removed. In order to do that, you must remove any components which may inhibit the transaxle, such as the brake master cylinder and booster, air

Properly disable the SIR system,

and then

tive

if

3.

Drain the engine coolant from the radiator and engine block into a

:•"::

When

c.

Crankshaft position sensor.

d.

EVO

e.

Canister purge solenoid.

in

mind

and dogs are

that cats

an uncovered container or

is left in

the ground. This will prove fatal

Remove

4.

Section 2.

vacuum con-

equipped).

(if

Powertrain Control Module

g.

ABS

(PCM) and oxygen

wheel sensor connector grounds

(if

sensor.

equipped and necessary).

away from

Carefully position the electrical harness

Always

the engine

and

and fan assembly. Refer

to the

may be

procedures

For

1992-98

X 2

in.

vehicles with a torque axis

long block of

wood between

ease removal and installation

of the

mount system, place a and cradle

the torque strut

Remove

torque engine mount.

1

in.

to

the 3

upper engine torque axis-to-front cover nuts and the 2 mount-to-

midrail bracket nuts, allowing the powertrain to rest

on the block

wood.

of

«»Placing a block of wrood under the torque axis mount prior to

removing the upper mount will allow the engine to rest on the wood, thus preventing the engine from shifting. If the engine is not to be removed from the cradle, this will allow you to install the engine and the upper mount without jacking or raising the engine.

contaminated or several years old.

the radiator

in.

1

right side

puddles on

in

in sufficient quantity.

drain the coolant into a scalable container. Coolant is

solenoid

f.

22.

draining the coolant, keep

it

bolts.

in

pressure sensor.

Knock sensor.

21

X

attracted by ethylene glycol antifreeze, and are quite likely to

reused unless

vehicles,

transaxle.

CAUTION

drink any that

as described

the remaining electrical and

all

Oil

the hood. Refer to Section 10.

suitable clean container.

starter,

b.

the positive battery cable.

Remove

and

a.

equipped. Disconnect the nega-

2.

and torque converter

the flywheel cover the alternator

On 1991

resistor bracket to the

nectors from the following components:

cleaner housing, battery tray, etc. 1

the powertrain stiffening bracket bolts.

possible to remove the engine on manual transaxle-

equipped vehicles

manifold, catalytic converter

at the

stiffening bracket.

The following procedure applies only to Saturn vetiicles equipped witti an automatic transaxle. For vehicles equipped with a manual transaxle, the

17.

3-9

in

this section.

Properly relieve the fuel system pressure, as described

5.

in

Section 5

Remove

6.

the complete air cleaner/intake duct assembly, as applica-

If

24.

Detach and label the following

7.

DOHC

connections and vacuum

electrical

of the way, in

Place a Vz starter

in.

x

a.

Coolant temperature sensor(s).

b.

Oxygen sensor and

c.

Idle Air Control (lAC) valve.

mount

and carefully

ets

bracket.

in.

block of

wood under

bolt, intake

engine slightly lifting

for clearance,

raise the hoist to relieve the

engine weight from

26.

module connector(s).

Remove

the 2 right side front engine

mount torque

Ignition coil

f.

Manifold Absolute Pressure (M^P) sensor

27.

Disconnect the spark plug wires

g.

Exhaust Gas Recirculation (EGR) solenoid.

28.

Support the transaxle assembly with a floor

h.

Brake booster vacuum hose from the booster or intake manifold,

29.

Remove

i.

2 ground connectors from the transaxle attachment studs

at

30.

X 4

8.

Disconnect the accelerator cable assembly.

9.

Separate the fuel supply and return lines

at their

31

disconnect service tool

SA9157E

equivalent. Plug the lines to prevent fuel contamination or loss.

keep them out 10.

lines

and

to

at

outlet,

and the

conditioning compressor from

compressor from the

1992-98 in.

For

1992-98

from the

its

if

equipped, remove the

air

brackets with the hoses attached. Support

32.

necessary to discharge the A/C compressor during engine

damage

or rupture the refriger-

ant lines.

To

Raise and support the front end of the vehicle safely.

13.

Remove

the passenger side front wheel

Remove

15.

Using a suitable hose clamp

and remove the fasteners

wood under

vehicles,

mount system, place

a 4

remove the engine

engine as an assembly.

strut bracket Lift

and torque

the engine slightly as

the

4 transaxle attaching bolts/studs and separate the

lift

the engine from the vehicle.

Installation of the

engine

is

the reverse of the removal procedure.

35.

Before lowering the engine into the vehicle, ensure that the torque in

the transaxle

is fully

seated.

Position one of the bolt holes on the torque converter facing straight

down. Also,

rotate the

engine so as to position one of the flywheel-to-

torque converter bolt holes facing straight down.

When mating

38.

Install all

the engine to the transaxle, ensure that the locating

fully seated.

the engine-to-transaxle bolts. Then, install the motor mounts.

fasteners to the proper torque specifications. Refer to the specifi-

cation charts in this section.

remove the lower

radiator

in.

the transaxle housing for support.

However, please note the following steps:

Tighten

the crankshaft pulley. tool,

vehicles with a torque axis

front of the

Carefully

dowels are

connecting the side and front fender shields to the cradle. 14.

the motion

install:

37.

12.

jack.

mount assembly and disconnect

long block of

Remove

converter

front crossbar.

removal, but be careful not to kink,

the ignition module.

transaxle assembly.

36. «»lt is not

at

applicable.

For

34.

the engine.

the serpentine drive belt and,

if

x 6

33.

of the way.

Remove

strut bracket-to-

necessary for removal.

or

The

fuel spillage

Disconnect the upper radiator hose and cylinder head

de-aeration hose 11.

master cylinder lines to help prevent

in.

strut

On

connectors.

the front

restrictor bracket,

the

Fuel injector electrical connectors.

tied to the

its

cradle nuts.

Sensor (TPS).

rear of the cylinder block,

may be

as necessary.

mounts.

Throttle Position

utilize fuel line

and

device to the engine service support brack-

e.

1991-94 models,

the axle shaft

manifold support brace (on

d.

j.

Support

engines), and 3 axle shaft bracket support bolts. Allow the bracket to

25. Attach a suitable

clip at the transaxle front

x 3

in.

1

bracket.

an upright position.

support bracket

rotate rearward. Lift the

as applicable:

lines,

remove the power steering pump and

applicable,

assembly out

remove the

ble.

the

23. the

manual.

of this

hose

39.

After

all

and disconnect the heater return hoses from the engine. Disconnect the

and

heater inlet hose at the front of the dashboard or engine.

transaxle and

hoses, lines, and connections are installed,

radiator with the proper type

power steering

and quantity

fluid levels.

fill

of fluids, then

the engine

check the

Adjust as necessary.

ENGINE AND ENGINE OVERHAUL

3-10

Rocker Arm (Camshaft/Valve) Cover REMOVAL & INSTALLATION SOHC

Engine

I See Figures 6, 7 and 8 Disconnect the negative battery cable. Remove the

1

assembly and

Disconnect the

2.

hoses or

cleaner

PCV

valve, fresh air

hose and any remaining vacuum

connectors from the valve cover.

electrical

Remove

3.

air

air inlet duct.

the 2 fasteners

and washers from the silicone insulators

located in the top of the valve cover.

Disconnect the de-aeration

4.

(located at

handy

to

The

line.

one end

of the cover)

line

wipe up the small amount

MAP

from the cylinder head outlet

and from the support of

bracket.

Have a rag

may escape from the and de-aeration line may

coolant which

sensor (1991-94 models only)

remain attached to the cover. Carefully

5.

Fig.

remove the valve cover and gasket from the engine.

If

7 Disconnect the de-aeration hose from the cylinder head

the

and the support bracket, but

it

may remain

attached to the cover

come off easily, tap the sides gently with a rubber mallet to cover. Do not pry against the mating surfaces or damage may

cover does not

loosen the

occur

To

install:

Inspect the silicone insulators located in the valve cover fastener

6

bores and replace

If

is

it

if

cracked or deteriorated.

Inspect the valve cover gasket which

7.

damaged,

remove

or

if

replacement

the gasket from the cover

is

is

bonded

to the cover flange.

necessary to assure a proper

seal,

and clean the old RTV from the flange

surface using a chlorinated solvent and a wire brush

Most carburetor

cleaners or brake clean solvents should be appropriate. 8.

RTV

If

the gasket

is to

be replaced, apply a thin 0.08

to the cover flange. Firmly press the

flange and install the cover while the

bond.

NOT

RTV

flat

in.

(2mm) bead

of

side of the gasket into the

is still

wet to assure a proper

only be placed between the cover flange and gasket, but

RTV should

onto the cylinder head mating surface, so that the gasket

will

separate

from the head easily and may be reused.

Apply a small 0.2

9.

joints

in.

(5mm) bead

where the head meets the

the only spot where

RTV

will

of

RTV

front cover to

to the cylinder

assure a good

head T-

seal. This is

be placed between the cylinder head and the

cover gasket. 10.

Install the

valve cover and gasket, then install the washers and fas-

teners. Tighten the fasteners to line to the

22

ft

lbs

(30 Nm). Connect the de-aeration

support bracket and to the cylinder head.

1 1

Conned

hoses or 12.

the

electrical

PCV

Install the air

hose and any remaining vacuum

to the valve

cleaner assembly and

tighten the fasteners.

DOHC

valve, fresh air

connectors

cover air inlet duct,

then carefully

Connect the negative battery cable.

Engine

I See Figures 9 thru 16 1

Disconnect the negative battery cable.

2

Disconnect the fresh

air

hose from the cover

fitting

and the

PCV

valve from the cover grommet. 3.

On 1991-94 models, disconnect the vacuum hose and electrical EGR solenoid located at the end of the camshaft cover,

connector from the near the

EGR

valve

and

the engine lifting bracket

f»On 1991-94 models, it it is preferred or necessary, the bolt may be removed from the EGR solenoid to disconnect the solenoid from the camshaft cover. 4.

The

illegible or

Fig.

6

Remove

the air cleaner

cables or wires that

may

assembly along with any hoses,

interfere

original spark plug wires are if

numbered,

if

the

numbers are

the wires have been replaced with non-labeled parts, tag the

wires for installation purposes. Disconnect the spark plug wires from the

plugs

ENGINE AND ENGINE OVERHAUL Remove

5.

the fasteners, wastiers and insulators, then

camshaft cover and gasket from the engine.

Do

sides gently using a rubber mallet.

not

the cover

If

damage

the

is

3-11

remove the

stuck, tap the

aluminum

cylinder

head by prying the cover loose.

To

install:

Inspect the silicone insulators through which the camshaft cover

6.

fasteners are installed and replace

flange. seal,

cracked or deteriorated.

if

Inspect the camshaft cover gasket vi/hich

7.

If

it

damaged, or

is

if

replacement

is

is

bonded

necessary

to

to the

cover

assure a proper

remove the gasket from the cover and clean the old RTV from the Most carbure-

flange surface using a chlorinated solvent and a wire brush. tor cleaners or brake clean solvents 8.

RTV

If

the gasket

to the

is to

should be appropriate.

be replaced, apply a thin 0.08

cover flange. Firmly press the

flat

in.

(2mm) bead

of

side of the gasket into the

RTV is still wet to assure a proper RTV should only be placed between the cover flange and gasket, but

flange and install the cover while the

bond.

NOT

onto the cylinder head mating surface, so that the gasket

will

separate

from the head easily and may be reused.

Apply a small 0.2

9.

joints

in.

(5mm) bead

where the head meets the

Ihe only spot

where RTV

will

of

RTV

front cover to

to the cylinder

head T-

assure a good seal. This

is

be placed between the cylinder head and the

Fig. 11 Lift the

cover

is

camshaft cover from

stuck, tap

it

tlie

top of the engine.

If

the

with a rubber mallet

cover gasket.

Fig. 9

Loosen the camshaft cover retaining fasteners with a

Torx® driver

Fig.

10 Remove the camshaft cover fasteners, washers and

insulators.

necessary

Examine

for cracks or deterioration

and replace,

if

Fig.

13 Examine the camshaft cover gasket material

deterioration, and replace

if

necessary

for signs of

ENGINE AND ENGINE OVERHAUL

3-12

Fig.

14

II

gasket replacement

is

necessary, carefully remove the

old gaslcet from the camshaft cover surfaces

Fig.

15 Exploded view

assembly

of the

DOHC

camshaft cover and gasket

ENGINE AND ENGINE OVERHAUL

3-13

o^v;

18 The rocker arm tangs or slots must be properly posi-

Fig.

tioned on the plungers and the springs must be positioned on the guide plate slots to prevent valve or piston

Apply a small drop

9.

Inspect the rocker

joint.

the gasket and rocker ft.

to

Fig.

if

all

.

.

.

necessary. Install

cover, then tighten the fasteners uniformly to

sure

19 Loosen the thermostat housing bolts

each cylinder head and front cover T-

arm cover gasket and replace

arm

Make

(30 Mm).

lbs.

RTV

of

damage

22

cover hoses and components are recon-

nected after installation.

Connect the negative battery cable,

10.

start the

engine and check for leaks.

Thermostat

REMOVAL & INSTALLATION I See Figures 19 thru 24 1

Make sure

.

the engine is cold,

AJJ^"

and position a suitable clean drainpan

^

under the radiator and engine drains. Open the radiator dram and remove the engine drain plug located at the front right of the engine, draining the

coolant into the container ::"•:

When

CAUTION

draining the coolant, keep

in

mind

that cats

and dogs are

attracted by ethylene glycol antifreeze, and are quite likely to

drink any that

is left in

an uncovered container or

puddles on

in

the ground. This will prove fatal in sufficient quantity. Always

drain the coolant into a sealable container. Coolant

reused unless

is

it

may be

contaminated or several years old.

2.

Disconnect the lower radiator hose from the thermostat housing.

3.

Remove

the 2 bolts from the water inlet housing, then

remove the

housing and thermostat assembly. Remove and discard the 0-ring from the mating surface.

Remove

4.

the thermostat from the housing using the tool provided

with the replacement thermostat element.

To

install:

«»The thermostat with

oil.

oil is

If

will not function correctly

found

in

if

it

has come

in

contact

the cooling system at any time, both the

thermostat cartridge must be replaced and the cooling system must

be flushed. 5.

Install the

careful not to

replacement thermostat using the tool provided, being

damage

or scratch the

aluminum

ment's retaining tangs are properly seated ton

is

6.

in

surface.

the 2 legs

Make

sure the ele-

and the element pis-

correctly positioned in the inlet housing. Install

a

new 0-ring and

the retaining bolts to

22

ft.

lbs.

position the housing to the engine. Tighten

(30 Nm).

Fig.

20

.

.

.

then remove each bolt from the engine block

ENGINE AND ENGINE OVERHAUL

3-14

Close Ihe radiator drain plug and

7

26

plug. Tighten the block plug to

hose

lbs.

ft.

install the cylinder

block drain

(35 Nm).

to the inlet housing.

8.

Install the

9.

Connect the negative battery cable and properly

fill

the engine cool-

ing system.

Run

10.

the engine

to the

is filled

proper

and check

for leaks.

Make

sure the cooling system

level.

Intake Manifold REIV10VAL

SOHC I

& INSTALLATION

Engine

See Figures 25, 26 and 27 Disconnect the negative battery cable and drain the engine coolant

1.

from the radiator and engine block,

into a suitable container.

Remove the air cleaner, disconnecting Remove the PCV tube and hose.

2 cover.

the fresh air tube at the valve

3.

Properly relieve the fuel system pressure

4.

Remove the retaining screw from On 1991-94 models, disconnect

5.

the fuel supply

fuel

of the retainer

On 1991-94 models, using Plug the line(s)

8.

Disconnect the

throttle

On

throttle

to prevent fuel

throttle

and

pulling.

a backup wrench, disconnect the steel

supply and return lines from the 7.

return lines at

or equivalent.

Ihe fuel line(s) at the quick-connect fitting(s)

by compressing the two tangs 6.

and

SA9157E

the close-coupled connectors using service tool

1995-98 models, disconnect

the test port.

at

the fuel line retaining bracket.

body

unit.

contamination or loss.

cable from the throttle body, then remove the

cable bracket attaching nuts and position the assembly aside. Label and disconnect the wiring from the intake manifold, throttle

9.

body and valve cover components, as follows: a.

The

b.

Idle Air

c.

Throttle Position

d.

Exhaust Gas Recirculation (EGR) valve.

fuel injector.

Sensor (TPS).

Manifold Absolute Pressure (MAP) sensor.

e.

Remove

10.

Control (lAC) valve.

and

the wiring tube

lay the

harness away from the manifold

Hood Junction Block (UHJB). 1 1 Label and disconnect all vacuum hoses from Disconnect the vacuum line from the brake booster.

onto the Under

Fig.

23 Use the tool provided

in ttie

replacement

kit to

remove

the old thermostat from the housing

body

unit.

Disconnect the heater hose from the intake manifold and the de-aer-

12.

Remove

ation line fitting at the cylinder head coolant outlet.

and

the throttle

onto the coolant

lay the line

Remove

13 starter.

If

the intake manifold support bracket bolt located next to the

the serpentine drive belt, then

pump

pump and

support the

away from

the intake manifold

Remove

15. throttle

clamps

necessary, the bolt can be removed from below the vehicle.

Remove

14.

the 2

bottle.

remove the power steering

next to the right side dash panel sufliciently

and cylinder head.

the manifold retaining nuts, then

nuts from under the

remove the manifold and

may be much easier to access the lower manifold vehicle. Remove and discard Ihe old gasket from the

body assembly

It

mating surfaces.

^^

To

install:

16

age

Thoroughly clean

or score the

lent to seal the

k Fig.

17

V

its

lbs.

24 Unlike most thermostats which

engine block, the Saturn thermostat

own

spring tension

new PCV

Position the

Tighten the nuts

18

is

sit in

the housing or

secured

to the

housing by

all

aluminum

Install the

in

new

gasket mating surfaces. Be careful not to surface.

If

replaced, use Loctite*

290

dam-

or equiva-

valve inlet tube into the manifold. gasket, then install the manifold and retaining nuts.

sequence

to

22

ft.

lbs (30

Nm).

power steering pump and lighten the fasteners

to

27

ft

(38 Nm).

19

Install the

20.

Connect the coolant hose, the de-aeration

serpentine drive

belt.

line

the manifold support bracket bolt Tighten the bolt to

21

engine

and clamps, then

22

ft

lbs.

install

(30 Nm).

Lubricate the male ends of the fuel lines with a few drops of clean oil,

then connect the fuel supply and return lines.

ENGINE AND ENGINE OVERHAUL On 1991-94 models connect

22.

and tighten the

fittings to

ft.

lbs.

to

36 inch

lbs. (4

body

the fuel lines to the throttle

unit

(25 Nm).

fuel line(s) in the retaining bracket

Secure the

23.

mounting screw

19

3-15

and tighten the

Nm).

vacuum TPS and EGR

Reposition the wiring harness and connect the wiring and

24.

hoses

to their original locations.

The harness leads

to the

solenoid must be routed between the intake manifold runners.

Install the air

check

I

from these loca-

tions— 1991-94 SOHC engine

PCV

if

neces-

valve hose.

OFF

ft.

the engine cooling system. fuel

for

system by cycling the ignition switch

10 seconds and repeating 2 times.

ON

for

Start the

5 sec-

engine and

for leaks.

DOHC

electrical connections

Fill

Prime the

27.

25 Unfasten the

and replace,

engine block drain plug. Tighten the block drain plug to 26

(35 Nm).

onds, then

Fig.

unit gasket

cleaner and fresh air tubes, then install the

Connect the negative battery cable, close the radiator drain and

26.

install the lbs.

body

Inspect the air cleaner/throttle

25.

sary

Engine

See Figures 28

thru

45

Disconnect the negative battery cable and drain the engine coolant

1

from the radiator and engine block,

Remove

2.

camshaft cover

into a suitable container

the air inlet tube, disconnecting the fresh air tube at the Lift

upward

the resonator

service support bracket.

Remove

PCV

the

to

disengage

3.

Properly relieve the fuel system pressure

4.

Remove the retaining screw from On 1991-94 models, disconnect

5.

by compressing the two tangs

from the engine

at

the test port.

the fuel line retaining bracket. the fuel supply

the close-coupled connectors using service tool

1995-98 models, disconnect

it

valve and hose.

and

SA9157E

return lines at

or equivalent.

On

the fuel line(s) at the quick-connect fitting(s) of the retainer

6.

Plug the line(s) to prevent

7.

Disconnect the

fuel

from the

throttle cable

throttle cable bracket attaching nuts

and

pulling.

contamination or loss. throttle

body then remove

the

and position the assembly aside.

Label and disconnect the wiring from the intake manifold and sur-

8.

rounding components, as follows: a.

The

b.

Idle Air Control (lAC) valve.

c.

Throttle Position

d.

Manifold Absolute Pressure (IVIAP) sensor.

9.

fuel injectors.

Disconnect the heater and de-aeration hoses from the intake mani-

fold outlets.

The heater hose may be removed

Disconnect the Fig.

26 1991-94

SOHC

engine's intake manifold and gasket

10.

EGR

solenoid

vacuum

if

necessary.

intake manifold support bracket bolt attached to the manifold

next to the brake master cylinder

Upper

at the firewall,

hose.

Position the wiring harness over the brake master cylinder, then

remove the

mounting

Sensor (TPS).

ENGINE AND ENGINE OVERHAUL

3-16

Fig.

32 Remove the intake manifold support bracl(et bolt

manifold, near

1 1

Remove

ttie

at ttie

master cylinder

the serpentine drive belt.

Remove

the

power steering pump

assembly with Ihe support bracket, then remove the upper pump bracket attachment bolts and position the

pump away

from the manifold and cylin-

der head, near the right dash panel. 12.

Remove

the 3 upper intake manifold attachment nuts, then raise

support the front 13.

Remove

and

ol the vehicle safely.

the lower

power steering

unit support bracket.

Remove

the

intake manifold support bracket bolt located next to the alternator, then the

lower bracket boll and remove from the vehicle. 14.

Disconnect the canister purge solenoid and brake booster vacuum

hoses. 15.

Remove

remove the supports and

Ihe intake manifold attaching stud,

lower the vehicle. 16.

Remove

the remaining fasteners

and the intake manifold assembly,

then remove and discard the old gasket.

To 1

or

7

install:

Thoroughly clean the gasket mating surfaces. Be careful not to score

damage

the

aluminum sealing

surfaces.

If

installing a

aeration tube elbow into the manifold use Loclite* Fig.

30

.

.

.

and

pull

back

tfie

ftose

clamp,

tlien

disconnect

tfie

Position the

new

gasket, then install the intake manifold

ing nuts. Tighten the nuts in

Fig. 31

Disconnect the heater hose

at the firewall.

It

sequence

to

22

ft.

may be

easier to access the hose from underneath the vehicle

new coolant de-

or equivalent to

achieve a proper seal. 18.

hose from the intake manifold

290

Fig.

33 Remove the serpentine drive bell

lbs.

(30 Nm).

and

retain-

ENGINE AND ENGINE OVERHAUL

3-17

^i'^'Mf^'

Fig.

34 Remove the power steering pump-to-upper intake mani-

fold bracl(et bolt

Fig.

35 Access the power steering pump

bolts througli the pulley holes

front bracket attactiing

Fig.

38 Remove the

mounting

intalte

bolt, located

manifold support bracket's top

behind the alternator

.

.

.

I/.

Fig.

39

.

.

.

then, after removing the lower bolt,

support bracket from the vehicle

remove the

3-18

Fig.

ENGINE AND ENGINE OVERHAUL

40 Disconnect the brake power booster vacuum hose

at the

nipple on the Intake manifold, between the manifold and firewall

Fig. 41

Remove

the intake manifold attaching stud

ENGINE AND ENGINE OVERHAUL 28

power steering pump and brackets. Tighten the fasteners

Install the

19. to

ft.

lbs.

(38 Nm).

Install the

20.

3-19

serpentine drive belt making sure the belt

is

properly

aligned on the pulleys. line to the manifold.

21.

Connect the heater hose and de-aeration

22.

Position the manifold support brackets and install the bolts.

Tighten the right block bolt to 41

ft.

lbs.

(55 Nm), then tighten the

block bolt and the support bracket to intake manifold bolts to 22

left

lbs.

ft.

(30 Nm). Lubricate the male ends of the fuel lines with a few drops of clean

23.

engine

oil,

then connect the fuel supply and return lines. fuel line(s) in the retaining bracket

Secure the

24.

mounting screw

to

36 inch

Connect the

25.

lbs. (4

throttle cable to the throttle

body and

bracket. Tighten the bracket retaining bolts to 19

Position the wiring harness and connect

and vacuum hoses

ft.

lbs.

install

the support

(25 Nm). Verify that

engaged when assembled.

the cable locking tangs are fully

26.

and tighten the

Nm).

all

electrical

connectors

in their original locations.

PCV

hose, the

tube and resonator.

27.

Install the

28.

Connect the negative battery cable, close the radiator drain and engine block drain plug. Tighten the block drain plug to 26

install the lbs.

(35 Nm).

onds, then

check

Fill

Prime the

29.

air inlet

OFF

Fig. ft.

47 Remove the pipe-to-manitold nuts

in

order to separate

the flanges

the engine cooling system. fuel

for

system by cycling the ignition switch

ON

for

5 sec-

10 seconds and repeating 2 times. Start the engine and

for leaks.

Exhaust Manifold

REMOVAL & INSTALLATION I See Figures 46 thru 56 1

Disconnect the negative battery cable, then raise and support the

vehicle safely using suitable jackstands. 2.

If

equipped, remove the two front exhaust pipe to engine support

bracket mounting fasteners. 3. 4.

Remove Remove

»When

the pipe-to-manifold nuts

the supports

and lower the pipe.

and lower the

performing the next step, do

vehicle.

NOT

disconnect the refrigerant

lines. 5.

If

equipped, remove the

from the engine, which

air

will first

conditioning compressor and bracket

require the removal of the serpentine belt,

Fig.

46 Remove the

mounting fasteners

front

Fig.

48 Pull down

slightly to separate the front pipe

from the

intake manifold

then position them aside.

exhaust pipe-to-engine support bracl(et

Fig.

49 Remove the A/C compressor mounting bracket bolts

the front of the engine

.

.

.

at

ENGINE AND ENGINE OVERHAUL

3-20

Fig.

50

.

.

.

and on the side, then move the compressor away

Fig. 51

Using a heavy wire hanger, or equivalent, secure the

A/C compressor

Fig.

53

.

.

.

and separate the exhaust maniioid Irom

tlie

cylm-

der head

from the engine

to the front

engine compartment crossmember

Fig.

54 Remove and discard the exhaust manifold-to-cylinder

head gasket. Be sure

Fig.

to

clean the gasket mating surfaces

55 Remove and discard the

flange gasket

front pipe-to-exhausi

manifold

ENGINE AND ENGINE OVERHAUL

3-21

ENGINE AND ENGINE OVERHAUL

3-22

Fig.

59

.

.

.

then disconnect the upper coolant hose from the

radiator

2.

Remove

the air intake ducts

connector, then remove the 3. If

air

and disconnect the temperature sensor

cleaner housing.

Loosen the clamp and disconnect the upper hose from the

radiator.

equipped with an automatic transaxle, disconnect the upper transaxle

fluid cooler line.

Plug the openings to prevent transaxle

fluid

contamination

or loss. 4.

Remove

5.

Loosen the clamp and disconnect lower hose from the

6.

Raise and support the front of the vehicle safely using suitable jack-

the electric cooling fan assembly. radiator.

stands. 7.

Disconnect the fasteners, the carefully lower the splash shield from

the vehicle to gain access 8.

If

lower transaxle cooler

9

below the

radiator.

equipped with an automatic transaxle, disconnect and plug the

Remove

line.

the 2 condenser bracket-to-radialor bolts from either side of

the radiator. Wire the condenser to the frame

assembly

to

keep

it

in place,

then remove the supports and carefully lower the vehicle.

10

Remove

the upper radiator nuts

and brackets On

equipped vehicles, remove the upper radiator Fig.

60

If

equipped with an automatic transaxle. loosen the

cooler line

Fig. 61

.

.

fitting at

.

the radiator

.

.

.

then disconnect the transaxle cooler line from the

radiator. Plug the line to prevent fluid loss

1

Carefully

lift

the radiator from the vehicle.

drain housing tabs and withdraw

Fig.

it

air

conditioning

seal. If

from the bottom

necessary, squeeze the of the radiator.

63 Disconnect the fasteners and carefully lower the splash

shield from the vehicle

ENGINE AND ENGINE OVERHAUL

Fig.

64

If

equipped with an automatic transaxle, loosen the

lower cooler line

fitting at

the radiator

.

.

.

3-23

ENGINE AND ENGINE OVERHAUL

3-24

To

install:

12

new

inslalling a

if

tiousing

is in

position.

ing, insert the old drain

into position

Be

If

radiator

on 1991-93 models, make sure the drain

the replacement did not

housing

into the radiator

careful not to press the

come

with a drain hous-

and press

until

it

snaps

housing through the hole and

into

the radiator tank. Install the radiator into the vehicle. Install the

13. ble,

to

upper

seal,

if

applica-

then install the brackets and retaining nuts. Tighten the retaining nuts

89 inch

lbs

(10

Nm) Be

radiator locating pins

and

sure the L-shaped brackets do not pinch the

that the radiator

moves

freely in the

grommets.

14.

Raise the front of the vehicle and safely support using jackstands.

15.

Install the

plugs and

condenser bracket

install the

denser bracket bolts cooler line to 20

to

lbs.

ft.

bolts, then

if

applicable,

lower automatic transaxle cooler

53 inch

lbs. (6

Nm) and

line.

remove the

Tighten the con-

the lower transaxle

oil

(27 Nm).

16.

Install the

splash shield, remove the supports and lower the vehicle.

17.

Install the

lower radiator hose with the clamp tangs positioned

18.

Install the

cooling fan assembly

19.

For 1991 vehicles with an automatic transaxle, connect the upper

at

11

o'clock.

transaxle cooler line and tighten. For

1992-98

vehicles with an automatic

transaxle, connect the upper transaxle cooler line at a

35 degree angle

SECTION A-A

Fig. 71

A

dirt

covered radiator, such as this one, should be

sprayed with a garden hose

Fig.

73

Make

sure the L-shaped brackets do not pinch the radia-

tor locating pins

Fig.

74 Pinch the drain housing tabs closed and remove by

pulling straight

out— 1991-93 models

ENGINE AND ENGINE OVERHAUL

Fig.

75 Exploded view

of the drain plug

3-25

and housing— 1991-93

models

Fig.

76 For 1992-98 models equipped with automatic

transaxles, install the upper transaxle fluid cooler line as

Fig.

shown

inward from vertical and hold while tightening. Tighten the lower transaxle oil

cooler line to 20 20.

Install the

ft.

lbs.

(27 Nm).

upper radiator hose with the clamp tangs

at 1 o'clock.

Tighten the hose clamp to 31 inch lbs. (3.5 Nm). 21

Install the air

22.

Install

23.

Close the radiator drain plug and

cleaner housing.

the intake air ducts

plug. Tighten the block plug to

24.

and connect the

26

ft.

air

install the

temperature sensor plug. cylinder block drain

(35 Nm).

lbs.

Connect the negative battery cable and properly

fill

the engine cool-

ing system. 25.

Start

and run the engine

Electric Cooling

to

check

for coolant leaks.

Fan

REMOVAL & INSTALLATION I See Figures 77, 78, 79 and 80 1.

Disconnect the negative battery cable.

2.

Remove

the air cleaner/intake duct

lure sensor connector.

assembly and unplug tempera-

78

.

mounting

.

.

then remove the top,

bolt

left

side fan motor assembly

ENGINE AND ENGINE OVERHAUL

3-26

?.

IMBVCOO A«CTDN tUXX

t'

'

m 80

Fig.

.

'•!

m

.to disengage the fan motor connector and remove

.

the assembly from the vehicle inUlIS 1

3.

Unplug the wiring harness from the

4.

Remove

5.

equipped with

I(

be necessary it

assembly

the top fan motor

to

motor

ian

.

axuc

electrical connector.

I

bolt(s).

conditioning and an automatic transaxle.

air

!•!

HI "\JL

loosen the top automatic transaxle cooler

line

it

Kc ncix

may

and position

aside (or clearance. 6.

assembly

the fan

Lift

assembly

to the left

and

past the radiator hose, then 7.

I(

lower mounting brackets.

off the

remove the assembly from the

the

up

vehicle.

necessary, remove the fan blade and motor from the shroud:

Hold the fan and remove the left-hand threaded

a.

Move

rotate counterclockwise lifting the right side

nut, then pull the

fan from the motor shaft.

b

Remove

c

Separate the motor from the shroud.

To

the motor

mounting screws.

install:

8

removed,

It

threaded fan nut to

9

install the

27-44

motor and fan blade. Tighten the left-hand

assembly with the lower

Install the

Fig. 81 Cooling fan electrical

inch lbs. (3-5 Nm).

bly clockwise to place the lower

left

left

corner

mount under

1st.

the lower radiator hose

4.

and position the assembly onto the mounting brackets. 10.

Install

11.

disconnected,

If

cooler

and tighten the upper retaining

line.

install

53 inch

lbs. (6

fitting to

22

lbs.

ft.

Nm).

12

Install the

13.

If

fluid

4

b

If

DVOM

cleaner/intake air duct assembly and the

Connect the negative battery cable

there still

at

terminal

conducting tests on the electric cooling fan and

Ohm

Meter

(DVOM)

is

circuit,

use

Check the 30 amp cooling

II

there

is

no open and voltage

If

is

no voltage

the

at

B

connected to terminal

wire, turn the engine

B.

unplug the

PCM

PCM

OFF

there

is

no voltage

PCM

is

terminal

at the

and with the

connector

connect a

DVOM

is

1

COOL FAN)

J2A03 (DRK GRN/WHT)

connector, the fan relay

is faulty.

to

2 in the

to the 2 wires

underhood junction block Connect the negative

II

the

motor

to

see

3 in

if

it

still

applied.

battery cable

operates

the motor operates with the relay removed, a short to

BLK/RED

wire (1991-94) or

underhood junction block

power

exists

LIGHT BLUE wire (1995-98) from

If

the fan

to the (an

the

motor

does not operate with the

relay

removed, substitute a new

order to prevent relay

and releasing

is

or

ground

the air conditioning system from overpressurizing

there is

Disconnect the negative battery cable and remove the cooling fan

relay from the

and inspect

Disengage the A/C compressor clutch connector

If

bad

in the

B wire (BLK/RED on 1991-94 models

LIGHT BLUE on 1995-98 models)

a

Coaling Fan Constantly On Test

OK, disconnect the cooling fan motor connector and

from terminal

Install

connector terminal and ground:

The fan motor may also be checked by jumping 12 volts

underhood junction block. the fuse

is

of a

necessary.

tan maxifuse (labeled

A (BLK)

Repair the open wire or replace the

faulty.

1995 models— PCM terminal J2A03 (DRK CRN) 1996-98 models— PCM terminal J1C01 (DRK GRN)

6.

Cooling Fan Inoperative Test

3

ON

open

(A = negative, B = positive) The motor should run while voltage

high impedance Digital Volt

If

for

1991-94 models— PCM

5

See Figure 81

2.

check

•

voltage, the

1

conditioning

.

.

When

must be

jumper wire between the following

TESTING I

air

wire,

faulty motor, as applicable.

temperature sensor connector 1

B

voltage at the

is

present, the motor

wiring harness plug to the fan motor electrical connector install the air

there

erwise good motor from operating

(27 Nm). For

position the transaxle cooler line 35 degrees inward from

removed,

If

wire to ground which would prevent circuit completion and keep an oth-

and hold while tightening.

vertical

engine and turn the

Start the a.

and tighten the automatic transaxle

Tighten the cooler line

1992-98 vehicles

bolt(s) to

schematic

Rotate the assem-

refrigerant

and watch

DRK GRN/WHT

for

or

operation

DRK GRN

If

the fan operates with a

If

new

relay,

wire for a short to ground and repair,

from the pressure valve a short does not exist, yet the fan operates, the

PCM

check the if

found.

is likely at fault

ENGINE AND ENGINE OVERHAUL

MP

Water Pump REMOVAL & INSTALLATION

^ee

Figures 82, 83, 84, 85 and 86 down.

1

Allow a sufficient amount

2.

Disconnect the negative battery cable. Drain the engine coolant from

of

time for

ttie

engine

to cool

the radiator and block drains into a suitable clean container.

:i"::

When

CAUTION

draining the coolant, keep

in

mind

that cats

and dogs

are attracted by ethylene glycol antifreeze, and are quite

any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant may be reused unless it is contaminated or several likely to drink

years old. 3.

Remove

4.

Raise the front of the vehicle and support safely using suitable jack-

stands. 5.

the serpentine drive belt.

Remove If

the right front to the water

access

and inner wheel well splash

tire

pump

is

shield.

desired from underhood, remove the

conditioning compressor bolts and position the compressor aside with

air

the refrigerant lines intact. 6.

Spray the water

pump hub

with penetrating

corrosion that might bind the pulley and 7.

freely

Remove

pump

the water

on the hub. A

1

it

oil to

loosen any rust or

during removal.

pulley bolts and allow the pulley to hang

(25.4mm) block

in.

be wedged between the

damage

pump and

of

wood

or a

hammer handle may

crankshaft pulleys to hold the assembly

while loosening the retaining bolts. 8.

Move

the pulley outward or

remove the 6 water pump flange

remove as necessary

bolts. Carefully pull the

for

access and

pump and

pulley

assembly away from the engine and remove the assembly from the vehicle. If

necessary, a gasket scraper

careful not to

To 9. ial.

damage

the

may be

inserted under the flange, but be

machined aluminum block sealing surface.

install:

Thoroughly clean the gasket mating surfaces

Apply a small amount

holes to hold the gasket

of

in

gasket sealant

at the

of all old

gasket mater-

outer edges of the bolt

place, then install the gasket onto the water

pump assembly 10.

Install the

pump assembly

with the small

bump

of the attaching bolts in the 11 o'clock position. Install in

a crisscross sequence as

shown

to

22

ft.

lbs.

located next to one

and tighten the bolts

(30 Nm).

3-27

ENGINE AND ENGINE OVERHAUL

3-28

Label and disconnect the following electrical connectors from the

5.

cylinder head assembly and components, as applicable

Long nose

pliers

When

are necessary to disconnect the coolant temperature connectors

dis-

connected, position the electrical harness over the underhood junction block and battery cover.

PCM

Coolant temperature and

a.

connectors. These connectors are

DOHC

located on the rear side of the cylinder head tor

nectors

engines.

injector connector (TBI Engine) or the

The single

b.

4 injector con-

Engine).

(IVIFI

Idle Air Control (lAC) valve,

c.

Pressure (IVIAP) sensor.

d.

IVIanifold Air

e.

Throttle Position

f.

Exhaust Gas Recirculation (EGR) solenoid

Sensor (TPS).

Label and disconnect the spark plug wires from the plugs. h.

Oxygen sensor.

i.

Air conditioning

compressor.

vacuum hoses, as

Label and disconnect the following

6.

applicable,

from the area around the cylinder head assembly.

Fig.

86 Water

pump

bolt torque

Canister purge valve.

b.

EGR

c.

tVlAP sensor, for the

d.

Brake booster vacuum hose

sequence

a.

valve.

1991-94 SOHC engine at the intake

only.

manifold or the brake

booster. 11.

pump pulley, as applicable and tighten the the pump hub exposed through the pulley is

Install or reposition the

bolts to 19 rusty, clean

ft

it

lbs.

(25 Nm).

If

serpentine drive

belt,

and

the right splash shield

repositioned, install the air conditioning compressor.

II

14.

Close the radiator drain plug and

Remove

8.

26

ft.

install

the intake manifold, or the healer hose at the intake

at

which retains the

Ihe boll

assembly. Disconnect the fill

the engine cool-

lower splash shield for access. Place a

Operate the engine and check for coolant leaks.

wood between of Ihe torque

Cylinder Head

«»Placing a block

and the 2 mount

on the block

ol

WARNING

10.

the

Remove

Disconnect the negative battery cable and remove the coolant bottle

cap. Drain the engine coolant from the radiator

and block drains

into a suit-

For

head water 12.

sary.

CAUTION

1

in.

x 2

SOHC outlet

Remove

Be sure

13.

attracted by ethylene glycol is left in

mind that cats and dogs are antifreeze, and are quite likely to in

an uncovered container or

in

puddles on

the ground. This will prove fatal in sufficient quantity. Always

drain the coolant into a sealable container. Coolant is

righl side

upper engine torque

to midrail bracket nuts, allowing

the torque axis

mount

prior to

allow the engine

to rest

on the

and

Remove

may be

contaminated or several years old.

to

SOHC

idler pulley to

the air cleaner/iniet duct

assembly Disconnect the

Disconnect the accelerator cable from the

bracket from the intake manifold. 4.

or raising the

the fasteners

It

1992-98

access the engine

engines, disconnect the de-aeration line

and from the support

at

is

not neces

vehicles front

it

will

cover

the cylinder

bracket.

and the camshaft cover, then inspect the

cover the valve train area to prevent

Remove

the

engine or 5

and replace as necesdirt

and debris from

power steering pump bracket attaching bolts (3 for the

the right side front of the

cylinder head

14

If

It

is

DOHC

PCV

Properly relieve Ihe fuel system pressure.

throttle

body and

the

for the

engine) and position Ihe assembly next to

dash panel away from the intake manifold and

not necessary to

equipped, remove the 3

bolts attached to Ihe cylinder bolts from the

valve and fresh air hose from the camshaft cover

3

allow you

will

belt tensioner.

pulley, however, for

air

remove Ihe water pump pulley conditioning compressor front bracket

head and block, then remove the

rear bracket

compressor or engine. Do not discharge the system

connect the refrigerant lines Support the compressor out 2

long block of

in.

entering the engine.

draining the coolant, keep

it

x

cover's silicone insulators for cracks or deterioration

able clean container

reused unless

will

pump

be necessary to remove the

drink any that

in.

wood.

the serpentine drive bell

sary to remove the water

11.

When

manifold

fuel rail or

engine.

is hot.

:•::•:

from the

wood, thus preventing the engine from shitting. This to install the mount during assembly without jacking

Only remove the cylinder head when the engine is cold. Warpage may result if the cylinder head is removed while

1

of

wood under

removing the upper mount

94

1

engine mount. Remove the 3

the powertrain to rest

thru

lines

the lorque strut and cradle to ease removal and installation

axis to front cover nuts

REMOVAL & INSTALLATION See Figures 87

fuel lines to the intake

and return

For 1992-98 vehicles with a torque axis mount system, unclip the

9.

ing system

fuel feed

as applicable

throttle body,

engine

the cylinder head outlet, the

the cylinder block drain

(35 Nm).

lbs.

Connect the negative battery cable and properly

::"•:

1995-97 SOHC engines.

or

at

manifold or front of dash.

plug. Tighten the block plug to

I

DOHC

1991-97

SOHC

MFI engines.

Disconnect the upper radiator hose

de-aeration hose

13.

16

for all

right tire

assembly.

15.

body

Fuel regulator, for

I.

7.

Install the

assembly on 1991-94

Injection (TBI) unit

throttle

with a wire brush and apply a thin coat ol primer to prevent

the pulley from rusting onto the hub. 12.

Body

Throttle

e.

Engines or the

or dis-

of the way,

from

the vehicle front support bar

15

Raise and support Ihe front of the vehicle safely using jackstands.

16

Drain Ihe engine

17.

Remove

oil into

Ihe righl side

a suitable drainpan.

tire

and splash

shield.

ENGINE AND ENGINE OVERHAUL DOHC

For

18,

engines, remove the intake manifold support brace bolt

:actied to the intake

Remove

19,

or a block of

manifold next to the alternator.

Use a

the crankshaft damper/pulley assembly.

wood wedged between

3-jaw puller on the jaw slots cast into the pulley

to

wrench

strap

rear lower side

spoke and the

the pulley

cover to hold the assembly while removing the

of the front

3-29

Then use

bolt.

a

remove the assembly.

Disconnect the exhaust pipe from the manifold, then remove and

20.

discard the gasket,

21 the

Install

crankshaft sprocket retainer tool

SA9104E

or equivalent, with

side toward the sprocket. Properly remove the engine front/timing

flat

chain cover; refer to the Timing Chain Cover procedure

section.

in this

WARNING to properly install the crankshaft sprocket retainer tool.

Be sure

Failure to hold the crankshaft timing sprocket in place will

cause timing chain damage. Rotate the crankshaft clockwise to the position 90 degrees from Top

22.

Dead Center (TDC) so

the timing

bearing cap

This will

mark and keyway align with the main Fig.

split line.

make sure pistons

contact the

will not

Remove

23.

87 Remove the intake manifold support brace

bolt, located

next to the alternator— DOHC engine

valves upon assembly. the timing chain, tensioner, guides, camshaft sprocket(s)

and chain. Use a

%

in.

(21mm) wrench

when remov-

hold the camshaft

to

ing the sprocket bolts.

SOHC

For the

24.

TBI engine, remove the throttle body assembly and

cover the intake manifold opening. Be sure to remove and discard the old

body gasket.

throttle

Use a 6 point socket

25.

passes

of the

removal

remove the 10 cylinder head bolts

to

proper sequence. Failure

of the

head when hot could

to

several

in

follow the proper sequence or

head warpage or cracking.

result in

may round

Also, the use of a 12 point socket on the cylinder head bolts

the

bolt heads.

26.

Lift

the cylinder head from the dowels,

if

necessary use a small pry-

bar for leverage between the cylinder head and block bosses. to

damage

the sealing surfaces

if

prying

is

necessary

to

Be

remove

careful not

the head

from the block. 27.

necessary, remove the intake manifold or the exhaust manifold by

If

loosening the mounting nuts

the proper sequence.

in

any cylinder head

If

studs back out, the threads should be cleaned, the studs carefully installed

and then tightened

To

to

106 inch

(12 Nm).

lbs.

install:

Fig.

^Before

installing the cylinder head,

it

should be cleaned and

88 Rotate the crankshaft clockwise

(the crankshaft sprocket timing

inspected for excessive wear or damage. Information on cleaning

vent valve

damage

mark

90 degrees past TDC

to

will

be at 3 o'clock) to pre-

during assembly

and inspecting the cylinder head can be found under the ENGINE

RECONDITIONING heading, 28.

removed,

If

and new gasket(s). Tighten 29.

later in this section.

install the intake

manifold and/or the exhaust manifold

to specification in the

proper sequence.

Clean the gasket mating surfaces. Be careful not

minum components. Make

to

damage

the alu-

sure the block bolt holes are clean of any resid-

ual sealer, oil or foreign matter.

30.

Using a

dial

gauge

4 points around each cylinder, check that the

at

cylinder liners are flush or do not deviate

Make sure

31

the crankshaft

is still

more than 0.0005

90 degrees past

(0.013mm).

in.

TDC and

camshaft(s) are properly positioned with the dowel pin(s)

at the

that the

12 o'clock

position to prevent valve damage. Install the cylinder head gasket and carefully

guide the head into place over the dowels.

32.

the head bolts and/or the block were replaced, install the bolts

If

tighten in

sequence

remove the 33.

34.

48

ft.

lbs.

(65

Nm)

to insure

bolts.

until finger-tight.

Tighten the bolts

in

Tighten the cylinder head bolts again,

for

SOHC

engines or

to

37

Snap-on' torque angle gauge to zero. In

degrees.

and

proper clamp load, then

Coat the cylinder head bolts with clean engine

by hand

Nm)

to

ft.

lbs.

(50

oil

sequence in

Nm)

and thread the

to

22

sequence for

DOHC

tool 360, or equivalent,

and

to

ft.

33

lbs. ft.

lbs.

engines.

bolts

(30 Nm).

(45

Install

calibrate the tool

sequence, tighten each cylinder head bolt an additional 90

89 Use a 6-point socket

to

remove the 10 cylinder head

bolts— make several passes

in

the proper sequence

Fig.

3-30

ENGINE AND ENGINE OVERHAUL

ENGINE AND ENGINE OVERHAUL Oil

3-31

Pan

REMOVAL & INSTALLATION I

See Figures 95 and 96 1

Raise the front of

stands.

Remove

tfie

ttie

vehicle and support

plug and drain the engine

it

oil

safely using jacl

JLJULLL

D D D D D

o

nri^'TrTnfn

r^.

D_

^

^^^ ^ '^

Fig.

57 Vacuum harness diagram

o

EGR VALVE

— VAPOR

CANISTER

—1991-94 DOHC engine MAP SENSOR

EVAP CANISTER PURGE VALVE-

FUEL VAPOR CANISTER Fig.

58 Vacuum harness diagram— 1995-97

SOHC

engine

EVAP CANISTER

MAP

PRGE VALVE

ppoacp DcoDDDcnnaaacaDcP

OoOoCJoUC Da

VAPOR CANISTER Fig.

59 Vacuum harness diagram— 1995-97

DOHC

engine

/

4-31

4-32

DRIVEABILITY

AND EMISSION CONTROLS MAP SENSOR EVAP CANISTER PURGE VALVE

VAC HARN

CANISTER PURGE LINE

1

1

l__

1

/ //

^PL^

Fig.

60 Vacuum harness diagram— 1998

FUEL FEED

UNE

SOHC engine

UAP-

SENSOR

Q

^

m

« »

i

iO

ULJJLXJl

OoOoOoQc

nnnn^innnry LINEAR-

EGR VALVE

VAPOR CANISTER

OOHC - LINEAR EGR Fig. 61

Vacuum harness diagram— 1998 OOHC engine

BASIC FUEL SYSTEM

DIAGNOSIS 5-2 FUEL LINES AND FIHINGS 5-2 SPRING-LOCK COUPLER FITTING 5-2 REMOVAL & INSTALLATION 5-2 QUICK-CONNECT FITTING 5-2 REMOVAL & INSTALLATION 5-2 THROHLE BODY FUEL INJECTION (TBI)

SYSTEM

5-3

'GENERAL INFORMATION 5-3 OPERATING MODES 5-3 RELIEVING FUEL SYSTEM PRESSURE 5-4 FUEL PUMP 5-4 REMOVAL & INSTALLATION 5-4 TESTING 5-4 THROTTLE BODY 5-6

REMOVAL & INSTALLATION 5-6 BASE IDLE SPEED ADJUSTMENT

5-7

FUEL INJECTOR 5-7

REMOVAL & INSTALLATION

5-7

TESTING 5-8 FUEL PRESSURE REGULATOR 5-8

REMOVAL & INSTALLATION 5-8 MULTI-PORT FUEL INJECTION (MFI)

SYSTEM

5-9

GENERAL INFORMATION 5-9 OPERATING MODES 5-10 RELIEVING FUEL SYSTEM PRESSURE 5-10

FUEL

PUMP

5-11

REMOVAL & INSTALLATION

5-11

TESTING 5-11

THROTTLE BODY 5-12

REMOVAL & INSTALLATION

5-12

BASE IDLE SPEED

ADJUSTMENT

5-14

FUEL INJECTORS 5-15 REMOVAL & INSTALLATION 5-15 TESTING 5-18 FUEL PRESSURE REGULATOR 5-19

REMOVAL & INSTALLATION FUEL TANK/FUEL PUMP

MODULE

5-19

5-21

TANK ASSEMBLY 5-21 REMOVAL & INSTALLATION

5-21

5

FUEL SYSTEM

5-2

BASIC FUEL SYSTEM DIAGNOSIS When

there

is

a problem starting or driving a vehicle, two ot the

most

important checks involve the ignition and the fuel systems The questions

most mechanics attempt fuel'!'" will

to

answer

often lead to solving

first, "is

there spark''"

most basic problems. For

and Is there ignition

diagnosis and testing, please refer to the information on engine electrical

components and tion

system

ignition

systems

system checks out (there

system

is

operating properly

in

Section 2 of this manual.

is

spark), then

(is

there fuel?).

the igni-

If

you must determine

if

the fuel

FUEL LINES AND FIHINGS For fuel lines and

tiiiings. all

1991-94 Saturn vehicles

lock coupler fitting at the engine side of the fuel fitting for the

remaining

fuel line

filter

utilized a spring-

and a quick-connect

connections However,

all

1995-98 Saturn

vehicles utilize quick-connect fittings throughout the entire fuel line system.

The spring-lock coupler

fitting is

an integral part

replacement

filter

kit.

The quick-connect

fitting

consists of a male and female plastic connec-

These two connectors can be snapped

tion.

assem-

of the fuel filter

bly that requires the use of a special tool, usually provided with the

into place (or

unsnapped) with-

out the use of any special tools.

Spring-Lock Coupler Fitting

REMOVAL & INSTALLATION Using the special

1.

SA9157E, disengage

tool supplied with the fuel

onto the male end ot the fuel line

«»To aid

in

filler kit,

or service tool

the spring-lock coupler fitting by installing the tool at the

connector

the disengagement procedure,

it

may

be necessary to

spray the lemale cavity end of the connector with penetrating

oil to

Fig. 1

Compress the two

plastic tabs while pulling

on the

fuel

line

remove any debris. 2.

Using hand pressure on the

tor until

it

has become

hose away from the

is

tool, firmly pull the tool into the

fully inserted.

Once

this

connec-

has happened, pull the

filter

To

install:

3.

Lubricate the steel male fuel line end with clean engine

4.

Firmly push on the female end of the spring-lock coupler until a click

heard or

felt,

FEMALE

fuel rail line.

then pull back on the

fitting to

oil.

confirm a positive engage-

ment.

Quick-Connect

Fitting

REMOVAL & INSTALLATION I See Figures 1

.

1

and 2

Disengage the quick-connect

tabs together and pulling on the fuel

fitting line.

by compressing the two plastic If

necessary, discard the plastic

retainer

«»To aid

in

the

disengagement procedure,

spray the quick-connect

titling

it

may be necessary

with penetrating

oil to

to

remove any

debris.

Fig. 2 Firmly

push

until a click is

To

install:

2

Lubricate the steel male fuel line end with clean engine

3.

Install the

new

plastic retainer

and

firmly

oil

push the female connection

onto the male end

tlie

female connection onto the mate end

heard

until

positive engagement.

a click

is

heard. Pull back

on the

line to

confirm a

FUEL SYSTEM THROHLE BODY FUEL

INJECTION (TBI) SYSTEM OPERATING MODES

General Information The

SOHC

engine on 1991-94 models

which

Injection (TBI),

body

throttle

equipped with Throttle Body

is

mounted

utilizes a single electric fuel injector,

Module (PCM). The

PCM

When

mixture and

air/fuel

operates the various output devices to provide peak performance within

ure occurs that

not serious

is

minate the SERVICE ENGINE

backup

mode.

or fail-safe

according

to inputs

PCM

The

attempt to maintain an air/fuel ratio

will

optimize catalytic converter operation.

of 14.7:1 in order to

In

enough

SOON

light

PCM

program are described

The

is

fuel

pump module is

modes

20rF

PCM

the

in

the fuel tank.

in

operated through a relay mounted

in

in

A check

the instrument Panel

valve

in

pump relay is enerWhen the cranlt-

PCM

that the

engine

turning over or

is

run continuously. In the start mode, the

engine

TPS and CTS

to

air/fuel ratio

-33°F (-36°C),

to 14.6:1 at

could range from 1.5:1

at

is

position

becomes

full throttle is

in

it

can be cleared by opening the acceler-

When

less than 400, the

turning over is

flooded,

position.

the throttle

PCM

will

is

open

all

order to clear the engine of excess fuel.

reduced below about 75 percent, the

PCM

the system for a period of time after the engine

is

Open Loop Mode When

PCM

the engine

operates

in

first starts

the

and engine speed

Open Loop mode

rises

until specific

above 400 rpm, the

parameters are met.

Fuel requirements are calculated based on information from the

sor and CTS.

oxygen sensor. The

many times

fuel injector is

amount

how

long the injector

is

is

is

stepper motor that controls the

the engine

this valve, the is

on each cycle and

The this reg-

part of the throttle body. Intake

cold or

PCM

when

amount

of air

mani-

is

is

a 2-coil

allowed to bypass the throttle

can closely control

there

valve

idle

speed, even

a high engine load at idle.

sen-

when

Mode

Closed Loop

When

the correct parameters are met, the

and adjust the

air control

MAP

pulses on

supplied to the regulator diaphragm, making system pres-

sure partly dependent on engine load. The idle

With

PCM

of fuel supplied to the engine.

The system pressure regulator fold pressure

a solenoid valve that the

per second to promote proper fuel atomization.

pulse width determines

plate.

throttle

mode.

Coolant Temperature Sensor (CTS), power steering pressure switch and an

ulates the

If

will return to the start

(lAC) valve. Throttle Position Sensor (TPS), Air Temperature Sensor (ATS),

oft

way and

the

close the fuel injector while the

order to aid hot starting. The fuel tank must be removed to

Other system components include a pressure regulator, Idle Air Control

and

PCM

determine the best

the tank unit

pump module.

access the

the fuel

Mode

the engine

ator to the

engine rpm

located under the center of the instrument

is

panel on the passenger's side of the vehicle.

maintains pressure

in

ON,

(94°C) engine coolant temperature.

Clear Flood If

pump mounted

will

sensor,

for starting. Ratios

a

in

delivers fuel

includes the gauge/sending unit, which can be

Junction Block (IPJB), which

stopped

MAP

will illu-

later

supplied to the engine from a

The pump

pump

turned

first

2 seconds to build system pressure.

for

shaft position signal tells the

cranking, the

checks the

PCM

PCM

fail-

replaced separately. Otherwise, the module must be replaced as an assembly.

the ignition switch is

gized by the

from the Manifold Absolute Pressure (MAP) sensor and

the Coolant Temperature Sensor (CTS). Other operating

Fuel

a system

and operate the engine

backup mode, the

the

If

stop the engine, the

to

Starting IVIode

accepts inputs from vari-

ous sensors and switches, calculates the optimum

specific emissions limits.

I See Figure 3

in the

and ignition functions are controlled by

unit. All fuel injection

the Powertrain Control

5-3

air/fuel

mixture

in

PCM

will

use O2 sensor output

order to maintain a narrow band of

exhaust gas oxygen concentration.

When

the

PCM

is

correcting and adjust-

ing fuel mixture based on the oxygen sensor signal along with the other

sensors, this into •

is

known as feedback

air/fuel ratio control.

The

PCM

will shift

Closed Loop mode when:

Oxygen sensor output voltage

warmed up

is

to operating temperature,

varied, indicating that the sensor

minimum 600°F (318°C)

has

FUEL SYSTEM

5-4 •

Coolant temperature

•

The

PCM

is

above 68°F (20°C)

a fuel spill through the disconnected

has received an rpm signal greater than 400

for

more than

1

minute

On 1992-93

•

vehicles, a

change

position

in throttle

is

detected

2.

Remove

3.

Wrap

a

Mode

SA9127E

tool

will

is

and manifold pressure

provide extra fuel

for

smooth

is

quickly increased, the

As the

closes and the manifold pressure decreases, fuel flow

throttle

PCM.

reduced by the

If

decides that

fuel flow is not

When

the

is

receiving a Vehicle

PCM

will

and

fuel

connect the negative battery cable and

system as follows:

ON

a.

Turn the ignition

b.

Repeat the

c.

Crank the engine

d.

If

e.

Run

ON/OFF

the engine

for

until

it

does not

the engine

OFF

5 seconds, then

cycle 2

more

for

10 seconds.

times.

starts.

readily start, repeat Steps a-c.

and check

for leaks.

Speed Sensor (VSS) signal and

engine speed goes above 6750 rpm, the injectors are shut engine overspeed. The

the test port

the air cleaner assembly.

Install

After servicing the vehicle,

Mode

PCM

remove the gauge from

7.

the flow by shutting off the injector.

Fuel Cut-Off

system pressure.

to bleed the

6.

needed and stops

pressure gauge

it.

prime the

both conditions remain lor a specific number of

PCM

engine revolutions, the

is

fuel

bleed hose from the pressure gauge into an approved con-

After the pressure is bled,

recap

Mode

acci-

luel test port fitting, located at the lower

remove the cap and connect the

and open the valve

tainer

acceleration. 5.

Deceleration

is

or equivalent.

Install the

4.

the throttle position

If

PCM

the ignition key

if

assembly

the air cleaner

shop rag around the

rear of the engine, then

Acceleration

components

dentally turned on.

also shut

off

the injectors

oft to if

the

prevent

VSS

signal

Pump

Fuel

and engine speed reaches 4000 rpm.

is

REMOVAL & INSTALLATION Low Mode

Battery If

PCM

the

compensate

it

will

increase injector pulse width to

low voltage and provide proper

fuel delivery.

It

will

also

When

terminals

PCM

Vh times

light will flash

A and B

of the

ALDL

will enter the Field

Open Loop Mode, about

the

are

Service

When

the engine

only about once per second.

engine

jumpered with the engine run-

Mode

SERVICE ENGINE SOON

per second

the time in Close Loop, the engine of the time, the

is

is

If

If

the engine

is

running

light will flash quickly,

is in

If

OFF most

the light

is

ON

of

most

Code 44 or 45 could indicate pressure regulator or syrstem presA pump pressure lest may be used to determine if the fuel

sure problems.

pump

delivering fuel at the proper pressure or

is

if

pump must

the

be

replaced

running rich

CAUTION

The lollowing procedure fumes. Make sure there

I See Figure 4

will

produce a small fuel

spill

and

proper ventilation and be sure

is

to

take

the appropriate fire safety precautions.

Unless battery voltage cable This

pump

Pressure Test

Trouble

Closed Loop Mode, the

the light stays

running lean.

Pump

:i::i:

1.

of the fuel tank.

section for proper

in

Relieving Fuel System Pressure

tive battery

ttiis

TESTING

Mode

Field Service

replacement or service requires the removal

Refer to the fuel tank procedure later in

replacement techniques.

increase idle speed to increase alternator output.

ning, the

pump

Fuel detects a low battery,

for the

will

is

necessary

tor testing,

prevent the fuel

pump

disconnect the nega-

from running and causing

Locate the pressure

1

behind the

remove

gauge from the

the fuel

gauge

gauge 3.

is

fuel

on the

fuel

below and

line,

lest port

and

install the port cap.

supply hose from the metal

then connect the

line,

capable of reading 0-100 psi (0-690 kPa).

tion switch

ON

in the

gauge shut-off valve

is

closed, then turn the igni-

pump and

without starting the engine to run the fuel

system The

pump

will

again as required to

fully

build

only run for about 2 seconds without

the engine running Bleed the air out of the

pump

supply

supply hose using a suitable adapter Make sure the

to the

Verify that the fuel

pressure

test port

valve Properly relieve any residual system pressure, then

Disconnect the

2.

fuel

EGR

gauge

line

and cycle the

fuel

bleed the gauge and establish an accurate

pressure reading.

Once maximum pressure has been achieved, allow the reading to sta30 seconds Normal pump pressure is 58-94 psi (400-650 kPa).

4

bilize for

Allow the gauge to

sit

undisturbed

running: pressure should leak

from the

maximum

only and the results

Bleed

5

off

for five

minutes

down no more

than

stabilized reading. This is a fuel will differ

psi

pump

from the system pressure

the fuel system pressure

pump

after the

6-8

and repeat the

stops

(41-55 kPa) pressure

test

test

lest a

minimum

of

additional limes to be certain of accurate results. 6.

Install the

bleed hose into an approved container, then bleed the fuel

system pressure and remove the gauge from the Fig. 4

luel

Connecting a gauge with bleeder to

supply line

llie test

port on the

end

of the fitting with clean

engine

oil

line.

Lubricate the male

and reconnect the

fuel line.

2

FUEL SYSTEM

5-5

System Pressure Test

CAUTION

:•::•:

The following procedure

will

fumes. Make sure there

is

produce a small fuel

spill

and

proper ventilation and be sure to take

the appropriate fire safety precautions.

Remove

1

connect

0-100

(0-690 kPa)

psi

Close the

2.

run the fuel

OFF

the air cleaner or air intake tube

pressure gauge

fuel

again.

SA9127E

system

to the fuel

gauge shut-off

fuel

pump and The pump

assembly

or an equivalent

access,

for

ttien

gauge capable

of

ON

to

test port.

valve. Turn the ignition switch

build pressure in the system, then turn the ignition will

only run for about 2 seconds without the engine

running. Bleed the air out of the gauge line and cycle the fuel

pump

again

as required to fully bleed the gauge. Start

3.

the

gauge

and run the engine

for

normal operating temperature, then check

to

proper operating pressure. At both

idle

and 3000 rpm, system

pressure should be 26-31 psi (179-214 kPa) for the throttle body injection system.

Fig. 6

Shut the ignition

4.

5 minutes with the than

6-8

5.

If

psi

Check

Replace the

c.

Check

for

d.

Check

the fuel

e.

Substitute a

If

to leak

down.

not running, pressure should leak

After

about

The

fuel

pump

relay is located in the Instrument Panel

Junction Block (IPJB)

down no more

pressure readings are low, do the following:

b.

for bent or fuel

pinched

proper fuel

pump

lines.

A

*

filter.

pump

pressure.

fuel

.». pressure regulator.

pressure readings are high, do the following: Inspect for a restricted fuel return line.

b.

Substitute a

known good

fuel

pressure regulator.

Electrical Test

I See Figures

On

5, 6,

7 and 8

^

HIGH

the Instrument Panel Junction Block (IPJB), located inside the

vehicle beneath the center of the instrument panel, check the condition of

fuse No. 12, the 10 2.

amp

fuel

pump fuse. pump relay

Locate and remove the fuel

be substituted, as they are

power

to the fuel

pump

identical. relay.

'

-

located to the top

relays in the IPJB. To test the relay, another relay from the

for

Using a voltmeter or

With the ignition switch

left

Connect a voltmeter

or test light to terminal

85 and

Blower

Rt*R OEfOG REL»r

-fUEL PUMP RELAY PUMP TEST HOLE

f UEL

of

same block may test light,

ON

or

check

OFF,

there

Fig. in

pump relay is IPJB— 1991-94 Saturn

7 The fuel

should be 12 volts between terminal 30 and ground. 3.

riASHES REL*

for flow.

known good

a.

Pump

1.

pump

and allow the system

(41-55 kPa).

a.

6.

OFF

the

at the top left of the relays located

vehicles

a suitable

IP

BATT

ni 'I"T CRO JUUPCRCONNCCTOR IN TRUM( tLECTOIC

Fig. 5

Remove

center console

the access panel from the base of the dashboard in

order to examine the fuel

pump

fuse and relay

Fig. 8

Schematic

vehicles

of the fuel

pump power

—

supply

all

Saturn

FUEL SYSTEM

5-6

When

ground. lor

the ignition switch

about 2 seconds. This

no voltage, the

is

PCM may pump

Locate the fuel

4.

terminals

87 and 30

should be 12 volts for the fuel

to chassis

be

ON,

turned

is lirst

power

is

for the relay coil

there will be voltage

PCM.

from the

there

If

faulty,

wiring harness connector

the trunk.

in

When

are jumpered together in the relay socket, there

at

terminal

gauge. The

A

on the connector. The other terminals are

pump ground

wire connects directly from the

pump

ground.

Throttle

Body

See Figure 9

I

The

throttle

The top

blies.

body

injection unit

is

made up

of 2

major casting assem-

piece, or fuel meter body, contains the fuel injector

and pres-

sure regulator The bottom piece, or throttle body, contains the throttle

lAC valve. TPS. and the vacuum manifold or tubes which supply

valve.

manifold vacuum to various engine control solenoids.

Fual lnt*c*or

'nvoni*

Fig.

10 Unplug the electrical connectors

Fig.

12 Removing the

at

these locations

AM«mMy

PoMlon SwMW (TP AmmmUtt

) ThnHIJB 0o«fy

4 Tub*

UoduM AMVmWv

5 !«• Air Control tIAOVatv* • Fual

MMw AM«mMy

7 t^Tummutm H>gu

t*

Fig.

21 Fuel ln|ection control schematic— 1995-98

DOHC

SOHC and

al

engines

OPERATING MODES

22 Data flow schematic

Fig. trol

PCM

increased, the

Mode

Starting

the ignition switch

PCM

gized by the

is first

2 seconds to build

for

shaft position signal tells the

pump

cranking, the

will

that the

run continuously

CTS

checks the TPS and

PCM

pump relay is enersystem pressure. When the crankON,

turned

to

In

quickly

the fuel

engine

mode, the

throttle

closes and the manifold pressure decreases, fuel flow

PCM

II

engine revolutions, the

PCM

flow by shutting

air/fuel ratio tor starting.

Ratios could range from 0.8:1 at -40°F (-40°C), to 14.6:1 at

As the

reduced by the

"turning over" or

is

the start

determine the best

is

provide extra fuel for smooth acceleration.

will

Mode

Deceleration

When

and manifold pressure

the throttle position changes

If

closed loop fuel injection con-

Mode

Acceleration

I See Figure 22

for

—MFI system

220°F (104°C)

off

is

both conditions remain tor a specific number of

PCM

decides

fuel flow is not

needed and stops the

the injectors.

Mode

Fuel Cut-Off

engine coolant temperature.

When

Mode

Clear Flood If

the engine

ator to the

engine

is

position

becomes

is

is

flooded,

position.

in

it

can be cleared by opening the acceler-

When

less than 400, the

cranking,

is

receiving a Vehicle

rpm goes above 6750,

full throttle

engine rpm

PCM

the

the throttle

PCM

open

is

all

the

way and

speed The

Battery

reduced below about 75 percent, the

PCM

fuel.

If

will also

shut

off

the injectors

if

the

VSS

signal

is

and

engine speed reaches 4000 rpm.

close the fuel injectors while the

will

order to clear the engine of excess

PCM

Speed Sensor (VSS) signal and

the injectors are shut off to prevent engine over-

Low Mode

throttle

will return to the start

mode

the

If

PCM

compensate

detects a low battery,

for the

it

will

increase injector pulse width to

low voltage and provide proper

fuel delivery.

It

will

also

increase idle speed to increase alternator output.

Open Loop Mode When

PCM

Field Service the engine

operates

in

the

first starts

and engine speed

Open Loop mode

rises

until specific

Fuel requirements are calculated based on information from the

MAP

sen-

CTS

sor and

and

adjust the air/fuel mixture, in order to

exhaust gas oxygen concentration.

When

PCM

will

use O2 sensor output

PCM

the

PCM

is

to

known as "feedback air/fuel ratio control will shift into Closed Loop mode when:

The

PCM

is

is,

a

minimum

of

sensor has

jumpered with the engine runthe engine

If

is

is

running lean

is

running

in

II

the light

is

ON most

running rich

Relieving Fuel System Pressure

Unless battery voltage

is

necessary

for testing,

This will prevent the fuel

pump

a fuel spill through the disconnected components, lor

more than

closed loop mode, 1992 and later veliicles also

require a change in throttle position.

engine

tive battery cable

above 68°F (20°C)

minute In

are

Service Mode.

the time in Closed Loop, the engine

1.

600°F (318°C)

has received an rpm signal greater than 400

p»To operate

ALDL

of the

I See Figures 23 and 24

varies, indicating that the

operating temperature, that

Coolant temperature

A and B

will enter the Field

correcting and adjust-

is

Oxygen sensor output voltage

warmed

PCM

of the time, the

maintain a narrow band of

ing fuel mixture based on the oxygen sensor signal, along with the other

The

ning, the

terminals

II

the correct parameters are met, the

sensors, this

When

Open Loop Mode, the SERVICE ENGINE SOON light will flash quickly, about 2Vi times per second When the engine is in Closed Loop Mode, the light will flash only about once per second the light stays OFF most of

Closed Loop Mode

When

Mode (1991-95 Models)

above 400 rpm, the

parameters are met.

1

accidentally turned

2

Remove

3.

Wrap

a

SA9127E

if

the ignition switch

is

ON

the air intake tube

and resonator

shop rag around the

rear of the engine, then tool

disconnect the nega-

from running and causing

fuel lest port fitting, located at the lower

remove the cap and connect the

or equivalent

fuel

pressure gauge

FUEL SYSTEM

5-11

TESTING

Pump

Fuel

A

Pressure Test Code 44

Trouble

pump

45 could

or

pump

sure problems. The

Indicate pressure regulator or

pressure

may be used

test

delivering fuel at the proper pressure or

is

to

the

if

system pres-

determine

the fuel

if

pump must

be replaced.

CAUTION The following procedure will produce a small fuel spill and fumes. Make sure there is proper ventilation and be sure to take the appropriate fire safety precautions. Locate the pressure

1.

EGR

behind the

remove

gauge

fuel

23 Connecting a gauge with bleeder

Fig.

fuel supply

to the test port

on the

gauge

fuel

tion switch

ON

pressure

the system.

and

test port

install the port

0-100

psi

cap.

then connect the

line,

(0-690 kPa).

gauge shut-off valve

is

closed, then turn the igni-

pump and

without starting the engine to run the fuel

The pump

will

again as required to

fully

build

only run for about 2 seconds without

the engine running. Bleed the air out of the

pump

below and

line,

supply hose from the metal

reading

of

Verify that the fuel

in

supply

fuel

any residual system pressure, then

supply hose using a suitable adapter. Make sure the

to the

capable

is

3.

line— 1991-97 models

gauge from the

the fuel

Disconnect the

2.

on the

test port

valve. Properly relieve

gauge

line

and cycle the

fuel

bleed the gauge and establish an accurate

pressure reading.

Once maximum pressure has been achieved, allow

4.

bilize for

30 seconds. Normal pump pressure

Allow the gauge

undisturbed for

to sit

maximum

stabilized reading. This

only and the results

Bleed

5.

minutes

five

down no more

running; pressure should leak

from the

will differ

off the fuel

58-94

is

is

(400-650

after the

6-8

than

the reading to sta-

psi

a fuel

from the system pressure

system pressure and repeat the

kPa).

stops

(41-55 kPa)

psi

pump

pump

pressure

test

test.

test

a

minimum

of

2

additional times to be certain of accurate results. Install the

6.

bleed hose into an approved container, then bleed the fuel

system pressure and remove the gauge from the

end

engine

of the fitting with clean

line.

Lubricate the male

and reconnect the

oil

fuel line.

System Pressure Test I See Figure 25

CAUTION 24 Connecting a gauge with bleeder

Fig.

fuel supply

to the test port

on the

line— 1998 models

The following procedure

will

fumes. Make sure there

is

the appropriate 4.

tainer 5.

recap

Install the

bleed tiose from

and open the valve

ttie

to bleed the

system pressure.

and

connect

0-100

Install the air intake

7.

After repairs,

duct and resonator tube.

2.

connect the negative battery cable and prime the

fuel

a.

Turn the ignition

b.

Repeat the

c.

Crank the engine

ON/OFF

repeat Steps a through

Run

ON

the engine

for

5 seconds, then

cycle 2

until

it

more

starts.

If

OFF

for

10 seconds.

the air cleaner or air intake tube

pressure gauge

(0-690 kPa)

psi

Close the

again.

air

the engine does not readily start,

3.

4.

Start

gauge

and

for

REMOVAL & INSTALLATION

5.

only run for about 2 seconds without the engine

to stabilize; after

pump

ru(i ttie

of the fuel tank.

Refer to the Fuel Tank procedure later in this section for the proper

pump

engine

to

psi

again

(276-379 kPa) on 1998

about 5 minutes with the

down no more

than

6-8

psi

31-36

psi

at idle

(214-248

the pressure regulator with the engine

nected, the pressure should vary about

replace the regulator.

at idle,

kPa).

by disconnecting the vacuum

sure reading does not change and

pump

(41-55 kPa).

normal operating temperature, then check

On 1991-97 models, check

running

replacement techniques.

to

proper operating pressure. With the engine running

pressure should be

replacement or service requires the removal

ON

the system, then turn the ignition

1991-97 models and 40-55

for

models. Allow the gauge

for leaks.

Pump

pump

in

Cycle the ignition and check the gauge; pressure should be 38-44 psi

(262-306 kPa)

the

Fuel

of

test port.

out of the gauge line and cycle the fuel

not running, pressure should leak

Fuel

for access, then

gauge capable

valve. Turn the ignition switch

build pressure will

assembly

or an equivalent

system

to the fuel

gauge shut-off

fuel

pump and The pump

running. Bleed the

SA9127E

as required to fully bleed the gauge.

times.

c.

and check

fuel

run the fuel

OFF

system as follows:

d.

Remove

1

test port

it.

6.

fire

pressure gauge into an approved con-

remove the gauge from the

After the pressure is bled,

produce a small fuel spill and proper ventilation and be sure to take safety precautions.

6-10

line.

psi

With the

(40-70

vacuum can be

felt at

line

kPa).

disconIf

the pres-

the line's

inlet,

FUEL SYSTEM

5-12

ON

switch

or

OFF.

30 and

there should be 12 volts between terminal

ground.

Connect

3.

When

ground.

about 2 seconds This

for is

a voltmeter or test light to terminal

the ignition switch

no voltage, the

Locate the fuel

4.

power

is

PCM may pump

is first

be

turned

for the relay coil

fuel

terminal

at

suitable

there will be voltage

PCM

from the

wiring harness connector in the trunk.

A on

If

there

faulty.

terminals 87 and 30 are jumpered together

be 12 volts

85 and a

ON,

the connector.

in

When

the relay socket, there should

The other terminals are

gauge The pump ground wire connects from the pump

for the

to chassis

ground

Throttle

Body

& INSTALLATION

REIVIOVAL

I See Figures 27 Fig.

ttiru

38

25 For 1991-97 models, disconnect the vacuum supply

from the

—

fuel pressure regulator

if

the regulator

is

1

Disconnect the negative battery cable.

2.

Remove

3.

Unplug the

good, fuel

pressure will vary

the air intake tube electrical

and resonator.

connectors from the

Idle Air

Control (lAC)

valve and the Throttle Position Sensor (TPS). 6.

pressure readings are low, perform

If

a.

Check

for

b.

Replace the

c.

Check

for

d.

Check

the fuel

e.

Substitute a

7.

Ifie

following:

bent or pinched lines. fuel

filter.

proper fuel

pump

pump

fuel

a.

Inspect for a restricted fuel return line

b.

Substitute a

known good

fuel

6.

Remove

damaging 7.

Electrical Test

If

the Instrument Panel Junction Block (IPJB), located inside the

amp

ket

pump fuse. The inside of the access panel will provide the pump fuse and relay. and remove the fuel pump relay On 1991-94 models, is

fuel

Locate

is

left

of the relays in the IPJB.

On 1995 and

test light,

check

i

unit is

throttle

going

body bore

to

for

power

for

Kan H

throttle

later

models,

Remove

to the fuel

pump

identical.

Using a

volt-

If

required,

to clean the bore.

if

necessary.

the old gasket

and discard, then thoroughly clean the gasthrottle

body

bolt threads

Remove for

the cloth from the intake manifold opening, then inspect the

any foreign debris or pieces

Position a

10. it

and

be installed on the intake manifold, excessive carbon build-up.

mating surfaces. Clean the old Loctite* threadlock from the

9.

located at the bottom right of the IPJB. To test the relay, another relay

from the same block may be substituted, as they are meter or

remove the

Block the intake mani-

install:

opening

it

located to the top

same

the

mounting

location of the fuel 2.

bolts, then

of the intake manifold.

not allow the solvent or cleaner to contact the lAC valve or TPS; remove

To

vehicle beneath the center of the instrument panel, check the condition of the 10

body retaining

the sensors from the throttle body,

8.

On

the throttle

use carburetor cleaner, or equivalent, and a shop towel

pressure regulator

I See Figures 5, 6, 7, 8 and 26 1.

throttle body.

throttle cable.

the engine.

examine the

Do

Pump

Disconnect the

fold entry with a clean cloth to prevent dirt or debris from entering

pressure regulator.

pressure readings are high, perlorm the following;

If

Disconnect the vacuum harness from the top of the

5.

body assembly from the side

pressure.

for flow.

known good

4.

new

to the intake manifold.

of gasket material

flange gasket, then install the throttle

Apply a coat

of Loctite*

threadlock, to the mounting bolts, then install

body assembly

242, or an equivalent

and tighten

to

23

ft,

lbs. (31

Nm).

relay With the ignition

ttmnamn rvtn

n*ck csmoi mm «»* '

iS^«

aoaai

..-/

INSTRUMENT PANEL BLOCK TRONT

Fig.

26 The

fuel

pump

relay

is to

the bottom right of the Instru-

ment Panel Junction Block (IPJB)— 1995-98 Saturn vehicles

Fig. air

27 Disconnect the

cleaner inlet hose

air

hose between the camshaft cover and

FUEL SYSTEM

Fig.

28 Loosen the

Fig.

29 Disconnect the

remove

Fig.

it

air inlet t)ose

air inlet

clamp

hose

at the throttle

at the throttle

body and

from the vehicle

30 Unplug the lAC and TPS wiring connectors

body

body

Fig. 31

Disconnect the vacuum line harness from the top

throttle

body

Fig.

32 Turn the

throttle lever to the

disengage the cable

at the throttle

5-13

of the

wide open position, then

5-14

FUEL SYSTEM

Fig.

37 Clean the

a rag.

Fig.

35 Block the intake manifold opening with a clean rag

prevent any debris from entering

to

Fig.

throttle

body

Do not allow solvent

to

and

unit with carburetor cleaner

contact the lAC valve or

38 Remove and discard the

TPS

body gasket. Be careful

throttle

not to score the gasket sealing surface

•»lf the throttle

new

body

being replaced, the idle stop screw on the

is

unit is preset by the

adjustment.

Minimum

manufacturer and should not require

idle

speed should ONLY be adjusted

if

other engine systems are operating properly and idle speed

all

still

cannot be maintained. 11.

Connect the

not hold the lever

throttle cable to the lever,

making sure the cable does

open when Ihe accelerator pedal

is

released.

12.

Conned

13.

Connect the lAC valve and TPS wiring harnesses

the

vacuum harness

to the top of the throttle body.

tube and resonator

14.

Install the air intake

15.

Conned

16.

Stan the engine and check

the negative battery cable

vacuum

tor

leaks.

BASE IDLE SPEED ADJUSTMENT For information concerning adjustment Idle

Speed and Mixture Adiustments

in

base

ol the

Section

1

idle

speed,

reter to

FUEL SYSTEM

5-15

Fuel Injectors

REMOVAL & INSTALLATION I See Figures 27, 28, 29, and 39 thru 54 1.

Disconnect the negative battery cable.

2.

Remove

3.

Properly relieve fuel system pressure.

4.

Remove

and return

the air intake tube w/ith resonator

wrench

air tube.

the fuel line bracket bolt, then disconnect the fuel supply

manner:

lines in the following

On 1991-94 models, be

a.

and fresh

sure to use a ^^/e

damage.

to prevent inlet port or bracket

fuel line bolts

and

rotate the

(24mm) backup

necessary, remove the

wrench access. Remove and

slightly lor

rail

in.

If

discard the old 0-rings from the fuel lines using a suitable seal removal tool or brass pick.

On 1995-98 models, disengage

b.

the fuel line(s) from the

rail

and

pressure regulator by compressing the two plastic retaining tabs of the

quick-connect

fitting

and pulling on the

line.

Remove and

discard the

Fig.

39 Loosen the supply and return lines from the pressure

regulator/fuel rail

plastic retainer

Disconnect the vacuum hose from the

5.

backup wrench fuel

pressure regulator on

assembly with the aid

of a ^^/e in.

(24mm)

—1991-94 vehicles

1?91-97 models. 6.

Detach the

7.

Remove

from the

PCV hose

from the camshaft cover.

the throttle cable bracket bolts, then disconnect the cable

throttle lever

Lay the cable over the intake manifold and out of the

way.

Unplug the

8.

Remove

9.

upward

the fuel

age the injector spray

tions to

remove

not

assembly by carefully pulling the

rail

done

tips

rail

back and

rail

from the manifold ports. Be careful not to dam-

and the

so

electrical connectors. Rotate the rail

downward, then

the

if

fuel rail bolts.

to pull the injectors

the injectors point

connectors and,

fuel injector electrical

remove the

already,

lift

the

rail

end opposite the

fuel

connec-

from between the camshaft cover and intake mani-

fold.

10.

sure the

IVIake

Remove and 11.

If

injector

injector

and

and connectors are clean and

rails

free of dirt.

discard the lower injector 0-rings seals.

removal

required, slide the injector retaining clip off the

is

pull the injector

from the

Remove and

assembly.

rail

discard

the upper injector 0-rings seals.

To

install:

12.

engine

If

removed, lubricate and

oil

and

install the

new

injector 0-rings with clean

with the injector assembly into the fuel

install

rail. Install

the

Fig.

injector retaining clip.

40 Disconnect the supply and return lines from the pressure

regulator/fuel rail

assembly

p»There are 3 types of injector retaining clips. The 1st design, which was used on some engines built prior to January 1st, 1991, may cause injector ticking noise. If injectors are removed from the fuel rail

assembly and

this type is found, they

must be replaced

with the 2nd clip design. Do not attempt to substitute the 3rd design of clip; only 13.

1995 and

Lubricate the

later

models can use the 3rd design.

new lower

injector 0-rings with clean engine

oil,

then

install.

14.

then

1991-94 models,

For

install

inlet of

15.

lubricate the

new

fuel inlet

and return 0-rings,

the 0-rings into the fuel outlet of the pressure regulator

the fuel

Starting with the proper

ing the pressure regulator),

guide the fuel

and

rail.

rail

end (on 1991-97 models, the end contain-

and with the

injectors pointing

downward,

assembly through the passage between the camshaft

cover and the intake manifold, from the power steering

pump

side of the

engine. Align the injectors with their respective ports, ttien rotate the fuel rail

and carefully push the injectors

into their ports.

16.

Verify that the injectors are properly seated in the intake manifold.

17.

Install the fuel rail retaining bolts

on 1991-94 models or 89 inch 18.

Connect

19.

Connect the

line to the

lbs.

(10

and tighten

to

22

ft.

lbs.

(30

Nm)

Nm) on 1995-98 models.

the fuel injector wiring harnesses.

PCV

valve hose to the camshaft cover,

and the vacuum

pressure regulator, making sure they are properly seated.

Fig. 41

Remove and

discard the 0-rings from the fuel line open-

ings using a suitable seal removal tool or brass pick

FUEL SYSTEM

5-16

Fig.

Fig.

42 Disengage

ttie

fuel pressure regulator

vacuum hose

Fig.

Fig.

44

.

.

.

then, while holding the throttle lever in the wide

open position, disconnect the cable

45

Lift tiie

cable and braclcet assembly up, and lay

the intalce manifold, out of the

way

46 Unplug the fuel injector electrical connectors

it

over

FUEL SYSTEM

5-17

x;^

Fig.

the

Fig.

48 Rotate the rail

rail

so the injectors point downward, then

end opposite the

fuel

connections to remove the

lift

rail

49 Using a small bladed screwdriver, slide the injector

Fig.

50 The fuel injector it

clip is

Fig.

each

fuel injector

small and bouncy

if

dropped. Be

Fig.

from the

52 Remove and discard the upper

Use a small bladed screwdriver,

retaining clip off the injector

careful not to lose

Fig. 51 Firmly pull

53 Lubricate and

engine

oil

install the

if

rail

assembly

fuel injector 0-ring seals.

necessary

new

injector 0-rings with clean

5-18

FUEL SYSTEM

c >^-^

FUEL SYSTEM *»lf difficulty is

encountered accessing the fuel return line nut,

loosen and/or remove the fuel supply and 5.

Disengage the

6.

Remove

fuel

the regulator

rail

attachment fasteners.

vacuum

pressure regulator

not

remove the 0-ring from the

unless

fuel outlet,

is

it

damaged and

discard the 0-ring from the fuel

To

Lubricate the

new

0-ring with clean engine

then

and tighten

to

106 inch

10.

Connect the

fuel

11.

Connect the

fuel inlet

Nm)

inch lbs. (15

leakage and replace

0-ring and, install the

if

necessary, the

O-ring(s)

Position the regulator assembly to the fuel

the bolt

for

remove and

inlet.

fuel inlet oil,

the attaching bolt with Loctite*

57 Check the fuel injector tips

retainer in the pressure regulator

requires replacing. Always

in

new

outlet

the pressure regu-

assembly.

9.

Fig.

with a clean rag

install:

8.

lator

rail

system contamination.

Do

7.

hose.

assembly attaching screw, then remove the

regulator assembly. Plug the regulator port in the fuel to prevent

5-19

242 lbs.

rail.

Coat the threads of

or an equivalent threadlock. then install

(12 Nm).

pressure regulator

and return

vacuum hose.

lines,

then tighten the lines to 133

using a backup wrench to prevent port damage.

faulty injectors

tors straight out so

may be necessary

ttie

injector tips are visible wtiile

Use wire

to rotate the throttle.

to

still in ttieir

ports.

It

hold the assembly back

against the intake manifold,

Wipe

5.

the injector tips free of fuel or debris

under them, just contacting the injector Cycle the ignition

6.

system pressure

1991-97 models

40

psi

Allow the pressure

7.

fuel

or

ON

leakage

injector(s)

psi

(317 kPa) on the gauge

(276 kPa)

for

1998 models.

to

hold for

a portion of the towel

If

starting the engine, to build

46

of

five

for

minutes, then check the cloth for

becomes wet

with fuel, the faulty

must be replaced.

Bleed

8.

and OFF, without

minimum

to a

and place a clean cloth

tips to spot leaking fuel.

the system pressure, cycle the ignition to rebuild fuel

off

pressure, then allow the system to

again for signs of leakage and,

if

minutes. Check the cloth

sit for five

any

is

found, replace the faulty

injector(s).

Release fuel system pressure again, then remove the gauge and

9.

recap the test port.

^Remember

to lubricate the injector 0-rings with

upon installation

of the fuel rail/injector

Install the fuel rail/injector

Attach the fuel line bracket retaining bolt.

For

oil

Fig.

58 Use a suitable wrench

Fig.

59

to

loosen

assembly.

10. 11.

12.

clean engine

assembly.

1991-97 models, perform

the following:

a.

Attach the fuel pressure regulator vacuunn

b.

Remove

the cap from the fuel

rail

line.

opening and connect the return

line to the fuel rail.

13.

Start the

engine and check the system

for leaks.

Fuel Pressure Regulator

REMOVAL & INSTALLATION 1991-94 Models I See Figures 27, 28, 29, 39, 40, 42, 58, 59, 60 and 61 1

Remove

2.

Properly relieve the fuel system pressure. Refer to the procedure

the air intake tube

and resonator assembly

earlier in this section, 3.

Remove

4.

Using a ^^/e

inlet port

the bolts from the fuel line clip. in.

(24mm) backup wrench

and bracket, disconnect the

pressure regulator/fuel

rail

assembly.

fuel inlet

to prevent

and return

damage lines

to the

from the

.

.

.

and remove the mounting screw from the pressure

regulator/fuel rail

assembly

FUEL SYSTEM

5-20

Remove and

7

discard the following from the fuel

socket or pres-

rail

sure regulator: •

Plastic

•

Upper

•

Filter

•

Lower (small) 0-ring

::::i:

backup

ring

(large) 0-ring

screen

WARNING

When removing lower 0-ring

the

must be retrieved. 8

fuel

must be used.

fuel rail

socket for foreign material and clean

careful not to scratch the surfaces of the fuel

Be sure

to lubricate the

When assembling

10.

pressure regulator assembly from the

rail

into the rail, the 0-ring

new

rail

that

if

neces-

mate

to the

upper and lower 0-rings with clean engine

before installing them onto the pressure regulator assembly,

oil

fuel

dropped

Install:

9

60 Remove the

If

not retrieved, a

pressure regulator 0-rings.

To

Fig.

If

Inspect the fuel

Be

sary.

screen, be careful not to drop the

filter

into the fuel rail.

components

fuel rail

11.

the fuel pressure regulator, install the these

a.

Plastic

backup ring

b.

Upper

(large) 0-ring

c.

Filter

d.

Lower (small) 0-ring

screen

Position the fuel pressure regulator onto the fuel

pressure only,

new

the following order:

in

install the regulator

assembly

pressure regulator one quarter turn

fully rotating the fuel

rail.

Using hand

into the fuel rail socket. Carewill aid in the

installation process.

12.

Install the

new

fuel

pressure regulator retaining

install the retaining clip correctly

fuel rail socket

rounds the rail

—

(down side) and the small side The retaining

regulator.

clip.

Be sure

to

the lower side of the clip surrounds the

clip

of the clip (top side) sur-

must be

fully

secured over the

fuel

socket tabs and body of the pressure regulator, 13.

Position the fuel pressure regulator

angle to the fuel 14.

rail

vacuum hose

nipple at a 10°

body

With the engine

OFF

and the

ignition switch in the

ON

position,

pressurize the fuel system and check for leaks

15

Connect the

PCV and

fuel

pressure regulator

vacuum hoses. Be sure

that they are properly seated

16.

Place the throttle cable bracket into position and

fasteners. Tighten the

12.

Cycle the ignition switch to prime the

engine and check 13.

fuel

system, then

start the

for fuel leaks.

Turn the ignition

OFF and

install the air intake

tube and resonator

assembly

1995-97 Models I See Figures 62. 63. 64. 65 and 66 1

2

Remove

the air intake tube, resonator

assembly and

PCV

hose.

Properly relieve the fuel system pressure Refer to the prxedure

in

this section

3

Remove

the throttle cable bracket

mounting

bolts,

disconnect the

cable from the throttle lever and place over the intake manifold. 4.

Disengage the

5

Remove and

ulator to the fuel 6.

socket. will

Pull

Do

occur

rail

upward

fuel

pressure regulator

vacuum hose

discard the retaining clip that secures the pressure reg-

socket to

remove the pressure regulator from the

not use any tools for this step, or

damage

fuel rail

to the plastic socket

mounting fasteners

to

19

ft.

lbs.

install

mounting

(25 Nm).

FUEL SYSTEM

5-21

CLIP TO BE ABOVE REGULATOR EARS AND BELOW SOCKET BODY EARS

C

V BACKUP RING

FILTER

SCREEN

LOWER Fig.

D

Q

UPPER ORING

O'RING

63 Components

(

of the fuel

C )

)

89565G03

Fig.

pressure regulator assembly

65 Correct installation

of tlie fuel pressure regulator retain-

ing clip

REGULATOR

d

BACKUP RING-

UPPER O'RING-

FILTER SCREEN

LOWER

O'RING

V ^-^ y

Fig.

64 Correct assembly

17.

Connect the cable

18.

Cycle

seconds

ttie

fuel

for

Turn the ignition

5 seconds and then

OFF

for

and

The ponent

install the air intake

tube and resonator

fuel

pressure regulator on 1998 Saturn models

of the fuel filter

is

an integral com-

assembly and can only be serviced as a single

component. For servicing the

fuel filter/pressure regulator, refer to

Sec-

tion 1.

assembly.

FUEL TANK/FUEL

PUMP MODULE

Tank Assembly

::::•:

REMOVAL & INSTALLATION

CAUTION

The following procedure

will

fumes. Make sure there

is

the appropriate

1991-97

10°

10

system. Perform this procedure 2 more times,

OFF

at a

rail

1998 Models

to ttie ttirottle lever.

ON

66 Position the regulator vacuum hose nipple

angle to the fuel

then start the engine and check for fuel leaks. 19.

Fig.

of the fuel pressure regulator

ignition switch

prime the

to

89565G0

1991-98

MES

HOT AT ALL Times

lEFT HEAD-

RIGHT HEAD-

T

HEADLICHTS W/O DRl

^1LAMP

LAMP

FUSE 10 A

LEFT

BEAM d) LOW

(

P

FUSE 10 A

RIGHT )

M-^

H OH

I

BEAM

LOW BEAM

f

(0)E'

STOP

(0)'5rf

/.

TROffT SIDE

(B lARKEH

PARK/

»

I

Z

^

MAR'FR

^ -^

MARKFB

^p

DIAGRAM 10

JLn womt .

q

STOf-

«

I

SMTCH

)

sTof/

I

jK

/Z (

p

.

q

)

right STOP/

(|)

-- (D

MANUAL TRANSAXLE

7-2

UNDERSTANDING THE MANUAL TRANSAXLE 7-2 IDENTIFICATION 7-2

BACK-UP LIGHT SWITCH 7-2 REMOVAL & INSTALLATION 7-2 MANUAL TRANSAXLE ASSEMBLY 7-3 REMOVAL & INSTALLATION 7-3 HALFSHAFTS 7-5 REMOVAL & INSTALLATION 7-5 CV-JOINTS OVERHAUL 7-8

CLUTCH

7-11

UNDERSTANDING THE CLUTCH DRIVEN DISC AND PRESSURE

7-11

PLATE 7-12

REMOVAL & INSTALLATION ADJUSTMENTS 7-14 MASTER CYLINDER 7-15 REMOVAL & INSTALLATION

7-12

7-15

SLAVE CYLINDER 7-15 REMOVAL & INSTALLATION 7-15

HYDRAULIC SYSTEM BLEEDING 7-16

AUTOMATIC TRANSAXLE 7-16 UNDERSTANDING THE AUTOMATIC TRANSAXLE 7-16 TORQUE CONVERTER 7-16 PLANETARY GEARBOX 7-17 SERVOS AND ACCUMULATORS 7-17 HYDRAULIC CONTROL SYSTEM 7-18

•

*^

MANUAL TRANSAXLE

CLUTCH AUTOMATIC TRANSAXLE

l^U

IDENTIFICATION 7-18

NEUTRAL SAFETY/SELECTOR/REVERSE LIGHT SWITCH 7-18

REMOVAL & INSTALLATION ADJUSTMENT 7-18 AUTOMATIC TRANSAXLE ASSEMBLY 7-19 REMOVAL & INSTALLATION

7-18

7-19

HALFSHAFTS 7-22 SPECIFICATIONS CHART TORQUE SPECIFICATIONS 7-23

^^

:^?M

7-2 7-11

7-16

7-2

DRIVE TRAIN

MANUAL TRANSAXLE Understanding the Manual Transaxle Because

of the

way an

duce torque, or twisting

combustion engine breathes,

internal

force, only within a

modern, overhead valve pushrod engines must turn produce that

their

about 2500 rpm

to

torque

little

lU DCITC

engine speed produce no power increases. The

in

torque peak on overhead camshaft engines

much

at

peak torque. By 4500 rpm they are producing so

continued increases

can pro-

it

narrow speed range. Most

is

much

generally

higher, but

2iid

The manual transaxle and clutch are employed between engine speed and the speed

power can be produced under

bdDnx

to vary the relationship

wheels so

of the

that

adequate engine

stop.

Consequently, the vehicle

The transaxle changes the

ratio

engine and the wheels by the use

power

to

be applied

to the

may be

smoothly from a

started

between the rotating speeds

The gear

of gears.

ratios allow

wheels during acceleration

full

of the

lull

engine

low speeds and

at

a front wheel drive transaxle, power

is

at

usually transmitted from the

and

input shaft to a mainshaft or output shaft located slightly beneath

side of the input shaft. input shaft, allowing

gears are

in

constant

the synchronizer

causes one another to slide

The gears

power

and clutch

of the gears to

it.

is

of the

mainshaft

employ synchronizers;

to the

with gears on the All

forward

are free from rotating with the shaft unless

engaged. Shifting from one gear to the next

be freed from rotating with the shaft and locks

of the

friction

same speed

mesh

be carried from one to the other.

Gears are locked and unlocked by

between the center

shaft to the

to

mesh and

internal

dog clutches which

gear and the shaft. The forward gears

members which smoothly

before the toothed

dog clutches

bring gear and are engaged.

Identification I See Figures

1

and 2

There are two 5-speed manual transaxles used

They are

virtually the

same by design and

in all

Saturn vehicles.

differ internally

almost only by

gear ratio The 2 transaxles are equipped with different ratio/toothed gears in

order to best utilize the engines to which they are mated The

transaxle

was If

inal

is

found only on vehicles with the

available only with the there

is

DOHC

SOHC

clutch housing.

identification

MP2 MP3

engine, while the

engine.

a question as to whether the transaxle in your vehicle

component, an

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4th

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