Chilton's General Motors Deville/Fleetwood/Eldorado/Seville 1990-98 Repair Manual [28540] 0801991048, 9780801991042

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28540

jimmmmmmmiii 1990-98 REPAIR

MANUAL

Covers

all U.S. and Canadian models of Cadillac DeVille, DeVille Concours, Eldorado, Fleetwood and Seville Front Wheel Drive Models

i^r^,

7See It

impossible to anticipate

IS virtually

all ol tlie

hazards involved with automotive maintenance and service, but care

and

common

sense

will

prevent

most accidents The rules

ol safety for

smoke around

"don't

tool(s) lor the iob." to

mechanics range trom

gasoline." to "use the proper

The

avoiding injuries

Irick to

is

develop sale work habits and to take every pos-

sible precaution

Do keep

a

lire

extinguisher and

lirst

aid

kit

handy. y

Do

Fig.

vrear safety glasses or

16 Screwdrivers should be kept

good condition

to

trom the screw

MSC

in

prevent injury or dam-

age which could result

IMC

goggles when cut-

it

the blade slips

GENERAL INFORMATION AND MAINTENANCE

1-7

FASTENERS. MEASUREMENTS AND CONVERSIONS Bolts, Nuts

to

and Other Threaded

deform w/hen tightened or

Whenever retainers

>

See Figures 20, 21. 22 and 23 Although there are a great variety

ol lasteners

that in

the

monly used

modern retainer

car or truck, the is

bolts, screws, studs, etc).

may

most com-

Most threaded

Some

it

note any special

of

which

removed and replace any

damage. Check

all

threads for

which can increase the torque

that fastener

damaged

retainers (such as

stretch bolts or torque prevailing nuts) are

is

was

originally selected. Addi-

be sure that the driver surface

tener has not been

of the fas-

compromised by rounding

or

designed

In

some cases

may

a driver surface

rounded, allowing the driver

partially

to catch in only

one direction

occurrences, a fastener

In

may be

many

ol these

installed

and

tight-

ened, but the driver would not be able to grip and

loosen the fastener again. (This could lead to frus-

down

tration

need

necessary to achieve the desired clamp load for

retainers

be reused, provided that they are not

use or during the repair

when

show signs

tionally, in

will

which should be replaced during a proce-

rust or corrosion

the threaded fastener (nuts,

damage.

other

become only

we

possible,

dure. But you should always inspect the condition ol a retainer

lound

use and should not

in

be reinstalled.

Retainers

If

the line should that

use the proper replacement.

same

whether due

fastener,

design or damage, you must

of the

component ever

be disassembled again).

to

you must replace a

ALWAYS In all

design, material and strength should be

used. IVIarkings on the heads ol most bolts

determine the proper strength

same

to

be sure to

cases, a retainer

will

ol the fastener

help

The

and pitch must be selected

material, thread

assure proper installation and safe operation

to

of the

vehicle afterwards.

Thread gauges are available to help measure a

Most automotive and hardware

bolt or stud's thread.

stores keep gauges available to help you select the size. In a pinch,

proper

bolt for a thread gauge. is

not too badly

you can use another nut or II

the boll

by finding another bolt which place.

the

If

you

find a nut

damaged

bolt,

Fig.

20 Here are a few

of ttie

is

will

select a

thread

match

in its

which threads properly onto

then use that nut to help select

the replacement bolt.

replacing

you are replacing

damaged, you can

If

however, the bolt you are

so badly damaged (broken or

drilled

most common screw/bolt driver styles

MMrT D

pp

\m

LTJ

\

-

3

-

;

-

3

-

E = -

—

Length Diameter (major diameter) Ttireads per

inchi or

mm

Triread length

Size of the wrench required Root diameter (minor diameter) TCCSI038

(CASTELLATED) Fig.

22 Threaded retainer sizes are deter-

mined using

tliese

measurements

T LOCKWASHERS

@

@ Fig.

23 Special fasteners such as these

Torx" head bolts are used by manufacturers to discourage people from working on Fig. 21 Tliere are

many

different types of tlireaded retainers found

on veiiicles

vehicles without the proper tools

GENERAL INFORMATION AND MAINTENANCE

1-8 out) that

Ifireads

Its

same assembly which

vehicle)

cannot be used as a gauge, you

by looking

migtit start

mounting

It

lor anottier boll (Irom the

or a similar location

will

thread into the

so. the other boll

H...go«

on your

damaged

bolt's

can be used to select

a nut; the nut can then be used to select the

replacement bolt cases, be absolutely sure you have

In all

selected the proper replacement. Don't be shy, you

can always ask the store clerk

tor help.

when you find a bolt with may also find the nut it was threaded into has also been damaged. If this is the case, you may aware

I

that

damaged

threads, you

He««on

or drilled hole

have

and tap the hole, replace the

to drill

nut or otherwise repair the threads.

replacement bolt

try to force a

damaged

to

fit

H...,oo

NEVER

Ixadboll

into the

threads. ll«^«boll

Torque

is

defined as the measurement ol resis-

tance to turning or rotating.

about an axis this

It

tends to twist a body

A common example

of rotation

would be tightening a threaded

retainer

a nut, bolt or screw Measuring torque

common ways

most

retainer has

When applied

in

ol the

assure that a threaded

is

three distinct areas, the head, the bear-

and the clamp

measured torque

bearing

one

haad to help

been properly lastened

tightening a threaded lastener, torque

ing surface ol the

is

triction.

This

is

load.

About 50 percent

used

in

overcoming

the friction

is

between the

bearing surface of the bolt head, screw head or nut lace and the base material or washer (the surface

on which the fastener

mately 40 percent

overcoming thread 10 percent lul

as

clamp load

much

of the

is

rotating).

(the lorce

means

Approxi-

applied torque

triction

is

used

in

This leaves only about

of the applied torque to

together). This

develop a use-

which holds a

that friction

joint

can account lor

as 90 percent ol the applied torque on a

lastener

TORQUE WRENCHES > See Figures 24, 25 and 26 In

used

most applications, a torque wrench can be to

assure proper installation ol a fastener

Torque wrenches come

in

various designs and

most automotive supply stores

will

carry a variety

Q=

czhbi^ ^^snzin xcsiois

Fig

t>e«d toll

ol

such as

24 Various styles

of

torque wrenches

are usually available at your local auto-

motive supply store

bolt

GENERAL INFORMATION AND MAINTENANCE your needs^

to suit

A torque

for

a fastener.

A

torque wrencfi can also be used

»

no worldwide standardization

is

See Figures 28 and 29

>

of fasteners,

Some

may

type)

allow

be equipped with a pivot head which can

to be

it

A

torque wrenches (usually of the click

m

used

areas of limited access,

BUT

the charts are a general guideline and should be

it

used with caution. Again, the general rule

wrench, grasp the handle lightly and as you pull

you are using the

right tool lor the job,

of

"if

you should

must be used

on the handle,

it

properly. To hold a pivot

point.

here.

extension during the process of pulling, there very

Beam Type

point.

See Figure 27

to

The beam type torque wrench It

is

one

most

of the

The design

in

(shaft) to a scale located near the handle.

is

pulled, the

beam bends and

beam

As the

make

it

Click (Breakaway) Type

Another popular design

To use the

to a

of

torque wrench

click type

is

the

wrench you pre-

torque setting. Once the torque

the torque readings will be inac-

of the

handle

is

val-

they

any position on the wrench without

to

be compact, easy to

read and have a great degree of accuracy.

is

usually such as

TORQUE ANGLE

causes a momentary breakaway of the torque

wrench body sending an impulse

»

IVIETERS

See Figure 31 I

the frictional characteristics of each fas-

clamp loads which

tener or threaded hole will vary

U-joInt,

be mentioned

ttiat tlie

wobble or extension

will

use of any

have an

what wrench you are using. For the most

are based strictly on torque will vary as well.

most

applications, this variance

effect on the torque readings, no matter

enough

type of

a manufacturer's engineers

cause worry. But,

to

in

is

may determine

precise clamp loads are necessary (such

on the wrench

with

driver.

If

necessary, straight

many aluminum

cases, a torque angle

cylinder heads).

method

In

not significant

certain applications,

accurate readings, install the socket directly

In

more

that

is

the case

these

of installation

would

the wrench driver) will have the least effect on

be specified.

the torque reading. Avoid any extension that

torque angle tightened, a predetermined seating

alters the length of the to the

wrench from the handle

head/driving point (such as a crow's

is

reached, the wrench has a reflex signaling feature that

is that

a

extensions (which hold a socket directly under

it

show torque

wrenches

inconvenient to deliberately misuse the

i»\\ sliould

the pointer

I See Figure 28

adjust

at

of these

because they tend

ferred

contact with the yoke

dial indicator to

accuracy These wrenches are often pre-

affecting

indicates the torque using the scale.

click type.

case or direct reading torque wrench

One advantage

wrench.

consists of a pointer attached to

the head that runs the length of the flexible

is

good chance

comes

ues.

curate because this could alter the wrench loading

popular types.

wrench

the handle

If

rigid

equipped with a

can be held

head

should be floated on the pivot

not have to strain to tighten a fastener" applies

>

See Figure 30

if

you are following the general guidelines in ttie accompanying charts. Keep in mind that because there

Rigid Case (Direct Reading)

Head Type

Pivot

wrencti should be

used any time we supply a specific torque value

1-9

foot). U-joInt or

wobble extensions can greatly

affect the readings; avoid their

use

at all

times.

to the operator's

When

installing fasteners

which are

torque and standard torque wrench are usually used first to

remove any compliance from the

fastener

joint.

The

then tightened the specified additional

is

portion of a turn measured in degrees,

A

angle gauge (mechanical protractor)

used

is

torque for

these applications. hand.

tVOTEO HANDLE

-DRIVE SOUABE

Fig.

28 A click type or breakaway torque

wrench

beam

27 Example

Fig.

29 Torque wrenches with pivoting

of a

—

note that this one has a pivoting

head

type torque wrench

Fig.

PIVOTED HANDLE TOROUE WRENCH

heads must be grasped and used properly to prevent

an incorrect reading

Fig.

30 The

rigid

case (direct reading)

Fig. 31

Some

use

show torque

protractor)

of

specifications require the

a torque angle meter (mechanical

torque wrench uses a dial Indicator to

1-10

GENERAL INFORMATION AND MAINTENANCE their installation

Standard and Metric

(It

lbs

kPa or >

Some

ol the

surements include length

Measurements See Figure 32

.

inch lbs or

mm Hg)

the proper

In

(in

Nm) and

common mea-

most or

cm/mm), torque

pressure

most cases, we

(psi. in

Hg,

strive to provide

measurement as determined by the man-

this

manual, specifications are given

Though,

you determine the condition

components on your

of

in

some

cases, that value

may

not be

conveniently measured with what

you

in

is

available in

ol the

measurmg will

have two

scales so the Standard or Metric measurements

may

easily be taken

II

any

ol the

tools which are available to

various measuring

you do not contain the

scale as listed in the specifications, use the

accompanying conversion

various

vehicle, or to assist

many

devices wtiich are available today

same

ufacturer's engineers

Throughout to help

your toolbox Luckily,

proper value

factors to determine the

GENERAL INFORMATION AND MAINTENANCE The conversion

used by taking the

lactor chart is

given specification and multiplying

first line,

you have a measurement

if

SERIAL

NUMBER

in

as "free-play should be 2 only

by the neces-

it

in

inches such

in.

50.8mm.

Likewise,

if

the specification

parts to be certain of the vehicle

A

Identification

Number

plate that

upper instrument panel and

is

is

17 characters

(VIN)

ber

is

used

for title

trol of

left

that represent

body

type, engine,

number.

It

is

a l^etric measurement, for example in

the

then look at the center

measurement

is

assembly

year,

and engine

ft.

identi-

applied to the engine and

used

may

for in-plant

con-

be used by law

proper

bers and letters as the vehicle identification

in a

num-

ber.

The eighth engine

line, series,

and consecutive

is

officials to identify

unit

in

digit of the

VIN plate

will specify the

the vehicle. All engines have a nine-digit

engine identification number.

important for servicing and ordering

VEHICLE IDENTIFICATION NUMBER digit Vehicle Identification Number used for license ond insurance identification and in qenerol reference to the outomobile. The number is located on a plate riveted to the windshield lower frame at the driver's side of the vehicle where it is visible through the windshield The 1997 Codilloc Vehicle Identification number is decoded as follows:

Eoch 1997 Codilloc corrres a 17

1G6KD52BXVU NATION OF ORIGIN

200001

-

1=USA

production sequence number

MANUFACTURER -

200001 = oeville/concours/o-elegance 600001 = eldora6o/etc 800001 = seville sls/sts

G=GEf4ERAL MOTORS

ASSEMBLY PLANT

CARUNE/SERIES

U = HAIlN

KE " DEVILLE O'EUEGANCX

KF = OEVILLE CONCOURS KO = DEVILLE EL = ELDORADO

MODEL YEAR•OtECK

KY = SEVILLE TOURING SEDAN (STS)

VIN

• 57 COUPE 2 1 5 = 69 SEDAN 4

I

ENGINE CODE

BODY CODE -BODY TYPE DOOR N0TCH8ACK OOOR / 4 WINDOW NOTCHBACK

Vehicle liientification Information— 1997 Cadillac shown, others similar

ENGINE AND VEHICLE IDENTIFICATION

V = 1997

DIGIT

(SEE BELOW)

New-

column

100 Nm, multiply

condensed form should contain the same num-

num-

and registration purposes and

model

If

the conversion factor of 0.738 to get 73.8

was given

engine/chassis combinations. This number

number con-

codes supplying

indicates the vehicle manufacturer, country of origin, type of restraint system,

is

these assemblies and

enforcement or other

visible through the

important information about your vehicle. The

number

transaxle. This derivative

is

fastened to the

windshield. The vehicle identification tains

in

Me[&s (Nm),

first.

nine-character derivative of the vehicle iden-

tification

The Vehicle

ton

fication.

See Figures 33 and 34

stamped on a metal

by the conversion

IDENTIFICATION

Vehicle Identification Plate I

only

but your ruler reads

in."

millimeters, multiply 2

factor of 25.4 to get the metric equivalent of

sary conversion factor. For instance, lool

See Figures 38 and 39 The transmission has two Identltying stamp-

ings: the transmission identification derivative.

and the VIN

The transmission Identification number

gives the transmission model, build dale, and the application code. The transmission identlllcation

FRONT OF CAR

number

Is

stamped on Ihe automatic transmission

case The VIN derivative

complete VIN and

is

Is

created from the

stamped

In

two

different

places.

Fig.

38 The location

ol the transaxle

stamping on the rearward corner

ol the

box

JULIAN DATE

OF THE YEAR SHIFT AND

TRANSAXLE

-LINE NUMBER

BROADCAST coot VEHICLE IDENTIFICATION NUMBER DERIVATIVE LOCATED ON PLATE ON ENGINE BLOCK IN FRONT OF

H-WILLOW RUN PLANT

THANSAXLE EXTENSION VISIBLE WITH VEHICLE ON HOIST Fig.

35 Engine identification number loca-

tion—4.6L

Norltistar V-8

SERIAL

NUMBER

iN

BASE CODE 31

Fig.

36 Engine Idenlltication location

lor

Ihe 4.5 and 4.9L engines

Fig.

37 This label

m

the engine

com-

partment contains emissions information

among

other things

Fig

39 The transaxle VIN derivative number

(1) Is

stamped

into the horizontal cast rib

right-hand rear ol the transaxle housing, the transaxle ID nameplate (2)

ward

ol the

VIN derivative

is

on Ihe

located just lor

1-14

GENERAL INFORMATION AND MAINTENANCE

ROUTINE MAINTENANCE

GENERAL INFORMATION AND MAINTENANCE >

cracks and tears.

See Figures 40 and 41

If

the ducting

1-15

torn

is

it

should be

placec

Proper maintenance and tune-up long and trouble-free vetiicle

can yield

its

own

to

The

and the work

actiieve better gas mileage

As a conscientious owner and

down which

the parts cost you, the date, and the ter

reading

Keep

at the time.

items as engine

oil

and

referred to in case of related

main component

how much exact odome-

The

In

to deter-

will

maximum and

originally delivered includes the factory

this literature,

provided

in

If

recom-

case you do not have the factory

Fig.

Fig.

42 Before any work can be done on side of the engine compartment,

Remove

to

remove the

strut rod.

See Figures 42

it.

The

the bolt at the radiator frame

fasteners are clips,

Remove

5.

Wipe

6.

To

the air

some

filter

are screws,

cover back to

in

the air

filter

element.

out the housing with a clean rag.

7.

Position the

make sure

it

air filter

element

in the

hous-

seats properly

Install the air

intake air duct

cleaner cover. Connect the

and tighten the clamp.

Install the lAT sensor,

if

removed, or recon-

nect as necessary

thru 52

cleaner

tilt

install:

10.

the engine compart-

air intake

Install the air

cleaner fasteners, and tighten

as necessary.

ducting for

Fig. 41 This sticker, located in the

engine compartment, gives

serpentine belt routing, as well as other pertinent information

Fig. it

of

expose the element.

40 This vehicle sticker gives the gross vehicle weight and body

left

duct as necessary.

Carefully

4.

ing,

air

air

depending on the vehicle configuration.

should be replaced every 30.000 miles

ment. Inspect the flexible

necessary

»Some

remove

otherwise, never run the engine without

Locate the

in the

duct clamp and

air

Disengage the fasteners securing the top

3.

reduce the potential for water

REMOVAL & INSTALLATION

lit-

equipped and mounted

if

airflow possible with a minito

configuration, as well as the federal law compliance

the

remove the

8.

I

temper-

or disconnect the intake air

Loosen the intake

9.

A maintenance schedule

replaced

the air cleaner.

you no longer

erature.

is

the air

it

replacement copies are usually

may be

element

cleaner housing.

an engine maintenance procedure requires

be invalu-

provided with your vehicle when

available from the dealer. is

is

potential

(50,000 km). literature

mended maintenance schedule. have

system

removes

cleaner housing and ducts are designed to

of noise,

air filter

The

air

2.

ingestion into the engine.

case of a

able.

was

of the air intake

Remove

1

ature (lAT) sensor,

flow restriction. The

the temporary removal of the air cleaner, it;

warranty problem, these receipts

air

mum If

was perlormed.

maximum

engine contaminants, particularly abrasive types.

do-it-yourselfer,

these receipts are the only proof you have that the required maintenance

minimum

the air cleaner element that

allow the

so that they may be

problems or

mine operating expenses. As a

with

air cleaner

easily.

cleaner assembly The air cleaner assembly houses

to jot

receipts for such

all

fillers,

element provides

flat air filter

air filtration

Keep your own personal log

services you performed,

A

driver, set

check or replace items that could cause major later.

The

air to the

cleaner assembly, resonator assemblies and

air

hoses.

aside a Saturday morning, say once a month, to

problems

system provides clean

induction noise. The intake air system consists of

an

an out-ol-tune

ttian

intake air

engine, optimizes airflow, and reduces unwanted

rewards. Studies fiave sfiown

tuned and maintained vetiicle can

that a properly

vehicle.

life,

is ttie l

supply solenoid and lines

uum

lines to the throttle

24.

25.

manifold bolt tightening

26.

sequence— 4. 5L and 4.9L engines

hose.

or retained in

sequence so they may be reinstalled

in their

original positions.

Remove

the right front and rear

the intal

4. 91

Engines

See Figures 54, 55 and 56 1

Disconnect the negative battery cable.

2.

Drain and recycle the engine coolant.

3.

Remove

the air

filter

assembly Disconnect

and remove the coolant recovery

tank.

4.

Disconnect and remove the cross brace.

5.

Remove

the water

Remove

the serpentine drive belt and the

6.

water

pump

pulley

pump

pulley bolts.

3-15

ENGINE AND ENGINE OVERHAUL

3-16

HRrdHBilGB Fig.

58 Remove the water pump

Remove

Fig. 61

tlie

pump

water

pulley retaining boit and

.

.

bell

adjuster

Fig.

59 Loosen the water

Fig.

62

.

.

.

pump

belt

remove the pulley from the

water pump

.

Cylinder Head

REMOVAL & INSTALLATION

4.5L and 4.9L Engines >

See Figure 65

RIGHT SIDE 1

Disconnect the negative battery cable. Drain

the engine coolant.

2 Fig.

3

64 Remove the water pump from the

Remove Remove

rocker

arm covers.

the lower intake

and

right side

exhaust manilolds.

engine and thoroughly clean the mounting

4

surlaces

tube

11

Inslaliihe drive belt

12

Tighten Ihe water

lbs (30

pump

pulley bolts to

22

It

Nm) cleaner

assembly

13.

Install the air

14

Connect the negative battery cable

15

Fill

cooling system and checl< lor

the engine and allow

it

temperalute Rpcheck

^Because

to

for

come i':>a'»:s

to

leal(S

Start

normal operating

Top-ud

I'n^

roolant

the engine block and radiator are

aluminum, make sure the antifreeze solution Is approved for use in cooling systems with a high aluminum content GM recommends the use

of a

supplement/sealant 3634621 or equiv-

alent, specifically

num engines

designed

to protect Ihe

for

use

in

alumi-

engine from

Remove engine

lift

bracket and

oil

dipstick

ENGINE AND ENGINE OVERHAUL Remove

4

the intake manifold-to-engine bolts

and intake manilold^

the exhaust manifold-to-cylinder head bolts

and the

exhaust manifold,

Remove

and the

the engine lifting bracket

Access

the timing chain guides.

screws

through the plugs

is

the

at

front of the cylinder head.

pipe, the exhaust pipe-to-exhaust manifold bolts,

6,

Removing

5.

to the retaining

Disconnect the exhaust manifold crossover

5,

3-17

6-

Remove

the water crossover.

7.

8.

Remove Remove

the cylinder head bolts.

9.

Remove

the cylinder head and gasket.

the exhaust manifold.

dipstick tube,

Remove

7,

move

the AIR bracket-to-engine bolts and

the bracket aside.

Remove

8,

With the camshafts remaining In the cylinder head some valves will be open at all

the cylinder head-to-engine bolts

and the cylinder head.

times. Do not rest the cylinder head on a

To install:

flat

Clean the gasket mounting surfaces,

9,

10.

Install

new head gasket

service with the cylinder face down, or

damage

valve

over dowels on

will result.

11.

Install

To

cylinder head,

Apply a suitable lubricant

12.

to the cylinder

14.

Tighten bolts,

head bolts

in

ft.

lbs.

lbs.

ft.

ft,

lbs,

18.

sequence,

to

lift

1

3 and 4 cylinder head bolts

,

AIR bracket.

Install dipstick

bracket,

Install

Using a new cylinder head gasket,

11

the cylinder head and the 10 1^111 and 3

exhaust manifold.

lower intake

Install

rocker

arm covers,

19.

Install Fill

21

Connect negative battery cable,

the 10

cooling system

Start

M6

Lube the washer and the underside

Mil

oil prior to installation.

bolts in

Allow engine

to

Tighten the 3

for coolant, oil

come

to

normal operating temperature and recheck

M6

sequence

bolts to

10

to

22

lbs,

ft.

Drain the engine

Install the

13.

Set the camshaft timing. Install the

14.

it

on

3,

Remove

the 13

oil

pan bolts and remove the

pan,

(30

Nm)

pan gasket is reusable unless damaged. Do not remove the gasket from the oil pan groove unless replacement is required.

•»The

oil

To

install:

4,

Install

camshafts.

12.

a new

oil

pan

seal,

if

required by start-

pan groove and working the

camshaft guide bolt access hole seal into the

plugs

assembly and place

oil,

head

ing the seal into the

tor

leaks.

the engine

2,

of the bolt

Tighten

(12 Nm).

lbs,

ft,

Remove

a stand,

install

plus 90°, plus an additional 90°for a total of 180",

engine and check

fuel leaks.

See Figures 68 and 69

oil

bolts.

head with engine

20.

%

1

avoid damaging the sealing surfaces.

tube and

manifold,

22.

cleaning aluminum gasket services, use only plastic or wood scrapers and/or an appropriate chemical dissolving agent to

(120 Nm),

Install

engine

in

(90 Nm).

Tighten No,

17.

and

Connect the negative battery cable.

.

4.6L Engine

16.

90

the crankcase

Fill

1 1

(50

When Tighten cylinder head bolts,

15.

to

pan installation—4.5L and

10-

finger-tight

sequence, to 38

Oil

engines

Clean the gasket services and combustion

chamber.

Install cylinder

Nm).

68

4. 91

install:

10.

head bolt threads. 13.

67

Fig.

cylinder block with either side facing up,

groove

in

both directions.

the cylinder heads. The plugs should be

in

seated and snug,

4.6L Engine »

^Because

Install the intake

15.

harmonic balancer,

See Figure 66 of the bulic

and complexity

4.6L engine, cylinder head removal

of ll)e

may

best

manifold, camshaft covers,

front cover

and

oil

16

Install the

water crossover.

17.

Install the

exhaust manifold,

18.

Install

pump,

Once the seal Is exposed to oil, it will expand and no longer stay in the groove If this happens, replace

without wrinkles.

the powertrain assembly.

with a

new

seal.

be accomplished with the engine out of the vehicle. For this procedure

economical

to

remove the

and cradle out the bottom

It

may be most

5.

entire powertraln of the

body and

1.

Remove

the powertrain assembly.

2.

Remove

the intake manifold, camshaft

covers, harmonic balancer, front cover and

4.5L and 4.9L Engines

oil

>

pump.

Remove

3.

ft.

REMOVAL & INSTALLATION

as an engine stand.

utilize the cradle

install

to

See Figure 67

the chain tensioner from the timing

Disconnect the negative battery cable. Raise

1.

chain

for the cylinder

4.

Remove

the

head being removed.

cam

and

sprockets from the head

being removed. The timing chain remains

in the

safely support the vehicle. Drain the crankcase.

Remove

2.

the 2 torque converter/flywheel

covers from the lower side of the transaxle.

chain case.

On

3.

the Eldorado

and

Seville,

remove

the

exhaust crossunder pipe and reposition.

Remove

4. oil

the

oil

pan-to-engine bolts and the

pan.

To 5.

install:

Clean the gasket mounting surfaces.

»Apply

a V* inch bead of

RTV

at the rear

main

bearing cap and front cover to block joints. 6.

Install the oil

pan and

bolts,Tightento14ft, 7.

Fig.

66 4.6L cylinder head tightening

sequence

Install the

lbs,

oil

pan-to-engine

(18Nm),

exhaust crossunder pipe.

the 2 torque converter/flywheel covers.

8.

Install

9.

Lower the vehicle.

lbs.

Position the

oil

pan to the crankcase and

the 13 retaining bolts. Tighten the bolts to 9

(10

Nm)

in

the sequence

shown

3-18

ENGINE AND ENGINE OVERHAUL

-# .g

Fig.

69

Oil

pan

boit torque

—4.6L engine

sequence

ENGINE AND ENGINE OVERHAUL 11,

Use

installer J

29774

or equivalent,

and

bottom the hub out on the crankshaft, 12,

Install the

crankshaft

washer and tighten

to

70

ft,

damper lbs,

and

(95 Nm),

13,

Install the right front air deflector

14,

Install the right front

wheel and

Raise and safely support the vehicle,

3.

remove the

bolt

Lower the

16,

Connect the negative battery cable.

vehicle,

right front

Remove

4.

wheel

the splash shields from the wheel-

house and remove the brace between the

pan

oil

and the transmission case. Support the engine cradle and remove the 3

5.

tire,

15,

3-19

bolts from the right side of the cradle.

Disconnect the

6.

RSS

sensor from the right

lower control arm,

4.6L Engine »

See Figures 75, 76 and 77

Install the

7.

equivalent and remove the balancer bolt.

Lower the engine cradle enough

8.

Fig.

damper—4. SL and

73 Crankshaft and

1

Disconnect the negative battery cable.

2.

Release tension from the accessory drive

tlywheel holder tool J 39411 or

ance

tor clear-

of puller tool, Install pilot tool

9.

J39344-2

into the

end

of

the crankshaft,

4.9L(

Remove

10. tool

HARMONIC BALANCER

J3841 6

To

the

harmonic balancer using puller

or equivalent.

install:

Position the balancer to the crankshaft and

1 1

using tool J39344 or equivalent,

ft,

install the balancer.

Clean the balancer bolts threads and apply

12. oil to

the threads. Tighten the balancer bolt to

lbs,

105

(145 Nm); plus 120 degrees. Raise the engine cradle into place and

13.

install the

3 bolts. Tighten the 3 bolts to 75

ft.

lbs.

(100 Nm).

74

Fig.

damper—4.5L and

Installing

4.9L

Reconnect the suspension position sensors

14.

to the lower control

Remove

15.

To

the

install:

Lubricate the bore of the

10.

hub and

75 Removing the harmonic bal-

16.

lubricant,

Position the

1 1

up the key

damper on

the cranl

side of the engine cradle. side engine cradle

16.

Install the right

17.

Install the right front air deflector.

18.

Install the right front

Lower the

19.

wheel and

body

1

Disconnect the negative battery cable.

2.

Remove

3.

Raise and safely support the vehicle.

4.

Remove

tire,

vehicle,

Fig.

Connect the negative battery cable,

20.

See Figures 78 and 79

bolts,

76 Installing the harmonic balancer—

4.9L Engine

See Figures 73 and 74 1

Disconnect the negative battery cable.

2.

Remove

3.

Raise and safely support the vehicle

the serpentine belt.

securely. 4.

Remove

the right front wheel and

5.

Remove

the right front air deflector.

6.

Loosen and reposition the heater by-pass

7.

Remove

tire.

line.

the crankshaft

damper

bolt

and

washer. 8.

To 9.

EP

Install

a puller and

remove the damper.

install:

Lubricate the bore of the hub and seal with

lubricant.

10.

Position the

up the key shaft.

damper on the crankshaft

slot in the

the right front

front air deflector.

4.6L engine

I

the serpentine

lining

hub with the key on the crankFig.

77 Tightening the harmonic balancer bolt— 4.6L engine

belt.

tire.

Remove

the right

3-20

ENGINE AND ENGINE OVERHAUL

ENGINE AND ENGINE OVERHAUL

82 Camshaft and timing cliain—4.5L and 4.9L engines

Fig.

1

Align Ihe timing nnarks on the sprockets;

b^

must lace

ttiey

eacti other,

Align the dowel pin

c.

and crankshaft.

Install the

CAMSHAFT SECONDARY DRIVE CHAIN

(50 Nm), Install

new

the

and

thrust button

install the

slinger to the crankshaft, 7.

Install

8.

Refill it

Fig.

Remove Remove

3,

Remove

the

left

side secondary chain ten-

Remove

the

left

side chain guide. Access the

the front cover. Connect the negative

83 Primary timing chain— 4. 6L

the front cover. the

side

left

cam

covers,

SETTING CAMSHAFT TIMING

sioner, 4,

upper chain guide mounting bolt through the hole

in

4.6L Engine

the cylinder head covered with the plastic plug.

battery cable,

allow

5

2,

1

ft.

INTERMEDIATE SHAFT PRIMARY CHAIN

SHAFT SPROCKET CRANKSHAFT SPROCKET KEY SPROCKET

See Figure 84

camshaft sprocket-

sprocket-to-camshaft sprocket bolt to 37 lbs,

2

3 INTERK^EDIATE 4

>

to-camshaft bolts. Tighten the camshaft

6.

engine assembly or the power-

assembly

the camshaft with

Slide the assembly onto the camshaft

d.

Install the

13, train

in

the index hole in the sprocket.

oil

the cooling system. Start the engine,

to reach normal operating temperatures and

Remove

5,

the

side

left

cam

sprocket bolts and

I

See Figures 85, 85 and 87

sprockets, Setting camshaft timing

check for

leaks.

6,

Remove

7,

Repeat Steps 2 through 6

the secondary drive chain, the

4.6L Engine

chain

To

CAMSHAFT PRIMARY DRIVE CHAIN

is

if

cam

See Figure 83

being replaced.

Remove

1

necessary whenever

the relationship between any chain

been

install:

lost.

Correct timing exist

Retime the camshafts.

9,

Install the front cover.

Remove

cam

timing marks aligned and

all

4 camshaft drive

cover(s). surface.

the engine

assembly and put

it

and

ley

on

the serpentine drive belt, idler pul-

belt tensioner.

if

not

done previously.

3.

Remove

the front cover and

4.

the

5.

Remove Remove

6.

Remove

the camshaft sprocket bolt from

Remove

oil

pump.

covers.

the three timing chain tensioners.

four camshafts and 7.

cam

all

remove the sprockets.

the secondary drive chains from

around the intermediate shaft sprocket. 8.

Remove

the

mary drive chain

one

bolt holding the

mtermedi-

and slide the gears and the

ate shaft sprocket

off

the crankshaft

pri-

and intermediate

shaft.

>»The intermediate shaft need not be removed unless wear is evident. 1

To 9.

install:

10,

Install the oil

11,

Install

12,

Install the

and

the

belt tensioner.

INTAKE

C

3

EXHAUST CAMSHAFT SECONDARY CAM DRIVE CHAIN

4

CHAIN GUIDE

2

Retime the camshafts.

pump,

cam

covers,

serpentine drive

belt, idler pulley,

Fig.

that

the crank

pins are perpendicular (90°) to the cylinder head Install the

an engine stand or remove the powertrain assembly, 2.

such

and sprocket has

when

sprocket and the intermediate shaft sprocket have

8,

10.

is

drive system has been disturbed

the right side

their

»

3-21

84 Secondary timing chain-—4.6L engine

5

RH SPROCKET - INSTALL CAM PIN IN RE SLOT FOR EXHAUST POSITION; Rl SLOT FOR INTAKE POSITION SPROCKET INSTALL CAM PIN IN SLOT FOR EXHAUST POSITION; LI SLOT FOR INTAKE POSITION

6 LH LE

ENGINE AND ENGINE OVERHAUL

3-22

#'^^^^^

INTAKE POSITION

1

2

EXHAUST POSITION

3

TIMING

MARKS

Fig.

85 Setting camsliaft timing

Fig.

86 Camstiaft

cliain

guides

—4.6L engine

—4.6L engine

To allow access the lollowmg components

1

must be removed: a

cam

Both

b

Front cover

The three chain tensioners. The lensioners

2

The

oil

Install the

1

o clock position Use J

crankshaft and intermediate shaft

positions but must be

ing marks adjacent to each other

5

Install the

crank and intermediate sprockets

over their respective shafts

pump.

6

The primary and secondary chain guides

should be reinstalled

3

approximately the

to rotate the crankshaft.

sprockets to the primary drive chain with Iheir tim-

in their instatted

fully retracted. d.

IS at

4

c

may be

key

39946 covers

if

previously removed

Rotate the crankshaft until the sprocket drive

Rotate the crankshaft as necessary to

engage the crankshaft key changing the relationship each other Use J 39946

in the

of the

sprocket without

timing marks to

to rotate the crankshaft

ENGINE AND ENGINE OVERHAUL wThe RE cam

sprocket must contain the

cam

position sensor pick-up.

To

install:

4,

Install the

valve

5,

Install the

camshafts,

6,

Install the

camshaft cover

Use a

3. lifters in their

original bores.

lips

3-23

suitable prying tool between the seal

and the crankshaft and remove the

seal.

Camshaft, Bearings and Lifters Use extreme care

Rear

IVIain

to avoid damage to the crankshaft sealing surface. NOTE: The pre-

Seal

REMOVAL & INSTALLATION

ferred

REMOVAL & INSTALLATION oValve

lifters

and pushrods should be kept

Some engines

mm)

and overas original equipment. The

oversize lifters are etched with an

Remove Remove

1

2.

blies

the oversize

if

the

II

the intake manifold

on their

and

lifter

the

lifters.

available,

lifters is

A

body. The

and

is

as dry

started.

which

is

helpful for this proce-

Unbolt and remove the flexplate from the rear

must be primed before seize

lifters will

Submerge

when

the lifters in

down on

mm)

drift Into

the

lifter

remove the old any

Lubricate the

lip of

Using

seal with

wheel

a Seal Installer tool

(this is the

purpose

J-34604

1

of the installer)

or equiv-

mm

and

indented,

To complete the installation, reverse the

6,

removal procedures. Tighten the flexplate-to-crankshaft bolts to

and push

down

and the

new

over the crankshaft and

press the seal into place. The seal must be

flush with the block to

shaft.

37

ft.

lbs,

(52 Nm),

rollers

molybdenum-

Refill

Operate the engine and check

^

now primed. of the lifters,

a

it

oil,

submerged; do not pump the plunger. Release the plunger. The lifter is

Coat the bottoms

or equiv-

engine.

lifter is still

with Molykote® or an equivalent

J-26868

into the seal bore with the spring facing inside the

installa-

the engine

SAE 10

tool

Thoroughly clean the

seal.

leftover seal material with a clean

rag.

square

the plunger. Hold the plunger

while the

the crank-

for leaks.

1

> 1

2 3

disulfide lubricant before installation. Install the lifters

and pushrods

into the

engine

4

Fig.

manifold gaskets and mani-

Install the intake

88 Rear main seal removal toolFig.

4.SL and 4.9L engines

fold. 7.

90 Rear main seal installation—4.6L

engine Position the rocker arms, pivots and bolts on

the cylinder head. Position

and rocker 8.

SEAL SPRING

BLOCK ASSEMBLY CRANKSHAFT

in their original

order, 6.

sealant at the

the transaxle.

Using a Seal Removal

3,

alent,

very thin. Carefully insert the end of a

Va inch (3

5.

Remove

5-

lifters

RTV

of the crankshaft,

4,

special tool for remov-

install;

i»New is

1,

2,

seal bore of

dure.

To

Place a small amount of

upper/lower crankshaft seal.

J-26868 or equivalent, and a Seal Installer tool J-34604 or equivalent. tool

bearing grease. Position

Remove

install:

4.

Removal

about 10

in

To

crankshaft split line across the end of the

arm assem-

minutes.

tion,

See Figures 88 and 89

alent,

solvent should dissolve the varnish

ing

»

end

are coated with varnish, apply

carburetor cleaning solvent to the

4.

spark plug

and

install the

rockers

shaft.

Install the «(ires,

valve covers, connect the

and

install the air

cleaner

assembly.

»An

EP lube, such as EOS, should always be added to crankcase for break-in when new lifters or a new additive containing

camshaft

is

oil

Installed. This additive is gener-

ally available in

automotive parts stores.

4.6L Engine 1

Remove

the camshaft cover,

Fig.

2.

Remove

the camshafts for the head being

4.5L and 4.9L engines

89 Rear main seal installation tool-

worked on. 3.

on

Remove

their

the valve

litters in order,

camshaft face so

and store

that the residual oil is

4.6L Engine

retained,

>

>»Retain the

lifters in

by

marked

gasl

is

component on

ALWAYS

It

fasteners and allow

Flange Type

connections, or other deterioration which could

compartment. Inspect

Type

dissolving agent onto the fasteners for ease ot to

the exhaust manifold

at

where the header pipe

under-car parts, not to

See Figure 103

both ends

under the vehicle and inspect the system com-

or turbocharger pipe

to the

faster

near the fuel tank,

could happen,

squirt a liquid rust dissolving

agent onto the fasteners

may even be wise

flanges

pletely. Start the

damage

Before removing any

systems,

large 0-rings (doughnuts) in

attached and work your

DANGEROUS

mention yourself.

Slip Joint

Before removing any

100

resulting in

may be

cutting torch

at the very least, accidents

compo-

to separate the

hot exhaust

components.

Fig.

and

on the com-

to lap

loosen the

to

use a hacksaw

fails,

Fig.

103 Example

type system

of a

common

slip joint

ENGINE AND ENGINE OVERHAUL

3-26

ENGINE RECONDITIONING

Anything that generates heat and/or

With

ited)

tremendous amounts

engine and heat

around the spark plug

tion

created by friction and

is

reduces the amount

you can have an

bustion.

system

either

If

will

is

and com-

friction

into the

No

spark plug hole

1

Check

If

you do not

Be careful not

to

crossthread the sparic plug

hole.

and

drain, flush,

refill

the radiator,

in

conned

it

filter:

if

changed

not

is

it

often

laden with contaminates and

your

to

enough

oil

and

becomes

it

wear.

at a specific

oil

Repeat the

of

methods

Compare

1 1

An

valve seats.

tions

Excessive

engine

pump

ing cylinder pressure

may

indicate

worn piston

uses no more than one quart

rings,

worn valve

75 percent

every 1000

of oil

is in oil

or

12.

more

in less

than 1000 miles should

for oil leaks.

II

any

would be 113

psi

psi

compression

lest.

rises after

adding

means

oil,

it

If

If

A

fuel

over an extended period are

engine wear

Worn

oil

mileage measured

all

and

if

in

is

is

oil

cold pressure

doesn't help raise

Change and

well

is

the

oil.

was lower than making sure

component

pump

wear,

crankcase, too high of an

pressure

relief

compression

^e .'..

,,.:

all

oil

of

determined

,-. :;j5t make

It

more

It

talces slightly

is

largely a Is

s being put into

would

m the crankcase.

lers

il

is

rebuilt'

worth keeping' Would

of

is

OFF

Disable ttw ignition system.

it

If

il

the car

be less

yoursell ot buy a used

On

Ihe other hand,

you have considered

and more, and have

still

it

is

all

decided

then ensure engine, then

it

gel

buy a new engine, have your engine

be simpler and less expensive

It

Is

it

lime to decide

lo

buy

these mai-

lo rebuild the

how you

will

charged the engine to normal operating

temperature, then shut Ihe engine 3.

lo

by a pro. retxiHd

another car' oil is

worth

subiedive matter and one

Ihe engine a popular one, or

engine from a salvage yard?

ettort to obtain a

sure that the proper amount and vis-

is fully

your engine

is

an obsolete model'' Are pans available' Will

more accurate reading.

Warm-up

that

some decisions The

each cylin-

rebuilt

2

viscosity or a faulty

possible

expensive

the battery

i

i

valve

question of whether or not an engine

the spar1( plug hole. Although

cosity of engine

too low High

Buy or Rebuild?

accurate than the type you simply hold against

worth the

is

low,

is

worn

»K screw-in type compression gauge is

is

t.

related problems,

If

personal worth

It

Ihe engine

oil in

use the proper grad'

to

or oil viscosity that

acceptable gas mileage once

Make

the

If

the specification,

pressure readings could be caused by an overfillec

com-

der will help locate the problem

1

low. check

pressure readings could be attributed

oil

oil level,

rebuilding

longer lo use.

is

above the specification, and

quantity, then repeat the test

Low

L

piston rings, scored or

of the

pressure reading to

indicators of internal

burnt valves, and worn valve seats are

A check

oil

the reading

If

leakage past the head gasket Oil

cylinder bores, blown head gaskets, sticking or

culprits

hoi

you may have the wrong viscosity

low

needed), or

that cylinder

any two adjacent cylinders

Ihe addition of

pression, there

Compare your

7

internal

or

may

the pressure remains low, the valves

compression

noticeable lack of engine power, excessive

consumption, and/or poor

and

that the cylinder's

head gasket may be blown near

the

See Figure 104

com-

damaged

will feel

the oil pressure reading again with the

that given in the chart.

the compression

not be seating properly (a valve job

>

Check

the cold pressure reading against the chart.

(779 kPa).

piston rings and/or cylinder bore are

worn.

Ihe engine until normal operating tem-

reached (upper radiator hose

is

the hot reading

repeal the

to run the

rpm. so check Ihe specifica-

OFF

(1034 kPa), then

(779 kPa).

if

when cold

the oil pressure reading

at a specified

Run

6

your highest read-

Ihe cylinder through the spark plug hole

present, have

COMPRESSION TEST

if

psi

a cylinder exhibits an unusually low

If

oil into

them fixed before determining how much oil is consumed by the engine, especially blue smoke is not visible at the tailpipe.

was 150

il

to idle

il

engine hot and record the number Turn the engine

within 75

pression reading, pour a tablespoon of clean engine

leaks are

oil

of that

than113

condition. Engines that use one

good

be checked

is

Therefore, the lowest reading cylinder should be no less

quart of

the lowest reading cylinder

reading cylinder. For example,

Check

5

percent of the pressure recorded for the highest the

4

perature

failures-

guides, and/or valve seals. Generally, an engine that

miles

if

pressure gauge and.

oil

engine and allow

warm).

com-

of oil in the

smoke from

area and/or bluish

air intake

tailpipe

oil

consumption, evidence

oil

com-

of

pression pressures are considered within specifica-

pressure test can warn you of

oil

possible engine bearing, or

Slarl the

tions.

first.

the highest readings from each

cylinder to that of the others. The indicated

head gaskef(s), valves, and

rings, cylinder bores,

same number

pression strokes and/or time as the lest

a mechanical

3

engine

on each cylinder, cranking

for evaluating

A compression

Following the manufacturer's instructions,

and record the number. You may need

on the gauge.

test

require

rpm

necessary, a tachometer to the engine

crank the

to

may

specifications

pressure sending unit

conned

posi-

compression strokes

Ihe engine approximately the

There are a number

can reveal the condition of your pistons, piston

oil

dash-mounted gauge) A tachometer may

some

(approximately 5 seconds of cranking) and record

and 10.

first

at least five

the highest reading

the condition of your engine.

OFF

the

use the remote starting switch

engine through

unable to properly

is

lubricate the engine. This increases friction

the sending unit

at

With the engine cold, locale and remove the

2 in

can extract tion,

from the coolant. The same applies

pressure

oil

running the engine 1

a remote starting switch to Ihe

With the ignition switch

9.

thereby reducing the amount of heat

proper

also be needed, as

According to the tool manufacturer's

the proper intervals,

at

begin to accumulate

will

for

installed

starting circuit.

deposits

blown

is

pressure gauge (as opposed to relying on a factory

instructions,

your cooling system

droplets

oil

a head gaskei

if

passage with an externally mounted mechanical

8.

your vehicle.

cooling system

PRESSURE TEST

OIL

of

lite

from cold

or

be evidence of water

droplets on Ihe engine dipstick and/or

until the lifting is

not maintained, a break-

be inevitable. Therefore, you can see how

regular maintenance can affect the service

warm-up

may

weather driving There

snug.

encountered by the

of friction

Ihe tailpipe,

alarmed by the normal white smoke emitted from

in the

screw-in type compression gauge

Install a

7.

fric-

for this, or

smoke from

problem However, don't be

assistant fully depress Ihe accelerator pedal

parts inside the engine, while the cooling

system reduces heat created by

down

open

the accelera-

combined

the combustion chamber,

ot this

the tailpipe during engine

You can block

throttle) position.

tor linkage

system

oiling

remove the spark

Set Ihe throttle plate to the fully open (wide-

6.

open

combus-

ports, then

symptoms

are

plugs.

engine has systems

reduce the effects of heat and

to help

and provide added longevity. The

moving

lim-

rotating parts inside the

tion of the fuel. However, the

designed

is

encoun-

of both; friction is

moving and

tered by the

span

its life

in

with blue or constant while

Thoroughly clean the cylinder head area

5.

mind, a running engine generates

this in

and coolant

the spark plug

all of

wires from the plugs.

friction will

eventually burn o( wear out (lor example, a light

bulb generates heat, therefore

Label and disconnect

4.

Determining Engine Condition

Fig.

-rebuild

104 A screw-in type compression

gauge

Is

more accurate and easier

without an assistant

lo

use

•The

it

editors at CtiiHon leal ttut

most engine

maclilning should be performed by a proles

ENGINE AND ENGINE OVERHAUL machine shop. Don't think of it as wastmoney, rather, as an assurance that the job

sjonal ing

has been done right the

many expensive and

time. There are

first

specialized tools required

perform such tasks as boring and honing an

to

engine block or having a valve job done on a

tvluch of the

assembly work (crankshaft, bear-

and other components)

ings, piston rods,

specifically formulated for this

used, but engine

well

is

within the scope of the do-it-yourself mechanic's tools

and

You

abilities.

will

have

to

decide

depth of involvement you desire

self the

in

lube

an

ings will

CLEANING

maximum

come from performing

The tools required

disassembly, assembly and installation of the

A complete

of the

above tasks.

new ones and

machining the non-moving wearing surfaces t)lock

and heads. Unfortunately,

may

this

have been damaged or worn, but

machined undersize

for a

may

it

is

wiser to replace only

those parts which are really needed, and, sible, repair the

break the engine

more expensive ones.

down

into

nents: the cylinder head will

if

Later

pos-

we

We

parts to replace during a rebuild

in-depth

IVIicrometers

•

Jaw and screw-type

overlooked

Scraper Valve spring compressor

•

Ring groove cleaner

•

Piston ring expander and compressor

Most

•

Ridge reamer Cylinder hone or glaze breaker Plastigage*-

of

from a

can be rented for a one-time use supply house spe-

called

are fairly stan-

in

also a guide to acceptable

engines, due to

along with specific details concerning your particu-

•

maximum In

performance,

most instances

for the do-it-yourself

it

mechanic

is

to

reliatiility

more

and

profitable

remove, clean

and inspect the component, buy the necessary and

deliver these to a

shop

for actual

parts

machine work.

is

105 Use a gasket scraper

to

etc.).

Use

of a wire

NOT RECOMMENDED on any aluminum

You should always wear eye protection dur-

any cleaning process involving scraping, chip-

for

low weight. Observe the

its

use

alternative to the

fol-

is to

mess and hassle drop them

garage or machine shop. They

all

of the parts for a

of cleaning

off at a local

will,

more than

have the necessary equipment

likely,

clean

Remove

•

all

aluminum

nominal

to properly

fee.

parts (identification tag,

compounds

Always wear eye protection during any

to the tanking.

lightly with

engine

oil

or

before installation, to prevent

cleaning process involving scraping,

Remove any

Never overtighten bolts or spark plugs espe-

cially in

aluminum

the engine,

frictional contact

provide lubrication

any parts

that will

must be prelubed

at initial start-up.

Any product

remove

the old gasket material from the mating

Fig.

surfaces

remove the piston

106 Use a

ring

expander

rings

oil

galley plugs, freeze plugs and/or

pressed-in bearings and carefully wash and degrease

threads.

When assembling be exposed to

cliip-

ping, or spraying of solvents.

to

all

of the engine

and etc.,

bolts.

tool to

components including

the fasteners

Small parts such as the valves, springs,

should be placed

in a

metal basket and allowed

^

to soak.

Fig.

using a

dations given by the manufacturer of the tool and/or

An

Always coat threads

seizure.

life.

require If

critical

ping, or spraying of solvents.

from engine parts prior

Competent and accurate machine shop services ensure

may

with a wire brush.

hot tank solution will eat the aluminum.

etc.)

anti-seize

engine

chisel.

Never hot tank aluminum parts (the caustic

engine.

will

drill

bearing saddles, cylinder bores,

book before substi-

the front of this

lowing precautions when handling aluminum parts:

•

rebuilding practice are given and should be used

and readily available sol-

be removed using a scraper and/or cleaning

solvent.

•

your individual

tools

machined surfaces (such as the gasket surfaces,

ing

rebuilding procedures. Examples of standard

lar

cleaning process can be carried out

the parts yourself

Most engine overhaul procedures

sludge or carbon.

of

components. Always follow any safety recommen-

on each.

dard. In addition to specific parts replacement pro-

is

of the

common hand

brush is

Aluminum has become extremely popular

engine, this section

hidden by a layer

wire brush, use extreme care around any

See the information on Special Tools and the in

if

the use of a power

automotive work.

Safety Notice

the

in

away using a hammer and a hard wooden

of these tools is illustrated in

Occasionally, the use of special tools for

A crack

Old gasket material and varnish or sludge can usu-

local parts jobber or tool

cializing in

sludge

components

of the

all

solvent. Extremely stubborn deposits

most

are

oil

vents or solutions. Carbon deposits can be chipped

•

Engine stand

components

engine block or cylinder head can easily become

•

•

its

must be thoroughly cleaned. You

remove any engine varnish,

pullers

•

•

to

to insure an accurate inspection.

Engine Overhaul Tips

for

need

and/or carbon deposits from

OVERHAUL TIPS

cedures and specifications

Before the engine and inspected, they

thousandths)

tuting another tool.

discuss each component, and the recom-

mended

l\/lore

of the following:

all

and telescope gauges

•

this section, tvlany

will

two main compo-

its

and the engine block.

or

dial indicator (reading in

The use

lee.

So, as you can see, you can replace everything inside the engine, but,

A

ally

can be

it

minimal

of the

not be

cost effective. For instance, your crankshaft

some

See Figures 105, 106, 107 and 108

with

parts (pistons,

rods, cranl(Shaft, camshaft, etc.) with

require

»

be the

mounted on a universal base

of the cost

moving

will

your

of

will

will

•

rebuild or overhaul of an engine all

depend on the depth

tools found in a mechanic's tool.

work

doing these yourself.

involves replacing

an engine overhaul or

involvement. With a few exceptions, they

Depending on the particular circumstances, you may save 40 to 60 percent

for

parts replacement will

sav-

the removal,

engine and purchasing or renting only the tools required to perform the

or

Loctite'-'

TOOLS

you

clean, and ready to assemble parts, saving

you time and aggravation. Your

a pre-

(locked, but removable)

should be cleaned and coated with

properly measure wear and clearances. In to

purpose can be

recommended as

another similar, commercial non-hardening sealant.

requires expensive micrometers and gauges to

machine shop can deliver

not

installation of bolts or nuts is desired, threads

engine repair or rebuild.

cylinder head. Even inspecting the parts

addition, a

oil is

most cases.

When semi-permanent

your-

tor

in

3-27

Fig.

Use pipe cleaner type brushes, and clean

107 Clean the piston

i

using a ring groove cleaner tool, or

all

ENGINE AND ENGINE OVERHAUL

3-28

BOLT OR SCREW

DAMAGED THREADS

X^

ICCSJ911

108

Fig.

.

.

use a piece

.

of

an old ring to

109 Damaged

clean the grooves. Be careful, the ring can

Fig.

be quite sliarp

be replaced with thread repair Inserts

bolt hole threads

can

Fig.

110 Standard thread repair Insert

(lett).

Fig.

and

sparic plug thread Insert

113 Screw the

Drill

out the

damaged threads

with the specified size

bit.

Be sure

to drill

completely through the hole or to the bot-

tom

of a blind hole

passageways

in the

pis-

Ion ring grooves with a special tool or a piece ot bro-

Scrape the carbon

ring.

piston.

in this

oft of

Ihe top ol the

Vou should never use a wire brush on the

pistons. After preparing

kit,

Thread the insert

tap the hole in

all

assemblies

ol the piston

manner, wash and degrease them again.

the tap well oiled and back

remove

out fre-

it

threads ol the insert) and an installation tool

Spark plug inserts usually

This

REPAIRING

will

lot ol

and they would not have wasted any

manufacturers

and

kit

containing a vari-

inserts plus installation loots

studs Penetrating

oil

damaged

or

can be used

put

shown and

accompanying

in the series ol

in the ki!

can be repaired, as

still

Several methods o* repairing are available

damaged threads

Heli-Coil' (shown here), Keenserls'.

and Microdot' are among Ihe most widely used. involve basically the

same

principle

All

—

drilling out

stripped threads, tapping the hole and installing a

prewound

insert

—making

welding, plugging and

Two types

ol thread repair inserts are usually

supplied a standard type for most inch coarse, inch line,

metric course and metric line thread sizes and

a spark lug type to

fit

most spark plug

remove

port sizes

it

Ideally

that

Irom Ihe engine,

it's

lime to strip

it

necessary components Belore you bling the engine, you

may want

oil

start

to lake a

moment

draw some

containers to mark the locations of various

contain a selection of prewound threaded

nents and

««

is

to

to

timing cover and require the vibratio'i

be removed before

reduce the engine to the bare

Finally,

shafts

and connecting rods).

components such as

and

oil

auxiliary shafts

remove the cylinder head(s) from the

semblv instructions

lor

each component follow

later

Cylinder Head

disassem-

determine exact applications Typical thread repair kits will

may

engine block and carefully place on a bench Disas

ol all but the

some

Iront, or

front covers

and coolant

Consult Ihe individual tool manufacturer's catalog to

pictures, ot fabricate

Some

plus any other in block'

the llywheel or flexplale

you have drained Ihe

pump

Then, unfasten

remove any covers remaining on the engine

pumps, balance

you have Ihe engine on a stand, and

thai

pan

block, crankshaft, pistons

before installing the engine to the stand

assuming

alternator, etc

necessities (cylinder head(s), valve train, engine

using the stand with your

Remove

such as the water

to the engine,

hand The idea

you should place your engine

access to the engine components Follow the manu-

particular engine

a rotating pari

damper and/or crank pulley

first

on an engine stand This allords you the best

lacturer's directions lor

ol

such as the rocker arm,

Irom the vehicle, then disassemble and it

will regret not

bracket which holds a wire

little

removed during the engine removal procedure

manufacturer's instructions.

To properly rebuild an engine, you must

Now

oversize fasteners unnecessary

anached

Finally

diagnose

that

it.

any manilolds (intake or exhaust) which were nol

illustrations

Engine Preparation

See Figures 109, 110. 111. 112 and 113

back when you assemble, you

power steering pump,

oil

>

by

il

You should begin by unbolting any accessories

removed

with locking pliers or using a screw/stud extractor

ol

when you disassemble

present

harness out of the path

to tree frozen

threads. The olfending item can usually be

it

its

If

remembering

bolls or

money designing your

time and

haphazardly placing brackets, clips or lasteners on the vehicle

avoid damaging the valve seals.

DAMAGED THREADS

mixed up The manulacturer

bolts that can be easily

vehicle,

After Ihe hole is clear, the thread

installed

brackets and

spent a

f^^ost

Before attempting to repair a threaded hole,

from the combustion chamber with the valves

lot ol little

mounted on studs and/or

require a tap equipped with pilot threads and a

also supply blister-packed thread repair inserts sep-

remove any snapped, broken

cleaning the cylinder head, remove carbon

a

which hold wiring harnesses and such, and

these holders are often

combined reamerAap section

ety ol taps

When

Modern day engines use clips

because they

differ

is

the tool and break off the tang

using a punch

a tap (corresponding to the outside diame-

arately in addition to a master

Use extreme care when cleaning around the cylinder head valve seats. A mistake or slip may cost you a new seat.

it

V4-V2 turn below the top surtace. then

inserts, ter

slot.

into the hole until

order to receive the thread insert. Keep

quently to avoid clogging the threads

components. Use a ring expander

and remove the rings from the pistons. Clean the

ken

112 Using the

Fig.

insert onto the installer

engages the

tool until the tang

111

Fig.

There are two basic types ol cylinder heads used

to

labels or

compo-

bolts and/or studs which fasten them.

on

today's automobiles the

Overhead Valve (OHV)

and Ihe Overtwad Camstan (OHC) The also be broken

down

into

latter

can

two subgroups: ttw Singir

ENGINE AND ENGINE OVERHAUL Overhead Camshaft (SOHC) and the Dual Overhead Camshaft (DOHC). Generally, single camshaft on a head,

OHC

an

head.

cylinder head l\/1ost

if

there

is

known as

also

is

alloy

due

and heat transfer

wear

a pushrod engine.

made

cylinder heads these days are

aluminum

an

of

and

Springs ual.

Some

seats.

more

hi-tech engines will utilize a multi-valve con-

When

and even 5 valves per

the valve contacts the seat,

cylinder.

does so on pre-

it

cision-machined surfaces, which seals the combustion

chamber

All cylinder

heads have

a valve

each valve The guide centers the valve

for

seat

and allows

move up and down

to

it

guide

within

vacuum, and/or damage the

oil,

Too

and the valve can

little,

lose

stick in the

ing the engine to run poorly

causing severe damage. The

it

at all,

opened by the valve

seat.

its

when

valve to this position

It

guide caus-

(sometimes called keepers). Aluminum heads to

to

wear

will

rpm

it

tolls

on

all

below

in

bumf,

is

if

1.

all

same goes

for

in

all

the

3.

f^Due

An

ideal

method

is to

disassemble and

all

Fig.

all

of

components.

tool,

and

retainer.

engine varnlsli, the retainer valve

locics.

A

may

gentle tap with a

help to brealc

Remove

loose.

It

the valve locks from the valve tip

A

retainer.

Lift

small magnet

may

the valve spring, tool

and

help

in

all, oft

remov-

of the

valve stem.

seal

If

equipped, remove the valve seal.

is difficult to

remove with the valve

removing the valve

first,

If

the

in place, try

then the seal. Follow the

steps below for valve removal. 7.

Position the head to allow access for with-

drawing the valve.

is

4.5Land 4.9L Engines

•^Cylinder heads that have seen a

lot of

miles

will

»

See Figures 114, 115, 116, 117, 118, 119

head

of the valves, guides,

Before disassembling the cylinder head, you

may want

to fabricate

some

containers to hold the

and/or abuse

may have mushroomed

the valve

lock grove and/or tip, causing dilliculty in

removal a metal

of the valve. file to

If

carefully

this

has happened, use

remove

the high spots

114 When removing an OHV valve 115 A small magnet

spring, use a compressor tool to relieve

Fig.

the tension from the retainer

removal

117 Remove the valve seal from

valve stem

—

0-ring type seal

shown

f

will help in

of the valve locks

^ Fig.

from the

ing the locks.

6.

DISASSEMBLY

keep the spring

of rebuilding the cylinder

4.

and/or

5.

from wearing away the aluminum.

would involve replacing

to

hammer may

After the cylinder

head(s) are disassembled, thoroughly clean the

Use a valve spring compressor

if

Unfortunately the only way to find out which

check each piece.

do so now.

envi-

as an insurance policy

components need replacing

shafts,

relieve spring tension

any other component on

it

not going to

is

easily accessed.

of the

same

there

Position the head so that the springs are

sticic to tlie

to replace

operating

if

you haven't already removed the rocker

If

arms and/or 2.

a cylinder head can be

may be wise were

will aid in

maintain a components original location;

be any machine work performed on the compo-

to the

machined and re-used, saving you money However, a valve

try to

Unfortunately mileage

it.

Also keeping

nents.

of the parts. Generally the valves,

guides, springs and seats

lost.

assembly and reduce confusion. Where possible,

wear or even burn.

to

often runs the engine

them can be quite small

components organized

yourself and the

this is especially important

rapidly.

running too lean,

also returns the

camshaft. The spring

shim

who

that stays well

takes

carefully

all

fastened to the valve by a retainer and valve locks

also have a valve spring

one

seat.

the valve has been

train or

it

out

against future problems related to that component.

cylinder heads have are valve springs The spring

holds the valve against

is

that is oil

of

(such as keepers) and easily

victim to the driving habits of the individ-

the cylinder head. Think of

and possibly

components

last

fall

driver

ronment. The

it.

Too much clearance and the engine may

consume

A

valves, since they

to the

The clearance between the valve and guide can be critical.

the lubricating

some

various parts, as

is

and seat

redline will wear out or break the springs faster then

use two valves per cylinder, while the

figuration using 3, 4

wash

guide with gasoline, causing

and seats allowing them

and

cylinder heads have valves

will often

Conversely an engine, which

num

all

often this

of valve, guide,

an improperly tuned engine. An engine

on many vehicles today Whether made from alumior iron,

was maintained,

A major cause

place higher combustion temperatures on the valves

used

is still

is

of the

However, cast iron was

the material of choice in the past,

the engine

running too rich

to its light weight, durability,

qualities.

how

not necessary

OHV

addition, an engine with an

In

new ones. However, depend-

seats, springs, etc. with

ing on

only a

referred to as

is just

it

3-29

Fig.

116 Be careful not

valve locks (keepers)

to lose the

small

ENGINE AND ENGINE OVERHAUL

3-30

around the lock grooves and/or

enough

A

to allow

8

Remove

9.

II

lip.

Only Hie

It

removal.

lively

unchanged One aspect

cylinder head

There

will

Ihe valve from the cylinder head.

equipped, lemove Ihe valve spring shim.

to is

followers as well as an exhaust camshaft and fol-

some

In

in

cases, the

components are

removal.

be installed incorrectly

ily

Repeat Steps 3 though 9

pay attention

be an intake camshaft and

lowers and they must be labeled as such

small magnetic tool or screwdriver will aid

10.

to

on Ihe dual camshaft

careful labeling ol Ihe parts

identical

and could eas-

DO NOT MIX

THEI*^ UPi

until all of the

Determining which

is

which

very simple: the

is

valves have been removed, intake camshaft

and components are on the same

side of the head as

4.6L Engine

versely, the exhaust

>

See Figures 120 and 121

on the same side

was

the intake manifold

Con-

camshaft and components are

of the

head as was the exhaust

manifold.

Whether

it

is

a single or dual overhead camshaft

cylinder head, the disassembly procedure

is

rela-

ROCKER ARM TYPE CAMSHAFT FOLLOWERS »

See Figures 122

thru

Fig.

124 Before the camshaft can be

removed,

removed

130

all ol .

.

Ihe followers

must

first

I

.

f^ost cylinder heads with rocker arm-type

camshaft followers are easily disassembled using a standard valve spring compressor However, certain

models may not have enough open space around the spring lor the standard tool and to

may

require you

use a C-clamp style compressor tool instead 1

II

remove the rocker

not already removed,

arms and/or shafts and

the camshaft.

If

applicable,

also remove the hydraulic lash adjusters.

positions lor 2.

t\/lark

their

assembly

Position the cylinder head to allow access

to the valve spring. 3.

Use a valve spring compressor

relieve the spring tension

from the

tool to

retainer.

Fig.

»Due

to

engine varnish, the retainer

stick to the valve locks.

hammer may

Fig.

120 Exploded view

may

A gentle tap with a

help to break

it

125 ..

removed by

.

then the camshaft can be

sliding

It

out (shown), or

unbolting a bearing cap (not shown)

loose.

of a valve, seal,

spring, retainer and locks from an

OHC

cylinder head

Fig.

122 Example

rocker arms on

Fig. 121

Eiample

head Note how

it

of a multi-valve cylinder

has 2 intake and 2

exhaust valve ports

Fig.

of the shaft

mounted

some OHC heads

123 Another example

Fig.

126 Compress the valve spring

Fig.

127 ..

.

of the rocker

arm type OHC head This model uses follower under the camshaft

a

.

then remove the valve locks

from the valve stem and spring retainer

ENGINE AND ENGINE OVERHAUL

3-31

TCCA3P52

129 Remove the valve seal from the

Fig.

128 Remove the valve spring and

Fig.

retainer from

Remove

4.

and/or

cylinder head

small magnet

may

help

in

•

remov-

•

Lift

the valve spring, tool

and

all, off

of the

seal

If

equipped, remove the valve seal.

is difficult

to

remove with the valve

removing the valve

first,

If

the

If

A

dial indicator or inside

have seen a

lot of

abuse may have mushroomed

and/or

miles

the valve

removal

of the valve.

a metal

file to

If

this

has happened, use

remove the high spots

carefully

around the lock grooves and/or to allow

tip.

Remove

9.

If

Only

»

Look closely

at the

equipped, remove the valve spring shim. in

squared edge with an even width

When

diameter.

The margin

is

should have a

It

around the

all

the

edges or dishing

and

will

usually not occur to

show

the center of

in

all

valves. All of the heads should look the same, any

seem dished more

until all of the

tips.

Check

especially

for

if

head components are

time to inspect them for wear and/or will

in.

them

should appear

to

flat,

remove the

flat.

worn valve

Last,

tips will

need

is

rolled

surface to check for bends

unworn area

of the

these inspections

on a

The

first

thing to check

the

is

most obvious, bro-

ken springs. Next, check the free length and square-

ness of each spring.

If

applicable, insure to

distinguish between intake and exhaust springs. ruler and/or carpenters

length.

A

square

to

measure the

carpenter's square should be used to

check the springs

for

squareness.

If

a spring pres-

measure the valve stem diameter with the

guide, especially towards the

Fig.

sure test gauge ing

available,

is

and compare

check each spring

to the specification chart.

springs that

fail

rat-

Check

Any

tip

where most

compare them

to

each

132 Use a micrometer

valve stem diameter

other.

of the

to

i

Wear

The spring

these inspections should be

retainers rarely

ever they should

still

need replacing, how-

be checked as a precaution.

retention areas for any signs of excessive wear.

Also, check for any signs of cracking. Replace any

normal.

be machined

micrometer. Measure the area that rides within the

length and

for the valves

may be

the

fail

Inspect the spring mating surface and the valve lock

although slight

to

wear occurs. Take several measurements along

micrometer

131 Valve stems

dam-

need some

specialized tools:

A 0-1

to file

rounding with high mileage engines Slightly

you

that

than others are probably

any burrs around the lock grooves,

you had

valve. Valve tips

INSPECTION

age. To accurately inspect them,

Any valves

the readings against the specifications given.

of the

bad. Next, inspect the valve lock grooves and valve

that all of the cylinder

no

the speci-

See Figures 133 and 134

Use a

a valve burns, the margin will look

lifting of

the head

that

valves have been removed.

it's

head, margin, and face for any

cracks, excessive wear, or burning.

valve head for any signs of tulipping. This will

removal.

small magnetic tool or screwdriver will aid

Now

mm) below

(0.025

in

it

the valve from the cylinder head.

Repeat Steps 3 though 9

in.

valve stem.

things to inspect are the valve heads.

first

melted and the edges rounded. Also, inspect the file

removal. 10.

0.001

to

little

given

Springs, Retainers and Valve Locks

as a 8.

flat

shop

See Figures 131 and 132

the best place to look for burning.

lock grove and/or tip, causing difficulty in

Fig.

to a

is

stem should not read more than

Valves

The that

no minimum diameter

in place, try

then the seal. Follow the

drawing the valve.

•

proper tools,

to the

them as well

should be replaced.

>

^Cylinder heads

all of

fications, then the

components

to bring the

If

iron

have these valve spring shims.

should be even along the length with taper.

Position the head to allow access for with-

7.

clean,

diameter gauge for

aluminum and some cast

All

will

Remove

spring pressure test gauge

you do not have access

130

heads

that does.

steps below for valve removal.

A

A

you may want

valve stem. 6.

Fig.

may

the valve guides

ing the small locks. 5.

gentle prying or pliers

help to remove stubborn ones

the valve locks from the valve tip

A

retainer.

ttie

Some

guide.

its

retainers that are questionable.

Valve locks should be inspected for excessive

wear on the outside contact area as well as on the inner notched surface.

Any locks which appear worn

^

or broken and

its

respective valve should be

replaced.

Fig.

133 Use a caliper

spring free-length

to

check the valve

3-32

ENGINE AND ENGINE OVERHAUL VALVE SEATS

Physical

A visual inspection ol the valve seats should show a slightly worn and pitted surface where the valve lace contacts the seat Inspect the seat carefully for severe pitting or cracks. In addition, a seat that is badly

A

head.

worn

seat concentricity gauge,

used

to

if

specification the seat is

If

must be machined

given use

002

no

(if

051

or

in.

mm)

Place a straightedge across the gasket surface feeler gauges, determine the clearance at the

center ol the straightedge and across the cylinder head at several points Check along the centerline

See Figure 135

Now

and diagonally on

the

exceeds

003

(0

cm) span,

or

in

0006

head surface

the warpage

If

076 mm) within a 6

in,

(0,152

mm)

in.

over the

length of the head, the cylinder head

you know the valves are good, you can check the guides, although a new valve,

that

use them

(15.2

total

must be resur-

faced.

thing, look at the guides carefully

After resurfacing the heads of a V-lype engine, the intake manifold flange surface should be checked, and if necessary milled proportionally

for

allow for the change

if

IS

to

available,

is

preferred. Before

you measure any-

and inspect them any cracks, chips, or breakage. Also, if the guide a removable style (as in most aluminum heads),

chamber, however,

(or higher) from another, the guide has

to crack in a

it

moved.

a dial indicator onto the spring side of the oil

the valve

stem and

insert

into the cylinder head. Position the dial indicator

against the valve stem near the

tip

Generally, cracks are limited to the

head or

A

and zero the

just is

ings fvlount the dial initial

ing.

point, zero the gauge,

Compare

condition.

an out

Check the readings against

tions given.

designed

and again lake a read-

the two readings for

An

Inside Diameter (I.D

for valve

guides

will

)

of

round

the specifica-

gauge

give you an accurate

valve guide bore measurement.

why

risk trying to

to

do

it

save a couple

all

over again'

Any valves

for the

head

spark plug hole, port, outside of the valve spring/rocker arm area The is

always the

Some more

reliable

iron)

IS

extremely good condition, as well as the valve seats

to

methods

without perform-

machine work has been pertormed and/or

valves have been purchased This insures a

"•Before lapping the valves

and seat

lo the seats,

read

head section to insure any related parts are in acceptable

enough condition it

lor

mag-

to continue.

-Before any valve seat machining and/or lapping can be performed, the guides must be within factory recommended specifications. Invert the cylmd-'i t'pjri

1

2 them

have your cylinder

for cracks, especially

have overheated and/or

and pricing

alter

in

practice lo lap the valves

Lightly lubricate the valve

stems and

insert

into the cylinder

head in their numbered order Raise the valve from the seal and apply a small amount of line lapping compound to the seat 3.

to

consumed coolant Contact

lor availability

recommended

LAPPING THE VALVES

that

light to reveal the cracks.

recommended

was known

a

dye penetrant

head checked professionally leaked or

is

the rest ol the cylinder

hottest: the

used only on ferrous metal (cast heads, Zyglo' uses a spray on fluorescent

strongly

were not replaced should be

and guides, they may be lapped ing machine work.

is

mixture along with a black It

that

combustion

uncommon

not

inspecting for cracks include Magnaflux", a

the engine

be replaced or machined

is

it

netic process or Zyglo*, a

l^agnaflux'

II the ID gauge is used, compare the readings with the specifications

these inspections should

tar

refaced and the tips ground flat Unless you have access to a valve grinding machine, this should be done by a machine shop II the valves are in

new

visual inspection should be performed, but because you don't see a crack does not mean

not there.

given Any guides that

fail

so

you might have

Valves

even

exhaust seat/port area.

gauge. Grasp the valve stem, wiggle towards and

and observe the readindicator 90 degrees from the

il

positive seal behveen the valve

in the

area to inspect

first

away from the

dial indicator,

bucks

It

mounting position.

in its

CRACKS AND PHYSICAL DAMAGE

for any looseness or evidence of movement. All of the guides should appear to be at the same height from the spring seat, II any seem lower

Mount

is not worn, can be pertormed yourinexpensively However, you spent a lot of lime

effort

to

check them

cylinder head Lightly

inspected part self

and

lor flatness.

ol

Using

VALVE GUIDES »

REFINISHING & REPAIRING Many

Alter

There are several things lo check on the cylinder head: valve guides, seats, cylinder head surface flatness, cracks, and physical damage.

Inspect the camshalt(s) and followers as

the procedures given tor relimshmg and repairing the cylinder head components must be pertormed by a machine shop Certain steps, if the

you have cleaned the gasket surface ol the cylinder head ol any old gasket material, check the head

not repairable

described earlier

square can be used

Cylinder Head

it

run-out exceeds a

See Figures 136 and 137

»

or,

head should be replaced

to

CYLINDER HEAD SURFACE FLATNESS

134 Check the valve spring tor squareness on a flat surface: a carpenter's Fig.

these delects should be lixed the

A

should be

available,

check the seat run-out.

specification

may need

cracked seats must be replaced.

All

usually very evident For

is

be recessed into the cylinder

will

severely worn or recessed seat

be replaced.

damage

example, a broken mounting ear from dropping the head or a bent or broken stud and/or bolt All of

if

ol these services

Moisten the suction head

4 tool

a local

and attach

shop 5

ii

to the

head

of a

hand-lapping

of the valve

Rotate the loot between the palms ol both

hands, changing the position ol the valve on the

Fig. 135 A dial gauge may be used to check valve slem-to-guide clearance: read

the

gauge while moving the valve stem

Fig

136 Check the head

lor flatness

across the center ol the head surface using a straightedge and feeler gauge

Fig

137 Checks should also be made

along both diagonals

ot the

head surface

ENGINE AND ENGINE OVERHAUL valve seal and

lifting

guides which were reamed. Oversize are generally

the tool often to prevent

0.003

grooving.

Lap

6. is

ttie

valve until a smootfi, polisfied circle

evident on the valve and seat.

Rennove the

7.

tool

traces of the grinding to

maintain

and the

to

0.030

(0.381

in.

mm)

(0.076 to 0.762 mm), with 0.015

common.

being the most

Wipe away

all

be drilled out, then reamed to accept replacement

store the valve

guides. This must be done on a fixture which will

allow centering and leveling

however welding

ASSEMBLY The

impossible to

it

tiave

been lapped. Ttiey must be put back same valve seat with which they

all

Replaceable-type guides are pressed into the

A hammer and

cylinder head.

punch may be used

were lapped.

record

repair or refinishing possible with

the springs, retainers

found

it

and valve

locks.

If

they are

for installation.

chamber side

of the head.

mine whether

or not the

(or

known good)

parts.

mended

drift,

machine

shop. Read below and review your inspection data

determine whether or not machining

necessary

is

VALVE GUIDE

if

it

If

there

to the valve guides, the seats

must be

oughly clean them

of

any

is to

of valve

thor-

(all

alumi-

recommended methods

worn guides.

for repairing

•

Knurling

•

Inserts

Replacing is

ing a true center,

in

which metal

and providing

expensive way

more than a short

oil

time.

It

control.

the

is

It

in

some

would not be cost

tools, unless

same

Installing a

good condition, the valves can

is

insert.

must be

perfectly centered to the valve guide,

the cylinder head

machined the head

flat.

If

the

is

is installed,

it

where

a special tool

Relieve the spring pressure slowly and insure

insert is then

is

is

then run

reamed

to the

for oversize valves restores

it

to

standard

normal

clearances and provides a true valve seat. cast-in type guides can be

may need to be replaced. In some may be possible to straighten a warped

reamed

to allow

Remove

9.

Repeat Steps 2 through 8

machining.

need

to

In

either case,

until all of the

stems and

Lightly lubricate the valve

of the valves into the cylinder head.

If

insert

possible,

2.

If

equipped,

install

any valve spring shims,

which were removed. 3.

If

equipped,

install

keeping the following If

in

the

new

lightly lubricate the outer

•

It

the seal

is

guide surfaces.

an 0-ring type,

before the valve locks. 4.

valve seals,

mind:

the valve seal presses over the guide,

has been resurfaced.

5.

Failure to align bore the camshaft bearing

journals could result in severe engine

dam-

age including but not limited to: valve and piston damage, connecting rod damage, camshaft and/or crankshaft breakage.

CRACKS AND PHYSICAL DAMAGE in

both cast iron

an

and aluminum heads. For cast is

installed

iron, a

tapered

along the length

of the

purchase

for all

the

tool.

maintain their original locations.

just after

crack.

and new, oversize stem valves

compressor

journals align bored after the cylinder head

Certain cracks can be repaired to accept

the spring

ROCKER ARM TYPE CAMSHAFT FOLLOWERS

•

threaded insert will

becomes dislodged by

8.

it

head enough

i\/lost

valve with an oversize stem. The cost factor tor this

can become quite high as you

the valve locks to the stem.

it

is

installed

compressing the spring but

Place the valve spring and retainer over the

stem.

the guide

insert, locking

the spring.

7.

4.6L Engine

all

must be

extremely severe,

is

size for proper valve clearance.

the reamer

Position the spring compressor tool and

1

warped,

warpage

style is the

to accept a split-sleeve insert. After

through the guide to expand the

Reaming

Place the valve spring and retainer over the

springs have been installed.

installed into a threaded guide.

the thin-walled insert

reamed oversize

One

installed

is

retainer

for

guide insert involves machining the

which

The

sev-

type cylinder head.

guide to accept a bronze

the guide.

to rebuild

it

Assemble

f^Any OHC cylinder head that shows excessive warpage should have the camshaft bearing

obtain proper

to

guide surfaces.

an 0-ring type,

is

compressing the spring but

that neither valve lock

contact a professional machine shop for service.

effective to pur-

you plan

the seal

6.

requires a special knurl-

and precision reaming tools

the insert

If

the valve seats are worn, cracked or damaged,

of repairing the valve guides.

cases, a knurled valve guide will not stand up for

is

valve guides, the seats must be

the seats are in

instances,

Another

replacements were

instructions.

dis-

is

not necessarily the best, and

is

It

or

assembled. See the procedure on lapping valves

If

coil-type,

4.

5.

CYLINDER HEAD SURFACE

a process

valve seals, keep-

stem.

specifications.

they must be serviced by a machine shop. The valve

placed and raised, thereby reducing clearance, giv-

eral of the

•

be lapped to the seats, and the cylinder head

If

new

the valve seal presses over the guide,

before the valve locks.

which requires very accurate machining.

Reaming oversize

•

izer

If

lightly lubricate the outer

formed, the guides must be within factory rec-

to the

any valve spring shims,

install the

ing the following in mind:

VALVE SEATS

seat

•

install

equipped,

If

•

machined.

heads) and the cast-in integral-type (most cast

iron heads). There are four

chase these

equipped,

If

just after

made

guides used on

automobile engines: the ^eplaceable-^ype

clearances.

3.

A

the installation process.

It

it

head.

thickness as the mea-

dirt or oil residue.

There are only two types

least

2.

into the cylinder

of the cylinder

insert

possible,

If

which were removed.

jacket,

Use the stepped

compress

replacing, the only service to perform

However,

no water

sured protrusion

»lf any machining

Unless the valve guides need machining or

Knurling

is

bore.

stack of washers the

ommended

machined.

num

its

of the valves into the cylinder head.

maintain their original locations.

does, use the recom-

and hammer the new guide

same may help

all

stems and

Lightly lubricate the valve

1

installing, deter-

•^Before any valve seat machining can be per-

any machining or replacements are made

>»lf

When

and

head from the spring side

refinishing procedures dealing with the

cylinder head must be performed by a

to

components necessary

if

to their respective positions.

4.5L and 4.9L Engines

guide also seals a water

grease the valve guide and

Cylinder Head

Most

be

the stepped drift to

sealing agent.

jacket in the head,

new

Use

out the old guide from the combustion

be worn or defective, they must be

to

replaced with

have a

to

that are to

the

all of

onto a suitable work space and,

is

thoroughly clean

to work. Next,

and components

arrange the parts

protrusion on the spring side of the head and

hammer no

is

which

guides. Before removing the guides, measure the

Springs, Retainers and Valve Locks There

in

of the parts

assembled. Finally place

a stepped drift or

and remove the

to install

step for any assembly job

first

clean area

properly machine the seat.

with the

repaired through brazing or

the original valve

off of

misalignment may occur making

not get the valves out of order after ttiey

Some

the preferred method.

advice for your particular dilemma.

seat or guide, otherwise a serious guide-to-seat

Do

is

damage can be

physical

welding. Contact a machine shop to get expert

To replace cast-in type valve guides, they must

valve.

compound and

lapped location.

its

in.

3-33

Aluminum can

also use the tapered inserts.

Position the spring compressor tool and

compress the spring. 6.

Assemble the valve locks

7.

Relieve the spring pressure slowly and

insure that neither valve lock

to the stem.

becomes dislodged by

the retainer 8.

Remove

9.

Repeat Steps 2 through 8

the spring

compressor

tool.

until all of the

springs have been installed. 10.

Install the

camshaft(s), rockers, shafts and

any other components

sembly

that

were removed

for disas-

ENGINE AND ENGINE OVERHAUL

3-34

and turn the crankshaft during disassembly Also, all

engine covers (timing,

Iront. side, oil

pan. what-

ever) should have already been removed. Engines,

GENERAL INFORMATION

which are seized

or locked up.

may

not be able to

be completely disassembled, and a core (salvage

A thorough

overhaul or rebuild of an engine

yard) engine should be purchased

block would include replacing the pistons, rings, bearings, timing belt/chain assembly and

OHV

For

pump.

oil

4.SL and 4.9L Engines

engines also include a new camshaft and

bored and honed oversize (or cylinder sleeves,

it

new sleeves

using removable

installed)

and the

new

crankshaft would be cut undersize to provide

wearing surfaces and perfect clearances. However,

may

your particular engine

worn

out.

What

if

not have everything

done during

not

If

The block would then have the cylinders

litters

drive assembly,

would be

your engine

in

is

are,

worn, other

if

one

you should always replace the

and

is

what

is

If

pick-up and

pump

necessary remove the cylinder ridge of the bore.

See the cylinder ridge

removal procedure.

rings, bearings

commonly

4.6L Engine

compoleast,

pump. This

oil

equipped, remove any balance or auxil-

It

from the top

nents are sure to follow, and soon. At the very

oil

in

pump

back together, but this

example. Chances

a very rare

component

oil

still

within factory specilications'' Well, you could just it

keeping them

the timing gears and/or

and withdraw the camshaft from the

engine block. Remove the

assembly iary shafts.

replace the rings and put

lifters,

Remove

timing chain assembly then remove the

only the piston rings have worn

out and the clearances on everything else are

head removal,

the cylinder

remove the pushrods and order for assembly

called a

II

not done during the cylinder head removal,

remove

the timing chain/belt and/or gear/sprocket

assembly Remove

"freshen up."

assembly and,

if

the oil pick-up

necessary the

and pump

pump

drive.

II

equipped, remove any balance or auxiliary shafts

Cylinder Ridge

Removal

the bore.

end

of the travel

is built

and the top

up between

past the ridge can be

difficult,

piston ring lands could occur.

removed before at all.

installing a

All

Engines

and damage II

new

the ridge

to the

is

not

piston or not

bore using a Rotate the engine over so that the crankshaft

exposed. Use a number punch or scribe and mark

each connecting rod with

engine

is

always number

1

.

to the front of the

However, depending on

the engine placement, the front of the engine could

»lt Is always recommended that you remove any cylinder ridges before removing the piston and connecting rod assemblies. II you know

either

new

pistons are going to be installed and

the engine block will be bored oversize, you

may be able to forego this step. However, some ridges may actually prevent the assemblies from being

removed, necessitating

There are several different types of ridge reamers of

Unless a great deal of engine rebuilding

is antici-

Turn the crankshaft until the piston

is at

the

Cover the head

3.

Follow the tool manufacturer instructions and

away

or scribe

main bearing caps from

the front

most cap being number

caps mark them

1

through

and also

front to rear with 1

(if

there are five

5. front to rear).

Take special care when pushing the connecting rod up from the crankshaft because

many

score the crankshaft journal. Insure that

two lengths

necting rod up about

1

from damage Using a

in

a

hammer, push the con-

(25

mm)

and remove the upper bearing

the piston

from the crank-

do the

and rod by hand, put the upper

the cap fasteners. this

to

if

manner, they tell

hall of

If

the parts are kept in order in

and you

will not get lost

will

be

which bearings came form what cyfmder

any problems are discovered and diagnosis

is

Remove all the other piston assemblies same manner On V-style engines, remove all

necessary in the

from one bank, then reposition the

ol the pistons

up and remove the piston assemblies

and as

Continue

The only remaining component

until all

block should

have been removed

now be

ol that

in the

the crankshaft

bank

engine

Loosen the

bearing caps evenly until the fasteners can be

lurned by hand, then remove them and the caps

See Figures 138 and 139

the crankshaH

oughly clean

The engine disassembly instructions following

all of

the

from the engine block Thor-

components

INSPECTION

you have the engine mounted on an If

not.

it

is

easiest to disassemble the

engine on a bench or the floor with

it

resting

on the

housing or transmission-mounting surface You

must be able

until the

Remove

bearing insert installed, and hand-tighten

its

mam

ttiat

Continue

insert

the bearing insert back into the rod, install the cap

with

Remove

bell

rubber hose over the rod bolts/studs

ol

wooden dowel and

sturdy

able to

hose

DISASSEMBLY

engine stand

the

connecting rod Remove the number

its

engine with the other cylinder bank head surface

of the cuttings as possible.

assume

is at

maximum

should allow the

one connecting rods fasteners and cap and place

or cut two pieces of rubber

of the piston with a rag.

the ridge reamer, the rag

of the cylinder ridges

»

number one piston

this

to protect the crankshaft

special plastic caps are installed over them,

the ridge, exercising extreme care to avoid

Remove

up Turn

cylinder bore (head surface)

Its travel,

pushing or tapping the connecting rod up

cutting too deeply

4

of

access to

shaft

same.

Its travel.

2.

cut

Use a number punch

the

the sharp threads of the rod bolls/studs will

which are inexpensive.

pated, borrow or rent a reamer

of

mark

bottom

its

removal.

bottom

ally the front of the engine laces the Iront of the

number one

the crankshaft until the

piston rings are out ol the cylinder bore

on the market, none

1.

be the flywheel or damper/pulley end. Gener-

vehicle.

Again, rotate the engine, this time to position the

respective cylinder

its

number. The cylinder closest

piston ring breakage and piston

of the

wooden dowel

is

damage may occur

that

139 Carefully tap the piston out

Fig.

of the cylinder bore.

Pushing the piston and connecting rod assembly

removed

See the cylinder ridge removal procedure

top piston ring does not travel to the

!

very top of the cylinder, a ridge the

If

necessary, remove the cylinder ridge from the top of

to

access the connecting rod lasteners

Now Fig.

138 Place rubber hose over the con-

that the

nents are clean

engine block and it's

and/or

and cylinder bores from damage

need some specialijed tools

damage To

all

of its

time to mspecJ them

necting rod studs to protect the crankshaft

compo-

lor

wear

accurately inspect Itiem, you wn'

ENGINE AND ENGINE OVERHAUL

The difference between these measurements

measure

or three separate micrometers to

Two

• ttie

A

•

Telescoping gauges

•

A

tell

dial indicator

the crankshaft centerline will always reflect the

bores

for the cylinder

wear. That is because at this position

rod alignment fixture to check for bent con-

components

to bring the

der bore the hardest. This

to the proper tools,

you do not have access

you may want

pare

you should not expect cracks

Generally,

engine block or

its

components unless

was severely overheated,

Fig.

not there.

is

it

for inspecting for

Some more

cracks include

Magnaflux-

is

recommended

strongly

or

consumed

on fluorescent mix-

to

availability

shop

the taper.

is

wear

com-

When you

compare these read-

tlie

Crankshaft Inspect the crankshaft for visible signs of wear or

same bore

the journals should be perfectly

All of

round and smooth. Slight scores are normal in its existing size

used crankshaft, but you should hardly

and condition, or

a

with your fingernail.

rebore to the next oversize

When measuring

feel

for

front

The amount

wear

of cylinder wall

and

at

the

each journal, then turn the

always

and

front

rebored.

known as

is

rear.

The difference between the

mm)

(0.305

in,

front-to-

degree reading

two points

at

at

each position;

that

measurement.

ness found, however, up

to

0.0005

can be overlooked.

In

in.

(0,0127

mm)

addition, the read-

at

is,

ings should

90 degrees from the crankshaft

the out-ol-round

of

and

for either

bottom and a point

is

Generally, there should be no taper or out-of-round-

number

the top, middle

at

and the first-to-90

has a

that

must be

or more,

are taken at a

each cylinder:

in

rear readings is the journal taper

Any cylinder

taper.

Measurements

positions

ENGINE BLOCK BEARING ALIGNMENT

rear of

micrometer 90 degrees and take two more readings, is

greater at the top of the cylinder than at the bottom.

taper of 0.0012

Engine Block

a

required (or in the

is

installed).

This wear

of these services.

for

them

the crankshaft

case of removable sleeves, have replacements

the

if

will

with a micrometer, you will take readings It

have overheated and/or leaked

coolant. Contact a local

and pricing

them

inspection will determine whether the cylinder can

be used

have your engine block

for cracks, especially

checked professionally engine was known

to

thrust

diameter— tal(e damage.

ture along with a black light to reveal the cracks. is

mea-

to

Msq-

used only on ferrous metal

(cast iron). Zyglo' uses a spray

gauge

a telescoping

several readings wittiin

reliable

naflux", a magnetic process or Zyglo', a dye penetrant.

140 Use

sure the cylinder bore

ponents, but just because you don't see a crack

does not mean

known as

wall clearance.

of

com-

of the

all

is

90 degree measurement. The

ings to your piston sizes and determine piston-to-

it

was evidence

or there

to your bottom,

measure your pistons, you

fluids,

bad bearings and/or crankshaft damage. A visual inspection should be performed on

it

difference between

in the

was

it

consume, or mix engine

to leak,

methods

most

where the

Take your top, 90 degree measurement and

shop

to a

that does.

known

is

engine power presses the piston against the cylin-

necting rods If

will

you all about the wear in your cylinders. The measurements which were taken 90 degrees from

pistons and crankshaft journals •

3-35

fall

within the factory specifications for

centerline,

journal diameters.

Remove

main bearing caps and,

the

if

as well as a point parallel to the crankshaft center-

still

If

main bearing

installed, the

inserts. Inspect all of the

line.

The measurements are made with

the crankshaft journals

tions,

main bearing saddles and caps or high spots.

damage

If

for

damage,

or,

if

found, and

is

it

will

is

caused

need

to

be

severe enough, replacement. Any

micrometer.

in

any clearance exists between the straight-

edge and the saddles, the block must be

to

it.

Also

to a

smoothed, thereby reducing the chance

you

if

means

of a flycutter

that runs through the bearing saddles.

have the necessary devices

will not

Take these components with you and save

yourself an extra

we

will

You

a micrometer.

bore

need one

is

is

The piston should be visually inspected

dirt,

carbon deposits, and old

or detonation), and scuffing or excessive wear

gauges lock and allow

two readings

first

will

be

to

it

finally the bottom,

making a

The wrist pin attaches the piston

expand.

connecting rod. The piston should the wrist pin, both sliding

at the top ot

total ol six

any

try to

move

on

to the

freely

on

and pivoting. Grasp the

connecting rod securely or mount

the cylinder bore, then proceed to the middle

and

for

signs of cracking or burning (caused by hot spots

the skirts.

called the deck. Insure that the deck

clean of

See Figure 141

Position the telescopic gauge in the cylinder

1

the engine block where the cylinder

Rods

of each,

size.

•Your head mounts

Pistons and Connecting

I

use a telescopic

will

with a measuring range which covers your cylinder

bore, loosen the

surface

of scoring

bearings.

PISTONS

DECK FLATNESS of

new

trip.

For our procedures,

Align-boring consists of machining the main

The top

within specifica-

be polished before

check the pistons, connecting rods and crank-

shaft.

gauge and

align-bored,

bearing saddles and caps by

it

insures that any minor burrs or high spots are

machine shop and have them mike chances are you

file.

Place a straightedge on the bearing saddles,

If

that

don't have the tools to check the cylinder bores,

the engine block, along the centerline of the crankshaft.

recommended

is

the necessary precision tools to

If

check the bore are not available, take the block

the

burrs or high spots should be carefully removed with a metal

it

being returned to service. Polishing the crankshaft

from a spun main bearing, the block align-bored

burrs,

fall

either a spe-

gauge and

cial dial indicator or a telescopic

it

in

a vise,

and

rock the piston back and forth along the cen-

measurements.

gasket material. Place a straightedge across the surface of the deck along

its

centerline and, using

gauges, check the clearance along several

feeler

2.

Hold the gauge square

tighten the lock.

straightedge placed along both diagonals of the

from the bore.

deck surface.

mm)

(0.076

0.006 deck,

in. it

If

the reading exceeds 0.003

within a 6.0

(0.152

mm)

in.

(15.2

3.

in.

cm) span, or

over the total length of the

Tilt

ivleasure the

the

gauge back

to

remove

record the reading. 4.

Again, hold the gauge square

in

the bore,

this time parallel to the crankshaft centerline,

must be machined.

CYLINDER BORES

back to remove 5-

See Figure 140

it

gauge with the micrometer and

gently tighten the lock. Again, you will

»

90

in the bore,

degrees from the crankshaft centerline, and gently

points. Repeat the checking procedure with the

it

tilt

and

the gauge

from the bore.

Ivleasure the

gauge with the micrometer and

record this reading. The difference between these

The cylinder bores house the pistons and

are

A com0001 5-0.0025 in.

slightly larger than the pistons themselves.

mon

piston-to-bore clearance

(0.0381

mm-0.0635mm).

cylinder bores.

is

Inspect and

measure the

The bore should be checked

of-roundness, taper and

size.

The

for out-

results of this

two readings

is

the out-of-round

measurement

of

the cylinder. 6.

Repeat steps

1

through

the next lower position, until the cylinder.

tinue until

Then go

all

5,

each time going

of the cylinders

to

you reach the bottom

to the next cylinder,

and con-

have been measured.

Fig. 141

ot

eter,

Measure the

piston's outer diam-

perpendicular to the wrist pin, with a

micrometer

ENGINE AND ENGINE OVERHAUL

3-36

wnsl

lerllne ol Ihe

There should not be any

pin.

Completely disassemble Ihe

excessive play evident between the piston and the pin,

there are C-clips retaining the pin in the pis-

II

ton then you have wrist pin bushings

the rods.

in

There should not be any excessive play between the

and the rod bushing Normal clearance

wrist pin

001-0 002

the wrist pin is approx.

lor

mm-O.051mm).

the reading to

measurement obtained

may be used

Ihe piston

piston

is

as

specilication, but the bore

new

installed. Generally

il

The diflerence

is.

the piston is out ol

II

is not.

you

will

need a will

to var

reliel

You should have straightness

rod

is

bent,

See Figure 142 Almost

all

will

the connecting rod

formed by a machine shop

II

Ihe cylinders are not to

be rebored, then the cylinder glaze can be removed with a ball hone.

When removing Do

lubricate the hone.

If

must be replaced,

II

may cause

Mount

need

to

II

new

pistons are

installed in the correct

damage can

and the

Use a

ol Ihe oil

all

down

soft bristle

brush

passages

Com-

engine and spray the entire assembly

with an anii-rust solution such as

WD-40*

similar product Take a clean lint-lree rag

up any excess

anti-rust solution

bearing saddles, etc Repeal the

final

cleaning pro-

cess on the crankshaft Replace any Ireeze or

which were removed during

oil

disasserr'

See Figures 144. 145. 146 and 147

2

II

II

Ihe

mam

the crankshaft

bearing inserts from the

main bearing lournals hav

to a definite undersize. install the

correct undersize bearing inserts

3

Be sure

that Ihe bearing

and bearing bores are clean Foreign mate;

under inserts

mea-

clearance.

Remove

been refinished

^^

and

will distort

bearing and cause lailure

Place the upper main bearing inserts

bores with tang

in

in slot

the

not within specifications, install

new Fig.

is still

is not,

142 Use a

ball type cylinder

remove any glaze and provide

out ol specilicalions, and Ihe

a

hone

new

to

sur-

face lor seating Ihe piston rings

Ihe rod will need to be recondi-

tioned by a machine shop.

»You

can also use Plastigage* to check Ihe

Pistons and Connecting

Rods

bearing clearances. The assembling proce-

dures have complete instructions on

> its

use.

See Figure 143 Only pistons with the wrist pin retained by C-

clips are serviceable by Ihe

Inspect Ihe camshaft

and

lifters/followers.

lit

home-mechanic Press

pistons require special presses and/or heaters to

remove/install the connecting rod and ^hnuid nniv

be performed by a machine shop

Bearings All of the

engine bearings should be visually

inspected for wear and/or

should look evenly worn scores or pits

damage The bearing around with no deep

all

the bearing

II

is

severely worn,

scored, pilled or heal blued, then the bearing, and

components

Ihe

machine shop

that

lor

use

It,

should be brought to a

inspection Full-circle bearings

(used on most camshafts, auxiliary shafts, balance shafts, etc

and

)

require specialized tools lor removal

installation,

machine shop Oil

and should be brought

to

a

lor service

Pump

»The

oil

pump

Is

responsible lor providing

constant lubrication

lo the

whole engine and

recommended that a new oil pump be installed when rebuilding the engine.

so

il

is

or

and wipe

Irom the bores,

Ihe rod and take another measurement.

in

the clearance

crankshalt

time using water and detergent

block and bearing caps.

tele-

the rods original crankshaft journal diameter

is

last

scrub the cylinder bores with a

pletely dry the

>

diameter of the bearings. Compare this reading to

clearance

one

Crankshaft

^

scoping gauge and carefully measure the inside

II

first

work area Next, clean

biy.

on these

ing inserts in place, install the cap to the rod

bearings

it

galley plugs

Place the connecting rod into a vice, with Ihe bear-

oil

dirt Iree

(dishwashing detergent works well) While washing

1

tighten the lasteners to specifications.

is

the engine block into the engine stand

occur.

only the bearing end ol the rod need be checked.

oil

it

may

the connecting

Ihe rods are straight

Ihe

it

into the piston

cleanliness

is

and thoroughly clean

wrist pin clearance is within specilicalions, then

is

ol Ihe piston, or

oil to

be installed lo the con-

lor

and wash

cylinder glaze with

excessive scoring of the cylinder

bores and wear on the hone.

or twisted connecting rods

surement The difference

manner Usually

in that

stamped

ASSEMBLY

It,

not allow the hone to run dry

relationship to the rod or engine

checked

F cast or

letter

assembly

unevenly wear Ihe bearing and

piston, as well as place greater stress

components Any bent

be the

engine block refinishing must be per-

shop as the pistons must be

machine shop.

a

at it

on the lop

give yoursell a clean,

necting rods This should be performed by a machine

CONNECTING ROD

engine and the must be

a notch or arrow

Ihe parts are in proper

all ol

required, they will

tons.

have a mark indicating Ihe direc-

engine

Betore you begin assembling the engine,

as this

block and purchase a complete set ol oversize pis-

Will

Installed into Ihe

and assemble Ihe pump.

a ball hone, use a light or penetrating type

best to rebore Ihe entire

is

due

or sticking

pistons

All

tion to the Iront ol Ihe

every engine component again The key to a good

»

two or more pistons/bores are

it

no binding

II

valve operates prop-

reliel

REFINISHING

need the cylinder rebored and oversize pistons

out of specilication,

is

nish or debris

within specilicalions,

both are out ol specilication, you

II

and there

thor

Ihe

wear and/or damage

lor

Ihe piston-lo-wall

is

the clearance

If

housmg

original cylinder

its

earlier.

between the two readings clearance

erly

pump and

oil

components Inspect

ol Ihe

the diameter ol

Ihe piston, perpendicular to the wrist pin, on Ihe

Compare

all

gears and

Insure that Ihe pressure

valve,

Use a micrometer and measure

skirt

pump

working condition, lubricate the gears and

(0.025

in

oughly clean

Fig.

143 Most pistons are marked

cate positioning

in

to indi-

Ihe engine (usually a

mark means Ihe side lacing the

front)

Fig.

144 Apply a

lo Ihe

strip ol

gauging material

bearing journal, then Install and

torque Ihe cap

ENGINE AND ENGINE OVERHAUL

DESCRIPTION Open

Transaxle T Cruise Control - Transaxle Cnjis© Control - Vent Sotei Cnjise Control - Vacuum £

Rear Healed Oxygen Sensor Not Ready Shorted Engine Coolant Temperature Sensor Open Engine Coolant Temperature Sensor Generator Voltage Out 01 Range [EVAP EGA,

CRUISE. TCC,

Too High

thru

54

1996-98 models, an OBD-II compliant scan

All

Problem [Cruise]

Transaxle Pressure Control, Long Tenri Fuel Trim) Front Heated Oxygen Sensor Not Ready Shorted Fuel Pump Circuit Open Fuel Pump Circuit Throttle Position (TP) Sensor [TCC, Shorted Transaxle Pressure Control) ... Open Throttle Position fTP) Sensor [TCC. EGR) Ignition Control Circuit Problem [Ignrtion Control)

See Figures 47

tool

must be used

low

tfie

how

to

scan

to retrieve ttie trouble

ttie

scan tool

to ttie vetiicle

[Cruise)

Cruise Control Servo Poslton Sensor

codes. Fol-

tool manufacturer's instructions

connect

on

and how

to retrieve the codes.

Failure [Cnjlse]

CnjIse Control - Engine RPM Too High (Cruise) Set/Coast Or Resume/Accel Input Shorted jCnjIse] Cruise Control Sen/o Position Out 01 n Cruise (Cruise]

r>rTCCl 1

Throttle Position (TP) Switch Circuit lEGfll

Open Throttle Position (TP) Switch Circuit [EGR] Transaxle Pressure Switch/Circuit Problem

;)

RPM

Air Temperature OAT) Sensor Speed Sensor Signal Interrupt [TCC] ... Transaxle Pressure Control Solenoid Circuit Malfunction [Trans, Pressure Control)

Vehicle

Out Of Range

.

CAM

To 4X Relerence Correlation Problem 24X Relerence Signal High Idle Throttle Angle Too High Undefined Gear Ratio Utana Pressure Control] Torque Converter Clutch (TCC) Not Disengaging (Trans Adapts) Long Shift and Maximum Adapt [Trans Pressure Control] TCC Brake Switch Input Circuit Problem [Cruise) Transaxle Range Switch Problem [Cnjlse] Heated Windshield Request Problem .

.

A)r Temperature (lAT) Sensor Open Intake Air Temperature (lAT) Sensor Torque Converter Clutch (TCC) Engagement Problem I4th Gear. TCC lor Ignition Cycle]

3

Cam

Traction Control

System

PWM

Unk

Failure

(Ist. 3rd, 4th Gear] Engine Stall Detected Torque Converter Overstress

Reference Signal From Ignition

Fig.

panel Sensor (EVAP Solenoid, EGR,

Open Brake Booster Vacuum (BBV)

DItterance

PCM/BCM

[EVAR EGR,

Data Unk Problem (EGR) S [EGR]

Cnjise,

TCC,

Lt

Sei Fuel Ti

Transaxle Adapts]

PROM Checksum Mismatch PCM Keep Alive Memory Reset

PCM/BCM

Data Unk Problem Mismatch

PROM Checksum

4X Reference Signal Intemjpt Fro

PCM Keep Alive Memory Reset Generator L-Termlnal Circuit Problem [TP Sensor Leam)

Total

EEPROM

Failure

Shift 'AVShlft 'B'

PASS-Key®

Fuel Enable Problem

[PASS-Key®

TELLTALE STATUS •SERVICE ENGINE SOON'

I

SERVICE VEHICLE SOON' message On DIG

PROBLEM - CAR MAY NOT RESTART message REDUCED ENGINE POVKER' message. NO CHARGE' message SYSTEMS ABE DISABLED WHEN CODE IS CURRENT

'THEFT SYSTEM

'BATTERY

Fig.

47 The OBO-II connector

Is

located

under the driver's side of the instrument

Oxygen Sensor Rich Exhaust Signal Rear Heated Oxygen Sensor Lean Exhaust Signal Rear Heated Oxygen Sensor Rich Exhaust Signal Front Heated

46 Diagnostic trouble

codes—4.6L

engine

arcult Output

Open Or Shorted

o

4-22

DRIVEABILITY

AND EMISSIONS CONTROLS

^sHMM 0>W«. S«~. {MOJSl C

Fig. 51

OBD

II

trouble codes (2 ol S)

OBD

52

Fig.

II

trouble codes (3 ol 5)

Fig.

53

OBD

II

Clearing Codes

particular vehicle,

Stored at

fault

trouble codes (4ol S)

Depending on the

codes may be erased Irom memory

any time by removing power Irom

ttie

PCM

lor at

electrical distribution of the

power

PCM may be di-; PCM fuse in the fu;

to the

connected by removing the

box. disconnecting the in-line fuse holder near '

least

30 seconds.

It

may be necessary

recurrence during a

stored codes

the negative battery cable to clear codes

The codes

ommended

may

still

but

test drive,

be required

lor

ttie

retrieved.

subsequent trouble-

shooting Whenever a repair

is

complete, the stored

codes must be erased and the vehicle confirm correct operation and

Ttie Ignition switch

power

is

caution

OBD

II

trouble codes (5 ol 5)

test

must be OFF any time

disconnected or restored

is

driven to

f

PCM. Severe damage may

54

positive battery terminal or disconnecting the P

power lead

must be written down when

Fig.

to clear

stored codes during diagnosis to ctieck lor any

not observed.

result

to the

if

this pre-

at the battery

as this

terminal Disconnectirg

will also clear other

is

not

ff-

memory

data in the vehicle such as radio presets

DRIVEABILITY

AND EMISSIONS CONTROLS

4-23

VACUUM DIAGRAMS I

See Figures 55

•The

thru 62

following

is

an assortment

of vehicle

emission control information labels. Following are vacuum diagrams

lor

most

of the

engine and emissions package combinations covered by

this

manual. Because vacuum circuits

will

vary based on various engine and vehicle options,

always

refer first to the vehicle

information label,

if

present.

emission control

Should the

label

engine from

refer to the

listed here,

underhood

always follow what sticker,

as

it

is

most

is

II

what

the is

on your

likely the

accurate label for your particular engine application.

be

missing, or should vehicle be equipped with a ferent

label on your vehicle differs from

dif-

the vehicle's original equipment,

diagrams below

for the

same

or similar

configuration. If

you wish

label, for

to obtain a

replacement emissions

most manufacturers make the

Fig.

labels available

purchase. The labels can usually be ordered

Fig.

56 Vacuum hose routing

Eldorado and Seville

55 Example

ol Veliicle

engine compartment

diagram— 1990

Emissions

Control Information (VECI) label

from a local dealer.

Deville, Fleetwood,

in

the

4-24

DRIVEABILITY

AND EMISSIONS CONTROLS (h°''

Fig.

60 Vacuum hose routing diagram— 1994-95 Deville and 1994

Eldorado with the 4.9L engine

BASIC FUEL SYSTEM

DIAGNOSIS 5-2 FUEL LINES AND FIHINGS 5-2 QUICK-CONNECT FITTINGS 5-2 SEQUENTIAL MULTI-PORT FUEL INJECTION SYSTEM 5-3 GENERAL INFORMATION 5-3 RELIEVING FUEL SYSTEM PRESSURE 5-4

THROnLE BODY

5-4

REMOVAL & INSTALLATION

5-4

FUEL INJECTOR(S) 5-6 TESTING 5-6 REMOVAL & INSTALLATION 5-7 FUEL RAIL ASSEMBLY 5-8 REMOVAL & INSTALLATION 5-8 FUEL PRESSURE REGULATOR 5-8 REMOVAL & INSTALLATION 5-8

FUEL TANK 5-9 TANK ASSEMBLY 5-9

REMOVAL & INSTALLATION ELECTRIC FUEL

PUMP

TESTING 5-12

5-9

5-9

REMOVAL & INSTALLATION

5-9

FUEL SYSTEM

5-2

BASIC FUEL SYSTEM DIAGNOSIS When

Ihere

two

vefiicle,

problem

a

is

ot the

systems The questions

fuel

most mechanics attempt spark?' and

answer

to

first,

'is there fuel'" will often

most tasic problems For and

starting or driving a

most important checks involve

and the

the ignition

ignition

"is there

lead to solving

system diagnosis

components and manual

earlier in this

out (there

system

fuel

is

systems found

the ignition system checks

If

spark), then

is

ignition

you must determine

operating properly

the

if

Ihere fuel?).

(is

Avoid sparks and any source of ignition

•

Use signs and any necessary warning

lo a is

process

on engine

testing, please refer to the information

electrical

While servicing the fuel system, fuel vapoi^ can colled in enclosed areas such as a trunk. To reduce the risk ol tire and increased exposure to vapors:

•

others in the work area that fuel system work

•

Use forced

•

Plug or cap any

air ventilation

fuel

Always wear safety goggles when working with tuel in order lo protect the eyes from

such as a fan

system openings

in

fuel splash.

order lo reduce fuel vapor formation •

Clean up any spilled

fuef

immediatety

FUEL LINES AND FITTINGS Nylon

same

fuel lines are

designed

perform the

to

function as the steel or rubber fuel lines they

replace. Nylon lines are constnjcted to withstand

maximum

tuel

additives,

and changes

The

system pressure, exposure

fuel feed, return,

in

assembled as a harness Retaining lines together

to fuel

temperature.

vacuum and EVAP

and provide a means

to chafing,

high temperature or vibration

are protected with heat resistant rubber hose and/or

"lastic Collar

l^etai Collar Quick-corinec; rining

Removal

for attaching the

lines to the vehicle. Sections of the lines that are

exposed

^=333

c=nil>

lines are

clips hold the

CAUTION TOBfOUC! AND PERSONA. INJURY,

THE RISKO'FIBc RELIEVE FUE:

SVSTEM PRESSURE BEFORE OlSCONNECTINC FUEL PIPE FITTINGS

coextruded conduit

Nylon

lines are

somewhat

flexible

and can be

formed around gradual turns under the vehicle However,

and

if

forced into sharp bends, nylon lines will kink

restrict fuel flow. In addition,

nylon lines

fuel,

to kink

may become

when working on

fire

to

likely

and personal

when working on nylon

Always cover a nylon

•

and more

a vehicle with nylon fuel lines.

To reduce the risk of injury

once exposed

stiffer

bent too far Special care should be taken

if

fuel lines.

fuel line with a

wet

towel before using a torch in the vicinity. Also,

never expose the vehicle to temperatures higher than 239'F (115°C) for more than one hour or more than 194'F (90°C) tor any extended period

Take care not to nick or scratch the nylon fuel lines

they

If

become damaged,

they must be

Quick-Connect Fittings >

See Figures

Some connect

early

and 2

fuef line fittings

make sure lines

1

model vehicles do not have quick-

to

On

these vehicles, just

use a back-up wrench on the

fuel

when disconnecting them

•It your vehicle is equipped with metal quickconned tittings. a special tool (J 37088A) or equivalent will be required to service the

fit-

tings. 1

.

2

Properly relieve the fuel system pressure If

equipped, slide the dust cover tack to

access the

fuel line fitting.

Grasp both ends connector

'/«

of the fitting. Twist Ihe

female

turn in each direction to loosen any

dirt within the fittings

Using compressed

air.

blow Fig.

out the

dirt

from the quick-conned

fittings

1

Disconnecting procedure lor quick-conned fuel

fittings

Ouick-connect =inins

FUEL SYSTEM

recommended when

Safety glasses are

try-

ing to clean debris from an enclosed area

with compressed

5-3

To reduce the chance of injury, apply a few

drops of lubricant (clean engine oil), to the male end of the tube before reconnecting

air.

the fittings. 3.

If

the fittings are metal,

size-releasing tool, insert

4.

It

female connec-

may be necessary

from the male end

of a

remove

to

rust or burrs fitting.

connections 10.

this

If

cloth to clean the tube by

back

rotating the cloth in a radial motion.

male

the

off

of the tube.

of the

they are secure.

dust cover

fitting

lines are connected, crank the

all

few seconds

for a

and then check

the engine starts, turn

(if

it

for fuel leaks.

which are hand

fittings,

releasable, squeeze the plastic retainer release tabs,

the quiclc-connect fitting

make sure

to

After

engine off)

For the plastic type

6.

on both ends

equipped, slide the fuel

If

you can

indicating they have locked.

clicl

ISOLATOR SLEEVE

SOUND INSULATOR

fil DEFLECTOR

rado and Seville

check

DAMPENER

BUMPER

in this

system

is

pari of the

sender assembly

II

it

is

accessible

is

accessible

34730-1A

39765

it

•When

4

Drain the luel lank to

5

If

at least

y*

of a tank,

il

sender lock nul wrench or equivalent

ated by handling the luel pipes could

damage

the joints

it

remove the 6

Drain the luel tank to no more than y* ol a ing ring or luel sender access panel in order to avoid possible luel spillage

7

8

damage

not accessible, safely drain and

fuel tank

Remove

the spare

the spare

tire

cover, the jack,

and

sender

to the float.

in

order

to

avoid

Place any remaining luel

Into

an approved container once the modular

luel

sender assembly

is

removed from

the luel

tank

tire

•Remove

tank before removing the tuel sender retain-

is

tuel

luel tank, the reservoir

bucket on the luel sender assembly must be tipped slightly during removal

full

••Do not handle the fuel sender assembly by the fuel pipes. The amount ol leverage gener-

Sender Spanner

removing the modular

assembly from the

procedure.

Fuel

the tuel sender retaining ring using

(or equivalent) Fuel

Wrench II

through the rear compartment, use the following

Special tools needed lor the repair J or equivalent, fuel pressure gauge. J

access the pump/sender, or

through the rear compartment

the rear compartment tloor trim to

Remove Remove

the rear

compartment

lloor trim

the bolts from the luel sender

The modular spring-up

luel

when

sender assembly

the locking ring

is

will

removed.

access panel

9

Detach the quick-conned

sender assembly

fittings at the luel

13

while

Pull the

pumping

modular

luel

sender straight up

the luel from the reservoir

FUEL SYSTEM

5-11

Legend

Fig.

14.

(1)

Fuel Feed

(2)

Fuel

(5)

Pump

(6)

(3)

External Strainer

(7)

Check Valve

(4)

Secondary Umbrella Valve

(8)

Convoluted Fuel Tube (Flex Pipe)

27 Diagram

of a

modular

Clean and inspect the

fuel

fuel

sender depicting the typical fuel flow

sender assembly

O-ring sealing surfaces.

ring

17.

Position the

on the

»Care the fuel

new

fuel

sender assembly 0-

fuel tank.

strainer

fuel

Ensure

that the fuel

full travel of

pump

strainer

does not

the float arm.

Reinstall the fuel sender

sender assembly retainer

when

sender assembly, as this

18.

Install the

cam using

quick-connect

the fuel

fittings at the fuel

sender assembly installing the fuel 19.

will restrict fuel flow.

Attach the electrical connector at the fuel

tank pressure sensor.

Attach the electrical connector at the fuel

20.

sender assembly

assembly and the

sender spanner wrench.

sliould be taken not to fold over or twist

pump

16.

block

To install: 15.

Fuel Flow from External Strainer Fuel Pump Strainer

Connect the negative battery cable.

21 22.

Inspect lor leaks. a.

Turn the ignition switch

ON

b.

Turn the ignition sw/itch

OFF

Turn the ignition swdtch

ON

for

2 seconds,

for

10 sec-

onds, c.

and check

for

FUEL SYSTEM

5-12 23 ttie

Reinstall the luel access panel,

fuel

sender access panel bolls

to

and

18

TESTING

tlgtiten

incfi lbs

long as the

t

compartment

24

Reinstall the rear

25

Reinstall the spare

spare

26

tire

tire,

fuel

See Figure 28

reinstall the fuel tank tiller

is

pipe

28 Diagram

the ignition switch

ON

the in-tank luel

is

turned

OH.

pump The

the

luel

PCM

pump

located inside the modular fuel sender The luel

pump

Fig.

IS

Feed Pipe

is

turned

ON

Fuel

In-Line Fuel Filler

(7)

(3)

Fuel Return Pipe

(8)

Fuel Pressure Connection

(4)

Fuel

(9)

Fuel Rail

(5)

Integral Reservoir

(6)

Flex Pipe

system pressure

(10)

test

Fuel Pipe Shut-off Adapters Fuel Pressure

will

remain

Gauge

Fuel Pressure Regulator

ON

as long as

cranking or running and the

is

PCM

II

there are

no

will turn the in-tank luel

after the ignition

switch

is

or 2 seconds after the engine slops run-

ning

not serviceable separate from the sender

(2)

of a typical fuel

pump

engine

pump OFF 2 seconds

(1)

Pump

luel t

receiving reference pulses

reference pulses The

When

and the

will turn

and

PCM

tloor trim

the jack,

cover

Add

The in-tank

(2

Nm),

UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS 6-2

REMOVAL & INSTALLATION 6-20 WINDSHIELD WASHER PUMP 6-21 REMOVAL & INSTALLATION 6-21

BASIC ELECTRICAL THEORY 6-2

INSTRUMENTS AND SWITCHES 6-22

HOW DOES

ELECTRICITY WORK: THE

WATER ANALOGY OHM'S LAW 6-2

WIRING & HARNESSES 6-3

INSTRUMENT CLUSTER 6-22 REMOVAL & INSTALLATION 6-22 GAUGES 6-25 REMOVAL & INSTALLATION 6-25 WINDSHIELD WIPER SWITCH 6-27 REMOVAL & INSTALLATION 6-27 HEADLIGHT SWITCH 6-27 REMOVAL & INSTALLATION 6-27 LIGHTING 6-28

CONNECTORS

HEADLIGHTS 6-28

6-2

ELECTRICAL COMPONENTS 6-2

POWER SOURCE GROUND 6-3

6-2

PROTECTIVE DEVICES 6-3 SWITCHES & RELAYS 6-3

LOAD 6-3 6-4

TEST EQUIPMENT 6-4 JUMPER WIRES 6-4 TEST LIGHTS 6-5

MULTIMETERS 6-5 TROUBLESHOOTING ELECTRICAL SYSTEMS 6-5 TESTING 6-6 OPEN CIRCUITS 6-6

SHORT CIRCUITS

6-6

VOLTAGE 6-6 VOLTAGE DROP 6-6 RESISTANCE 6-6 WIRE AND CONNECTOR REPAIR 6-7

BAHERY CABLES

6-7

DISCONNECTING THE CABLES 6-7 AIR BAG (SUPPLEMENTAL

RESTRAINT SYSTEM) 6-7 GENERAL INFORMATION 6-7 SERVICE PRECAUTIONS 6-7 DISARMING THE SYSTEM 6-7 ARMING THE SYSTEM 6-7 HEATING AND AIR

CONDITIONING 6-9 BLOWER MOTOR 6-9 REMOVAL & INSTALLATION 6-9 HEATER CORE 6-10 REMOVAL & INSTALLATION 6-10 AIR CONDITIONING COMPONENTS 6-10 CONTROL PANEL 6-10 REMOVAL & INSTALLATION 6-10 CRUISE CONTROL 6-11 ENTERTAINMENT SYSTEMS 6-12 RADIO RECEIVER/TAPE PLAYER/CD PLAYER 6-12

REMOVAL & INSTALLATION 6-12 REMOTE RADIO RECEIVER 6-14 REMOVAL & INSTALLATION 6-14 SPEAKERS 6-15 REMOVAL & INSTALLATION 6-15

WINDSHIELD WIPERS AND

WASHERS

6-18

WINDSHIELD WIPER BLADE AND

ARM

6-18

REMOVAL & INSTALLATION 6-18 WINDSHIELD WIPER MOTOR 6-20

REMOVAL & INSTALLATION 6-28 AIMING THE HEADLIGHTS 6-29 SIGNAL AND MARKER LIGHTS 6-30 REMOVAL & INSTALLATION 6-30 FOG/DRIVING LIGHTS 6-36 REMOVAL & INSTALLATION 6-36 TRAILER WIRING 6-40 CIRCUIT PROTECTION 6-40 FUSES 6-40

REPLACEMENT

6-40

FUSIBLE LINKS 6-47

REPLACEMENT 6-47 CIRCUIT BREAKERS 6-47 RESETTING AND/OR REPLACEMENT 6-47

FLASHERS 6-47

REPLACEMENT 6-47 WIRING DIAGRAMS 6-48

CHASSIS ELECTRICAL

6-2

UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS HOW DOES ELECTRICITY WORK THE WATER ANALOGY

Basic Electrical Theory »

See Figure For any 12

negative ground, electrical syselectricity

tfie

plete circuit Tfiis simply

from

ttie

must

positive (+) terminal ol

travel in

a com-

an

in

battery

Along

around the center core

orbit

an atom The center core

must

terminal ol

is

comprised

and neutrons

(positive charge) (-)

way.

ttie

When

positive charge of the protons

and components.

cir-

another atom to balance out

for

attached to

imbalance

this

it)

light

battery—one wire attached

to the

l^any people have been taught electrical theory to

wire to the positive (+) terminal. With the two wires

touching the battery terminals, the circuit would be

using an analogy with water

light

be the water and the wire

bulb and back

ol electricity

bulb would illuminate. Elec-

would follow a path from the It's

How

like the

easy

with longer wires on our light bulb,

mounted anywhere.

Further,

a comparison with

is

the pipe

much

can be measured

to

see that ated as

amps

volume

ol water flowing

could be

it

one wire could be

You can compare amperage

(a).

to the

When

through a pipe

con-

fitted

with a switch so that the light could be turned on

nected to a

circuit,

actual

amount

When

relatively

an ammeter

of current flowing

through the

circuit.

off.

The normal automotive simple example

in

circuit differs

from

First,

ing a return wire from the bulb

How through a circuit, When many electrons How, the

few electrons

this

amperage

the

two ways

is

low

instead ol hav-

amperage

is

(-) battery

cable

attached to

is

measured

is

ol electrically

units

in

circuit.

power from a single

amount

of wire

ground wire

Secondly, most automotive

circuits contain multiple

is

measured

voltmeter

is

(psi);

The

electrical pres-

When

in units called volts (v)

connected

to a circuit,

it

is

I

in

these lormulas. E

ol

the current in

Is

ohms The

as the resistance

is

the voltage in

amps and R

basic point to

is ttie

resis-

remember

is that

a circuit goes up. the amount of

ol

expressed as power The unit ol power

is

The relationship between power,

watt (w)

and current

Power (w)

is

equal to amperage

(I)

times voltage

lxE

=

This

is ttie

voltage.

expressed as

Is

only true lor direct current (DC) circuits;

is

The alternating current lormula

is

a tad diflerent. but

since the electrical circuits in rrwst vehicles are

we need

AC

not get into

DC

circuit tfKory

Components

Electrical

a

measuring

POWER SOURCE

the electrical pressure.

The actual flow

components

of electricity

depends not only on

that receive

voltage and amperage, but also on the resistance ol circuit

times resis-

such as

conductive metal).

the frame ol the vehicle can serve as a

complete the

pounds per square inch sure

(made

(I)

to the battery, the

current travels through the frame of the vehicle.

the frame

each

tance

type,

high.

Water pressure Since the negative

In

volts,

(E);W

measure the

will

law

Other forms ol the formula are R = E/1 and = E/R

lorm

amperes, frequently abbrevi-

is

Ohms

equal to amperage

R

X

1

Hows in the circuit will go down, if voltage remains the same The amount ol work that the electricity can per-

water through a pipe. The unit ol

ol

E =

is

current that

battery to the

measurement used to the battery

In

water flowing through a pipe, the electrons would

The tlow complete and the

kept up. electrons will continue to

is

eleclrical tlow will exist,

bulb (with two wires

the negative (-) terminal ol the battery and the other

to

If

to visualize a circuit is

move and an connecting a

'

tance

to function properly.

cease

Perhaps the easiest way to thinl( of

and

Voltage (E)

unbalance

ted by that circuit

atom and look

and resistance can be summed up

current, voltage,

by a statement known as

an outside

of electrons to

the charge ol the protons, the electrons will split off

component

the

tricity

number

a direct relationship between current,

is

and resistance The relationship between

voltage,

If,

force causes the

any reason, the flow of current through the

cuit is interrupted, the will

There

protons

ol

(neutral charge).

ttie

current will travel

ttiis

OHM'S LAW

ot

Electrons have a negative charge and balance out the

ttirougti wires, fuses, switches,

lor

the subatomic

current (power)

ttiat

ttie

—

panicles that constitute the outer shell ol an atom. Electrons spin

means

eventually return to the negative tHttery.

ot the

sensors on the engine

volt,

to operate,

m many

These principles are used

cient)

1 Electricity is the flow of electrons

tem

higher temperatures (negative temperature coelti-

This lessens the

needed to power components on the

the circuit

The higher the resistance, the higher the

lorce necessary to

push the current through the

cir-

Power

IS

supplied to the vehicle by two devices;

The battery and the

alternator

power during

electrical

The battery supplies

starling or during periods

vehicle.

The standard

cuit

an

ohm

cuit

LOAD

DEVICE

iBULBi

Resistance

amount and type

the

PnOTECTION

unit for

•

The main

measuring resistance

is

a circuit varies depending

in

ol

components used

in

on

the cir-

factors that determine resistance are;

Material— some materials have more

tors

used

in

some

ol the

most

common

among BETUBN

BETUBN CONOUCTOB

CONOOCTOB GBOUND

GBCXJNO

be conductors Copper wire

the best conductors Silver

superior conductor to copper and

is is

used

in

needs

ol the vehicle, but

it

the

recharges

relay contacts, but its high cost prohibits

its

common

is

•

example

illustrates a

the switch

from the positive

is

simple

closed, power

(+) battery terminal

wiring

Most automotive wiring

use as

made

ol

larger the wire size being used, the

then to the light bulb. The light illuminates and the circuit

Is

completed through

the ground wire bacl( to the negative

(-)

battery terminal. In reality, the two ground the illustration are

•

use large amounts

ol electricity usually

Length— lor

a given thickness ol wire, the

longer the wire, the greater the resistance. The shorter the wire the less the resistance

determining the proper wire lor a

and length must be considered that

•

attached to the metal frame

that

com-

have large wires supplying current to them

flows through the fuse and the switch, and

to

can handle the current needs

Temperature— with many

circuit,

When both size

design a

circuit

ol the

component

materials, the

ol the vehicle,

back

to the

most modern

vehicles, the battery is a

subsections (cells) connected

the unit

IS

capable

ol

m

series,

so

2

thai

producing approximately 12

volts of electrical pressure

Each subsection con-

sists ol a series of positive

and negative plates held

(positive temperature coefficient) exhibit the opposite

trait

Some

and water The two types

ol plates are ol dissimilar metels.

This sets up a chemical reaction, and

it

is this reao»:

lion that

produces current How Irom the battery

when

positive

Its

and negative terminals are con-

nected to an electrical load The power removed

Irom the battery

is

ing the battery to

replaced

its

t>y

the allemalor. restor-

orioinal chemical state

circuit

higher the temperature, the greater the resistance

which completes the

In

a short distance apart In a solution ol sulluric acid

Size—the

ponents

The Battery

volt

some

less resistance the wire will have This is wtiy

battery

when

running The alternator does not |ust sup-

is

lead/acid electrochemical device consisting ol six

is

actually a

copper

In

ot the alternator.

alternator supplies electrical current

vehicles as they have a very high

als are said to

shown

The

the battery

Insula-

resistance to electricity Very low resistance materi-

points

ol the vehicle's electrical

said to be insulators Rubber materials (or rubberlike plastics) are

When

demand

system exceeds the output capacity

engine

ply the current

resis-

tance than others Those with high resistance are

(BATTEBY)

Fig. 1 This

the current

''"5E'

POWEB SOunCE

circuit.

when

Tlie Alternator

On some

vehicles mere isn

generator The dillerence

materials

ol lower resistance with

plies alternating current, direct current lor

is thai

which

i

an ailernaior, out a

an altemator supis

then changed to

use on the vehicle, while a genera-

CHASSIS ELECTRICAL produces

tor

more

direct current. Alternators tend to

and

efficient

sist of coils of

wires

wound

One group

electromagnets.

causes a current

of coils

drawn

to flow.

and ted

off the coils

spins within

This current

of current flows

through the system, these

work as follows

Fuse—when

•

an excessive electrical current

ductor melts) and opens the then

is

to protect the cir-

cuit:

passes through a fuse, the fuse "blows" (the con-

magnetic

of the

passage

into the vehicles electri-

system.

cal

amounts

protective devices

con-

tfiat

making big

togettier

another set and the mteraction fields

be

wtiy ttiey are used.

ttiat is

Alternators and generators are devices

•

—

a self-repairing fuse.

same

GROUND

preventing the

circuit,

of current.

Circuit Breaker

It

a circuit breaker

will

open the

fashion as a fuse, but

when

basically

is

circuit in the

the surge sub-

sides, the circuit breaker can be reset

and does not

need replacement.

Two types

grounds are used

of

electric circuits. Direct

grounded

to the

points. All other

ground wire

link) is a short length of special,

The

frame or chassis

electrical current

(-)

runs through

and returns

cable;

if

to the battery

you look,

you'll

see

ground cable connects between the

and the frame or chassis

gauge wire inside

the thin

link,

ing an intentional

open

newer type fusible ules,

problems can be traced

to

bad

it's

the

first

housed

and

is

plug-in

in

like a fuse,

mod-

while

must be cut and spliced is

very early

place to look

if

seems

vehicle works, yet the battery

grounds.

To

must be replaced. Some

links are

which are simply replaced

cal path,

an

the link melts, creat-

to protect the circuit.

repair the circuit, the link

older type fusible links

of the vehicle.

should be noted that a good percentage of

electrical

When

excessive electrical current passes through a fusible

sort of

they melt. Since this link '»lt

high temper-

ature insulated wire that acts as a fuse.

the chassis of the vehicle

that the battery

fusible link (fuse link or

components use some

through the ground

battery

main

ground components are

Link— a

Fusible

frame through their mounting

that is attached to the

of the vehicle

•

automotive

in

in

if

the electri-

nothing on the to

be charged

properly connected.

PROTECTIVE DEVICES I

Always replace fuses,

See Figure 2

circuit breakers,

fusible links with identically rated It

is

possible for large surges of current to pass

through the electrical system surge

it.

It

ness

were

of current

cuit, the

of

your vehicle.

If

this

to reach the load in the cir-

surge could burn

it

out or severely

to get hot

connected

and melt the

into the

component

weak spot

in

the system.

higher or lower amperage

rat-

insulation. To prevent

SWITCHES & RELAYS

and/or fusible links are

supply wires of the

electrical

>

See Figures 3 and 4

system. These items are nothing more than a builtin

of

ing be substituted.

damage

can also overload the wiring, causing the har-

this, fuses, circuit breakers,

and

compo-

nents. Under no circumstances should a

When abnormal

Switches are used the

passage

in electrical circuits to

of current.

open and close

circuits

various electric devices rated according to the

The most

common

control

use

is

in

the system. Switches are

amount

of

amperage

amperage they can

handle.

If

used

a circuit, the switch could overload and

in

a sufficient

to

between the battery and the

rated switch

not

is

cause damage.

Some large

electrical

amount

components, which require a

of current to operate

use a special

switch, called a relay. Since these circuits carry a large in

amount

the circuit

.*

Fig. 2 IVIost vehicles

panels. This one side kick panel

is

use one or more fuse

located on the driver's

of current, the is

also greater.

thickness of the wire If

'-^^^^

this large wire

were

6-3

6-4

CHASSIS ELECTRICAL

ual wires are color

coded

them

lo help trace

through a harness where sections are hidden from view.

Automotive wiring or

circuit

Pinpointing the exact cause of trouble

conductors can be

either single strand wire, multi-strand wire or

printed circuitry. Single strand wire has a solid

metal core

usually used inside such

is

It

made

ol

conductor Most

system

electrical

ol the wiring in is

either

diagnosis

clearly of multi-strand

is

identification stripe.

color coded on the insulator,

A

printed circuit

copper or other conductor

is

an

a thin film

insulator backing. Occasionally a printed circuit

sandwiched between two sheets protection

and

flexibility

Fig. 5

Hard shell

(right)

connectors have replaceable termi-

(left)

and weatherproof

Never use jumper wires made from a thinner gauge wire than the circuit being tested. If the jumper wire is of too small a gauge, it

consisting of conductors. Insulating material, and

connectors

for

lamps or other components

place ol individual wires or harnesses

where space

limited,

is

is

in

may overheat and

called

is

used

in

lumpers

places

such as behind instrument

creates a shorl circuit. This may,

properly sized wires repaired.

in

resistance, the selection of

when systems

is critical

are

A

loose or corroded connection or a replacement wire that is too small for the circuit

add

extra resistance

Jumper wires will

are used to bypass sections of a circuit Although

an expression of the

commonly used

cross-section area of the conductor. Vehicles from countries that use the metric system will typically

describe the wire size as

square millimeters. wire, the greater the

tem

lor

its

In this

cross-sectional area

number Another common sys-

18 gauge wire

weather

smaller than a 4 gauge wire.

number

the elements

A

and

dirt

size refers to the size of the strands of

are bent

erly seated

possible, therefore, to have two

same gauge

other. It

is

essential to understand

schematic shows the a circuit

why

how it

ual circuits

In a

An

electri-

down

is

and components as they

physically appear on the vehicle: switches and other

components are shown as simply as possible Face views of harness connectors show the cavity or terminal locations in all multi-pin connectors to help locate test points.

CONNECTORS >

See Figures 5 and 6 Three types ol connectors are

commonly used

automotive applications—*eatherprool molded

and hard

shell

it.

all

•

leads

Molded— these

tive

This

into the

means

harness

splicing a All splices

if

found to be detec-

new connector assembly should be soldered

to

Use care when probing the

in

in them, as it is possible to create a short circuit between opposite terminals If this happens to the wrong terminal pair it

is

possible to

nals in order to prevent accidental grounding

damage

in

any jumper wire This

to as a "fused

certain

components

a 5

amp

the circuit or

on

component

ground

(+) side

If

(-)

an

open

side of

electrical

operate, connect the jumper wirt

fails to

between the component and a good ground If the component operates only with the jumper Installed, the ground circuit

is

open

If

the ground circuit

J

is

good, but the component does not operate, the circuit behween the power feed and component may I

open By moving the jumper wire successively I from the component toward the power source, you located

When

power

is

the

cut

ol the circuit where the open is i component stops functioning, orl the open is in the segment of

oft.

wire between the jumper and the point previously

terminal contacts in hard-shell connectors can be

tested

replaced Replacement usually involves the use ol a special terminal removal tool that depresses the

directly

You can sometimes connect the jumper wire trom the battery

to the "hot" terminal ol thsfl

locking tangs (barbs) on the connector terminal and allows the connector to be removed from the rear of

component, but

lirst

uses 12 volts

operation

the shell The connector shell should be replaced

nents.

of borning, meltino. cracks,

in-line fuse

primarily to locate

either the

on the power

the

shows any evidence

is

fuse lo provide protection against voltage

Jumper wires are used

proof seals.

it

It

referred

spikes

can isolate the area

Hard Shell— unlike molded connectors, the

commonly

jumper" By inserting an

Always use jumper wires between connectors lor circuit checking and NEVER probe through weather•

is

holder between a set of test leads, a fused jumper wire can be used for bypassing open circuits Use

electrical circuits,

connectors require complete

In

also advisable to include a standard automotive

of the sealing rings are in place

connections or replacing terminals

into individ-

schematic, usually no attempt

lo represent wiring

of a

certain that the connectors are prop-

and

insure proper contact.

electrical current paths

operating properly Schematics

is

break the entire electrical system

made

a circuit works

doesn't

use

the tool required to service

replacement of the connector

before trying to figure out

when

Make

when connecting

with different diameters

because one may have thicker insulation than the

cal

and

that is required

being tested

cramped, hard-to-reach areas, it is advisable to have insulated boots over the jumper wire termi-

fuse

erproof terminals cannot be straightened once they

the conductor, not the size of the complete wire

wires ol the

Terminals are protected against mois-

tight seal. All repairs require the

clip. j

Unlike standard blade type terminals, these weath-

with insulator.

is

connector (alligator

spade connector or pin connector)

by sealing rings, which provide a

special terminal

will carry less

current than a wire with a lower gauge number.

It

of

Is

• Weatherproof—these connectors are most commonly used where the connector is exposed to

the American Wire

is

ture

Gauge wire

and whatever types

method, the larger the

expressing wire size

is

fabricated from lengths ol standard automotive wire

the engine comparl-

lor the particular application

Gauge (AWG) system. As gauge number increases, area decreases and the wire becomes smaller. An wire with a higher gauge

in

menl or wherever the connector exposed to the elements

in

lumper wires can be purchased, they are usually

Weatherproof connectors are most

Fig. 6 is

are simple, yet extremely valuable,

pieces of test equipment They are lest wires, which

and an additional voltage drop

to the circuit.

The wire gauge number

in turn,

cause damages and fires. Jumper wires should only be used to bypass lengths of wire or to simulate switclies.

Since automotive electrical systems are very

changes

possibly melt. Never use bypass high resistance loads in Bypassing resistances, in effect,

lo

a circuit.

panels.

sensitive to

test pro-

is

printed circuit,

a printed circuit board Printed circuitry

understood before attempting any

JUMPER WIRES

more

of plastic for

A complete

in

nals

on an

that is printed

briefly

addition to the information covered

in a

either as a solid color or as a colored wire with

of

In

cedures

conductor or grouped together

harness. All wiring

ti

commonly used test explains how to use them

below, the tool manufacturer's instructions booklet (provided with the tester) should be read and

an automotive

made up

equipment The following

ol special test

equipment and

many

small strands ol wire twisted together into a single

wire, as a single

an

most times accomplished by

use

describes different types of

compo-

nents as alternators, motors, relays, and other

devices Multi-strand wire has a core

in

electrical circuit is

if

in

such as

make sure

the

Some

fuel injectors or

component

electrical

j compo-|

sensors are

or breaks. Replace individual terminals that are

designed to operate on about 4 to 5 volts, and rur)-'| ning 12 volts directly to these components will

burnt, corroded, distorted, or loose.

cause damage

'

CHASSIS ELECTRICAL »A self-powered test light should

TEST LIGHTS >

not be used on any computer-controlled system or component. The small amount of electricity transmit-

See Figure 7

ted by the test light

The

test light is

ponents while them.

used

is

It

a 12 volt lest

used

check

to

and com-

circuits

and ground

lor voltage

connect the ground

light,

The

test light will illuminate

particular

means

voltage

voltage

present.

is

advisable

is

It

form and have

either analog or digital

in

any budget,

A

multimeter

a

is

before using the test light to touch

ground

its

ammeter and ohmmeter (along with other combined into one instrument. It is often

clip

features)

and probe across the battery posts or terminals

make sure

to

used when testing solid the light

high input impedance (usually 10 more).

•

not use a test light to probe electronic

ignition, $parl< plug, or coil wires.

use a picl(-type test

brief description ol the

of

used

to

measure

voltage drop across any part ol a circuit. Voltmeters

usually have various scales and a selector switch to

allow the reading of different voltage ranges. The

tion that is pierced

by the test light probe should be taped and sealed with silicone

voltmeter has a positive and a negative lead. To

after testing.

ative lead to the negative (-) side of the circuit (to

avoid

damage

to the meter,

to isolate

opens

jumper wire

is

in circuits.

used

to

of voltage in a circuit.

minates, there if

the test light

is

power up

used

is

to

meter

illu-

to that point in the circuit:

circuit (no power), fVlove the test light in

is

is

successive in

test light is similar in

design

to

handle.

It

is

most

often

used

when power

cuits

isolated from

is

circuit (conti-

ttie

nuity test),

provide vide

a self-powered test light does not

current,

enough power

when is

much

in

A weak is

made

in the circuit).

that the test battery is strong. briefly light

may

(especially

if

if

designed

is

ohms) will

in

a circuit or

switch

Some ohmmeters

1,000 and 10,000),

powered by an

ter

like a

means

Since the meters are

internal battery, the

self-powered

ohmmeter can

When the ohmme-

test light.

connected, current from the

ohmmeter's

there

and voltage are known values, the amount

for

ity

of cur-

through the meter depends on the resis-

test for

also be used to perform a continu-

suspected open

using the

circuits. In

continuity

C^^

in

ohm

in

made

circuits,

electricity is flowing.

in

the circuit,

the circuit.

in the

cir-

Excessive

Systems When

diagnosing a specific problem, organized

A high

Checks

you approach

that

which are standard: •

Establish

when

problem occurs. Does the

the

problem appear only under certain conditions?

Were

there any noises, odors, or other unusual

symptoms?

Isolate the

make some simple

problem

do

area. To

this,

and observations, then

tests

eliminate the systems that are working properly.

Check

for

obvious problems, such as broken wires

and loose or

dirty

connections. Always check the

obvious before assuming something complicated

is

the cause.

Test for

the

problems systematically

once the problem area

the cause

Is

all

their

switches and motors. Per-

to electrical

forming careful, systematic checks the

determine

to

isolated. Are

is

components functioning properly?

power going

•

Test

traced to

will often turn

up

inspection, without wasting

first

little

all

repairs after the is

fixed.

work

no

or

is

work

is

important

pick up additional malfunctions that

problem

done

to

to

Some causes

more than one component, so

verilication ol repair

open

except that the circuit must be isolated

from both power and normal ground.

demands

relationship to the problem,

for short circuits lor

mod-

a must. The complexity of

is

a logical organized manner. There

sure that the problem

resistance

same manner as checks

in

are certain troubleshooting techniques, however,

reading, indicates

reading where there should be none indicates a

problem

and

most causes on

the circuit. Infinite resistance indi-

cates an opening

are

measure current draw only when the

will

time checking components that have

concerned with the actual resistance readings. Zero resistance, or any

be accurate.

resistance to cur-

not operate properly.

•

meter for making continuity checks, do not be

testing.

will not little

run slowly, lights to dim and other components to

internal resistance

tance of the circuit or component being tested. The

ohmmeter can

the

enough

are

the meter itself will

to use.

flows through the circuit or component being

rent flow

it

any problem

to

allows the multiplication of the meter reading by

is

has very

itselt

troubleshooting

have a selector

of resistance (usually the selector

ohmmeter

ammeter reading

ern automotive vehicle

"auto-ranging" which

normally

lor the current to

Troubleshooting Electrical

color other than black

tested. Since the

Always make sure

brightly, the battery is strong

but

that the positive volt-

even

To check the battery,

touch the ground clip to the probe;

glows

not pro-

to illuminate the test light

a complete circuit

high resistance

battery

and

read resistance (measured in

be used

•

The battery

any other path

is

that the negative voltmeter

some

determine which scale

series with the

in

All of the current that

of the circuit)

component. Most ohmmeters

10, 100,

in

place of a multimeter to check for open or short cir-

there

it

cuit is closed

to the positive (+)

Ohmmeter— the ohmmeter

ranges

the 12 volt test light, but contains a 1,5 volt penlight battery in the

•

be

rent flow and, therefore, will not affect the circuit,

switch which permits the measurement of different

between the

probe and a point, which was previously probed.

The self-powered

always be

will

will

be high.

will

while a reduced current draw can cause motors to

(usually red).

an open

steps back toward the power source until the light

The open

power source). Note

lead will always be black

to locate the

does not illuminate, there

the handle illuminates.

est

operate

the test light

If

and connect the positive lead

always connected

being tested.

The ammeter

side of the circuit (to the power source or the near-

However, whereas the

bypass the open

the load, the 12 volt test light

presence

used

is

not allow

will

or circuit will have an

current draw can blow fuses and drain the battery,

always connect the neg-

ground or nearest the ground side is

The ammeter

ammeter:

measure the

a circuit, or to

in

example,

so the ammeter reading

flows through the circuit must also flow through the

computer controlled systems unless specifically instructed to do so. Any wire insula-

Like the jumper wire, the 12 volt test light

amperes

its

or

multimeter main

is

circuit, for

to flow,

increased current draw, so the reading

follow, the

Voltmeter— the voltmeter

voltage at any point

Never

probe wiring on

liglit to

A

megaohms

functions follows:

test

Do

of

circuit to aid in diag-

A damaged component

circuit

because

state circuits

operating properly.

is

An open

any current zero,

voltmeter,

happening within the

is

nosis.

troubleshooting electrical problems. They can be

only

it

have a characteristic amount

circuits

current draw rating, then measuring the

what

detected.

is

12 volts (or any

that

measures the amount

circuit in units called

and comparing the two values, one can determine

a price range to suit

some

that

when

mean

MULTIMETERS

good Multimeters are an extremely useful tool for

ol voltage) is present;

most

through a

amps. At normal operating voltage,

or

amperes, called "current draw" which can be mea-

pick.

purchased

amount

damage many

to

amperes

sured using an ammeter. By referring to a specified

To use

tests.

clip to a

ground and probe wherever necessary with the

This does not necessarily

enough

is

electronic automotive components.

through

electrical current is flowing

Ammeter— an ammeter

•

of current flowing

6-5

make

can be

a careful

in

order to

may cause

a

reappear or a different problem to arise,

A blown fuse, lor example, is a simple problem that may require more than another fuse to repair. If you

Infinite

resistance indicates no continuity, while zero

don't look for a

resistance indicates a dead short.

a shorted wire (for example)

problem

that

caused a fuse

may go

to

blow,

undetected.

Experience has shown that most problems tend to

Never use an ohmmeter ICCS2006

Fig. 7

A 12

volt test light is

used

to detect

the presence of voltage in a circuit

be the result of a

fairly

simple and obvious

cause, such as loose or corroded connectors, bad

to

check the resis-

tance of a component or wire while there voltage applied to the circuit.

is

grounds or damaged wire insulation, which causes a short. This

makes

components during

careful visual inspection of

testing essential to quick

accurate troubleshooting.

and

CHASSIS ELECTRICAL

6-6

4

To isolate the short, probe a

either

end

OPEN CIRCUITS

Leave the

5

should be

test light

parts, etc. until the light

> See Figure 8

drop

probe engaged and

open

and

the circuit

in

it

the existence of an

used

is

to help locale the

the last

goes out or continuity

two

the light goes out. the short

is

circuit

components

that

between

is

were opened

open portion Isolate the circuit

2.

Connect the sell-powered

meter ground clip

to the

circuit,

in

a voltage

component

first

probe the groundside

A

readings

are

in tfie

component

ol the

wilti

small voltage drop should be noticed.

This voltage drop

6

ohm-

hght or

test

ground side

VOLTAGE

down

of the circuit

ol the circuit sequentially.

battery.

the light

is

out or there

is infinite

should be the

It

first

open

is

step in any electrical

Repeat the

is

caused by the resistance

test for

ol t(«

each component (load)

the circuit.

7

If

a large voltage drop

is

noticed, the preced-

component, wire or connector

ing

is

suspect

resis-

troubleshooting procedure tance, the

While operating the

5

This test determines voltage available from the

and prot)e sections If

If

in the circuit

component from power and ground.

1

3.

no voltage drop

or

component

connectors

the positive meter lead and observe the voltage

When

6

little

first

exists, the wire or

suspect

broken.

assumes

This test already

the circuit prior to the

open connectors or switches, remove

sequentially

There should be

4

test point at

of the isolated circuit (the light

on or the meter should indicate continuity)

between the prot)e and the

circuit

Many

electrical

inspection

after visual

problems, especially on computer

RESISTANCE

ground. 4

the light

It

is

on

or the meter

shows continu-

controlled systems, can be caused by a low state ol

charge ity,

open

the

is

between the probe and the end

the battery Excessive corrosion at the

in

I

See Figures 10 and 11

ol

battery cable terminals can cause poor contact that

the circuit toward the power source. will

prevent proper charging and

battery current

full

flow

SHORT CIRCUITS

1

.

Set the voltmeter selector switch to the

20V

Is

applied to the circuit under test. The test light

can be damaged by outside power. Isolate the circuit

2.

Connect the sell-powered

meter ground clip

to a

there

is

in

a short

test light or

ohm-

3.

or there in

is

and the posi-

post or termi-

continuity,

the circuit.

r

Turn the ignition switch

ON

4.

A

well charged battery should register over

volts.

the meter reads

If

power may be

battery

electrical

below 11.5

volts, the

insufficient to operate the

>

current flows through a load, the voltage

beyond the load drops This voltage drop to the resistance created

nectors and

damaged

is

insulation

at

the con-

on the wires. The

allowable voltage drop under load

especially

if

the circuit, since

there all

due

by the load and also by

small resistances created by corrosion

.

is

is

more than one load

voltage drops are cumula-

Set the voltmeter selector switch to the 20

Connect the multimeter negative lead

V.

3.

Operate the circuit and check the voltage first

component

(loadl

-^^/^v

4i=^ Fig.

Fig

to a

good ground prior to the

^/••##iif'-

9 This voltage drop test revealed high

resistance (low voltage) in the circuit

Where necessary, also

key

is

C

OFF when

isolate at least

will

one

order to avoi'J

in

always give a lower reading than the

Connect the meter leads

circuit (wire or

When

1

open

3

4

See Figure 9

2

reading on this multi-

from the power source

that the ignition

actual resistance of either of the branches

volt position

that the circuit Is

Ensure

disconnecting any components or the battery

tances

VOLTAGE DROP

in

infinite

2.

side ol the circuit to be checked,

system properly

tive

The

the meter!

Isolate the circuit

reading parallel resistances Parallel circuit resis-

critical,

Fig. 8

damage

the vehicle.

maximum

meter Indicates

operate on

1

to provide a

load.

12

the circuit.

comes on somewhere

the light

It

to the

nal.

good ground. Then probe

any easy-to-reach point 3.

battery's negative (-) post or terminal tive lead to the battery's positive (+)

from power and ground.

1

Connect the multimeter negative lead

2

Never use an ohmmeter with power applied The ohmmeter is designed to its own power supply. The normal 12 volt electrical system voltage could

to the circuit.

position

•»Never use a self-powered test light to perform checks for opens or shorts when power

10 Checking the resistance

ol a

coolant temperature sensor with an ohmmeter. Reading

is

1.04 kilohms

selector switch

to both sides ol the

component) and read

measured ohms on the meter is

scale.

set to the proper

the actual

Make

ohm

sure the

scale tor

the circuit being tested, to avoid misreading the

ohmmeter

test value.

6-7

CHASSIS ELECTRICAL Be sure the ends

IJIIJAI.I.I.).I.I.IJJI.II.IJ,I,II]

wires are

ol all the

See Figures 63. 64 and 65

assembly Opeiale the wipers and turn (he ignilion

1

when

the wipers are at the

OFF

mid-wipe position.

3

Lift

the wiper

am from the windshield and

pull the retaining latch

Fig. 61

Wiper arm attachment— 1991-93

Deville and Fleetwood

4

Remove

To

intlall:

5

Install the

6

Push the

arm

arm down and engage h

the

arm Irom

the transmission shaft

retaining latch in

to the windshield.

and

return the

(

the slide latch

Close the adiustment window and place

Check the wiper

as sliown

in

pattern

and park

v

i

Figures '84206094' and

'84206095' Ttie outwipe dimensions are shaft

t

screen i

arm on the transmission

beic

arm assemblies on the ramp slop on the

the

hose connector

arm assembly is still arm and

to the transmission shaft approxi-

mately one inch below the ramp slop Push

Detach the hose on the wiper arm from the

2

left

slop, position the right

mined with the wipers operating wet glass

at

(

low speed]

6-19

CHASSIS ELECTRICAL Remove

9.

the pivot prevention pin from the

wiper arm. 10.

Install

11.

Lift

install the

a

new wiper arm

the wiper

retaining nut.

arm over the park ramp and

wiper blade.

Tighten the nut to 15-19

12.

ft.

(20-26

lbs,

Nm). Operate the wipers and check

13.

wipe

pattern.

The left-hand blade

WIPER ARM

from iyi6

TRANSMISSION SHAFT

shield molding.

RETAINING LATCH

to

should wipe

3^16 from the inner edge

of the

wind-

The right-hand blade should overwipe

lap the left-hand

WIPER BLADE REMOVAL WIPER INSERT REMOVAL WIPER BLADE ASSEMBLY

tip

for correct

pattern.

Install the protective cap.

14.

WIPER INSERT

SCREWDRIVER BLADE RETAINER INSERT RETAINER

WASHER NOZZLE HOSE HOSE CONNECTOR 84206093

Fig.

63 Wiper arm and blade —Eldorado and Seville

Eldorado and Seville— Late Models >

See Figures 66 1

74

thru

Turn the ignition

ON, place

park position. Turn the ignition 2.

the wipers

the

in

PROTECTIVE CAP

HOSE CONNECTOR

WIPER ARM HOSE

NUT

-

20 26

Nm

OFF.

Detach the washer hose from the hose con-

nector. 3. 4.

or

pop

Remove Lift

rivet

Fig.

the protective cap.

the wiper

arm and

insert a suitable pin

66 Hose, cap and nut removal— Eldo-

rado and Seville

completely through the 2 holes located

next to the pivot of the arm. 5.

Remove

6.

Lift

the

the wiper

arm

arm from the

retaining nut.

shaft using a rocking

motion. >»lf the

arm

will not

lift

off

the shaft using a

rocking motion, use a battery terminal

remover or similar

E'

tool to aid removal.

Clean

the knurls of the shaft with a suitable wire

WITH LEFT HAND WIPER BLADE IN THE FULL OUTER WIPE POSITION, DIMENSION A SHOULD BE NO GREATER THAN 78mm (3 1/16 IN )

Fig.

64 Wiper

in full

stroke

brush.

To install: 7.

Connect the washer hose,

8.

Install

the wiper

arm (without

the blade)

one g

OR POP RIVET

inch below the park ramp.

|T| WIPER BLADE

67 Example

—Eldorado and

RAMP

WIPER ARM SHOULD FULLY SEATED ON PARK RAMP

65 Checking the wiper

pop

Seville

E

[7] WIPER ARM

Fig.

of pin or

ASM

[J] REVEAL MOLDING [Tj PARK

Fig.

tion

[T]

In

the park position

Fig.

CLEAN DRIVE SHAFT KNURLS

68 Wiper arm removal

rivet inser-

6-20

CHASSIS ELECTRICAL Windshield Wiper Motor REMOVAL & INSTALLATION

Deville and Fleetwood I

See Figures 75 and 76 On 1991-98

1

vehicles, disconnect the

washer hoses.

Remove

the wiper

3

Remove

the cowl screen.

4

Disconnect the motor drive

2.

arm and blade assem-

blies.

[T] PARK

—

RAMP

ARM 25mm (1 m) BELOW

Fig.

72 Loosen the retaining nut

link

from the

motor crank arm by loosening the nuts

rri WIPER

P

5.

Detach the wiring connectors.

6

Remove

the wiper

motor mounting bolts and

remove the wiper motor, guiding the crank arm through the hole.

To Fig.

69 Wiper arm

installation, park posi-

Install:

Guide the wiper motor crank arm through

7

tion—Eldorado and Seville

the hole

and position the wiper motor.

mounting bolts and tighten

to

Install the

80 inch

lbs. (9

Nm).

8

Attach the wiring connectors

9

Attach the motor drive link to the molor

crank arm and tighten the nuts, Install the

cowl screen,

1

Install the

wiper arm and blade assemblies.

12

Conned

10.

Fig.

73 Disconnect the washer hose,

the washer hoses.

Eldorado and Seville If

On 1992-98

1

vehicles,

remove

the

A/C pipe

shroud.

2 3

Remove the wiper arms On 1990-91 vehicles, remove

the wind-

shield reveal molding

4 5.

Remove

the cowl vent.

Disconnect the wiper arm drive

link

Irom

•

wiper molor.

ft| left hand wiper blade Outer wipe position

in

6.

Detach the wiring connectors

7

On 1992-98

vehicles,

remove the A/C pip

shroud bracket Irom the wheelwell

[T| PILLAR

8

WITH LEFT HAND WIPER BLADE IN THE FULl OUTER WIPE POSITION, DIMENSION A SHOULD BE NO LESS THAN 35mm ,13/16 llv DIMENSION B SHOULD BE NO GREATER THAN 80mm (3-3/16 IN FROM THE INNER

Remove

the wiper motor

mounting bolts a

remove the wiper motor.

To 9

Install:

Position the wiper molor and install the

)

e

DOE OF THE WINDSHIELD MOLDING

mounting bolts Tighten Fig.

Fig.

70 Checking the wiper arm

74 Pull the wiper arm

10 off

the stud

On 1992-98

shroud bracket

In full

stroke position— Eldorado and Seville

%:;f'

^;^ --®-

®®--® S: =^-^®

s.

°-^\^

—

z

iiii

ill!

r—

6-55

6-56

CHASSIS ELECTRICAL

3.

S

fa

CHASSIS ELECTRICAL

6-57

6-58

CHASSIS ELECTRICAL

cn


»^^' 'HI

iiiil

7«u

qn

lylii

—

oils

JS

Disconnect the negative battery cable.

vehicle

4,

20 cal

Remove the wheel and tire assembly On Eldorado and Seville, detach the electri-

connector trom the top ol the

5

On

housing

When ful

working near the halfshatts, be care-

not to overextend the inner CV-joints.

the joint

ponents

is

If

overextended, the internal com-

may

separate resulting

6.

tie

Deville

strut,

if

equipped.

and Fleetwood, loosen the

bar through bolls

On Eldorado and

9

On Eldorado and

lizer link

tree.

at

each end

strut

ol Ihe bar

10. 1 1

Irom Ihe

Remove Remove

remove the

Seville,

strut

remove the

stabi

strut

the brake line bracket Irom Ihe the strut-to-knuckle bolls

si'

and

Support the knuckle with wire

strut

knuckle must be supported

to prevent

damage

the ball loinl and/or hailshatt

Seville with 4.6L engine,

remove the road sensing suspension position sensor trom the lower control arm. 7

in joint fail-

Remove

strut to the 8.

On

the nuts attaching Ihe top ol the

body Deville

and Fleetwood equipped with

Be careful not

to scratch or crack the coat

ing on the coil spring, as damage may cause premature spring failure

ii Fig.

14

When

3rr-

unbolting the stabilizer link,

hold the retaining nut with a wrench, and

12 Loosen the strut housing

Fig,

lie

bar

Fig.

Fig.

13 Unbolt the

strut

mounted brake

15 Matchmarfc the upper

drive the stud through

it,

using a driver

and ratchet

bracket

bolts

strut control

nuts

Fig.

16 Loosen the upper mounting nuts

Fig.

18 Detaching the electrical connector

\ SOUEFZE TABS TO HEMOVE

at

Fig.

17 Remove the strut-to-knuclde bolts

'

tf

the top of the strut—elecfronleally con-

trolled

suspension

Fig

19 MacPherson

Deville

strut installatlott—

and Fleetwood

SUSPENSION AND STEERING Loosen the compressor screw while guiding

4.

the strut shaft out of the assembly. Continue loos-

ening the compressor screw

until the strut

and

tool

install:

J-34013-20

tool

hold the strut shaft Install the

6.

J-34013-38

compressor

strut.

The

flat

on

when mounted

in

direction as the steering knuckle

9.

mounting

flange.

10.

Nm)

necessary, use

same

the strut shaft threads are visible of the strut

assembly,

install

the

nut.

Remove clamping

tool

J-34013-20 from the

Tighten the strut shaft nut to 55

lbs.

ft.

(75

while holding the strut shaft with a T-50 Torx®

bit. 1 1

»lf the bearing was removed from the upper spring seat, It must be reinstalled in the spring the

If

strut shaft.

the strut

compressor, the spring seat must face the same

In

When

through the top

washer and

spring over the

line of the vehicle, or

8.

tool.

or equivalent, to

in place.

the upper spring seat must face out from the center-

seat

assembly

or equivalent, to guide the

shaft.

Ivlount the strut in the strut

5.

Use clamping

Turn the compressor screw to compress

the spring, while guiding the strut shaft through the top of the strut

spring can be removed.

To

7.

8-7

Remove

the strut assembly from the

com-

pressor tool.

position before attaching to

the strut mount.

20 MacPherson

Fig.

strut installation-

Eldorado and Seville

To

install:

Attach the strut to the knuckle with the bolts

12.

and

nuts.

Attach the strut to the body with the nuts.

13.

On

Deville and Fleetwood, position the

and

washer

bar prior to installing the strut-to-body

tie

nuts.

1

brake line bracket to the

14.

Install the

15.

On Eldorado and On

16.

Spring seat Spring insulator

strut.

connect the stabi-

Seville,

the strut.

5.

Jounce bumper

6.

Dust shield Spring Spring lower

7.

and Fleetwood with anti-lock

Deville

brakes, install the wheel speed sensor bracket

8.

and Strut

connect the sensor

On Eldorado and

17.

mount

Strut

3. 4.

lizer link to

Stru1-lo-mount nut

2.

Seville, install the

road

MacPherson

sensing suspension sensor to the lower control

Fig. 21

arm.

rado and Seville Connect the

a.

of the strut,

18.

140 (24

ft.

it

connector

strut

assembly— EldoFig.

23 Removing the

Fig.

24

strut shaft nut

at the top

equipped.

Tighten as follows: Strut-to-knuckle bolts: lbs.

Nm)

(190

Nm)

Strut-to-body nuts: 18

Stabilizer link nuts:

bar through bolts: 19.

electrical

Install the

48

ft.

lbs.

(65

ft.

Nm)

lbs.

(27

Nm)

wheel and

tire

assembly and

20

ft.

lbs.

Tie

lower the vehicle. Check and adjust the front wheel alignment.

OVERHAUL »

See Figures 21 thru 26

Be careful not

to

scratch or crack the coat-

ing on the coil spring, as damage may cause premature spring failure.

1

I^ount the strut assembly

in strut

compres-

sor tool J-34013 or equivalent. 2.

Turn the compressor forcing screw until the

spring compresses slightly 3.

Use

a

T-50 Torx-

bit to

S4208011

keep the strut shaft

from turning, then remove the nut on the top strut shaft.

of the

Fig.

22 Mount the

pressor

strut in the strut

com-

strut

Installing the strut

compressor

damper

in

the

SUSPENSION AND STEERING

8-8

knuckle boss. Check the torque

U^

nut— a worn

ol the castelialed

loose nut can indicate a beni stud or an

enlarged hole

in the

damaged

or

knuckle boss. Replace a

ball loint

and/or

knuckle. 4.

If

the ball stud

knuckle and looseness stud can be twisted

disconnected from the

is

detected, or

is

11

the ball

socket using linger pres-

In its

sure, replace the ball joint,

REMOVAL & INSTALLATION >

See Figures 27. 28. 29, 30 and 31 1

.

Raise and salely support the vehicle, allow-

ing the front suspension to

2

Remove

the wheel

hang

and

free,

tire

assembly

Guiding tool Sliut Strut

Be careful when working

compressor assembly

CV-joInt boot.

Damage

in

the area of the

to the

boot could

result in eventual CV-joint (allure. Fig.

25

If

necessary, use tool J-34013-38

neces-

If

sary, Install CV-joint boot protector tool J-

or equivalent, to guide the strut shalt

34754 3.

or equivalent, to protect the boot.

On Eldorado and

Seville with 4. 61 engine,

remove the road sensing suspension position sensor Irom the lower control arm, 4.

Remove

joint stud.

Use

the cotter pin

ball joint

equivalent, on Deville

and nut from the

separator tool

ball

J-36226 or

and Fleetwood or

ball joint

separator tool J-35315 or equivalent, on Eldorado

Fig.

26 Reassembling the

strut

Fig.

27

control

Lower

Drilling the rivets out of the

arm

Ball Joint

INSPECTION

Replace the lower

ness

In the joint or

ball joint

it

II

there

Is

the tall joint seal

any loose-

Is

damaged

Inspect the ball joint as lollows:

Raise and salely support the vehicle, allow-

1

ing the front suspension to

hang

Iree

Have an assistant grasp the

2

tire at

the top

and bottom and move

the top of the tire in

Check

movement

lor

any

vertical

ative to the lower control arm.

ment, replace the

3

Check the

II

ol the

there

and out

knuckle

is

ball loinl

ball

slud tightness

in

the knuckle

boss by shaking the wheel and feeling

lor

ment

at

ol the stud

rel-

any move-

end or castellated nut

movethe

^

I

SUSPENSION AND STEERING and

8-9

from the steer-

Seville, to separate the ball joint

ing knuckle,

On

5. lizer

and Fleetwood, loosen the stabi-

Deville

bar link nut, out the 3 rivets retaining the ball joint

Drill

a.

to the lower control

'^Recommended To

arm and remove the

drill bit Is

ball joint,

mm).

Vz inch (13

install:

new

Attach the

6.

arm with 3 mounting

On

a.

ball joint to the

and

bolts

lower control

nuts.

and Fleetwood, the bolts must

Deville

be installed from the top of the control arm

On Eldorado and

b.

c.

d.

lbs,

(68 Nm),

Tighten the nuts to 26

ft,

lbs.

(35 Nm).

and Fleetwood, tighten the stabi-

Deville

Connect the

knuckle and

On

9.

arm

ft,

bar link nut to 13 8.

of the control

Tighten the nuts to 50

On

7.

lizer

must be

Seville, the bolts

from the bottom

installed

lbs,

(17 Nm),

ball joint to the steering

install the castellated nut,

and Fleetwood, tighten the

Deville

joint nut to

ft,

88 inch

lbs.

ball

(10 Nm). Then tighten the

nut an additional 120", during which a tighten of 41 ft.

lbs.

Nm) must

(55

10.

joint nut to

84 inch

Frame welded nuts

be obtained.

On Eldorado and lbs.

Seville, tighten the ball

(10 Nm). Then tighten the

nut an additional 120°. during which a

torque of 37 the

ft.

minimum

torque

stripped threads. ball joint

11.

(50

lbs.

is

Nm) must be

32 Stabilizer bar mounting— Deville and Fleetwood

Fig.

minimum

obtained.

If

not obtained, check for

the threads are okay, replace the

If

and knuckle.

Install

a

new

cotter pin.

the cotter pin can-

If

not be installed because the hole in the stud does not align with a nut castellation, tighten the nut up to

an additional 60'

NEVER

to allow for installation,

loosen the nut to

provide for cotter pin installation, 12.

On Eldorado and

Seville with 4,6L engine,

road sensing suspension position sensor

install the

Tie rod

to the lower control arm.

13.

If

end

Steering knuckle

necessary, remove the CV-joint boot pro-

tector tool.

14.

Install the

wheel and

tire

assembly and

33 Separating the

Fig.

tie

rod end from the

Fig.

34 Correct position

of the stabilizer

lower the vehicle.

bar for removal or installation

steering knuckle

Remove

5.

the cotter pins and nuts from the

tie

rod ends. Use separator tool J-24319-01 or equiva-

REMOVAL & INSTALLATION

lent, to

separate the

tie

rod ends from the steering

the nut

6.

12,

>

Disconnect the exhaust pipe from the

ft.

7.

Turn the passenger side strut

all

way

the

to

ft,

1

Raise and safely support the vehicle, allow-

2,

Remove

the wheel

hang

and

free,

tire

8.

assemblies.

the frame.

To 9.

Be careful when working CV-joint boots.

Damage

in

the area of the

to the

boots could

result in eventual CV-joint failure.

If

neces-

or equivalent, to protect the boots.

Remove

the stabilizer bar link bolts from the

lower control arms, 4,

Remove

from the frame.

the stabilizer bar bushing brackets

bar clears

Tighten the stabilizer bar link bolt nuts to 13

Connect the exhaust pipe

vehicles or 18

15,

over the frame, and slide

Tighten the stabilizer bar bracket bolts to 35

(48 Nm).

ft.

lbs.

ft,

(25

to the manifold.

lbs. (20 Nm) on 1990-91 Nm) on 1992-93 vehi-

cles.

Slide the stabilizer bar over the steering it

ft.

Tighten the bolts to 15

install:

position. Loosely install the

mount bushings,

If

necessary, remove the CV-joint boot pro-

tector tools.

16,

into

it

Install the

wheel and

tire

assemblies and

lower the vehicle.

brackets and bolts. 10.

nents

Loosely to the

install the stabilizer

bar link

compo-

Eldorado and Seville

lower control arms.

I

Connect the

tie

rod ends to the steering

knuckles. Install the

tie

rod end nuts and tighten to

1 1

3.

down until the stabilizer Remove the stabilizer bar.

knuckle, raise

sary, install CV-joint boot protector tools J-

34754

Slide the stabilizer bar over the steering

knuckle and pull

maximum of 52 lbs. (70 Nm) to NEVER loosen the nut to pro-

lbs,{17l^m), 14,

the right.

ing the front suspension to

lbs.

13,

exhaust manifold.

See Figures 32, 33 and 34

to a

vide for cotter pin installation.

knuckles.

Deville and Fleetwood

up

allow for installation.

new

35

ft.

ter

pin cannot be installed because the hole in the

lbs.

(48 Nm).

Install

cotter pins.

If

a cot-

stud does not align with a nut castellation, tighten

See Figure 35 1

Raise and safely support the vehicle, allow-

ing the front suspension to 2.

Remove

hang

the wheel and

the right side of the vehicle.

free.

tire

assembly from

SUSPENSION AND STEERING

8-10

When

12

the weight of the vehicle

is

sup-

ported by the lower control arms, lighten Ihe

Be careful when working

Damage

CV-joInt boot.

in

the area of the

to the boot

result In eventual CV-joint failure.

neces-

(190 Nm).

lbs

ft

(123

lbs

It.

Nm).

Check

13

sary. Install CV-jolnl boot protector tool J-

34754

140

to

then the rear mounting nut lo 91

could If

mounting nut

Iront

the front wheel alignment

or equivalent, to protect the boot.

Eldorado and Seville 3

Remove

the stabilizer bar-to-conlrol

4.

Remove

the colter pin and nut from the ball

arm

See Figure 37

>

bolt.

Use

joint stud

ball joint

separator tool J-36226 or

Raise and salely support Ihe vehicle, allow-

1

ing the front suspension to

Remove

2

equivalents, to separate the ball joint from the steer-

hang

and

Ihe wheel

tree

assembly

lire

ing knuckle

When working When working ful

near the halfshafts, be care-

not to overextend the Inner CV-jolnts.

the joint

If

overextended, the Internal comseparate resulting in joint fail-

Is

may

ponents ure.

near the halfshafts, be carenot to overextend the inner CV-joints. If

ful

the joint

Is overextended, the internal components may separate resulting In joint Be careful when working in the area of the CV-joint boot. Damage to the

failure.

boot could result

Remove

5.

Fig.

35 Stabilizer bar mounting— Eldorado

remove

and Seville

To

3.

On

vehicles with 4.6L engine, remove the

Torx'

Remove bit,

pliers or a

Remove

nut.

and

Remove

lbs.

ft.

9. If

(55

9.

Connect the exhaust pipe

tighten the nut

fold.

of the vehicle. Install the brackets install the

slits to the rear

and loosely

12.

Tighten the bracket bolls to 35

1 1

stabilizer link nuts to

pliers, or a

Torx'

bit to

It

lbs.

48

88 inch

lbs.

new

(47

cotter pin in the ball joint stud.

up

to

NEVER

an additional 60'to allow

On

lor

loosen the nut to provide for

If

.

necessary, remove the CV-joint boot pro-

Install the

tire

assembly and

lower the vehicle-

arm bushing

retainer,

and

and

boll

insulator.

arm to the frame and bushing bolt and brake reaction rod

Position the control

6

install the

and

nut, retainer,

insulator.

Do

not tighten at this

time.

Connect the

knuckle and

ball joint to Ihe steering

install the castellated nut

84 inch

Tighten Ihe

Nm) Then

(10

lbs

tighten the nut an additional 120'. during

which a minimum torque o( 37 ft. lbs. (50 Nm) must be obtained If the minimum torque is not If

the

threads are okay, replace the ball joint and

knuckle Install

8.

stud

lower control arm.

bly

the control

obtained, check for stripped threads.

ball

vehicles with 4.6L engine, install the

Install the right

Remove

5.

Remove the control arm. To install:

ball loint nut to

wheel and

stud Use ball joint separa-

or equivalents, lo separate the ball

brake reaction rod nut,

road sensing suspension position sensor to the

14.

ball joint

from the steering knuckle

7.

stud from turning.

13

joint

(10 Nm). Then tighten

obtained.

tfie

the cotter pin and castellated nut

J-35315

tor tool

Tighten the

lbs.

ft.

keep the

vehicles with 4.6L engine, remove the

Remove

4

(17

tector tools.

Install the stabilizer links.

(65 Nm), using

lbs.

On

3.

lower control arm.

cotter pin installation.

10

mounting bolts

11.

Nm). Tighten the

ft.

stud does not align with a nut castellation,

installation.

bushings with the

Install the

to protect

road sensing suspension position sensor from

con-

the ball joint to the steering

Nm) must be

Install a

in the

fO.

washers and nuts. Do

stabilizer bar to the lower

Ihe cotter pin cannot be installed because the hole

Position the stabilizer bar in the vehicle.

mani-

J-34754 or equivalent,

frame and

the nut an additional 120°, during which a torque of

the stabilizer bar.

install:

in eventual CV-joint failnecessary, install CV-joint boot pro-

If

from Ihe lower

8.

to the

to the

install the castellated nut.

ball joint nut to

Disconnect the exhaust pipe from the mani-

41 7.

bolts,

arm

tighten the link nut to 13

Conned

knuckle and

fold.

To

mounting

Connect the

arm and

8.

the bracket bolts, brackets

bushings. 6.

trol

ure.

tector tool

Nm).

as required, to keep the ball stud from

fuming while loosening the 5.

Use

and

the boot.

Position the control

install the

7.

the stabilizer links.

bolts

the frame.

not tighten the mounting nuts at this time.

lower control arm. 4.

arm from

Install:

6.

road sensing suspension position sensor from the

arm mounting

the control

the control

side wheel and

tire

a

new

and lower the vehicle

cotter pin in the ball joint

the cotter pin cannot be installed because

11

Ihe hole in the stud

assem-

does not align with a nut

castellation, tighten the nut

60' lo

to

allow for installation

provide

On 1993-98

9

install the

lo

an additional loosen Ihe nut

vehicles with 4 6L engine,

road sensing suspension position sensor

to Ihe lower control

arm

Install the tire

1

up

NEVER

tor cotter pin installation

and wtieel assembly and

lower the vehicle

Deville and Fleetwood

When

1

»

See Figure 36

by the lower control arms, tighten

bushing 1

Raise and salely support the vehicle,

ing the front suspension to 2.

Remove

the wheel

the weiflJit of the vehicle

hang

and

free

lire

assembly.

lbs

i

Fig.

36 Lower control arm installation—

Deville and Fleetwood

58

boll lo

(123

Nm)

lbs

(78

It

12

103

It

lbs

(140

ttie

Nm)

is

supported

control

arm

or nut lo 91

ft

Tighten the brake reaction rod nut to

Nm)

Check Ihe

front wtieel J

SUSPENSION AND STEERING J-21474-5

8-11 end facing

or equivalent, with the large

the bushing. 6.

Position the large end of bushing driver

J-21474-13

bush-

or equivalent, facing the

ing. 7.

Thread on nut J-21474-18 or equivalent.

8.

Tighten bolt J-21474-19 or equivalent, until

the bushing 9.

is fully

Remove

seated.

the bushing driver tool and reinstall

the control arm.

CONTROL ARM-MOUNTED BUSHING I

See Figures 40 and 41 1

2.

Fig.

37 Lower control arm Installation

—Eldorado and

Remove Remove

the control

arm from the

vehicle.

the bushing from the control

by tapping do//n the

flare

v\(ith

a

arm

hammer and

punch.

Seville

To install:

CONTROL ARM BUSHING REPLACEMENT

21474-13 or

equivalent,

and position the small end

lacing the bushing. 3,

Deville and Fleetwood

lent,

4,

FRAME-MOUNTED BUSHING

Place bushing receiver J-21474-5 or equiva-

on the

See Figures 38 and 39

is

driven

Remove

2.

Insert bolt, »/asher,

21474-19

the control

tool.

arm tram

tlie

vehicle. 5,

and bearing assembly J-

or equivalent, through

bushmg

Insert bolt, v^asher,

21474-19

bushing receiver

driver J-

^ Bustling driver J21474-13 v^itti small

Frame Bushing Bolt,

bearing and

washer assembly J21474-19

Fig.

end facing bushing Bushing receiver J21474-5 with large end facing bushing Nut J-21474-ie

38 Removing the frame-mounted bushing

or equivalent,

and position the small end

4.

Position flaring tool J-23915 or equivalent,

with the small flare facing the bushing.

45°

and bearing assembly J-

or equivalent, through

and bearing assembly J-

or equivalent, through bushing driver J-

5.

To Install: 1.

Insert bolt, v^asher,

21474-13

facing the bushing,

front of the bushing.

Tighten the bolt until the bushing

out of the frame, then remove the bushing driver

»

3.

21474-19

Install the nut

flare is

J-21474-18 and tighten

obtained and the bushing

is

6.

Install the control

arm on the

until a

secure

the control arm. vehicle.

in

SUSPENSION AND STEERING

8-12

Eldorado and Seville »

1

Remove

Ihe lower control arm.

Position

ttie

arm

in a

REMOVAL & INSTALLATION

press with tools

Press out

To

Install:

4

Lubricate a

ttie

control

with a suitable rub-

Remove

2

arm and bushing

in

16

Install Ihe

wheel and

assembly and

tire

Hub and Bearing

Front

ing the Iront suspension to hang free.

ber lubricant

Position the control

hub and bearing assembly

and Seville

Raise and safely support the vehicle, allow-

1

5.

Install Ihe

ment

Devllle. Eldorado, Fleetwood

arm bushing.

new bushing

provide lor

lo

1

lower Ihe vehicle Check Ihe Iront wheel align-

J-35561-1 and J-35561-2 or equivalents 3

loosen the nut

colter pin installation

2

control

NEVER

for installation

Knuckle and Spindle

See Figures 42 and 43

the wheel

and

lire

assembly

REMOVAL &

a

INSTALLATIOfJ

press with tools J-35561-1. J-35561-2 and J-

35561-3

shown in Fig. 43. the new control arm bushing the control arm

or equivalents, as

6.

Press

7.

Reinstall

in

When

working near the halfshafis, be care-

not to overextend the inner CV-joints.

ful

the joint

II

Deville, Eldorado, Fleetwood

»

Be carelul when working

ure.

and Seville

See Figures 44, 45. 46 and 47

overextended, the Internal components may separate resulting in joint lallis

Damage

the CV-joint boot.

the area ol

in

to the

result In eventual CV-joint failure.

Raise and safety support the vehicle,

1

ng

Jront

it>?

boot could

suspension

R-:iin.(; the

,_'

to

hang

wheel and

alio/.

Iree.

tire

assembly

neces-

If

sary, install CV-joint boot protector tool J-

34754 or equivalent, Remove Remove

3. 4.

the

to protect the boot.

Be careful when working

the cotter pin and nul from the

separate the

the area of the

boot could

neces-

II

tie

rod end from the steering

tie

in

to the

result In eventual CV-joint failure.

rod end. Use separator tool J-24319-01 or equivalent, to

Damage

CV-joint boot.

hub and bearing assembly

sary, install CV-joint boot protector tool J-

34754

or equivalent, lo p rotect the boot.

knuckle.

Remove

5.

ball joint

equivalent, on Deville

separator tool J-36226 or

and Fleetwood; or

6.

2 3

7

Bushing

Remove

the brake hose.

Remove

spring with wire, do not

Remove

5.

Ihe strut-to-knuckle bolts

Fig.

42 Removing Ihe control

Ing— Eldorado and

i

Seville

6.

knuckte bolts Tighten the strut-to-knuckle bolts

II

retaining bolls to

(190Nm). the sensor

II

was removed on

Eldorado and Seville, anti-corrosion

must be applied 10.

1

On

lbs.

12

9

and Fleetwood, lighten the

84 inch

ball joint

(10

Nm) Then

Nm) must be

(50

2 3

TOOIJ3S561-3

TOOIJ-3SS61-2

to

obtained

43 Installing the control arm bush-

ing—Eldorado and Seville

cotter pin

If

Ihe colter pin in the

stud

caslellation, tighten the

loosen the nul to provide

Connect Ihe

Nm)

tie

lor installation

lor cotter

pin

rod end to the steering

rod end nut and tighten to 35

lie

Install

new

a

does not align with a nut nut

up

ft

lbs.

to a

12

Install the

13

Insert a drift

disc brake rotor and caliper

cotter pin

II

maximum

ol

Ihe cotter

castellalion, lighten the

52

ft

lbs

(70

Nm)

punch

into the caliper

and

loior

If

pin cannot be installed because Ihe hole in the stud Fig.

70

equipped, attach the anti-lock brake wheel

speed sensor connector

the threads are okay, replace the

II

new

an additional 60'to allow

lbs (48

If

the ball

and knuckle.

Install a

knuckle. Install the It

nut

dust shield and Ihe hub and bear-

tighten the

minimum

installation

14

Install the

(95 Nm). 11

not obtained, check lor

is

does not align with a nut

NEVER

new hub and bearing

new hub

ing assembly retaining bolts. Tighten to

to prevent the rotor

torque

cannot be installed because Ihe hole

Tod J-35S61-I

coating ol grease to Ihe

ball

10.

lbs

lbs

It

stripped threads

1

light

Install the

Ihe hallshaft with a

(10 Nm). Then tighten Ihe

lbs.

Nm) must be obtained On Eldorado and Seville, lighten

minimum

up

Apply a

knuckle bore.

88 inch

torque of 37

nut

half-

install:

assembly Draw the hub and bearing assembly onto

nul an additional 120', during which a

13

or equivalent, to sepa-

hub and bearing assembly Irom Ihe

(55

joint nut to

the

J-28733-A

ball loint to the steering

nut an additional 120", during which a torque of 41 ft

To

compound

install the castellated nut

Deville

joint nut to

hub and bearing assembly

Ihe

and Ihe dust shield

tool

sensor before assembly.

to the

Connect Ihe

knuckle and

hang by the brake

shaft.

wheel speed sensor.

j—Zr~-

Use

8

necessary, connect the anti-lock brake

If

it

equipped, detach the anti-lock brake

Remove

rate the 9.

let

the disc brake rotor

wheel speed sensor connector.

Position the knuckle and install the slrut-to-

140f1. lbs

equipped

Ihe caliper Irom the coi

and

install:

7. 8.

il

the caliper without disconnecting

Suspend

equipped.

if

remove the knuckle.

To

caliper

hose.

wheel speed sensor,

ToolJ 35561-2

and

all dirt

punch through Ihe

keep the rotor Irom turning

then remove Ihe hub nut and washer,

from the steer-

necessary, disconnect the anti-lock brake

II

Insert a drill

into Ihe rotor to

4.

Seville, to separate the ball joint

ing knuckle

Too' J 35561

and

ball joint

separator tool J-35315 or equivalent, on Eldorado

and

Clean the halfshatt threads of

3

lubricant

Use

joint stud.

the cotter pin and nut from the ball

to allow

Irom turning On 1990-91 vehi-

SUSPENSION AND STEERING cles, tighten the hul3 nut to

On 1992-98 lbs.

185

lbs.

ft.

vehicles, tighten the

(251 Nm).

hub nut

to

110

eguipped with J55 torqueis130ft. 14.

Install

tirake option, in

lbs.

which case the

(177Nm).

the wheel and

tire

this is described

Wheel Alianment

caster tends to

It.

(145 Nm), except on Deville and Fleetwood

If

stable on the

uneven

assembly and

lower the vehicle.

worn unevenly,

the tires are

highway or

first

check

It

the vehicle

the handling

in spirited driving, the

should be checked. pected,

if

if

an alignment problem

improper

and

for

tire inflation

sion or steering components, accident tires.

II

sus-

worn suspen-

damage

the wheels sell-centering, increas-

uneven caster

the wheels hard to steer, while an

cause a

will

is

as positive caster Having a positive

make

ing directional stability. Excessive positive caster

makes

seems

wheel alignment

other possible causes. These can be

even unmatched

not

is

8-13

one

pull to

sagging rear springs

Overloading the vehicle or

side.

will affect caster,

the rear of the vehicle.

will raising

the rear of the vehicle

II

than normal, the caster

as

becomes more

is

lower

positive.

or

any worn or damaged com-

CAMBER

ponents are found, they must be replaced before the

wheels can be properly aligned. Wheel alignment

>

requires very expensive equipment and involves

minute adjustments which must be accurate;

Following

is

to a properly

Looking from the

When

tilt

negative camber;

alignment In

they affect vehicle handling. Although these

too

much

they are

if

of the tire

negative camber

line stability,

usually only the front suspension

is

tlie

I

»

See Figure 48 Looking

at

a vehicle from the side, caster angle

describes the steering axis rather than a wheel angle.

The steering knuckle

is

attached to a control

and a control arm

wheel pivots around the steer the vehicle.

positive.

increases

compromises

bump

steer

straight-

and torque

steer.

arm

Looking down

at

the wheels from above the

vehicle, toe angle

is

the distance between the front of

the wheels, relative to the distance between the back

When

line

at

the bottom.

or

wheels.

If

the wheels are closer at the front,

The they are said to be toed-in or to have negative toe.

between these points

A

to

small

amount

of negative toe

enhances

the upper point is tilted back. stability

Hub and

is

See Figure 50

of the strut at the top

Dust shield

it

with the road. However,

TOE

hub and bearing

assembly from the halfshaft

tilted out,

adjustable.

CASTER 45 Separating

in, this is

a turn, a slight amount of negative camber helps

maximize contact

angles can apply to both the front and rear wheels,

Fig.

is

of the top of wheels.

the tops of the wheels are tilted

equipped shop.

a description of the

angles which are adjustable on most vehicles and

how

camber

front of the vehicle,

the inward or outward

should only be performed by a trained technician. Take your vehicle

See Figure 49

it

and provides a smoother

ride

directional

on the highway

bearing

Wheel speed sensor connector Steering knuckle

ER ISPOSITIVSWHENTHE LOAD ER BALLJOINT) IS AHEAD OR PUL

46 Hub and bearing assembly and

Fig.

related

components— Deville and

Fleet-

LOAD

IS

PULLING

Fig. 48 Caster aflects straight-line stability. Caster wheels used on shopping carts, for

example, employ positive caster

q::^

^-

Hub

nut Disc brake rotor Retaining bolt

5.

Hub and bearing assembly

Dust shield

6.

Steering knuckle TCCA8G02

Fig.

47 Hub and bearing assembly and

related

components— Eldorado and

Seville

Fig.

49 Camber Influences

with the road

tire

contact

Fig.

50 With toe-in, the distance between

the wheels the rear

is

closer at the front than at

SUSPENSION AND STEERING

8-14

REAR SUSPENSION

s

^

SUSPENSION AND STEERING

8-15

SUSPENSION AND STEERING

8-16 The

late

model

Deville, Eldorado, Fleetwood,

Seville uses an independent short/long

suspension. are

All the rear

mounted on a suspension support

noise.

bushings and insulators

Each

rear

wheel

and

rear

that is

attached to the body at lour points and lated with

arm

suspension components

is

connected

is fully

iso-

minimize road

to

to the

suspen-

sion support through the suspension knuckle using

and upper and lower control arm and toe

Rear suspension components

—

link

Deville

and Fleetwood, with drum brakes

Rear suspension components

—

early

model Eldorado and

Seville, with leal spring

7

8

Stabilizer bar

I

Stabilizer bar

bushing 9 10

Rear suspension components

—

late

model Eldorado and Seville

Shock Shock absorbef I

SUSPENSION AND STEERING As a

7.

Coil Springs

the spring

REMOVAL & INSTALLATION

Slowly maneuver the jack

9. in

the front control

See Figures 51, 52, 53 and 54 Raise and safely support the vefiicle so that

arm hangs

free,

Remove

the wheel

3.

Remove

the height sensor link from the

arm and/or

retaining clip from the 4.

Remove

and

tire

assennbly,

the parl

1990-92

^Leaf

spring removal requires disassembly of

either the Fig.

52 Coil spring removal/installation-

Deville and Fleetwood

Fig.

54 Coil spring positioning— 1991-93

Deville and Fleetwood

MODELS

> See Figures 55 and 56

left

or right suspension while leav-

ing the other side intact.

removed from

The spring can be

either side of the vehicle.

SUSPENSION AND STEERING

8-18 1

Raise and salely support the vefiicle

2.

Remove

3.

If

wfieel

ttie

and

disassembling the

connect the electronic

19

assembly

lire

conlfol arm, dis-

left

level control height

sensor

link

4

II

equipped with a

mounting

stabilizer bar

stabilizer bar.

remove the

to

Remove

6.

the rear brake caliper as follows:

Loosen the parking brake cable

a.

loads the spring at

the

adjuster.

free the

end

of the cable

Remove

c.

the bolt

of the cable spring to

from the lever

Remove Do

caliper in the wheelwell with

not disconnect the brake hose or allow

hang by Ihe brake hose

the caliper to

on the outer end

port the outer

end

of the control

of the control

jack or jacksland to slightly

arm. Sup-

arm with a

compress

the 3 spring retainer bolts, retainer,

suitable

the spring

downward

also be securely positioned or personal

may

remove

the

mounting

connector and

nut, retainer

and upper insu-

Slowly lower the lack or remove the jackstand

lator

Compress

the strut by

on the other

tact

hand and remove the

lower insulator Detach the wheel speed sensor con-

the knuckle control

arm

knuckle,

the inner control

arm

nuts.

bolts

strut,

and remove the control arm,

hub and bearing and

rolor

from the

vehicle as an assembly. 1 1

Place a jacksland under the outer end of the

pads on the ends

damage and

replace as nec-

essary

hub

and nuls

lighten at this time

Attach the wheel speed sensor connector Install Ihe lovrer strut insulator

and position

Position a jack or jackstand under the outer

of the lower control

arm

to slightly

compress

The jack/jackstand must be strong enough support the weight ol the vehicle. It must

to

also be securely positioned or personal Install the

When

lators, the

previously removed spring installing Ihe

molded arrow on

Injury

the insulator

upper outer insulator nuls to 21

may

result.

upper inner insu-

must

point toward the centerline of the car Tighten the It

lbs

(28

27

Install the

upper

strut insulator, retainer,

nut Tighten the upper strut nut lo 65

Nm), the knuckle pivot

bolt to

59

and the Inner control arm bolts Install the

spring

in

Ihe suspension support

28

centered on the spring Insulators when the spring Is positioned in the suspension sup-

may be Impaired

port. Vehicle

handling

the spring

not positioned correctly.

Is

1

2 3

to

It

lbs

66

ft

Attach the electrical connector

29

The outer Insulator locating bands must be

It

ana

lbs (88

Nm)

(80

lbs (90

Nm)

through the disassembled side ol the vehicle

Remove

If

ing boll

30

and tighten

Remove

at

the top of

the lack or jackstand

equipped,

install the stabilizer bar

to

43

It

lbs

mount-

(58 Nm).

the 2 lug nuts that were installed to

retain the rotor

31

Install the caliper

II

with

new mounting

bracket bolls Tighten the mounting bracket bolts lo ft

lbs

(113

Nm)

Spring Spring rcUilner Suspension support

55 Leal spring— 1990-92 Eldorado Fig

bolts

and the control arm con-

of the spring for cuts,

83

and Seville

arm

Ihe spring

spring.

Fig.

strut,

the suspension

in

25

26.

Support

and control arm, then remove the inner

arm knuckle,

assembly

24

the strut

Remove

rotor

Install the inner control

Inspect the spring insulators, insulator

nector 10.

Position the control

do not

but

end

Install:

cracks, tears, or other

18

ft

the strut in the suspension support assembly.

required

To

of the

Raise the vehicle and remove the jack-

support

the upper spring insulators, as

Nm).

to relieve the spring pressure 9.

retainer

suspension sup-

Nm).

23

the

the spring from the rear suspen-

Remove

insulators strut electrical

Remove

In the

stand

spring no

sion support on the disassembled side of Ihe vehicle.

oi

lower insulator and spring

and on the disassembled side

retainer

side of the vehicle.

17.

result.

Detach the

until the

and lower insulator from the

Remove

end

vehicle Tighten the spring retainer bolts to 21

22

the spring retainer bolts, retainer

locating pads, retainers

The jackyjackstand must be strong enough to support the weight of the vehicle. It must

8

and

Install the

and bearing and

Remove

not dis-

free

vehicle, allowing the vehicle

spring Into position

lbs (28

longer exerts force on the jacksland.

14

was

port

Slowly raise the vehicle, allowing the

13.

16

Injury

Lower Ihe

21

lower insulator from the retainer nearest the sup-

15

Loosen, but do not remove, the knuckle

7.

pivot bolt

20

the lacksland

jacksland

the caliper mounting bracket bolts

and suspend Ihe wire.

downward on

spring to dellect

and washer attaching the

cable support bracket to the caliper d.

weigh!

that the vehicle

ported end of the spring.

up on the end

Lift

b.

Remove

ol the vehicle that

the spring

weight to load Ihe spring and dellect Ihe tree end

result.

Lower the vehicle so

12

lower insulator and spring

on Ihe side

assembled Place a lackstand under the

of Ihe

hold the disc bral(e

on the hub and bearing assembly

rolor

may

Injury

bolt at the strut

2 lug nuts

Reinstall

5.

Install the

retainer

The jackstand must be strong enough to support the weight of the vehicle. It must also be securely positioned or personal

56 Removing the laal spring— 1990-92 Eldorado and Seville

Install the

parking brake cable

SUSPENSION AND STEERING support bracket and tighten

ttie

bolt to

32

ft.

lbs.

1;^--^

(43 Nm). 32.

Lift

up on the end

and work the end notch on the 33.

It

of the

lever.

of the cable spring clip

parking brake cable into the

Adjust the parking brake.

assembling the

left

side of the suspen-

sion, connect the electronic level control height

sensor 34.

link.

Install the

wheel and

tire

assembly and

lower the vehicle. Check the rear wheel alignment.

Shock Absorbers REMOVAL & INSTALLATION Deville and Fleetwood >

See Figures 57, 58 and 59

The control arm must be supported with a suitable jack to prevent the coil spring from forcing the control arm downward, causing component damage and possible bodily injury.

8-19

SUSPENSION AND STEERING

8-20

Clean the connector and surrounding area

a

Rotate the spring clip 90'to release the

b

connector lock and pull the connector from the

Remove the upper mounting nut, retainer, Compress the shock absorber by

8.

insulator.

hand and remove

To

damage

b

the insulator attached in the suspension support.

upper shock absorber insulator,

retainer,

and nut

jelly

engaged position and push the

and connector

12,

Install the

air

ol the

Remove Do

of the

cable spring to

cable from the

the bolt

55

tt,

lbs.

nutto75tt, 13,

the

caliper in the wheelwell with

(75

Nm) and

(102Nm),

the lower shock absorber

Attach the electrical connector at the top of it

equipped with 4,9L engine.

the rear suspension supporl,

if

equipped with 4,6L

on the outer end end

of the control

of the control

jack or jackstand to slightly

end

(55

Nm)

lower insulator on the strut and

Position a jack or lackstand under the outer

of the lower control

arm

compress

to slightly

the spring.

arm. Sup-

arm with a

compress

suitatile

the spring.

The jack/jackstand must be strong enough support the weight of the vehicle. It must

to

also be securely positioned or personal injury

may

result.

wheel and

tire

assembly and

nut Tighten the upper strut nut to

65

ft

Nm) and

59

ft,

also be securely positioned or personal

Remove

injury

may

18

result.

8

II

equipped, detach the Computer

Disconnect the

9.

at

Command

the top of the strut,

air line

from the

strut

as

1

Raise and safely support the vehicle,

Remove

3

Disconnect the electronic

tire

removing the

II

Clean the connector and surrounding area

20

from entering the system,

mounting

air

fully into the lifting

Command

equipped, attach the Computer

equipped with a

II

21

stabilizer bar, install the

and tighten

bolt

Install the caliper

to

43

with

ft,

Nm),

lbs (58

new mounting

bracket bolts. Tighten the mounting bracket bolts to

fitting,

83

assembly.

Remove

nut. retainer,

it

0-rings with petroleum

engaged position and push the

connector lock and pull the connector from the

10,

the wheel and

19

Rotate the spring clip 90° to release the

b

2.

the jack or jackstand,

and connector

line

Nm)

equivalent lubricant, rotate the spring

retainer to the

lol-

and

lbs (88

(80

Ride electrical connector of the top ol the strut a.

See Figures 61 and 62

the knuckle pivot bolt to

IVIoisten the air line

lelly or

to prevent dirt

Seville

strut insulator, retainer,

The jack/jackstand must be strong enough to support the weight ol the vehicle. It must

lows:

lower the vehicle

1993-98 Eldorado and

upper

Install the

1

Ride electrical connector

engine,

height sensor link

in the

in the

Loosen, but do not remove, the knuckle

Attach the shock absorber electrical connector to

I

bottomed

hang by the brake hose,

the caliper to

pivot bolt

lully into the fitting,

lbs

Install the

lbs

ft

strut

position the strut rod in the suspension support

16

the caliper mounting bracket bolts

40

Install the

15.

seated

is lully

it

knuckle pinch bolt and

Install the

slot

shock absorber lower mounting

shock absorber,

14,

Position the strut so

tighten to

lever.

and washer attaching the

nut and bolt. Tighten the upper shock absorber nut to

strut insulators

darnage and replace

not disconnect the brake hose or allow

port the outer

or equivalent lubricant, rotate the spring

retainer to the line

0-rings with petroleum

air line

up on the end

end

and suspend the

7,

Moisten the

14

knuckle with the tang on the

at the

knuckle

Lift

and lower

as necessary,

cable support bracket to the caliper,

wire.

Inspect the upper

lor cuts, cracks, tears or other

the rear brake caliper as lollows:

Remove

c.

Install:

13

Loosen the parking brake cable

d

Position the top ol the shock absorber with

1 1

To

on the

remove the

stabilizer bar,

bolt at the strut,

Remove a.

and replace as necessary,

Install the

to hold the rotor

adjuster

and lower shock absorber

insulators lor cuts, cracks, tears or other

2 lug nuts

equipped with a

tree the

Inspect the upper

1

II

mounting

through the upper control arm.

it

install:

9

Install

5

6

tittlng.

and

4

hub and bearing assembly

from entering the system

to prevent dirt

the upper strut rod cap.

and

insulator.

mounting

Slowly lower the jack or

(113

lbs,

ft,

Nm)

Install the

parking brake cable

support bracket and tighten the bolt (43

32

to

tt

lbs

Nm)

level control

remove left

the jackstand to relieve the spring pres-

22

Lift

up on the end

of the cable spring clip

strut

and work the end

sure,

Compress

1 1

the strut by

hand and remove the

bly outward by pivoting 12,

Remove

on the knuckle pivot

the knuckle pinch bolt and

bolt,

23

installing the

If

left strut,

connect the elec-

tronic level control height sensor link

remove

the strut from the knuckle.

parking brake cable into the

ol the

notch on the lever Adjust the parking brake

lower insulator. Rotate the strut and knuckle assem-

24,

Remove

the 2 lug nuts that were installed to

retain the rotor

25

Install the

wheel and

tire

assembly and

lower the vehicle.

SQUEEZE TABS TO REMOVE FRONT OF CAR

TESTING t

See Figure 63 The purpose

ol the

motion

of the

limit the

and rebound cycles

If

shock absorber

is

is

to

not equipped

with these motion dampers, the up and

motion would multiply

the vehicle

until

nately trying to leap off the Itself into

simply

spring during compression the vehicle

ground and

down was alterto

pound

the pavement

Contrary to popular rumor, the shocks do not adect the ride height of the vehicle This trolled by other

springs and

affect handling:

is

con-

suspension components such as

tires if

Worn shock absorbers can the tront ol the vehicle

is

rising or falling excessively, the 'loolprinf of the tires

changes on the pavement and steering

is

affected

The simplest Fig.

62 Detaching the Computer

Ride electrical connector

Command

test ol the

push down on one corner and release IS

it

shock absorber of the

it

will

simply

unladen vehicle

Observe the motion

released In most cases,

is

ol the

body as

come up beyond

it

it

SUSPENSION AND STEERING

8-21

SUSPENSION AND STEERING

8-22

lower insulator. Detach the wheel speed sensor con-

and remove the

l(nuckle pivot bolt

hub and bearing and

remove

arm from the

the control

arm

bolts

LOWER CONTROL ARM

vehicle.

arm

in the vehicle

Do

bolts.

arm hangs

Remove

Support the inner end

knuckle pivot

install the

bolt.

the control

Do

not tighten the

Attach the wheel speed sensor connector.

15.

Install the

arm with a

the wheel and

tire

ol the lower control

arm

stabilizer bar

and shock

and

bolts, then slowly lower the control

6

Pull the lovrer control

also be securely positioned or personal

To

arm

to

arm down and remove

the lower control

arm outer

bolt

8

and

result.

75

the upper strut insulator, retainer,

Tighten the upper strut nut to 65

the knuckle pivot bolt to

19

It

ing bolt 20.

arm

59

bolts to

lbs

ft

66

Remove

Nm).

Position the lower control

install the

ft.

lbs.

at

install the stabilizer

and tighten the

to

43

ft

lbs

2 lug nuts

the top ol

to

ft,

lbs,

with

new mounting

(113 Nm),

Install the

to

32

f1,

lbs

(43 Nm). Lift

its

in

tight-

the normal ride

14

Install the

wheel and

tire

assembly and

flat

will

its

UPPER CONTROL ARM See Figure 67 1

Raise and salely support Ihe vehicle

2

Remove

3

II

the wheel and

4

If

assembly

equipped with 4 6L engine, remove Ihe

arm

in the

vehicle

nut. Tighten the nut to

5

Remove

spring and insulators

To

Is

6

installed in the

surface prior to installation.

stand up straight

when

will lean or tip

when

and outer control arm

arm up over

install:

Lower the control arm over the shock tower it

outer control

arm

in the

vehicle Install the inner and

bolls.

7

Position a suitable jack under Ihe outer end

ol the

lower control arm Raise the suspension with

Ihe lack until

Raise the inner end of the lower control arm

with the jack to slightly

compress

the coil spring.

arm

nuts and bolts

lower control

Connect the shock absorber and lower control arm.

the shock tower

from the vehicle.

it

and position

resting

over

top end.

Ihe inner

bolts Raise the control

it

is in

the normal ride height position,

then tighten the upper control

link to the

tire

equipped with 4 9L engine, remove the

nuts to 42

ft

lbs

(57

arm

inner

and outer

Nm)

stabilizer

The inner control arm nuts must be lightened with the suspension in the normal ride height position to reduce wind up in the bushings.

up on the end

and work the end notch on the

o( the

lever.

ol the cable

spring clip

parking brake cable into the

Adjust the parking brake

II

equipped with 4 6L engine,

install the

road sensing suspension position sensor and bracket to the shock lower

Fig

arm

Nm)

arm nuts must be

ened with the suspension

and remove

lower end, but

resting on

It.

parking brake cable

support bracket and tighten the bolt

22

on a

Install the inner

Install the caliper

bracket bolts Tighten the mounting bracket bolts to

83

Install the coil

The spring

10.

were installed

retain the rotor

21

and

proper position, rest the spring (without insu-

on bar mount-

(58 Nm).

that

outer bolt

(102 Nm).

•»To ensure the spring lators)

the jack or jackstand.

equipped,

Remove

inner control

the lower control

(102

lbs

bracket from Ihe shock tovrer

and

(90 Nm).

lbs.

ft.

lbs (88

ft,

(80 Nm). and the

Attach the electrical connector

18.

the strut.

Nm) and

ft

road sensing suspension position sensor and

Install:

9

inner control

(102

electronic level control height sensor link

Remove

7

Install

(60 Nm), the shock absorber lower nut

lbs

I

and remove the lower control arm.

7

lbs

ft

arm nuts

the inner lower control

relieve the spring pressure.

compress

to slightly

Remove

5

The jack/jackstand must be strong enough to supporl the weight of the vehicle. It must

1

It

75

lower the vehicle Check Ihe rear wheel alignment

the coil spring.

nut.

44

to

ings.

assembly

absorber from the lower control arm.

assembly

the spring

may

to

of the lower control

suitable jack. Position the jack to

Disconnect the

4

lower strut insulator and position

the suspension support

Position a jack or jackstand under the outer

injury

suspen-

the normal ride

securely hold the control arm.

14.

strut in

in

height position to reduce wind up in the bush-

3.

in

until the

the normal ride height position

With the suspension

13

free

2.

assembly

Is in

^The

Raise and safely support the vehicle so that

1

arm

rotor

bolt at this time.

16.

See Figure 66

the control

Position the assembled knuckle, strut, hub

and bearing and

sion

inner nuts to 75

and

not lighten

the bolts at this time

end

lower control arm Raise the lack

assembly and

height position, tighten the stabilizer link lower nut

and

»

arm

Position the control

both inner control

13.

lire

Position the jack under the outer end ol the

12

control arm, connect the

1993-98 Eldorado and Seville inner control

install:

12

the

left

wheel and

from the vehicle as an

rotor

Remove both

1

install

installing the

Install the

lower the vehicle. Check the rear wheel alignment

l^nuckle. strut,

assembly.

To

It

24

While supporting the l(nuckle, remove the

10

and

23.

electronic level control height sensor link

nector

65 Control arm installation

Eldorado and Seville

1990-92

Fig

67 Upper control arm installation

1993-98 Eldorado and Seville

SUSPENSION AND STEERING 9.

equipped with 4.9L engine,

It

surface. The spring will stand up straight

install the

resting on

electronic level control height sensor link, Install the

10,

wheel and

when

assembly and

tire

its

lower end, but will lean or

resting on

its

when

tip

compress

See Figure 68 Raise and safely support the vehicle

securely 2.

Remove

3.

Support the inboard end

Attach the shock absorber lower attachment,

15,

Install the stabilizer link

16,

Remove

link

Remove

6.

arm

the inboard lower control

75

ft,

bolts

75

spring pressure, Pull the lower control

8.

arm down

remove

to

the spring,

in

in the

design

Deville and Fleetwood

the bushings,

•A rear wheel

the lower control

arm outboard

bolt

Remove Remove

wheel and

Remove

4.

alignment

tire,

is

necessary when-

10,

75

ft,

11,

arm

in

lbs,

To

install:

6.

Install the stabilizer

Bend

Insure proper orientation of the spring,

the wheel and

tire

Disconnect the electronic

3,

spring and insulators,

rest the spring (without insulators) on a flat

assembly

level control height

the link

Remove

the inner

the control

Lift

remove

To

17

ft.

37

lbs.

it

arm up over

the

lizer

it

in

in

and outer control arm

bolts.

The inner control arm nuts must be

the design position to reduce

installation, use drive-on

wind up

in

arms as

the

NUT,

LOWER CONTROL ARM OUTER

-

FT,)

68 This diagram

of the rear

suspen-

sion shows the removal of the steering

knuckle to access the upper and lower control

arms

necessary to

far

&

or support the

outboard as possible with

1

Raise and safely support the vehicle.

2.

Remove

ft.

lbs.

(57 Nm).

3.

Remove

the stabilizer bar attaching nut

the stabilizer link bolt

suspension support.

3

BOLT LOWER CONTROL ARM OUTER

is

ramps

and

bolt at the strut.

t^--

19

Install the stabi-

If It

jacks.

tight-

Tighten the upper control arm inner and

outer nuts to 42

remove and

bar with the vehicle on the ground and

supported by the wheels.

control

bushings. a.

MODELS

raise the vehicle for stabilizer bar removal

the vehicle.

lower control arm to bring the suspension to design position.

24

ft.

See Figure 69

>»lt is easier to

Place a screw jack under the outboard end of the

22

lbs. (17 Nm) and (50 Nm) on 1990-91 vehiNm) on 1992-98 vehicles.

lbs.

shock tower

from the vehicle.

Install the inner

8,

UPPER CONTROL ARM BOLT, UPPER CONTROL ARr^ OUTER NUT, UPPER CONTROL ARM OUTER 57 N-m (42 LBS, FT.) REAR BFIAKE CAUPER ASSEMBLY

ft.

(23

Eldorado and Seville

1990-92

Place the control arm over the shock tower

to install

ened

bushings, retainers, support

and outer control arm

install:

7,

Fig.

facing the rear

around the

install the link bolt,

the link bolt to

»

6,

to

102NTn(75LBS,

slit

to close

Disconnect the road sensing suspension

4,

position sensor and bracket from the shock tower

bolts,

17

upward

Tighten the link nut to 13

cles or

on the vehicles with the 4,9L engine,

link,

5,

16

and bushings.

bar and bushings. Install

and nuL

9.

on the vehicles with the 4,6L engine,

15

and bend the open end

the stabilizer bar

Install the link

8.

bolt

Remove

2,

sensor

»To

bushing and

Raise and safely support the vehicle

1,

securely

(102 Nm).

Install the

the link bolt

Remove

the vehicle and

outboard control arm bolt and nut,

Tighten the lower control arm outer nut to

a.

assemblies,

of the vehicle.

UPPER CONTROL ARM

Position the control

install the

tire

stabilizer bar bracket,

downward.

5.

7.

install:

and

the bushing into the link with the

have been loosened.

and the control arm.

To

the rear wheel

the stabilizer bar link bolt, nut,

and bushings from the

of the link

(102 Nm),

lbs,

Raise and safely support the vehicle.

retainer

(102 Nm),

Install the

1

2. 3.

to

ever the inner lower control arm fasteners

Remove

9.

assembly

REMOVAL & INSTALLATION

Tighten the lower control arm inner nuts to

ft,

to relieve

17,

it

(60 Nm),

lbs,

c.

Slowly lower transmission jack

vehicle.

to

Tighten the shock absorber lower nut

b.

nuts, 7.

Lower the

design position. Inner

Tighten the stabilizer link lower nut to 44

lbs,

ft.

and

its

arm nuts must be tightened

a.

Unbolt the shock absorber lower attachment.

and place

lower control arm

of the

position to reduce wind up

lower attach-

ment, 5.

12.

tire

lower attachment,

the transmission jack

bring the suspension to

jack. Position the brackets

hold the control arm.

Disconnect the stabilizer

4.

wheel and

bolts

14,

control

arm with a transmission to securely

of the lower control

arm

level control height

on the vehicles with the 4.9L engine.

Install the

nuts,

under outboard end

and wheel assembly.

tire

link

1 1

the spring,

Insert the inboard lower control

13-

and

the

sensor

inboard end of the lower control arm to slightly

LOWER CONTROL ARM

on the jack

Connect the electronic

10.

Raise the transmission jack under the

12,

1

sensor bracket and sensor on the vehicles with

the 4.6L engine,

lower the vehicle,

1994-98 DevJIle

>

Connect the road sensing suspension posi-

9.

tion

top end.

8-23

ff^

and nut

at the

SUSPENSION AND STEERING

8-24

Remove the stabilizer bar from the 4 Remove the stabilizer link and bushings,

vehicle

Eldorado and Seville

Hub & Bearings

required

it

install:

5

Inspect the bushings lor cuts, cracks or tears

REMOVAL & INSTALLATION

Raise and safely support the vehicle

1

and replace as necessary. Install the

6.

Remove Remove

2

bushings and

links

on the

stabi-

Deville

lizer bar.

3

and Fleetwood

Position the stabilizer bar

7

and

and nuls

the vehicle and

in

See Figure 71

lbs.

1.

(58 Nm).

2

1993-98

MODELS

3. 4.

» See Figure 70

Remove Remove

3

Remove

the rear vi/heel

and

tire

assemblies.

Install:

7.

Position the stabilizer bar in the vehicle.

Raise the exhaust system into position and

4

9.

10

Install the link

the lower link bolt to

upper nuts and lower

1 1

lbs.

44

ft.

ft.

lbs.

(52

bolts.

Nm) and

(60 Nm).

lbs,

Tighten the stabilizer bracket bolt to 44

that attach the

hub and bearing

When

the

removed, the brake assembly

(60 Nm),

12.

Position the

6

Install the

wheel and

tire

assembly and

lower the vehicle.

and

the knuckle

52

lo

Install the disc

8

Install

install: Install the

(113

9

hub and bearing assembly with the

retaining bolts. Tighten the bolts to

52

ft.

lbs.

(70

Nm)

mounting bolts Tighten

new mounting

mounting bracket bolls

Install the

to

brat*

83

•

ft

parking brake cable supi

and

tighten the bolt to

Lift

up on the end

and work the end

32

It

lbs (43

Nm)

of the cable spring cNr

of the parking brake cable into the

notch on Ihe lever Adjust the parking brake

Nm).

10 Reconnect the anti-lock brake sensor wire, as

and remove

brake rotor

the caliper with

lbs

5.

bolts

Nm)

7

bolts Tighten the

To

the disc brake rotor

hub and bearing assembly on

install the

(70

lbs

ft

by the brake line or anti-lock brake electri-

6. ft.

Remove

Install:

cal wire.

install the brackets,

Tighten the upper link nut to 38

equipped, remove and discard the disc

If

Remove

bracket

Position the bushings on the stabilizer bar

caliper In the wheelwell with

hang by the brake hose

the hub mounting hub and bearing assembly

To

secure.

and

the caliper mounting bracket bolls

not disconnect the brake hose or allow

the caliper to

must be supported with wire or other means. Do not let the brake assembly hang

8.

Do

5

also support the brake assembly.

lever

the bolt and washer attaching the

brake rotor retainers

bolts are

the stabilizer bar.

Remove

d

wire

around the sensor wires; disconnect them as

The bolts

at the

spring to

II

the

at

of the cable

from the

of the cable

and suspend the

and remove the

the axle

and remove

Lower and support the exhaust system

Remove

assembly

of the vehicle.

the stabilizer brackets

the rear of the vehicle. 6.

tire

drum

the retaining bolls

equipped with anti-lock brakes, be carelul working

the bushings from the stabilizer bar. 5.

the brake

assembly

cable support bracket to the caliper

the stabilizer link lower bolt and

upper nut on both sides 4.

the wheel and

hub and bearing assembly from

Raise and safely support the vehicle.

1

2,

Remove Remove Remove

end

Remove

c

Raise and safely support the vehicle,

up on the end

Lift

Iree the

Tighten the link bolt and stabilizer mounting It

tire

the rear brake caliper as lollovre

adjuster b.

t

strut.

8,

nuts to 43

To

MODELS

199l>-93

suspension support

at the

the wheel and

Loosen the parking brake cable

a install the bolls

MODELS

1990-92

To

Install the

wheel and

assembly and

tire

lower the vehicle.

necessary. 7.

Install the

brake drum.

8.

Install the

wheel and

tire

1993-98 Eldorado and assembly and lower

Seville,

and 1994-98

Deville

the vehicle.

Raise and safely support the vehicle.

1

2.

3.

Remove Remove

the wheel

and

tire

assembly

the parking brake cable bracket

from the knuckle 4.

Remove and discard the caliper mounting Remove Ihe caliper and suspend m

bracket bolts

it

Ihe wheelwell with wire

Do

hose or allow the caliper 5.

6 the

Remove Remove

not disconnect the brake

hang by the brake hose

the disc brake rotor the

hub mounting bolts and remove

hub and bearing assembly

To 7

Install: Install the

tighten the 7

to

Slabilizef link

hub and bearing assembly and

mounting bolts

8

Install the

9

Install the caliper

52

to

ft

lbs (70

Nm)

disc brake rotor with

new mounting

bracket bolts Tighten the mounting bracket bolts to

83 Fig.

70 Stabilizer bar Installation—

1993-98 Eldorado and Seville

Fig. 71 ille

Hub and bearing assembly— Dev-

and Fleetwood

ft

lbs

(1

13

Nm)

Install the

bracket and tighten the boll to

10

Install the

lower the vehicle

wheel and

parking brake cable

32

tire

ft

lbs (43

Nm)

assembly and

SUSPENSION AND STEERING

horn contact

Install the

Wheel

steering

8-25

to the steering col-

umn. Attach the electrical connectors to the infla-

9.

REMOVAL & INSTALLATION

tor

module. Position the

inflator

module on

steering wheel taking care to ensure

the

no wires are

pinched. 10.

Install the inflator

module

retaining

bolts/screws and tighten to 27 inch

covered by this manual may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the Impact sensors, the air bag module, steering column, and

Some models

base

install

VIEW A

Disconnect

b.

Turn the ignition switch OFF.

c.

Remove

the SIR fuse.

On 1990

Deville

1990-91 Eldorado and

and

Fig.

73

Inflator

module and steering wheel

Connect the negative battery Turn the ignition switch to

Seville,

No. 19 from the fuse panel.

»

left

On 1992-93

Remove

e.

If

does not function as specified, there

the is

a

SIR system.

special tools

perform

this repair

may be necessary

to

procedure.

1.

Disable the supplemental inflatable restraint

system.

On Eldorado and

sound

See Figures 75, 76 and 77

»Some

They include: J 185g-A, J42578

Eldo-

and Fleetwood, remove the

side

Verify

indicator

7-9 and then remains OFF

remove SIR fuse

rado and Seville, remove SIR fuse No. All from

remove the

cable.

RUN.

"INFLATABLE RESTRAINT"

removal/installation

and Fleetwood,

the engine compartment fuse panel.

lower sound insulator.

Seville,

insulator.

Seville— Late Models Deville

remove SIR fuse No. 18 from the fuse panel. On

Deville

On Eldorado and

sound

SIR fuse.

e.

fault in the

Fleetwood, remove SIR fuse No, 3 from the fuse

On

side

the

install the left

negative battery cable.

a.

On 1991-93

left

at

CPA.

install the

d.

light

d.

the

light flashes

I

Disable the SIR system as follows:

panel.

column and

and Fleetwood,

Install the

that the

ttie

Deville

c.

and Fleetwood-

See Figures 72, 73 and 74 1

On

lower sound insulator.

I

>

of the steering

b.

Models

Early

Connect the yellow 2-way connector

a.

instrument panel disable the SRS.

Deville, Eldorado, Seville

Nm).

lbs. (3

Enable the SIR system as follows:

1 1

left

2.

3.

the Connector Position

Assurance

(CPA) and detach the yellow 2-way connector

Insert a flat-bladed tool into

openings

Seville,

insulator.

in the

back

of the steering

one

of the four

wheel.

Turn the tool counterclockwise to disengage

the wire from the slot in the inflator module.

at

the base of the steering column.

Remove

2.

the bolts/screws from the back of

the steering wheel

Remove

3.

slightly

and remove the

inflator

module,

the horn contact by pushing

and twisting counterclockwise. Detach the

electrical

connectors from the

inflator

Fig.

74 Steering wheel removal

module.

When

carrying a live inflator module,

make

sure that the bag and trim cover are pointed

away from you. Never carry the inflator module by the wires or connector on the underside of the module.

In

case

Fig.

of acciin

75 Disengaging the wire from the slot

the Inflator module

dental deployment, the bag will then deploy

with minimal chance of injury. ing a live inflator

module on

a

When

plac-

bench

or

other surface, always face the bag and trim

cover up, away from the surface. 4.

Remove

the steering

column

shaft nut.

If

not

already marked, mark the steering wheel and steering

column

shaft to ensure proper alignment during

installation. 5.

Remove

the steering wheel using steering

wheel puller J-1859-03 or equivalent.

To 6.

install:

Feed the SIR

coil

assembly lead through the

slot in the steering wheel. Align the

steering wheel with the

umn Fig. tor

72 Yellow 2-way SIR harness

and CPA

t

shaft 7.

and

install the steering

Install the steering

tighten to

30

ft.

lbs. (41

mark on the

mark on the steering

column

Nm).

col-

wheel. shaft nut

and Fig.

76 Remove the steering wheel nut

SUSPENSION AND STEERING

8-26

Connect the horn conlaci lead

18

19 wise

steering wheel until Ihey are disengaged Irom the inllator

Rotate the horn contact turn Vi turn clock-

module

Remove

3

the inllalable restraint steering

wheel module form the steering wheel

to lock,

20 tor

Into Ihe

column cam lower

steering

Attach the inllator

module

electrical

4

conne(

and CPA

Disconnect the horn contact by pushing

and twisting counterclockwise

slightly

Unplug the connector position assurance

5,

(CPA) and

coil

assembly connector from the

inllator

module.

Route the driver

inllator wires, the

redun-

Remove

6

dant control wires, and the horn wires cor-

the steering

Using the special

7

column

tool J

shaft nut

1859-03. pull the

sleeting wheel.

To 21

Align the driver inflator module fasteners to

column

Ihe steering

77 These special tools are used to

Fig.

22

Push the

fastener holes

driver inflator

module

Install:

8

9,

pull the steering

wheel

column

the steering

23

to

ensure the fasteners engage

module gently away Devllle and

from the steering wheel.

I

Eldorado— Late Models

See Figures 78

thru

84

tions, the

inflator

wire routing posi-

redundant control routing positions,

and the horn wire routing positions

may be necessary

•^Rotating the steering wheel so that the

the connector position assurance

module

inflator

electrical

connec-

tor

wheel are will

of

Remove

7.

threaded hole

at the

of the steering

12 and 6 o'clock positions

allow tool access and reduce the potential

marring the steering column.

tt

lbs

OFF

Attach Ihe horn contact to the steering col-

umn, 13

Connect the

the inllator

the steering wheel,

14

coil

assembly and the

CPA

wheel securing 15

module that

it

module

to the steering

with the four screws

Align the inflatable restraint steering wheel to Ihe steering

no wires

al

wheel taking precautions so

the back of Ihe inllator

1,

Disable the SIR system,

module

2

Loosen the

four screws from the back of the

inch lbs, (3 Nm),

16

Enable Ihe SIR system

turn.

Remove

9 steering

the horn contact lead from the

column cm tower

Remove

the inflatable restraint steering

wheel module. 1 1

Remove

the nut

on the steering column

shaft.

12.

Using special

tool J

1859-A and J 42578

separate the steering wheel from the steering shaft 13.

To

Remove

the steering wheel

Install:

14,

Feed Ihe wiring through Ihe steering wheel.

15

Align the steering wheel with the mark on

the steering shaft 16.

Install the nut for the steering

tighten to 17, left

30

ft

lbs

threaded hole

Fig

(41

wheel and

Nm),

Connect the horn ground lead in

into the tower

the steering wheel

80 Gently disengage the module from

the wheel

to

module

Install the inflator

get

pinched during assembly Tighten the bolts to 27

grounded lead from the

Rotate the horn contact lead counterclock-

8.

wise Vi

10

the horn

in

to

perlorm this repair procedure, including J 1859-03 or equivalent steering wheel puller.

access holes on the backside

Remove

6.

the

is in

lor the cor-

re-assembly.

rect

(CPA) and driver

Tighten the column shaft nut to 30

Ensure the ignition switch

12

w^Note the driver

special tools

(

position

holes.

•»Some

slot

(41 Nm). 1

Repeal the same steps lor the three other

5

assembly lead through

coil

Attach the steering wheel to the column

shaft in the proper position

Enable the SIR system 10,

Pull the driver inllator

4.

Feed the

the steering wheel, firmly into

Fig.

78 Loosening the module retaining

module

Fig

81

.

.

Fig.

.

Remove

Assurance (CPA)

the Connector Position clip

79

.

.

.

requires a

Ton* head

driver

SUSPENSION AND STEERING

V^V RIGHT SIDE

Fig.

83 The

left

and

right side ol the steering

v-^ Fig.

84 View

inflator

of the horn lead (A)

module

Turn Si

and

electrical connector

(B)—

column

8-27

SUSPENSION AND STEERING

8-28

On 1992-93

c

vehicles, reposition the con-

nector cover

On

21

and

and 1990 Eldorado

Seville, install the nfiulti-lunction turn signal

Make sure

the lever

is in

the

OFF

posi-

Push the

lever into the turn signal switch.

position

the cruise control vniring connec-

b

d

Install the

On

rado,

umn

housing

22

Install the inner race,

to the steering col-

Install the turn

and

upper bearing inner

24.

LOCK

signal canceling cann

Position the shaft lock Use tool

shall lock retaining ring.

firmly seated in the Install

26.

If

the

on the upper steering

assem-

J-23653-C

The ring must be

(he SIR coil

is

off-center,

LOCK

c.

Remove

d.

Hold the

tom up

fol-

of the

differ-

and the

arrow

until

stops.

it

hub

The

in

coil

approximately

Vh turns.

lock between the locking labs

Release the spring in front ol

the

arrow

^\\ a new SIR coil assembly Is being Installed, assemble the pre-centered coil assembly to the steering column. Remove the centering tab and dispose. 27

Install the

SIR

tower on the canceling jection

28. ring

coil

assembly, using the horn

cam assembly and

on the housing cover Install the coil

must be

for

firmly seated in the

the pro-

alignment

assembly retaining

ring.

The

groove on the

shaft.

Fig.

87 Removing the upper shaft compo-

nents

Fig.

88 Removing the mulli-funclion turn

signal

lever— 1992-93 Eldorado and

Seville shown, others similar

Fig.

89 Removing the turn signal switch

Fig

90 Turn signal switch Installed—

1992-93 Eldorado and Seville shown, ers similar

oth-

to

Enable the SIR system as lollows a

Connect the yellow 2-way connector of the steering

On

Deville

column and

and Fleehwood.

install the

On Eldorado and

Seville,

side sound insulator

SIR fuse

Install the

d

Connect the negative battery cable.

e

Turn the ignition switch to

STYLE

at Ih-

CPA

install the left

c

the direction

ribbon should

or

may cause damage

Install the steering wtieel

30

assembly, depress

coil

Rotate the coil hub in the opposite direc-

I.

tion

86 Removing the shaft lock retaining

29

install the left

clear bot-

There are 2

to see the coil ribbon

While holding the

remove any slack

inside the steering col-

do so the wire harness. to

lower sound insulator

assembly with the

be wound up snug against the center hub

Fig.

may be

umn. Failure

other rotates counterclockwise e.

lows:

nal harness wires to

b

the SIR coil assembly, coil

Gently pull the coil assembly and turn sigkinks thai

base

position.

the spring lock to rotate the

proceed as

that

The vehicle wheels

ent types ol coils one rotates clockwise

groove on the shaft

wave washer

so

shall is at

should be straight ahead. Turn the ignition

lubricate with suitable grease

25.

Oeville, Fleetwood, Eldo-

Seville, set the steering shaft

the block tooth

switch to the

or equivalents, to depress the shaft lock, then install

new

and

model

late

the 12 o'clock position.

race seat, and upper bearing spring

a

o'clock position and the vehicle wheels straight

Conned

access cover

12

at the

the end of the shaft should be at the 12

at

b.

tor.

and

that the block

o'clock and 6 o'clock positions The alignment

c.

23.

so

ahead. Turn the ignition switch to the

tion.

bly

early Oeville, Fleetwood. Eldorado,

on the upper steering shaft are

teeth

mark

lever as lollows: a.

On

a

Seville, set the steering shaft

Deville, Fleetwood,

^^

RUN

Verify

SUSPENSION AND STEERING that the

1NFU\TABLE RESTRAINT"

light (lashes

21

indicator

7-9 times and then remains OFF,

the light does not function as specified, there a fault

in

If

is

Temporally

install the special tool J

C and push down the shaft lock until it is possible new shaft lock bearing retainer. Ensure

to install a

the bearing retainer

the SIR system,

is

firmly seated in the groove

on the shaft Deville, Eldorado and Fleetwood— Late Models

•»Set the steering shaft so that block tooth on the upper steering shaft

>

See Figures 94, 95 and 96

is at the 12 o'clock wheels on the vehicle should be

position, the

Gently pull the lower coil assembly, turn signal and pivot and pulse wires

Disable the SIR system,

2.

Remove

the inflator

the

module and

the steering

"LOCK

position, to ensure no

"

occur to the

damage

t

remove

any wire kinks that may be inside the steering column assembly. Failure to do so may cause damage to the wire harness.

straight ahead, then set the ignition switch to 1.

8-29

23653-

will

27.

Install the

wiring protector.

28.

Install the

remaining components

the

in

reverse order of the removal procedure.

coil.

wheel, 3.

Disconnect the negative battery cable.

4.

Remove

Remove

22.

Install the

wave washer

Seville

the coil assembly retaining ring.

assembly and allow

the SIR coil

to

it

I

hang

freely. 5.

Remove

6.

Install

the

The SIR

wave washer.

special tool J

23653-C

push down

to

Remove

the shaft lock, the special tool, the

turn signal canceling

assembly. Failure

cam assembly, and

to

do so

may cause

See Figures 97 and 98

>»Some

special tools

may be necessary

to

perform this repair procedure.

Remove

and the inner

is

turned.

They include:

the upper bearing inner race seat,

Ensurethatcoilassembly hub

is

centered, 24,

Pull the wire tight while positioning the

SIR

race.

fyiove the turn signal to the

1

J

41352 and J 42640

"RIGHT TURN"

Disable the SIR system.

3.

Remove Remove

the steering wheel.

4.

5.

Remove

Align the opening

the two nuts (1) securing the steer-

the knee bolster.

ing column.

coil to the steering shaft,

25,

Disconnect the negative battery cable.

2.

the upper

23,

9.

no slack while installing the SIR

and cut when the steering wheel

bearing spring. 8.

assembly wires must be kept

wires to be kinked near the shaft lock area

retainer. 7.

tight with coil

the shaft lock and remove the shaft lock-bearing

coil

in

the coil with the horn

6.

Lower the column, remove the

tilt

handle

position,

10

Remove

the multi-function lever

and hazard

11.

Carefully take out the 2 screws and the sig-

13.

Remove

26,

the coil

Ensure the ring the turn signal switch screws.

is

assembly retaining

8.

Remove Remove

the upper and lower shroud. the

two wire harness

straps.

Remove

one wire harness strap from the steering column

ring.

firmly seated in the groove

on the

Remove

the wire harness

assembly from the

wire harness strap.

from the bulkhead connector. 14.

Remove

and gently

the wiring protector,

the wire harness through the steering

remove the

To 15.

column

pull

to

turn signal switch.

Install:

Feed the turn signal switch assembly wire

harness through the steering column. 16.

bulkhead

Attact the switch connector to the

connector. 17.

Install the turn signal

switch assembly an

KEEP LOWER WIRES TIQKT WHILE SEATINQ SIR COIL ASM HEAD IN STEERING COLUMN.

tighten the screws to 31 inch lbs. (3.5 Nm). 18.

Replace the switch arm and tighten the two

screws. Tighten the top screw to 27 inch

Nm). Tighten the bottom screw

to

lbs. (3

22 inch

lbs. (2.5

Fig.

Nm). 19.

Install the

95 Routing the

coil

assembly wires

Hazard knob assembly and multi-

function lever. 20.

Install the

inner race, upper bearing inner Fig.

race seat, and upper bearing spring. Lubricate the

canceling

cam assembly and

97 Dropping the steering column by

removing the two nuts install

it.

SIRCX)IL/

TURN SIGNAL SWrrCH WIRE HARNESSES

THROUGH HERE.

Fig.

5

O'CLOCK POSrTION.

94 Wire harness route through the

column shown here

Fig. Fig.

96 Centering the

coil

assembly

tilt

head assembly. 9.

shaft.

Detach the turn signal switch connector

lever. 7.

Seat the coil assembly into the steering col-

umn. Attach

nal switch arm.

12.

tower and "locating bump" between the two tabs on the housing cover,

knob assembly

from

98 Disengaging the wire harness its

strap (2)

(1)

SUSPENSION AND STEERING

8-30

remove SIR luse No. 3 Irom the luse panel On

Ignition Switch

1991-93

vehicles,

remove SIR luse No 18 Ifom

the fuse panel

Remove Remove

d e

When

performing service around Supple-

be disabled. Failure injury, or

to

do so could result

unneeded SIR system

repairs.

REMOVAL & INSTALLATION

See Figures 99

thru

sound

insulator

Assurance

in

2.

Lower and support the steering column

at

3.

Remove

ignition switch

the screw

and washer retaining the

and dimmer switch. Remove Ihe

ground wire (rom Ihe mounting stud. 4.

Remove

the

dimmer switch (rom

5.

Remove

the

dimmer and

6.

Devllle and Fleetwood

lo«fer

the Connector Position

the base ol Ihe steering column.

mounting

>

left

(CPA) and detach the yellow 2-way connector

mental Inflatable Restraint (SIR) system components or wiring, the SIR system must possible air bag deployment, personal

the

the rod

ignition switch

stud.

Remove

the ignition switch

from the ignition

switch actuator 7.

109

Remove

Ihe wire harness strap,

if

equipped Disable the SIR system as follows:

1

To

a

Turn the ignition switch OFF.

b

Disconnect the negative battery cable,

c

Remove

the SIR luse.

On 1990

8

vehicles,

9.

10.

Detach the necessary

electrical

connectors

install:

Attach the electrical connectors.

Move

the ignition switch slider to the

84206079

Fig.

102 Removing the upper

stiaft

compo-

nents

Fig.

99

Ignition switch

removal— Devllle

and Fleetwood

^ Fig.

100 Ignition switch

—

Devllle and

Fleehvood

Fig.

103 Removing the multi-lunction turn

signal Seville

lever— 1992-93 Eldorado and shown, others similar

ruHN SIGNAL SHWTCH CONNCCTOn

Fig ring

101 Removing the shati lock retaining

SUSPENSION AND STEERING To

PROJECTIONS ON HOUSING COVER USED FOR ALIGNMENT OF COIL ASSEMBLY

To

install:

8.

Il/love

the ignition switch slider to the

extreme right position, then move to the

INSTALL

the

ASSEMBLY SHAFT AND

tion switch

left

OFF-LOCK

it

position. Install the igni-

must be

switcti

OFF-LOCK

the switch in the

108 SIR

Fig.

coil

Remove

switch

installed on the column. Failure to

may cause

the

column harness and

signal switch

do

switch damage.

attach the ignition

column harness connectors

Install the ignition

switch wiring protector

Install the steering

column reinforcement

Install the

knee bolster and secure with the

Position the switch on the

Connect the yellow 2-way connector

b.

to

the

Install

the SIR fuse.

Conned

e.

Turn the ignition switch to

remove

Remove

the

drill bit

and tighten the nut

35 inch

lbs. (4

left

the

column harness and

column. Failure

do

to

switch damage.

Attach the turn signal switch connector to attach the ignition

column harness connectors

Install the ignition

9.

and turn

to the

switch wiring protector

Raise the steering column to the support

bracket and the bolt and nut or 2 bolts to the lower

Do

not tighten at this time.

Align the steering column to the instrument

1 1

umn

in

A

small shim (wedge) placed

column can be used

to

hold the col-

place while tightening the support bolts.

(and nut,

7-9 and

RUN.

then remains

Verify

OFF

If

if

equipped)

Install the

12.

to

20

ft,

(27 Nm).

lbs.

instrument panel steering column

reinlorcement plate and knee bolster

the negative battery cable.

does not function as specified, there

light

to

may cause

Enable the SIR system as follows;

13.

"INFL7\TABLE RESTRAINT" indicator

light flashes c.

A new OFF-LOCK

the plastic pin after the

so

bracket and the

at

install the

side sound insulator

Install

d.

that the

and screw

installed with

position.

Tighten the upper and lower column support bolts

lash.

all

column and

c.

column and

push against the dimmer switch rod

Installed on the

Is

to

between the instrument panel column support

Enable the SIR system as follows;

b.

Deville and Fleetwood

switch

panel opening.

CPA.

109 Adjusting the dimmer switcti—

Remove

support bracket.

the base of the steering Fig.

OFF-LOCK

position.

center trim plate and secure with

the 2 screws.

a.

one detent

Install the igni-

bracket. Install the 2 bolts to the upper support

5 screws.

14.

must be

ignition switch

10.

and secure with the 4 screws.

Install the

it

instrument panel harness.

1 1

13.

move

position

and secure with the retaining screws.

signal switch

10.

12.

the ignition switch slider to the

OFF-LOCK

ignition switch will be pinned in the

8.

and turn

to the

instrument panel harness.

plate

to the

the switch in the

Attach the lurn signal switch connector to

9.

and Seville

Deville, Fleetwood, Eldorado

is

the plastic pin after the

so

assembly Installed—

left

•»The

A new OFF-LOCK

position.

the

tion switch

installed with

position.

ignition switch will be pinned in the

Move

extreme right position, then

to

and secure with the retaining screws.

i»The ignition

install:

7.

one detent

8-31

Connect the yellow 2-way connector

a.

the

base

of the steering

a

b.

Install the left

is

column and

install the

the

at

CPA.

side sound insulator

Nm). fault in the

SIR system.

Install the

c.

SIR fuse.

Raise the column into position and secure.

14.

Enable the SIR system as follows:

15.

Eldorado and Seville— Late Models

Connect the yellow 2-way connector

a.

d.

Connect the negative battery cable.

e

Turn the ignition switch to

at the

that the

base of the steering column and Install the left

b.

install the

Install

d.

Connect the negative battery cable.

e.

Turn the ignition switch to

RUN.

Verily

does not function as specified, there

a fault in the

Disconnect the negative battery cable,

On 1991 Eldorado and

d.

SIR system.

e.

Remove Remove

the

left

side

2.

a.

Turn the ignition switch OFF.

b.

Disconnect the negative battery cable.

c.

Remove SIR

e.

Remove

at

the knee bolster and instrument

panel steering column reinforcement plate.

injury, or

Remove Remove

side

sound

the

left

the

Connector Position Assurance

insulator.

ported by only the lower support bracket at

alone.

Damage

to the

and the center trim

Remove Remove

the 5 screws

and the knee bolster

upper column support from the instrument panel.

the 4 screws

and the instrument

Lower the steering column and

and the 6.

the ignition switch wiring protector

ignition switch retaining screws.

Detach the ignition and turn signal switch

column harness connectors from

the instrument

panel harness. 7.

Remove

the 2 bolts or bolt

Remove

and nut and the

let

it

rest

on the

driver seat. 4.

and the 5.

Remove

the ignition switch wiring protector

ignition switch retaining

screw and

nut.

Detach the ignition and turn signal switch

column harness connectors from

Remove

the ignition

6.

I

See Figures 110

thru

and Seville

115

the 2 bolts and the

the instrument

panel harness.

Detach the turn signal switch connector

from the column harness. switch

3.

lower support bracket.

Remove

REMOVAL & INSTALLATION Deville, Fleetwood, Eldorado

the 2 screws

panel steering column reinforcement plate. 5.

repairs.

column lower bearing

Remove

plate.

4.

unneeded SIR system

adapter could result.

the base of the steering column.

3.

performing service around Supplemental Inflatable Restraint (SIR) system or wiring, the SIR system must be disabled. Failure to do so could result in

components

The steering column should never be sup-

(CPA) and detach the yellow 2-way connector

2.

When

possible air bag deployment, personal

fuse No. 19 from the fuse

panel. d.

Lock Cylinder

the Connector Position Assurance

the base of the steering column.

Disable the SIR system as follows;

a

sound insulator

(CPA) and detach the yellow 2-way connector

1

is

from the engine compartment fuse panel.

is

Eldorado and Seville— Early Models

specified, there

SIR system.

Ignition

Eldorado and Seville, remove SIR fuse No. All If

If

does not function as

fault in the

remove SIR

On 1992-93

fuse No. 19 from the fuse panel.

"INFLATABLE RESTRAINT" indicator 7-9 times and then remains OFF.

light

b. c.

Seville,

RUN. Verify INFLATABLE RESTRAINT" indicator 7-9 and then remains OFF the

light flashes

Turn the ignition switch OFF.

a.

light flashes

the light

Disable the SIR system as follows;

1

the SIR fuse.

c.

that the

CPA.

lower sound insulator.

Detach the turn signal switch connector

Disable the SIR system as follows;

1. a.

Disconnect the negative battery cable.

b.

Turn the ignition switch OFF.

c.

Remove

the SIR fuse.

On 1990

Deville

and

Fleetwood, remove SIR fuse No. 3 from the fuse panel.

On 1991-93

Deville

and Fleetwood,

remove SIR fuse No, 18 from the fuse panel. On

1990-91 Eldorado and

Seville,

No. 19 from the fuse panel.

remove SIR fuse

On 1992-93 Eldo-

from the column harness. Remove the ignition

rado and Seville, remove SIR fuse No,

switch.

the engine

compartment fuse panel.

All

from

SUSPENSION AND STEERING

8-32 On

d.

and Fleetwood, (emove the

Oeville

On Eldorado and

lower sound insulator

remove the

Remove

e.

(CPA) and base

ttie

left

nal switch.

ttie

delacti

Connector Position Assurance tfie

yellow 2-way connector at

column.

steering wheel

Itie

left

Seville.

sound insulator

of ttie steering

Remove

2.

side

When removing

and the turn sig-

the turn signal switch,

allow the switch to hang (reely; do not detach the electric connectors.

4.

Remove Remove

5.

Reinsert the key in the lock cylinder and

3.

the key Irom the lock cylinder.

LOCK

turn the key to the

Remove

6.

removal—

111 Ignition lock cylinder

Fig.

assembly

the buzzer switch

114 Pass key wire harness routing—

Fig.

1990-91 Eldorado and Seville

without pass key lock cylinder

position

the lock retaining screw

If

not

equipped with pass key lock cylinder, remove the lock cylinder.

On 1990-91 Eldorado and

7

Seville

equipped

with pass key lock cylinder, remove the lock cylin-

der as follows:

Detach the terminal connector.

a.

Remove

b.

the retaining clip from the hous-

ing cover and the wiring protector

terminal connector to aid

in

112

Fig.

reassembly.

Gently pull the wire through the bracket

d.

and column housing and remove the lock

115 Pass key wire harness

Fig

Attach a length of mechanics wire to the

c.

Ignition lock cylinder

removal-

1992-93 Eldorado and Seville

cylin-

der.

12

On 1991-93

8.

Oeville

and Fleetwood and to

1992-93 Eldorado and

Install the lock retaining

22 inch

Seville equipped with pass fol-

lbs

(2.5

On 1990

13.

key lock cylinder, remove the lock cylinder as

RUN

to the

Detach the pivot and pulse switch connec-

screw and tighten

Nm) and Fleetwood and

Oeville

1990-91 Eldorado and

lows: a.

routi

1991-93 Oeville and Fleetwood, and

wlth pass key lock cylinder

position

key

Seville, turn the ignition

On

all

remove

other vehicles,

the key. tor

from the bulkhead connector and remove the Install the

14.

13-way secondary

lock.

15. b.

Remove

the

2 terminals

of the

It

the key

pass key sure

the

is in

II

buzzer switch assembly

was removed,

LOCK

Install the turn signal

16.

reinstall

it

and make

position

wire harness from cavities 12 and 13 of the

switch and steering

switch connector

wheel c.

Remove

d.

Attach a length of mechanics wire to the

the wiring protector.

Fig.

terminal to aid in reassembly e.

Remove

113 Pass key wire connection loca-

tions— 1991-93

1

Connect the yellow 2-way connector

a

and 1992-93 Eldorado and Seville

the retaining clip from the

Enable the SIR system as follows:

7

Devllle and Fleetwood,

Install the lock

9.

a

Connect the mechanics wire

nal connector

equipped with pass key lock cylinder, route the wire from the lock cylinder as shown In Figs. 114 or 115, and snap the the hole in the housing.

Failure to route the wire properly In

component damage

may

result

install the left

c

Make

sure the wires are not interfered with

d

e

inside the

to

RUM VenW MNFU^TABLE RESTRAINF indicate7-9 times and then remains Of •

the light does not function as soecitied in

tfie;-

the SIR system

at the

remove any wire kinks

that

Steering Linkage

column assembly.

Connect the pass key connector

On

Turn the ignition switch to

a fault

to the

REMOVAL & INSTALLATION

vehicle harness. 11

Connect the negative battery cable

light flashes

travel of the switch actuator rack

Gently pull the lock cylinder wire

may be

d

that the

and lock cylinder sector gear base of the column

Seville

SIR fuse

e

to the termi-

the clip into the hole in the housing

install the left

On Eldorado and

Install the

the lock cylinder

Snap

and Fleetwood,

side sound insulator

c

column housing

b

by the normal

or maltunctlon ot the

pass key lock cylinder.

and gently feed

wire through the

Oeville

lower sound Insulator

equipped

Seville

with pass key lock cylinder, proceed as follows:

II

On

b

cylinder

On 1990-91 Eldorado and

10.

install:

in

;: t;

CPA.

through the column Remove the lock cylinder.

retaining clip

install

hous-

ing cover and gently pull the wire harness

To

column and

the base of the steering

Oeville. Fleetwood.

equipped with pass key lock

Eldorado and Seville

cylinder,

proceed as

Outer Tie Rod

follows:

a

Route the wire terminal through the col-

umn and snap

^

»

See Figure 116

the retaining clip into the hole in 1

the housing

b

Conned

2 the 2 terminal of the pass key 3.

Raise and safely support the vehicle

Remove Remove

the wheel

and

lire

assembly

the cotter pin and nut Irom the

tte

wire harness to cavities 12 and 13 of the pivot

rod ball stud

and pulse switch connector Fig.

110 Removing the buzzer swilct)—

1990-91 Eldorado and Seville shown, ers similar

oth-

4

13-way secondary lock

c

Install the

d

Connect the switch connector to the bulk-

5 head connector

Loosen the lam nut on the inner tie rod Separate the outer lie rod from the steering

knuckle using tool J-24319-01 or

e

SUSPENSION AND STEERING

^.

8-33

SUSPENSION AND STEERING

8-34

return lines ing,

Failure to disconnect

from the rack and pinion stub

damage

result in

stiatt

damage can cause

loss of steering control,

which could result

Disconnect both

4,

Loosen the

9 rear

»

See Figure 119

front

frame bolts Remove the

Raise and safely support the vetiicle

Remove

2

rod ends from the steer-

tie

the line retainer

Disconnect the outlet and pressure

7,

Remove

sliding

To

it

the 5 rack

(76

in

tire

assem-

mm)

out to the side.

the

bolts. Tighten to

50

ft.

lbs.

outlet

and pressure

lines to the

rack and pinion assembly and tighten the fittings to

(27 Nm).

lbs.

Install the line retainer.

1 1

Connect the

Install the rack

tie

frame bolts

tighten the bolt to

13

Install the

30

lbs.

ft.

tire

14

—

Remove

2.

15.

The front wheels must be In the straightahead position and the steering column In

LOCK

the

kit

No,

must be used. Tighten the

(68 Nm),

sequence shown.

the

in

cause the

the front wheel

if

filter

and

tire

assem-

ttie

Disconnect the

3.

Remove

4

equipped with speed sensitive steering,

6

16.

Install the line retainer.

1 7.

Connect the

tie

rod ends to the steering

Connect the intermediate

Install the front

35

shatt lower

ft.

lbs

wheel and

tire

(47

cou-

Nm)

assemblies

Fill

and bleed the power steering system.

Loosen the

assembly

in

8

Remove

9

Disconnect

10

12

(68

shaft lower

Disconnect both

tie

connec-

tfie

5 rack and pinion mounting

out to the side

Install:

Position the rack and

tod ends from the steer-

20

VIEW a| E

BU

.-..I

•

•

IS

lbs.

ft

lbs

(27

Nm)

Install the line retainer

Raise the frame Into position and tighten

LB FT ). UAXIUUM VoROOt loWiCN COnER Wm (52 LB TT.)

76

to

Connect the

tie

ft.

STEERING KNUCKLE

lbs (103

tfie

Nm)

rod ends to the steering

knuckles

Connect tt» intermediate shatt lower cou-

1

70

and

18.

lighten the bolt to

35

It

lbs (47

Nm).

Attach the pressure switch connector and

coninstall the heat shield

19 connection

It

lines to the

14

16

--rrp';:; gear *• -i-m (ii '. T

equipped with speed sensitive steering,

tfie electrical

50

15

pling electrical

to

Connect the return and pressure

body mount bolls

NW

BOLT, 68 (SO LB ri ) TIGHTEN IN SEQUINCE A TMHU

r

Detach the pressure switch

plmon assembly and

5 mounting bolts Tighten

the line retainer

at the control

Install

the front wheel and

tire

assemblies

valve

and manifold. 7

it

rack and pinion assembly and tighten the fittings to

ing knuckles

detach

retainer

power steering pressure and

Nm)

13

I

Deia

ttie

Detach the pressure switch connector.

Remove

To

cause

will

ttie line

and remove the rack and pinion assembly by

install the

the steering col-

become off-center, which damage to the coil assembly.

body mount bolts and

rear

slowly lower the rear of the frame

position before disconnecting the

to

If

steer-

return lines.

the steering gear. Failure to do so will

6

ttie

frame with a jack

gain access to the steering gear. 7

20

steering column or intermediate shaft from

nection

rod ends from

of the

vehicle.

stiaft

The front wheels must be in the straightahead position and the steering column In

Remove

botli lie

The frame must be properly supported before partial lowering. The frame should not be lowered any further than needed to

sliding

5

InterrTiediate shall lower

Support the rear

1

4.

cause

ing knuckles.

the electrical connections at the control

bolts

3

will

the heat shield

Disconnect

5

Attach the pressure switch electrical conIf

and lower the

intermediate

from the rack and pinion stub shaft can result in damage to the steering gear and/or Intermediate shaft. This damage can cause loss of steering control, which could result In personal injury.

coil

the steering col-

coupling.

(27 Nm).

knuckles.

19

umn

in

to become off-center, which damage to ttie coil assembly.

on speed sensitive

removed) and tighten the con-

lbs.

ft

pling and tighten the bolt to

Failure to disconnect

cause the

assembly

coll

umn

Connect the power steering pressure and

make

18.

LOCK

position before disconnecting the

the steering gear. Failure to do so will

valve and manifold.

Raise and safely support the vehicle.

-

Loctite" thread locking

lbs.

ft,

steering systems,

also

See Figure 118 1

2 washers and 5 rack and pinion

or equivalent

50

14.

nector

Late Models

in the vehicle.

(103 Nm). Remove the

steering column or Intermediate shaft from

nections to 20

and bleed the power steering system.

Fill

lbs.

return lines (including the

assemblies and

lower the vehicle,

Deville and Fleetwood

tt.

Install the

1052624 and

(50 Nm).

wheel and

76

to

jackstands.

bolts to shaft coupling

it

Raise the rear of the frame and tighten the

mounting bolts

rod ends to the steering

Connect the intermediate

and pinion assembly through

wheel opening and position

left

knuckles. 12.

personal Injury.

in

Install:

1 1

the

13.

10.

and pinion mounting bolts

wheel opening

left

12.

Connect the

9.

the rack

and remove the rack and pinion assembly through

To

5 mounting

result.

Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result In damage to the steering gear and/or intermediate shaft. This damage can cause

loss of steering control, which could result

Remove

10.

Position the rack and pinion assembly and

8

may

cowl

tlie

far,

engine components near-

to the

lines.

install:

install the

not lower the rear of the frame too

damage

and pinion mounting

remove the rack and pinion assembly by

(68 Nm).

ft.

Do

est to

6.

bolts and

the

the front wheel and

frame bolts and lower the rear of the frame

about 3

as

Remove

5.

»

Eldorado and Seville— Early Models

access

personal injury.

ing l(nuckles,

20

for

1

intermediate shatl. This In

needed

the inter as

Support the body with jackstands to allow

lowering of the frame

can

gear and/or

to the steering

equipped with speed sensitive steer-

It

remove 8

intermediate shad

ttie

Disconnect the power steering pressure and

Fig.

118 Racit and pinion assembly

—

lation

late

and lower the vehicle instal-

model Deville and Fleetwood

20

Fill

and bleed

Itie

power steering system

SUSPENSION AND STEERING Loosen the

8,

rear

8-35

body mount

and

bolts

slowly lower the rear of the frame,

Remove

9,

the heat shield

and the

plastic line

retainer,

Disconnect the power steering pressure and

10,

return lines,

Detach the speed sensitive steering solenoid

11,

valve connector.

Remove

12,

bolts

the 5 rack and pinion mounting

and remove the rack and pinion assembly by

sliding

To

it

out to the side.

install:

Position the rack and pinion assembly and

13,

5 mounting bolts. Tighten to 50

install the

ft,

lbs,

(68 Nm). Attach the speed sensitive steering solenoid

14,

rn BOLTS

(68 N.m;50 FT

L8S

I

AFTER

SECOND FiEUSE OF BOLT, L0CTIT6 THREAD LOCKING KIT •1052624 MUST BE USED STEERING GEAR Q]

valve connector.

Connect the return and pressure

15,

|T|

WASHER

lines to the

rack and pinion assembly and tighten the fittings to

[T| STEERING KNUCKLE

20

Q] FRAME

(27 Nm),

lbs,

ft.

Install the plastic line retainer

16,

and the heat

shield.

Raise the frame into position and tighten the

17,

Fig.

119 Rack and pinion assembly installation— Eldorado and Seville

body mount 18,

Eldorado and Seville— Late Models I See Figure 120

umn to become off-center, which damage to the coil assembly.

cause

will

If

ft,

(103 Nm),

lbs,

the catalytic converter,

at

Connect the

19,

76

bolts to

equipped with 4,6L engine, connect the

exhaust pipe

tie

rod ends to the steering

knuckles. 1

Disconnect the intermediate shaft lower

coupling.

Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or

damage can cause which could result in

Raise and safely support the vehicle.

3.

Remove

4.

If

the front wheel

and

tire

assemblies.

equipped, connect the road sensing sus-

21

Disconnect both

tie

Install the left front

wheel and

assembly

tire

and lower the vehicle,

equipped with 4,6L engine, disconnect the

road sensing suspension position sensor, 5.

If

pension position sensor,

2.

intermediate shaft. This loss of steering control

20,

Connect the intermediate shaft lower cou-

22, pling

rod ends from the steer-

and tighten the

23,

Fill

bolt to

35

ft.

(47 Nm).

lbs,

and bleed the power steering system.

ing knuckles.

personal injury. 6.

II

equipped with 4.6L engine, disconnect the

exhaust pipe 7.

Power Steerina Pumo

at the catalytic converter,

Support the rear of the frame with a

jack.

REMOVAL & INSTALLATION The front wheels must be in the straightahead position and the steering column in

LOCK

the

steering

position before disconnecting the

column

or intermediate shaft from

the steering gear. Failure to do so will

cause the

coil

assembly

in

the steering col-

The frame must be properly supported before partial lowering. The frame should not be lowered any further than needed to gain access to the steering gear.

Deville and »

Fleetwood— Early Models

See Figures 121, 122 and 123 Remove Remove

1

2.

the serpentine drive belt, the

power steering

fluid

from the

reservoir,

Remove

3.

the reservoir

mounting bolts and

remove the reservoir from the vehicle by disengaging the reservoir tubes from the adapter, 4.

Remove

the belt tensioner,

5.

Remove

the

power steering pump pulley

using tool J-29785-A or equivalent. Hold the body of the tool with a

body

wrench and turn the

of the tool to

remove

bolt into the

the pulley from the shaft.

Remove

the pressure line fitting from the

7.

Remove

the

8.

Use a small prybar

6.

pump,

line adapter clip

1

RACK AND PINION STEERING GEAR BOLT - 68 N-m (50 FT LBS,)

fvlake sure the

To

3

WASHER TIE ROD END STEERING KNUCKLE

tioning or

5

ROD END NUT COTTER PIN

rings.

6

TIE

120 Rack and pinion assembly installation— late model Eldorado and Seville

bolts.

disengage the return

is

pump

removed from the

inlet,

inlet port,

the adapter from the return

line.

install:

1 1

12.

adapter Fig.

0-ring

Remove

10.

4

2

to

Disengage the adapter from the

9. 1

pump mounting

from the adapter,

Inspect

all

adapter 0-rings for proper posi-

damage. Replace any cut or damaged 0-

Insert the return line adapter clip at the return line port, l^/lake

on the

sure that the

beveled edges of the clip are facing outward.

SUSPENSION AND STEERING

8-36 13.

the

Position the adapter on

pump 14.

inlet

tube

Position the

pump,

ttie

inserting

until lully seated.

pump

in the vehicle

while

inserting the return line into the adapter port.

sure that the line

is lully

seated and

Is

Make

15

Install the

Tighten the

pump mounting

bolts but

do not

pressure line

Nm) and

pump

bolts to 18

20

tt

20

pump

the

shall using

10

Install the reservoir

mounting nut

55

to

22

Install the

23

Fill

Use a

in the

ft.

tensioner and tighten the lbs

is lully

The

reser-

fully seated.

pc

seated

pump mounting

bolls but

do

lu;

13 (25

lbs

(27

pump

Remove

the power steering

18

20

Press the pulley onto the

J-25033-B

pump

The face

or equivalent

Install the belt tensioner,

mounting nut

tighten the

See Figure 123 the

bolts to

Nm) and Nm)

hub must be Hush with the pump 15.

Remove Remove

pump mounting

the pressure line fitting to

Tighten the

lbs

14

Fleetwood— Late Models

tilting to the

pump

tool

belt.

pressure line

Install the

12.

(75 Nm).

serpentine drive

and bleed the power steering system.

Deville and

1

it

Install the

11.

adapter

mounting bolts

Install the belt

2.

be

to

tighten at this time.

rocking motion to fully seat the tubes

»

mserii

the vehicle while

Insert the return pipe into the adapter

making sure

shaft

the reservoir tubes into the adapter porls

^^O^

pump on

do not need

voir lubes

ol the pulley

by carefully inserting

Install the reservoir

.

pump,

tube until lully sealed

inlet

Position the

inserting the adapter into the reservoir.

pump

The face

or equivalent

the vehicle

21

9

Position the bell tensioner mounting bolt in

19.

Position the adapter on the

8.

pump

the

(t

Nm).

J-25033-B

hub must be Hush with

tighten at this time.

titling to the

pump mounting

the pressure line lilting to

Press the pulley onto the

18. tool

Install the

(25

lbs (27

retained by

the adapter clip

16 17. lbs.

16.

Install the

17

Fill

pump

to

55

fi

f1

shaft using of the pulley

shaft. if

removed, and

Nm)

(75

lbs

ft

drive belt

and bleed the power steering system

drive belt.

the belt tensioner,

if

necessary

for

Eldorado and Seville

access. 3.

pump

pulley

using tool J-29785-A or equivalent. Hold the body of the tool with a

body (T| J-297e5 A

Q]

PULLEY

[T)

PUMP

jT|

J

of the tool to

Remove

4

pump. Remove

25033 B

wrench and turn the

remove

4.5L ENGINE >

See Figures 124, 125 and 126

bolt into the

the pulley from the shaft

1

2.

the pressure line fitting from the the return line from the adapter

3.

using tool J-36391 or equivalent.

Remove

5.

Fig.

121 Power steering

pump

pulley

removal & installation— Deville and Fleet-

pump

pump mounting

bolts

and the

pump

sure the

O-ring

is

pump

removed from

the

7

the belt tensioner.

Remove

the

pump mounting

just

enough

the

pump

access the

the

all

adapter 0-rings for proper posi-

tioning or damage. Replace any cut or

pump

remo.-

pulley

wrench and turn the

of the tool to

bolt into the

remove the pulley from the

shaft.

pump and mounting

bolts

Tighten the bolts just enough to hold the

pump

damaged 0-

rings.

bolts, then

for the pulley

using tool J-29785-A or equivalent Hold the body

body

Inspect

necessary

if

the power steering

of the tool with a

install:

drive belt

shaft.

Remove

4.

inlet.

inlet port.

To

move to

Disengage the adapter from the

6.

Make

the

adapter assembly.

pump

Remove Remove

access

Reinstall the

5.

in

place lor disconnecting the power steering pressure

pump Remove the pressure hose from

hose from the 6.

the

pump.

Remove the pump adapter, if necessary Remove the return line from the adapter using tool 7.

J-36391 or equivalent

If

the adapter

removed from the

To

install:

8.

Inspect

all

is

inlet port

adapter 0-rings for proper posi-

damage Replace any

tioning or

removed

is

pump O-nng

from the pump, make sure the

cut or

damaged 0-

rings. 9.

With a new 0-ring

in place,

adapter on the ptjmp, inserting the

position the

pump

tube

inlet

until lully seated.

10.

Loosely connect the pressure hose to the

pump, but do not

\T\puup

(T) ADAPTER

(JIpomp [7] PUMP MOUNTING BOLTS (JSNm/ien lBS>

(T) RESERVOIR

|T| ADAPTER CI

Q] PUMP AND

m ^ RETURN

PRESSURE LINE

\7]

rri GENERATOR

BRACE LINE

TENSIONER BRACKET

(T] BOLTS

(44

Nm#J3fT LBS

[i]NUT|«Mm(UfT

J-25033-B

12

Position the

to

be

lully

the adapter port, I

I

pump on

pump

The lace

shaft using of the pulley

shaft

the vehicle mating

adapter to reservot. The reservoir lubes do not sealed Insert the return pipe into

making sure

it

is fully

spa'pd '

jhien pump rDounling bolts ttNm) Tighten the pressurling to 20 lbs (27 Nm) 14 Install the bell tensioner and the pump drn«

13

LBS

[T]NUT,J5Nmn«fT IBS.

or equivalent

hub must be Hush with the pump

need

[T] BRACE

tighten the lilting at this lime

Press the pulley onto the

1

tool

to

18

Install the

ft

lbs

(25

.•

:

•

It

Fig.

122 Power steering pump lines and

adapter—early model wood

Deville and Fleet-

Fig.

123 Power steering pump mounting

late

model Deville and Fleetwood

belt

15.

Fill

artd bleed ItK

power steering system

SUSPENSION AND STEERING

[T| COOLER

pr| BOLT, 8

Nm

(71

LB

[T\ RETURN HOSE ASM

fs] SHIELD ASM

fa] BOLT. 8 NTT

(71

LB. IN.)

[Tl RETAINER

[7] BOLT

rn

Fig.

PRESSURE HOSE ASM

124 Power steering

line

(2). 8

I

(71

LB. IN.)

routing—4. SL engine

rn RESERVOIR [T] PUMP

[Tj GENERATOR SUPPORT BRACKET [Tj RESERVOIR

Fig.

INLET AND OUTLET TUBES

125 Power steering reservoir and adapter-^. 5L engine

jT]

NUT. CLIP RETENTION

IN.)

8-37

SUSPENSION AND STEERING

8-38

d

pump to disengage pump inlet

Reposition Ihe

adapter from the

Disengage the return

e

the

from Ihe adapter

line

and remove Ihe adapter Irom Ihe reservoir tubes

To

Install:

7

Inspect

all adapter O-nngs for proper posidamage Replace any cut or damaged 0-

tioning or rlngs

Make

8.

sure that

0-rings are properly

all

positioned on Ihe adapter, including the

pump

port

0-ring and seal protector

9

Lubricate

all

adapter ports with petroleum

jelly

8

PUMP AND RESERVOIR ASSEMBLY

17

PULLEY

18

MOUNTING BRACKET BOLT PUMP TO BRACKET

19

20

- 24

Nth

(18

BOLT. PUMP & BRACKET ASSEMBLY 47 N-m (35 FT, LBS )

FT LBS

to

127 Power steering pump mounting— 1992-98 Eldorado and Seville with 4.6L engine

13.

Connect the return

14.

Install ttie

15.

Fill

and bleed

tfie

Install Ihe

Position the

lube

adapter on Ihe return line

pump

positioned

is

so the adapter

pump

in the

extremely careful to prevent seal

TO ENGINE -

Fig.

line to the reservoir

serpentine drive

10 1

Inlet

12.

Install Ihe

13

Install the

18

pump Be

adapter on the reservoir lubes

pump mounting Nm)

(24

H. lbs

inlet

damage

14.

Install the retainer nut

15

Connect the pressure

16

Install the pulley

bolts

and tighten

on the block line at the

pump.

using installation tool J-

25033-B

belt,

»0n

power steering system.

1990 vehicles the pulley hub must be end of the shaft. On 1991-93

flush with the

ENGINE

4.9L >

vehicles, the pulley hub

Disconnect the negative battery cable.

1

2. 3.

Remove Remove

J-25034-B

the

pump

pulley using removal tool

5.

Remove Remove

17

Install the

18

Fill

'

BLEEDING

the

pump,

line at the

pump mounting

the adapter from the

the

II

bolts.

pump

as

power steering hydraulic system has been

serviced, an accurate lluid level reading cannot be

fol-

lows:

Remove

the

power steering

fluid

Remove

the pressure line retainer nut

engine block to ease removal

Remove

air is

bled Irom Ihe system The air

in the lluid may cause pump cavitation noise and may cause pump damage over a period Bleed the

from the

reservoir,

c.

serpentine drive belt

and bleed the power steering system

obtained unless

b.

it

or equivalent,

Disconnect the pressure

a.

installed until

the serpentine drive belt.

4.

6.

is

contacts the internal stop.

See Figures 128 and 129

air

on the

Irom the system as lollows

The engine must be

1

of the return line.

support Ihe front

the return line from the adapter

wheels are

using tool J-36391 or equivalent.

off

the

3.

Add

mark on

OFF

Raise and safely

so the front

ground

Turn the front wheel

the

all

way

povirer steering lluid to the

to the

left

FULL COLO

Ihe fluid level indicator Leave the capsticii

removed Irom the reservoir Bleed the

4

air

Irom Ihe system by turning Ihe

wheels Irom side-to-side without

hitting the stops

Keep the

lluid level at the

FULL COLD mark and

check

color Fluid with

air in

its

It

has a

light tan

appearance Repeat Step 4 about 12 limes

5

had been

II

the engine

started before Ihe bleeding procedure

was

begun, repeal Step 4 about 20 limes with the engine

PUMP

OFF

RESERVOIR

PRESSURE

RETURN

6 PIPE (TO GEAR)

PIPE

7

ttie

ground

Install the capstick

on the reservoir and

the engine With the engine idling, recheck

RESERVOIR TUBES J 36391

Return the wheel to the center position and

lower the vehicle to

(FROM COOLER)

level.

QUICK DISCONNECT

II

start

itip iluid

necessary, add fluid to bring the v..

t-

the

FULL COLD mark

TOOL

8

ADAPTER

Road

test the vehicle to

ing functions normally

V,-0-RING

9

SEAL PWOTECTOfl

Check

and

make

is free

for fluid leaks at all

sure i^e steer-

from noise

power sleefing

system connection points 10 Fig.

129 Power steering pump

Recheck the

should be i

._.

,

at the

bili^ed al its

Eldorado and Seville with 4.9L engine |

fluid level

HOT

j

m j|

of the vehicle just

2

|

]

J

The

fluid level

nrark after the system has stt-

normal operating temperature

BRAKE OPERATING SYSTEM

9-2

BASIC OPERATING PRINCIPLES 9-2 DISC BRAKES

9-2

DRUM BRAKES

9-2

POWER BOOSTERS 9-2 BRAKE LIGHT SWITCH 9-3 REMOVAL & INSTALLATION 9-3 MASTER CYLINDER 9-4 REMOVAL & INSTALLATION 9-4 POWER BRAKE BOOSTER 9-5 REMOVAL & INSTALLATION 9-5 PROPORTIONING VALVE 9-6 REMOVAL & INSTALLATION 9-6 BLEEDING THE BRAKE SYSTEM 9-7 BRAKE BLEEDING 9-7 FRONT OISC BRAKES 9-8 BRAKE PADS 9-8 REMOVAL & INSTALLATION 9-8 INSPECTION 9-9

BRAKE CALIPER 9-9 REMOVAL & INSTALLATION 9-9

OVERHAUL

9-11

BRAKE DISC (ROTOR) 9-12 REMOVAL & INSTALLATION 9-12 INSPECTION 9-12 9-13

DRUM BRAKES

BRAKE DRUMS 9-13 REMOVAL & INSTALLATION 9-13 INSPECTION 9-13

BRAKE SHOES 9-13 INSPECTION 9-13

REMOVAL & INSTALLATION ADJUSTMENTS 9-17 WHEEL CYLINDERS 9-18 REMOVAL & INSTALLATION OVERHAUL 9-18

9-14

9-18

REAR OISC BRAKES 9-20 BRAKE PADS 9-20 REMOVAL & INSTALLATION 9-20 INSPECTION 9-21

BRAKE CALIPER 9-22

REMOVAL & INSTALLATION OVERHAUL 9-24

9-22

BRAKE DISC (ROTOR) 9-24 REMOVAL & INSTALLATION 9-24 INSPECTION 9-25

PARKING BRAKE 9-25 CABLES 9-25

REMOVAL & INSTALLATION 9-25 ADJUSTMENT 9-27 ANTI-LOCK BRAKE SYSTEM 9-27 GENERAL INFORMATION 9-27 TEVESMKII 9-27 TEVES MKIV 9-28 BOSCH ANTI-LOCK BRAKE

SYSTEM 9-28 PRECAUTIONS 9-28 TROUBLE CODES 9-29 READING CODES 9-29 CLEARING CODES 9-32

SPEED SENSORS 9-32

REMOVAL & INSTALLATION 9-32 CONTROL MODULE 9-36 REMOVAL & INSTALLATION 9-36 HYDRAULIC CONTROL UNIT 9-38 REMOVAL & INSTALLATION 9-38 BLEEDING THE ABS SYSTEM 9-40 SPECIFICATIONS CHART BRAKE SPECIFICATIONS

9-41

BRAKES

9-2

BRAKE OPERATING SYSTEM that

Basic Operating Principles

modern automobiles

ol all

system transports

Ttie

the power requited to force

Irlctional surfaces ol

ttie

system together Irom the pedal

the braking

Individual brake units at each wheel

system

Is

used

lor

A

system

ol the

flexible

lorward

pistons

until

will

bottoms against the

it

II

given to the brake pedal end ol the system, and the fool pressure required to actuate the brakes

ton takes place, and

until direct contact with the will force the

it

moves

The master cylinder consists

when only

driver

Double type master cylinders are designed

tional.

This switch

which

is

and

the front

case of a

Into hydraulic pressure within

the lines. This pressure

mechanical motion

(dmm

vehicle's frame near

wheels by either the wheel

each

ol the vehicle's

the master cylinder.

secondary pis-

The

pressures are

on the

two pistons, one

outward

shoe

in

at either

cylinder con-

In

the calipers. At least

used

one cylinder

to force the brake

pistons employ

All

made

of rubber, to

in

each caliper

pads against the

some

minimize

tioning valve.

push the piston

A

Warning

rubber

may be

lights

brake pedal and holding

wheel cylinder bleeder screws, cause the

The boot

dirt

Ills

on disc brake

around the outer end

calipers,

ol

make

and around the

The hydraulic system operates as follows;

ter

When

the entire system, from the piston(s) in the

brake

fluid.

Upon

mas-

steadily

This

sion of

ders. Here,

forces the pistons outward, in the case ol

and inward toward the

with a constant pressure

it

disc, in the

brakes The motion of the pistons

is

case

brakes,

Upon

and by spring

lor leaks

cylinders

in

problem

seals, in disc brakes

vrfiich is

does not

to the

has compensating ports

drilled in

uncovered as the pistons reach

it.

their

The piston check valves allow

for teaks

and

at

fluid reservoir

is in

It

is

dmm is

by rotating the

relaxed,

relum

drum

is

moving

in

when

to sell-

the

reverse This motion causes

both shoes to rotate very slightly with the drum, lever,

screw

thereby causing rotation

Some

dmm

brake systems

lor

mainte-

nance adjustments and keeps both the brake func-

and pedal

leel satisfactory

Instead of the traditional expanding brakes that

utilize

POWER BOOSTERS

a disc (rotor) with brake pads posi-

tioned on either side ol

the released position

vehicle

tion

press outward against a circular drum, disc brake

through the compensating ports

brake

(known as sefvo adion) When

adjustment system reduces the need

it

An

easily-seen analogy

squeeze onto the rim of the bike wheel, slowing

during the time the pedal

action forces the bottoms ot the

slightly

are designed to self-adjust during application

systems

excess

assembfy

ol the adiusting

normal posi-

into the released position, the

to contact the

whenever the brakes are applied This on-board

the

shoes

drum This

two shoes

adjust themselves during application

inside the master cylinder

withdraw Then, as the return springs force the brake or

shoes are then forced against the inner

side ol the

Most modern drum brakes are designed

wheel

toward the wheel cylinders or calipers as the pistons

pads

actuating links outward Since these

vtfheel cylinder's

springs pull the shoes back away from the

DISC BRAKES

flow

When

the brakes are applied, hydraulic pressure forces the

entire

position of the pedal

lines

in align-

lop ol the hacking plate.

pressure within the wheel cylinder

These are

fluid to

at the

rocking an adjusting all

(wtien they are

dnjms

links bear directly against the top ol the brake shoes,

normal position The

pistons contain check valves and the master cylinder

mounted

the tops ol the

no external leaks are apparent, the

II

is

along

dmms

applied) while keeping the linings and

ment. The shoes are actuated by a wheel cylinder

release ol the brake pedal, a spring located

inside the master cylinder immediately returns the

master cylinder pistons

tion

this

by springs. This

in place

allows tfiem to slide toward the

the system leaks, there

II

in the

pivot

same

dmm which rotates with ttie wtieel

assembly The shoes are held

not to be confused

is

within the lines

air

be a gradual change

Check

opposed

by return springs mounted outside the cylinders

drum

never be

with a springy or spongy feel due to the compres-

will

brakes,

will

go on, substitute a new lamp,

leak.

Some

on mounting

slide

result is the

a stationary backing plate. These shoes are positioned inside a circular

the pedal sinks very slowly to the floor,

If

system has a

any event, the end

Dmm brakes employ two brake shoes mounted on

until

continuity checks, and, finally, replace the

ton(s) is forced through the lines to the wheel cylin-

of disc

wheels

by applying pressure to the pedal gradually and

the

application of the brake

pedal, fluid trapped in Iront ol the master cylinder pis-

drum

Iront

The hydraulic system may be checked

at

cylinder to those in the wheel cylinders or calipers,

is lull ol

II

In

DRUM BRAKES

cases, a propor-

switch as necessary.

brake actuating rod on wheel cylinders.

rest,

light to

bolts

some

side, closing

while opening one of the

dust and

There are various

ol attaching floating calipers

the bottom or top. and

by

not held in a

is

bringing the outside

slightly,

into contact with the rotor

methods at

tested by depressing the

it

into contact with the rotor

moves

fixed position,

pad

the

sure to the rear brakes to lessen the chance ol rear

dust boot seals the outer end of the cylinder against

the piston

both designs, the pad on the inside of

moved

wheel lock-up during very hard braking.

disc.

these two types are often lumped

In lact,

lar

hydraulic force. The caliper, vifhich

used alone. The proportioning valve controls the pres-

is

and

floating designs are quite simi-

In

pressure

When

The sliding and

body also con-

brakes

that the front

each side of

rigidly

is

The metering valve keeps pressure Irom on the

mounted

together

activating the brake warning light

some

is

the rotor

however, the

one

to

uses two pistons

either side ol the rotor (in

body

the brake shoes on the rear wheels have contacted the

type ol seal, usually fluid leakage.

leak,

disc brake systems, this valve

drums, ensuring

drum.

disc brake systems, the cylinders are part ol

In

has a

traveling to the disc brakes

end, which push

opposite directions and force the brake

into contact with the

ol the piston.

circuit

sliding caliper

below

hydraulic piston receives

tains a metering valve and. in

drum brake systems, each wheel

In

and

the switch

pension and steering movements.

opera-

the lirewall or the frame

circuit's

lloating caliper

lixed caliper design

does not move

greater pressure in that circuit during application of

cylinders by llexible lubes In order to allow for sus-

tains

A

lixed caliper,

the caliper) The caliper

balance, the piston remains sta-

in

When one

the brakes will

wheels.

is

ol the rotor or

the by the pads Also, the equal clamping

mounted on

available.

usually located in a valve

pressure from both circuits, each

tionary

and wheel

fluid is then carried to the calipers

is

mounted on

being applied to one end

translated back into

is

at the

brakes) or the caliper (disc brakes).

Steel lines carry the brake fluid to a point

The

in

The master cylinder coverts mechanical

leak.

motion from the pedal

cylinder

to separate

systems hydraulically

rear braking

• •

brake system

hall ol the

along with a double cylinder and piston assembly

off

and

drasti-

contaminants are

by the centrifugal action

off

A A A

•

dual circuit systems use a switch to warn the

All

ol a fluid reservoir

is

and water do not

adjusting. There are three general types ol disc brake:

the brakes are

applied, and less braking power

between the braking sur-

less sensitive to heat buildup

action ol the two brake pads tends to ensure uniform,

secondary pis-

brake pedal

wheel cylinders or calipers.

thrown

move

will

cylinder pistons smaller than that of any of the pis-

when

resistant to fade Dirt

straight line stops. Disc brakes are inherently self-

ton to actuate the Iront brakes. In either case, the farther

making them

more

the rear

reduced by making the surface area of the master

moves

laces

scraped

a leak

Iront ol the

II

a casting, usually equipped

air to circulate

cally affect braking action since

actuated

it

primary piston

leak, the

forward

in the

This enables

trapped between the

lluid

operate the rear brakes.

brakes develop a

can be

is

the secondary piston,

in Iront ol

(rotor) is

with cooling tins tietween the two braking surfaces.

actuated directly by

trapped between the two pistons.

master cylinder, and the

of

Second, a great mechanical advantage can be

tons

The disc

will

same

other, in the is

power booster. The secondary piston fluid

develops

problems

or posing routing

one behind the

The primary piston

cylinder.

by to all

hoses without taking up a significant amount

room

tons, located

the

hydraulic

two reasons.

an automobile by small pipes and

parts ol

has leaked out

fluid that

Dual circuit master cylinders employ two pis-

mechanical linkage Irom the brake pedal through

to the

under pressure can be carried

First, fluid

any

be replaced through the compensating ports.

Hydraulic systems are used to actuate the brakes

is

hand brake arrangement on a bicycle The pads its

motion Automobile disc brakes use the identical principle but apply the braking effort to a

s

Virtually all

modern

vehicles use a

vacuum

assisted power brake system to multiply the braking force

and reduce pedal

effort.

Since vacuum

always available when the engine

system

disc instead of the wtieel is

is

located

simple and

on the

efficient

is

is

operating, the

A vacuum daphragm

Iront ol the masler cylinder

and

BRAKES assists the driver in applying the bral

4 Master cylinder, antilock brake system

fluid level

See Figure 8 Disconnect the negative battery cable

2

Detach the

3 Fig. 5 llle

Master cylinder Instatlatlon

and Fleetwood

— Oev-

DO NOT

brake fluid

reuse

cap before proceed-

electrical

connector from the

sensor switch

Disconnect the brake lines from the master

prevent lluid loss

Remove

7 electrical

connector from the

and remove the master cylinder

Disconnect the brake lines Irom Itw master

and proportioning valves Plug the

8

II

the vehicle

is

equipped with anti-lock

brakes and the master cylinder

is

being replaced,

lines

and master cylinder and proportioning valve ports to prevent fluid loss

the master cylinder mounting nuts

fluid

sensor switch

cylinder

ol

cylinder Plug the lines and master cylinder ports to

1

level

equipped with anti-lock brakes, dram the

II

brake fluid from the master cylinder reservoir, then disconnect, and plug the reservoir hose

6

1SN.m(133lbin)

ttie

ing

1990-91 Eldorado and Seville

3 Brakepipe.

connector from

as possible from the master cylinder reservoir

the master cylinder and bleed the brake

system

1 Master cylinder assembly 2 Nut 27 N-m (20 lb 11)

electrical

fit-

cable.

9

Detach the

before removing

tighten the

connector to the

cylm

use with Traction con

Using a syringe, remove as much brake

4

electrical

for

lluid level sensor. 3.

mounting nuts

access

sensor switcti

Disconnect the negative battery cable

1.

Position the master cylinder on the power

fluid level

trol.

2.

install:

6.

has a

it

front reservoir

the master cylinder.

To

incorpo

It

rates the functions of a standard dual master der, in addition,

and

to prevent fluid loss

and remove

brakes served by the secondary piston)

remove the master cylinder reservoir as follows a

Clamp

the nrounlino flange

on the master

BRAKES

Master cylinder

assembly

Tube Nut

nut

9-5

BRAKES

9-6

The brake proportioning valves improve

tront-

Severe brake application transfers part of the

vehicle rear weigtit to the IronI wheels. ing decrease

weight

in

The

Clean

8

all

parts in clean denatured alcohol

With the ignition OFF, pressure switch

new 0-rings and

50

proportioning

of pedal force

lbs

valve seals as well as Ihe stems of the proportion-

in

The valves

ing valve pistons with silicone grease.

discharged.

limit the

pressure to the rear brakes to

10.

new

Install the

upward toward

REMOVAL & INSTALLATION

the cap)

on the proportioning valve

proportioning valve pistons,

and springs Install the

12.

into the

in the

Install Ihe

grooves

ft.

Disconnect the negative battery cable. Disconnect the brake lines from the propor-

Lubricate

Remove

3

the proportioning valve

and 0-rings

from the master cylinder.

To

new 0-rings and

the external pro-

portioning valve threads with clean brake the

new 0-rings on

Install the

5.

fluid.

24

Connect the brake

8

proportioning valve and connect

Tighten the brake line fittings to 11

ft

lbs

(15 Nm).

Lower the

9.

10

onto the master cylinder

Fill

vehicle.

Ihe lluid reservoir and bleed the brake

system

until the pin-

ft,

lbs. (31

Tap

16.

in

Nm).

1991-98

the pins to retain the reservoir, being

damage

the reservoir or master cylin-

>

ft.

lbs

Install the

17.

master cylinder on the vehicle

and bleed the brake system. (15 Nm).

1

Raise and safely support the vehicle

2

Clean Ihe proportioning valve and brake Im'

connections

With Anti-Lock brakes

3.

1990

to

make sure

the system will not be

contaminated during servicing

Connect the negative battery cable. Bleed the

brake system.

MODELS

See Figures 15 and 16

der

lines to the proportioning

valves and tighten the fittings to 11 7.

Install the

the brake lines

fluid.

fully sealed.

Install the reservoir

careful not to

the proportioning valves,

proportioning valves on the master

cylinder and tighten to 6.

the master cylin-

to prevent fluid loss

Ihe proportioning valve.

Install:

holes are aligned.

Lubricate

4.

To

20

0-rings on the master cylinder,

making sure they are 15.

is

Disconnect the brake lines from the propoi

7

new 0-rings and

by pressing straight down by hand

install:

Install

Install the

14.

change is

Remove

6

proportioning

der reservoir bayonets with clean brake

tioning valves. Plug the lines to prevent fluid loss.

the at least

delinile

Raise and safely support Ihe vehicle

5.

(27 Nm),

lbs.

13. 1

2.

A

occur when the accumulator

Honing valve Plug the lines

the

in

valve caps in the master cylinder and tighten to

See Figure 14

each lime

stroke Ihe pedal a lew additional limes to

4.

master cylinder body.

new 0-rings

proportioning valve caps.

1990 VEHICLES >

felt,

pump

25 limes using

a delinite increase in pedal effort

feel will

When

3

of

remove hydraulic pressure from the system Install the

1 1

seals,

pedal

seals (seal lips lacing

pistons.

Without Anti-Lock brakes

minimum

brake pedal a

Lubricate

disconnected or the

negative battery cable disconnected,

reduced braking elficiency and rear wheel lockup.

reduce the tendency lor reduced brake elticiency.

pump motor

disconnected,

air

To install: 9

It

following procedure should be used:

2

and dry with unlubricated compressed

result-

Depressurize the hydraulic accumulator

1

and

deformities and replace as necessary

the rear wheels can cause

at

the seals from the pistons Inspect

the proportioning valve pistons lor corrosion

to-rear brake balance under severe brake application.

Remove

7

Proportioning Valve

MODELS

Disconnect the brake lines Irom the pro-

portioning valve. Plug Ihe lines to prevent fluid loss

The hydraulic system contains brake fluid at extremely high pressure. It Is mandatory that the system be depressurized before disconnecting any hoses, lines or fittings, or personal injury

may

4

Remove

To

install:

5

Install the

Ihe proportioning valve.

proportioning valve and conneci

the brake lines Tighten the brake line fittings to ft

result.

1

Nm)

lbs

(15

6

Lower the vehicle

7

Fill

Ihe ffuid reservoir

and bleed Ihe brake

system

14 Proportioning valve installation

Fig.

—

1990 vehicles without anti-lock brakes

1991-93 DEVILLEAND FLEETWOOD 1

Remove

.

the master cylinder from the

vehicle.

Clamp

2

body

cylinder

the mounting llange in a vise

Do

nol

on the master

clamp on the master

cylinder body.

Tap back the spring pins

3 of the

4

until

they are clear

master cylinder reservoir Be careful not

damage

to

RiAfl

Ihe reservoir or master cylinder

Remove

cnossovcn wvwe

PflOPOniONER VAIVE LEFT REAR BRAKE PIPE FUEL FILTER

the reservoir and Ihe reservoir

seals Inspect the reservoir lor cracks or deformities

FITTING

liN^Uin

LB-FT)

and replace as necessary 5 rings.

6

Remove

Ihe proportioning valve caps.

0-

and springs Using needle nose

portioning valve pistons

pliers,

remove the pro-

Fig.

15 Proponionlng valve

—

with anil-lock brakes similar

Davllle and Fleetwood with anti-lock brakes, Eldorado and Savllle

BRAKES

On 1990 models equipped with

9-7

the Teves

Mk

II ABS system the hydraulic accumulator must be depressurized before bleeding the

brakes.

•»The ABS pump/motor assembly will keep the accumulator charged to a pressure between approximately 2000 and 2600 psi any time the

RUN

ignition is in the

position.

The

pump/motor cannot operate if the ignition OFF or if a battery cable is disconnected.

is

Detaching the pressure switch connector or the

pump motor connector from the hydraulic unit prevent the pump from operating.

will also

Unless otherwise specified, the hydraulic accumulator should be depressurized before

working on any portion

of the hydraulic sys-

tem. 1

Mk tor

II

On 1990 models equipped

.

ABS

with the Teves

system, depressurize the

ABS accumula-

using the following procedure:

With the ignition OFF, pressure switch

a.

disconnected,

pump motor

disconnected or the

negative battery cable disconnected,

brake pedal a least

VIEW D I

50

change "I

Is ielt,

16 Proporlioner valve and brake

is

pedal

of

pump

25 times using

pedal force each time. feel will

A

the at

definite

occur when the accu-

discharged.

When

b.

Fig.

lbs. of in

mulator

minimum

a definite increase in pedal effort

stroke the pedal a few additional times

connections— 1991-93 Deville and Fleetwood with

line

anti-lock brakes

When

Bleeding The Brake Syster

bleeding the brake system, bleed one

brake cylinder

at a time,

beginning

al

the cylinder

with the longest hydraulic line (farthest Irom the

BRAKE BLEEDING

master cylinder)

first.

ALWAYS Keep

the master

cylinder reservoir filled with brake fluid during the

bleeding operation. Never use brake fluid that has

I See Figures 17 thru 23

been drained from the hydraulic system, no matter

When any

part of the hydraulic

system has been

disconnected for repair or replacement, into the lines

(because

air

air

may

get

and cause spongy pedal action can be compressed and brake

cannot). To correct this condition,

it

is

fluid

necessary

bleed the hydraulic system so to be sure

all air is

how

clean

it

is.

The primary and secondary hydraulic brake systems are separate and are bled independently. During the bleeding operation,

to

reservoir to run dry.

do not allow the

Keep the master cylinder reser-

Fig.

17 The bleed screw

brakes

voir filled with brake fluid.

purged.

is

for the rear

drum

located on the rear of the back-

ing plate, just

above the brake

line

/''

?/

Fig. Fig.

18 Remove the protective rubber cap

forthe bleed screw

19 Attach a hose connected

to a bottle

with a small amount of brake fluid the bleed screw

in

it

to

Fig.

20 Slowly open the bleed screw and

have an assistant depress the brake pedal while observing the hose for bubbles

BRAKES

9-8

*e\

Fig.

Remove

Fig. 21 tor ttie

the protective rubber cap

bleed screw on

ttie

front brake

22 Attacti a hose connected to a bottle a small

remove

all

hydraulic pressure Irom the sys-

all

din Irom around the master cylin-

tem Clean

2 der

remove the cap and

cap.

fill

(ill

der with brake fluid until the level

(6mm)

ol the top

edge

the master cylin-

is

within 'A

in.

at all

4 wheels.

The bleeder screws are located on the back

of the

brake backing plate (drum brakes) and on the top of

brake fluid

in

it

Bleed the system

in the

following sequence:

23 Slowly open the bleed screw on

the brake caliper and have an assistant

depress the brake pedal while observing

to

the hose lor bubbles

When

Lett front

•

Lett rear

the bleeder hose, close the bleeder screw

•

Right front

remove

4

7

Attach a length of rubber hose over the

5

jar,

submerged

Open

in

the bleeder

brake

in

Vz-^

turn.

Have an

assistant slowly depress Ihe brake pedal. 6.

Close the bleeder screw and

Continue this process

to

purge

8.

add

fluid.

screw

tell

all air

bubbles cease

to

appear

end o

at the

and

hose Tighten the bleeder screw

the

to the

proper torque:

bleeder screw and place the other end of the hose

Check the master cylinder

fluid

accordingly

Do

and

fluid level

this after bleeding

each

wheel. 9.

your

Repeat the bleeding operation

at the

remain

ing 3 wheels.

assistant to allow the brake pedal to return slowly.

the brake calipers (disc brakes).

•

of

•

a glass

of the reservoir.

Clean the bleeder screws

3

amount

the bleed screvK on the brake caliper

caliper

to

Fig. vKith

Irom the

10.

Fill

the master cylinder reservoir to the

proper level

system

Right rear

FRONT DISC BRAKES •»Disc brake pads must be replaced

in

axle

sets only. 1

REMOVAL & INSTALLATION

Use

a syringe or similar tool to

of the brake fluid

»

See Figures 24

thru

30

remove

Raise and safely support the vehicle

3

Remove

reinstall 4.

the wheel and

2 lug nuts

Remove

%

from the master cylinder reservoir

2

tire

assembly, then

to retain the disc brake rotor.

the disc brake caliper from the

mounting bracket, but do not disconnect Ihe brake

Older brake pads or shoes

may

contain

asbestos, which has been determined to

hose from Ihe caliper Suspend Ihe caliper with wire Irom thftcoil spring

be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake clean-

hose. The hose

ing fluid.

causing possible brake failure.

Do not

let

the caliper hang from the brake

may become damaged,

Fig.

Fig

24 Remove the locating pins and

27 The caliper piston can be

depressed using this

a special tool,

one Irom Lisle'

II

such as

a tool like this

Is

not available, a C-clamp works well also. Fig.

25

knuckle

.

remove the caliper from the

Make

sure you leave Ihe Inner pad

while doing this

In

BRAKES

29 Use mechanic

Fig. Fig.

28 Remove the inner pad from the

caliper

Use a small prybar

5.

to

disengage the buttons

on the outboard disc brake pad from the holes

Remove

the caliper housing.

in

flat

brake pad. 6.

Remove

7.

Inspect the disc brake rotor and machine or

the inboard disc brake pad.

To

Wipe

damage

clamp

the inner

edge

and be

Install the

air;

the boot

must

lay

pad lays

flat

touch the boot.

wheel and

assembly and

tire

the pad contacts the boot,

Install the

remove

also equipped with a

is

worn, the sensor

is

pad replace-

necessary.

to posi-

and seat the brake pads

in

Brake Caliper

the brake fluid level in the master

REMOVAL & INSTALLATION

of the

is at

1990 Deville and Fleetwood

is at

the trailing

pad during forward wheel rotation on

the leading

edge

of the

»

See Figures 31, 32 and 33

all

On 1990 Devthat the

pad during

»

wear for-

6000 miles and

any time the wheels are removed. Check both ends of the outer

See Figures 34, 35, 36 and 37

pad by looking

in at

each end

of the

These points are where the highest

1

.

If

equipped with anti-lock brakes, depres-

surize the hydraulic accumulator. Refer to Teves II

rate of

down through

the hole in the top of the caliper

When any

lining thickness

(0.76mm)

of the

must be replaced

is

worn

backing plate or in

axle sets.

to within '/32 in.

rivet,

Some

the pads

inner

pads have

a thermal layer against the backing plate, integrally

molded with

the lining; don't confuse this extra layer

The hydraulic system contains brake fluid at extremely high pressure. It Is mandatory that the system be depressurized before disconnecting any hoses, lines or fittings, or personal injury

with uneven inboard-outboard lining wear

V/EAR INDICATO

Fig. 31

View

of the disc

Deville. Note the

trailing

edge

of the

1

INBOARD LINING

2

ROTOR

3

CALIPER

4

CALIPER MOUNTING BRACKET

brake pads from a

wear sensor on the

outboard pad

Mk

Anti-Lock Brake System.

wear normally occurs. Check the inner pad by looking

outboard disc brake pad. Position

and Fleetwood, position the pad so

1992

is

the lining

ing noise, indicating that disc brake

ment

Apply the brake pedal several times

Check

When

contacts the disc brake rotor and produces a warn-

INSPECTION

caliper.

against the piston and does not If

except 1990 Deville and Fleetwood.

sensor

Install the

Inspect the disc brake pads every

inboard disc brake pad by snap-

the pad so that the wear sensor

ille

13.

15.

flat.

the pad and reseat or reposition the boot.

edge

wear sensor.

and

ping the retainer spring into the piston. tVlake sure

11.

Disc Brake Quiet or

The outer disc brake pad

lay

the piston or piston boot. After

of the boot next to the piston

press out any trapped

the

pad must

cylinder and add fluid as necessary.

slowily,

bottoming the piston, use a small plastic or wood tool

10.

ol

new pads

Using a C-clamp, bottom the caliper piston

careful not to

lift

of the

disc brake caliper.

the caliper.

into the caliper bore. Tighten the

to

The back

Install the

14.

the outside surface of the caliper pis-

ton boot clean using denatured alcohol. 9.

rotation.

against the caliper. 12.

tion the caliper piston

install:

8.

30 A coating

equivalent silencer should be applied to the backs of the

lower the vehicle.

replace, as necessary.

Fig.

device to support the caliper out of the

way

ward wheel

the outboard disc

s wire or a similar

9-9

Fig.

32 Front disc brake pad inspection

may

result.

9-10

BRAKES

\\

O^ \

CALIPER

BRAKES 1991-93 Devilte and Fleetwood; 1992-98 Eldorado and Seville The hydraulic system contains extremely high pressure.

It

bralce fluid at

system be depressurized before disconnecting any hoses, lines or fittings, or

that the

may

personal injury

from

ol tfie brake fluid

tool to

%

remove

remove

similar tool to

Raise and safely support the vehicle.

3.

Remove

4.

and

the wheel

tire

%

the caliper

remove the

is

in

5.

2 lug nuts II

remove

vehicle,

caliper housing

be removed from the

is to

the bolt attaching the brake

hose

Discard the gaskets. Plug the open-

to the caliper.

Install a large

5.

to retain the disc bral»Depending upon the vehicle, there are two different ways to remove the piston from the

not let the caliper hang from the brake

and

if

any

Position the caliper over the rotor

mounting bracket, making sure the

in

the

bolt boots are in

Lubricate the shaft of the mounting bolts

9.

9.

lbs.

ft.

10. caliper.

32

greater than

ft.

1 1

10.

12.

of the

bushings

and sleeve assem-

is

is

lbs.

new

gaskets. Tighten the bolt

and

(44 Nm).

any corrosion, remove

it

using a

1

in.

Install the

Check

wheel and

tire

assembly and

ft.

caliper.

lbs.

new

using the

gaskets. Tighten the bolt

(44 Nm).

if

any

of these condi-

For the second method, you must rotate the

from the

it

caliper.

equipped, remove the anti-rattle

4.

If

5.

Use

a prytool to

remove the

make

7.

Remove

the piston seals from the groove in

Carefully loosen the brake bleeder valve cap

8.

9.

caliper housing.

Inspect the caliper bores, pistons and

mounting threads

for

Use crocus

scoring or excessive wear.

cloth to polish out light corro-

sion from the piston and bore.

use

sure to keep your

Fig. 41

Withdraw the piston from the

caliper bore

clip.

caliper boot,

being careful not to scratch the housing bore.

and valve from the

Nm).

to the caliper

inlet hole.

the caliper bore.

38

Position the brake hose on the disc brake

Connect the hose

into

com-

tions are found.

piston to retract

the

bolts to

applied into the caliper

air to drive the piston out of

the caliper, but fingers clear

of calipers,

ft.

in

mounting

air

^#

--.^^.i

40 For some types

32

over the rotor

bracket. Tighten the

attaching bolt and 2 to

compressed

lbs. (51

12.

the brake fluid level in the master

wood

Inspect the piston for scoring, nicks, corrosion

6.

Install the caliper

or a block of

the caliper piston using

If

wheel

lubricate.

1 1

as follows:

and/or worn or damaged chrome plating. The

3.

Inspect the mounting bores for corrosion.

mounting

Bleed the brake system.

is

piston must be replaced

required or mechanical

needed, remove the mounting bolt and

with clean denatured alcohol, replace the bushings

using the

cylinder and add fluid as necessary

Fig.

bolt

bushings using hand pressure only

hand force

method

shop towel

Remove

pressed

mounting

Connect the hose

lower the vehicle. 13.

is

first

Stuff a

a.

b.

cylinder honing brush. Clean the mounting bores

to the caliper

personal injury!

the caliper to catch the piston.

Coat the inside diameter

Install the

The

2.

try to

Position the brake hose on the disc brake

attaching bolt and 2 to

do not

sleeve assemblies along with the bushings.

there

(85 Nm).

corrosion and the bushings for cuts

blies through the

with silicone grease. Install the bolts and tighten to

63

lor

away corrosion.

8.

If

the pis-

Inspect the mounting bolt and sleeve

nicks. Replace parts as necessary;

assistance

place.

in

in front of

pad replacement procedure to make sure you have the correct procedure for your vehicle.

with silicone grease.

found; do not try to polish away corrosion. 8.

place your fingers

caliper. Refer to the brake

install:

polish

replace as necessary Inspect the mounting bolls for

is

may become damaged,

causing possible brake failure.

7.

corrosion and replace them and the bushings

and

Do

To

and

the caliper from the vehicle

on a clean workbench.

NEVER

assemblies

.

Remove

.

tons in an attempt to catch or protect the pistons when applying compressed air. This

causing possible brake failure.

lor cuts, tears or deterioration

the excep-

and dust

pads are being replaced, suspend the caliper with

hose. The hose

support bushings

u/lth

wire from the coil spring.

may become damaged,

Inspect the bolt boots and mounting bracket

same

and

wire from the coil

not let the caliper hang from the brake

dual piston

to overhaul the

essentially the

could result

hose. The hose

7.

1

:

spring.

Do

The procedure

is

boots.

until the pis-

enough

calipers.

caliper

tion of multiple pistons, 0-rings

of the

of the out-

board pad. Slowly tighten the C-clamp ton

47

thru

may be equipped

the caliper off the rotor.

loss.

bracket.

and brake hose

vehicles

to

the caliper. Discard the gaskets. Plug the openings the caliper

See Figures 40

'»Some

hose

Raise and safely support the vefiicle.

reinstall

assembly and

be removed from the

to

bolt attaching the brake

Remove

assembly, then

tire

OVERHAUL

4.

tire

wheel and

the brake fluid level in the master

cylinder and add fluid as necessary.

»

rotor.

3.

wheel and

Check

assembly then

2 lug nuts to retain the disc brake If

vehicle,

voir.

ttie

Install the

brake fluid from the master cylinder reservoir

2.

reinstall

master cylinder reser-

ttie

Use a syringe or

1.

ol the

result.

Use a syringe or similar

2.

Bleed the brake system.

14.

15.

mandatory

is

13.

lower the vehicle.

See Figure 37

>

9-11

Fig.

42 On some vehicles, you must

remove the

anti-rattle clip

BRAKES

9-12

^

^'•^ Fig. Fig.

43 Use a prytool

around the edge

to carefully pry

ol the

boot

.

.

44

.

.

.

tlien

f.

remove the boot from

Fig.

the caliper housing, taking care not to

score or

.

damage

45 Use extreme caution when remov-

DO NOT

ing the piston seal:

the bore

scratch the

caliper bore

6 rotor

To 7

Remove

the disc brake rotor Inspect Ihe

and machine or replace, as necessary Install: Install Ihe

disc brake rotor over

ttie

wtieel

studs and hub assembly

8

On 1990-91 Eldorado and

the caliper

mounting bracket using new mounting

bolts Tighten the bolts to

!r*.

9

'f0

10

Seville, install

Install the

83

lbs

II

(112 Nm).

brake caliper

Install Ihe wtieel

and

tire


See Figure 79

3.

Remove Remove Remove

4.

Lift

1

2

the door panel. the door speaker the water deflector

upvrard to remove the inner belt sealing

strip.

5.

Remove

the retaining bolt and the front run

channel retainer

6 ets

Drill

out the 2 regulator sash-lo-window riv-

and remove the window from the door.

To 7

board

install: Install the

ol the

door

window fraine.

to the

door from out-

Fig.

80 Electric

and Fleetwood

motor— Oeville

Fig. 81 Electric

window motor.

door— 1990-91

Eldorado and Seville

IronI

BODY AND TRIM -

1

10-25

10-26

BODY AND TRIM mirror

is fully

ble "click"

is

seated on the support

when an

audi-

heard

Attach the electrical connectors.

5

3 swivel

To 4

CONVENTIONAL MIRROR t

See Figure 90

Remove arm

Install the lock tooth

to the swivel

5

the Torx* screw at the rear of the

Install:

washer and mirror base

arm

Install the

Torx" screw to the swivel

arm and

tighten until snug, 1

Remove

,

base

to the mirror support,

2

Lift

ror

88 Use the other hand up and away from

.

.

to pull the mir-

6

Install the

screw

the mirror base from the support.

1

Fig.

the set screw retaining the mirror

,

Rearview mirror Mirror base Lock tooth washer

.

Screw Swivel arm

Fig.

90 Conventional mirror— 1993-98 Eldorado and Seville

mirror support and install the set

TROUBLESHOOTING INDEX 11-2 SECTION SECTION SECTION SECTION

1:

2: 3: 4:

ENGINE 11-2 DRIVE TRAIN 11-3 BRAKE SYSTEM 11-3 WHEELS, TIRES, STEERING

AND SUSPENSION

11-3

SECTION 5: ELECTRICAL ACCESSORIES 11-4 SECTION 6: INSTRUMENTS AND

GAUGES 11-5 7: CLIMATE CONTROL 11-5 DIAGNOSTIC PROCEDURES 11-6 SECTION

SECTION 1: ENGINE 11-6 ENGINE STARTING PROBLEMS 11-6 ENGINE RUNNING CONDITIONS 11-6 ENGINE NOISES, ODORS AND VIBRATIONS 11-8 ENGINE ELECTRICAL SYSTEM 11-8 ENGINE COOLING SYSTEM 11-9 ENGINE EXHAUST SYSTEM 11-9 SECTION 2: DRIVE TRAIN 11-10

AUTOMATIC TRANSMISSION 11-10 AXLES 11-10 OTHER DRIVE TRAIN CONDITIONS 11-10 SECTION 3: BRAKE SYSTEM 11-10 BRAKE SYSTEM TROUBLESHOOTING 11-10 SECTION 4: WHEELS, TIRES, STEERING AND SUSPENSION 11-11

WHEELS AND WHEEL BEARINGS 11-11 TIRES 11-11

STEERING 11-11

SUSPENSION 11-12 DRIVING NOISES

AND

VIBRATIONS 11-12 SECTION 5: ELECTRICAL

ACCESSORIES 11-13 HEADLIGHTS 11-13 TAIL, RUNNING AND SIDE MARKER LIGHTS 11-13 INTERIOR LIGHTS 11-13

BRAKE LIGHTS 11-13

WARNING LIGHTS 11-13 TURN SIGNAL AND 4-WAY HAZARD LIGHTS 11-14

HORN

11-15

WINDSHIELD WIPERS 11-15 SECTION 6: INSTRUMENTS AND

GAUGES 11-15 SPEEDOMETER (CABLE OPERATED) 11-15

SPEEDOMETER (ELECTRONICALLY OPERATED) 11-15

TEMPERATURE AND OIL PRESSURE GAUGES 11-16

FUEL,

SECTION 7: CLIMATE CONTROL 11-16 AIR CONDITIONER 11-16 HEATER 11-16

TROUBLESHOOTING

11-2

Section/Item

Condition The following troubleshooting charts are divided into 7 sections covering engine, drive

and gauges, and climate

sories, instruments

train,

control. The first portion (or index) consists ol

selecting the appropriate condition, refer to the corresponding diagnostic procedure in the

a

list

of symptoms, along with section

second portion's specified

and item numbers.

location.

INDEX

SECTION

1.

ENGINE

A. Engine Starting

Problems

Gasoline Engines Engine turns

1-A.1

over, but will not start

Engine does not turn over

v^t\en

attempting to

Engine

stalls

Starter

motor spins, but does not engage

Engine

is difficult

Engine

is difficult to start

B.

1-A,2

start

1-A,3

immediately wtien started

to start

1-A,4 1-A,5

when cold when hot

1-A.6

Engine Running Conditions

Gasoline Engines 1-B.1

Engine runs poorly, hesitates

1-8,2

Engine lacks power

economy Engine runs on (diesels) when turned Engine has poor

1-8,3

fuel

Engine knocks and pings during heavy acceleration, and on steep Engine accelerates but vehicle does not gain speed

C.

1-8,4

off

hills

1-8,5

1-8,6

Engine Noises, Odors and Vibrations

Engine makes a knocking or pinging noise when accelerating Starter

motor grinds when used

1-C.1

1-C.2

Engine makes a screeching noise

1-C.3

Engine makes a growling noise

1-C,4

Engine makes a ticking or tapping noise

1-C,5

Engine makes a heavy knocking noise

1-C,6

Vehicle has a fuel odor

when

driven

1-C,7

Vehicle has a rotten egg odor

1-C,8

Vehicle has a

1-C,9

when driven sweet odor when driven

Engine vibrates when idling

1-C, 10

Engine vibrates during acceleration

1-C, 11

D. Engine Electrical

System

Battery goes dead while driving

Battery

E.

goes dead overnight

-D,1

-D,2

Engine Cooling System

Engine overheats

1-E.1

Engine loses coolant

1-E,2

Engine temperature remains cold when driving

1-E,3

Engine runs hot

1-E,4

F.

Engine Exhaust System

Exhaust

rattles at idle

speed

Number

brakes, wheels/tires/steering/suspension, electrical acces-

1-F,1

Exhaust system vibrates when driving

1-F,2

Exhaust system seems too low

1-F,3

Exhaust seems loud

1-F4

After

TROUBLESHOOTING Section/Item

Condition

SECTION

2.

11-3

Number

DRIVE TRAIN

A. Automatic Transmission 2-A,1

Transmission

shifts erratically

Transmission

will

not engage

2-A,2

Transmission

will

not downstiift during heavy acceleration

2-A,3

Front

Wheel Drive

Front wheel

makes

Veliicles

2-G,1

a clicking noise

2-G,2

Rear wheel makes a clicking noise

H. Otiier Drive Train Conditions Burning odor from center

of vehicle

when

accelerating

Engine accelerates, but vehicle does not gain speed

SECTION

3.

2-H,1; 2-C,

1i

3-A,9

2-H,2; 2-C,

1;

3-A, 9

BRAKE SYSTEM

Brakes pedal pulsates or shimmies when pressed

3-A,1

Brakes make a squealing noise

3-A, 2

Brakes make a grinding noise

3-A, 3

Vehicle pulls to one side during braking

3-A, 4

Brake pedal feels spongy or has excessive brake pedal travel

3-A, 5

Brake pedal

feel is firm,

but brakes lack sufficient stopping power or fade

Vehicle has excessive front end dive or locks rear brakes too easily

Brake pedal goes to floor when pressed and

will not

pump up

Brakes make a burning odor

SECTION A.

4.

3-A, 6 3-A, 7 3-A, 8 3-A, 9

WHEELS. TIRES. STEERING AND SUSPENSION

Wheels and Wheel Bearings

Front

Wheel Drive Vehicles

Front wheel or wheel bearing loose

4-A,1

Rear wheel or wheel bearing loose

4-A,2

nnifgi Tires

worn on inside

Tires

worn on outside

Tires

worn unevenly

Excessive play

in

4-B,1

tread

4-B,2

tread

4-B,3

steering wheel

Steering wheel shakes at cruising speeds Steering wheel shakes

when braking

becomes

Steering wheel

stiff

when turned

4-C,1

4-C,2 3-A,1

4-C,4

Suspension Vehicle pulls

to

one side

very bouncy over

Vehicle

is

Vehicle

seems

Vehicle ride quality Vehicle

4-D,1

bumps

to lean excessively in turns

seems low

seems excessively harsh or leans to

one side

4-D,2 4-D,3 4-D,4 4-D,5

TROUBLESHOOTING

11-4

Condition E. Drivina

Section/Item

Noises and Vibrations

makes a clicking noise when driven makes a clunking or knocking noise over bumps

4-E,1

makes a low pitched rumbling noise when driven Vehicle makes a squeaking noise over bumps

4-E,3

Vehicle Vehicle

4-E,2

Vehicle

4-E,4

Vibrations Vehicle vibrates

SECTION

5.

when

driven

ELECTRICAL ACCESSORIES

One headlight only works on high

beam beam

or low

Headlight does not work on high or low

5-A.1

5-A,2

Headlight(s) very dim

B. Tail,

5-A.3

Running and Side Marl(er Lights

Tail light,

running

light or side

marker

light inoperative

Tail light,

running

light or side

marker

light

Tail light

running

light or side

marker

light very

5-B,1

works intermittently

5-B,2

dim

5-B,3

C. Interior Lights Interior light inoperative Interior light

works

Interior light very

5-C,1

5-C,2

intermittently

dim

5-C.3

raimm One brake

light inoperative

5-D.

One E.

1

5-0,2

Both brake lights inoperative

dim

or both brake lights very

5-D, 3

Warning Lights

Ignition, Battery

and Alternator Warning Lights, Check Engine

Light,

Anti-Lock Braking System (ABS) Light, Brake Warning Light, Oil

Pressure Warning Light, and Parking Brake Warning Light

Warning

light(s)

Warning

light(s) flickers

Warning

light(s) inoperative with ignition on,

F.

remains on

alter the

on and

oft

engine

when

is

started

driving

5-E.1

5-E.2

and engine not started

5-E,3

Turn Signal and 4-Way Hazard Lights

Turn signals or hazard lights

come

on, but

do not

flash

Turn signals or hazard lights do not function on either side

5-F,1

5-F,2

Turn signals or hazard lights only work on one side

5-F.3

One

5-F4 5-F5 5-F6 5-R7

signal light does not

work

Turn signals flash loo slowly Turn signals flash loo

fast

Four-way hazard flasher indicator

light inoperative

Turn signal indicator light(s) do not work

One

turn signal indicator light

in either direction

does not work

5-F,8

5-F.9

Horn does not operate

5-G.1

Horn has an unusual lone

5-G.2

Number

TROUBLESHOOTING Section/Item

Condition iffi'iffpiffipi'i'lffin

5-H,1

Windshield wipers do not operate Windshield wiper motor makes a

humming

noise, gets hot or blows fuses

Windshield wiper motor operates but one or both wipers Windshield wipers

SECTION A.

6.

will not

fail

to

move

INSTRUMENTS AND GAUGES

6-A,

Speedometer needle fluctuates when driving Speedometer works

at

6-A, 3

(Electronically Operated

Speedometer

Speedometer works C. Fuel,

6-B,1

erratically

Gauge operates

fully

air

Oil

Pressure Gauges 6-C,1

not register

Gauge operates

SECTION

6-8,2

intermittently

Temperature and

Gauge does

7.

air

7-A,1

conditioner vents

blows warm

Water collects on the Air conditioner

6-C,2 6-0,3

pegged

CLIMATE CONTROL

coming from

Air conditioner

1

6-A,2

steady speeds

intermittently

Speedometer does not work

No

5-H,3

Speedometer (Cable Operated)

Speedometer does not work

B.

5-H,2 5-H,4

park

7-A,2

air

interior floor

when

the air conditioner

has a moldy odor when used

is

used

7-A,3 7-A,4

Blower motor does not operate

7-8,1

Heater blows cool

7-8,2

air

Heater steams the windshield

when used

7-8,3

11-5

Number

TROUBLESHOOTING

11-6

DIAGNOSTIC PROCEDURES

I1J?MI?U Measure

d

Engine Starting Problems

-A.

the luel

pump

delivery

volume and pressure Low

when

pressure can also be noticed as a lack ol power

Gasoline Engines

sure the luel

Engine turns over, but

will not start

a.

Check

fuel level in luel lank,

add

b.

Check

battery condition

1.

and

fuel

state of charge.

Check

e

c.

Check

and cable condition and tightness. Clean terminals

battery terminal

and replace damaged, worn or corroded cables. d.

Check

fuel delivery

system.

If

fuel is not

pump and

and

fuel

replacement to

electrical connectors.

A

loose or

dirty,

tailed

output

Make

is

not

repair.

management system

ignition

pump

fuel

accelerating

pump

Inspect the sen-

damaged sensor

or

component.

the exhaust system tor internal restrictions.

4. Starter

reaching the fuel injectors, check

loose electrical connector or defective fuse, relay or fuel

for a

Check

pump

module wire can simulate a

control I.

and

the engine fuel

sor wiring

voltage and load test below/

If

specification, charge or replace battery.

The

lines are not restricted

adjustable and requires fuel

empty.

if

pump

a.

Check

b

Remove

motor spins, but does not engage

the starter motor lor a seized or binding pinion gear.

the flywheel inspection plate

and check

for a

damaged

ring gear.

replace as necessary. e.

may have

Engine

damage such as low

excessive w/ear or mechanical

cylinder cranking pressure, a broken camshaft drive system, insufficient

5.

Engine

a.

Check the

valve clearance or bent valves. f.

Check

for fuel

contamination such as water

months, the water may freeze and cause a

may

additive

g.

however the

help,

purging with fresh

fuel.

Check

system

for ignition

damaged

ignition

in the fuel.

During winter

fuel restriction.

Adding

a fuel

for

loose or shorted wires or

system components. Check the spark plugs

sive wear or incorrect electrode gap.

the

If

problem

is

worse

for

in

exces-

Check

management system

the engine

for a failed

Check

wet

for

a.

sensor or control module.

the battery state of charge

and condition.

dim when turning

and

motor cur-

starter

marginal and the starter motor

battery cable condition. Clean the battery terminals

the cur-

it

and replace

fuel

system

for

proper operation

A

fuel

pump

with insufficient

the engines tune-up status. Note the tune-up specifications

and check

On

coolant temperature sensor, and replace

for a failed

if

out ol speci-

fication.

Check

t.

visible or very

if

items such as severely worn spark plugs; adjust or replace as needed.

Check

the dash lights are not

If

battery

specification.

adjust to specification.

Engine does not turn over wtien attempting to start Check

beyond

vehicles with manually adjusted valve clearances, check for tight valves and

e.

2.

is

pressure or clogged injectors should be replaced.

fuel d.

weather, check lor shorts between the spark plugs and the ignition coils. h.

draw

Check the

c.

Check

draw Replace the

rent

corroded or damaged cables.

system may require draining and

fuel

failure.

battery condition, battery state of charge

rent

Check the

b

when cold

is difiicull to start

the ignition key on, the battery has either

the operation of the engine

tion; repair or replace failed

management systems

lor fuel

and

igni-

components as necessary.

failed internally or discharged, the battery cables are loose, excessively

corroded or damaged, or the alternator has failed or internally shorted,

8.

discharging the battery. Charge or replace the battery, clean or replace the

a.

battery cables, b.

c.

and check the

On automatic transmission vehicles, try starting the vehicle in both Park and Neutral. On manual transmission vehicles, depress the clutch pedal and attempt to start. On some vehicles, these switches can be adjusted, fylake sure the switches or Check

Engine Check the

and

air filter

system. Replace the

air intake

Check the

air filter

if

it

is dirty

fresh air intake system for restrictions or

the operation of the neutral safety switch.

Check

b.

lor

loose or deteriorated engine grounds and clean, tighten or

replace as needed

Check

c.

lor

needed maintenance Inspect tune-up and service related items

wire connectors are no! loose or damaged. Replace or adjust the switches

such as spark plugs and engine

as necessary.

the engine fuel

Check

when hot

is difficult to start

or con-taminated.

alternator output.

the starter motor, starter solenoid or relay,

and wires. Check the ground from the engine the wires are not loose,

and

starter

to the chassis

damaged, or corroded.

If

and

ignition

oil

condition, and check the operation ol

management system

motor cables

1-B. Engine Running Conditions

l^ake sure

battery voltage

is

pres-

Gasoline Engines

ent at the starter relay, try using a remote starter to start the vehicle tor test

purposes only Replace any damaged or corroded cables,

to replacing d.

any

failed

Check the engine

in

addition

II

may have

may have

rusted to the

suffered internal damage, or could

b

Check

c.

Check the tions

be hydro-locked from ingesting water Remove the spark plugs and carefully

If

the engine

is

resistant to

and then binds, do not force the engine any

slightly

moving, or moves

d.

2.

a.

Engine stalls Immediately when started Check the in

the run position

with

all

electrical

key on an

oft will

may be worn

accessories help

has shown signs of b.

Check

for loose,

tem and c.

Check

and operation The

ignition switch condition

in

or

damaged.

in the off

emergency

failure,

corroded,

it

a

situations,

Sometimes turning

b.

manifold vacuum teaks or vacuum hose leakage and repair or

luel

pump output and delivery Inspect luel lines lor pump pressure is below specification, replace

the luel

restric-

the luel

ol the

engine management system and repair as nec-

Engine lacks power Check

the engines tune-up status Note Ihe tune-up specifications

and check

items such as severely worn sparV plugs; adjust or replace as needed.

Check the

air filter

or con-taminated

On

and

and

air intake

Check the

system Replace

Itie air tiller

if

it

is dirty

Iresh air intake system lor restrictions or

blockage

or shorted wires for the ignition sys-

repair or replace

lor

replace parts as necessary

possible, or

adjust to specification

should be replaced as soon as possible

damaged

if

and replace as necessary

vehicles with manually adjusted valve clearances, check for tight valves

the

however once the switch

II

Check the operation

for

electrical contacts

Try restarting the engine

position

system operation and adjust

essary

further before deter-

mining the problem 3.

ignition

for restricted fuel injectors

pump.

attempt to rotate the engine using a suitable breaker bar and socket

on the crankshaft pulley

Engine runs poorly, hesitates Check the engine

replace defective parts

the engine has not been started for a long

period of time, internal parts such as the rings cylinder walls The engine

1. a.

components

for seizure.

c.

Check the operation

ol the

engine

Check Ihe sensor operation and and

repair or replace

fuel

and

wiring.

ignition

Check

for

components as necessary

management systems.

low

fuel

pump

pressure

TROUBLESHOOTING d.

Check the

make sure

adjustments. Check to

throttle linkage

opening the

fully

the linkage

is

d.

Replace any worn or defective bushings or link-

throttle.

speed use,

Check

for

a restricted exhaust system. Check for bent or crimped exhaust

pipes, or internally restricted mufflers or catalytic converters. inlet

outlet temperatures for the converter or muffler.

and

but outlet cold, the f.

Check

tor a

component

is

w/ill

install

level, or i.

Check kets or

oil level for

change the engine

and

and top

filter,

an intake manifold or vacuum hose

for

off to the

Check

for

k.

Check

tire air

mended

tire

wear

and

b.

octane rated

leak.

Replace leaking gas-

recommended

the pressure to the

a.

c.

filter

used during

Check ate

for

any

for

refilling,

air filter

if

air restrictions

and use a higher

is dirty

it

going into the

air

or contaminated.

the

and

fuel mixture,

tire size, tire

wear, alignment and

tire

set to specifica-

pressure. Large tires cre-

rolling resistance, smaller tires require

tire

tire

more engine speed

to

work harder

and maintain a

to accelerate

A

vehicle's speed.

parking brake cable or linkage can create a significant drag, brake wear

economy Check

of fuel

the brake system operation and repair as

necessary.

for idle

b.

Check

the operation of the idle control valve,

through the

speed

set too high

the ignition timing

and readjust

and adjust

detective sensors or related

Check

engine should be determined before lengthy

for a

injected vehicles rely on

in fuel

metering

fuel

which use the incoming

jets in

air

speed

to

order to provide a proper fuel-to-

amount

of fuel

which

is

and the amount

tion to the

engine control unit using low voltage

recommended

to

components and replace

When

components. Make sure the

vacuum for

leak at the intake manifold or

the

fully

to the related

connected, clean

should not be used, as they could leave a

the insulation of the wiring.

electrical

system provides the necessary

power

electrical

Because engine management systems are sensitive

to voltage

to

changes,

an alternator which over or undercharges could cause engine running prob-

combustion chamtors

ber Use a recommended decarbonizing

connectors

electrical

connectors are

necessary, clean the electrical contacts using

operate the vehicle's electrical accessories, electronic control units and sen-

vacuum hose and

in

If

cleaner The use of cleaning agents not specifically

damage

lems or component

excessive carbon build-up

a

for

detective.

replace defective gaskets or hoses.

Check the engine

and

electrical

for electrical contacts

The engine

Check

As

troubleshooting a fuel related engine condition on fuel injected

vehicles, carefully inspect the wiring

defective.

settings.

if

electrical signals.

an unplugged sensor or a poor electrical contact could cause a poor

designed if

throttle

in turn,

running condition similar to a failed sensor.

to specification.

and replace

engine speed and

of air entering the engine,

operates the fuel injectors by electrical pulses. The sensors provide informa-

sors.

e.

help

require over-

The sensors monitor the engine's operating temperature, ambient temper-

surface film or

d.

of the

a fuel injection system provides a specific

electrical contact

Engine runs on (diesels) when turned off Check Check

may

filter

may

reliability.

management systems

fuel

and not physically damaged.

a.

c.

too

is

introduced by the fuel injectors into the intake manifold or intake port, based

result,

sticking brake caliper,

overly adjusted brake shoe, broken brake shoe return spring, or binding

4.

situation a transmission

position to provide information to the engine control unit, which,

pressure, incorrect wheel alignment or a suspension prob-

Inspect the brakes for binding or excessive drag.

and loss

fuel

air ratio,

ature

wear can be caused by

lem. All of these conditions create increased rolling resistance, causing the engine to d.

the fluid level

low, top off using the

on the information provided by electronic sensors.

maintain a vehicle's road speed. Excessive incorrect

If

is

troubleshooting an engine running or performance condition, the

mechanical condition

draw

possible.

more

in this

cise fuel metering. Unlike carburetors,

tune-up and related adjustments. Replace worn ignition

check the engine ignition timing and if

and condition. the fluid level

electronic sensors to provide information to the engine control unit tor pre-

and check

housing. Replace the

parts,

If

the fluid exhibits a burning odor, the transmis-

troubleshooting procedures are performed.

Check the engine

tions

hot,

is

ENGINE PERFORMANCE TROUBLESHOOTING HINTS

Poor fuel economy filter

b.

If

hauling to ensure long-term

fuel.

Inspect the air

fluid type.

temporarily however

recom-

When

rating of the fuel

Compare

the inlet

vehicles, check for a slipping transmission.

the transmission fluid level

high, adjust to the correct level.

The engine 3.

If

is restricted.

vehicles, check for causes of a slipping

On automatic transmission Check

oil

correct level.

increased fuel usage.

Check the octane

component

Engine accelerates, but vehicle does not gain speed

causing increased rolling resistance, decreased acceleration and

I.

outlet temperatures lor the converter or muffler.

On manual transmission

possible alignment problems

for

replace

bent or crimped exhaust

for

sion has been slipping internally Changing the fluid and

wear Adjust

tire

Check the

settings.

management system and

mation.

dragging brakes and replace or repair as necessary. pressure and

fuel

exhaust system. Check

clutch. Refer to the clutch troubleshooting section for additional infor-

worn vacuum hoses.

j.

a.

mechanical

internal

being overfilled. Adjust the engine's

oil

engine

of the

for a restricted

but outlet cold, the

An engine

power

rebuilt or replaced to restore lost

the engine

Check

inlet

6.

which has severe mechanical wear, or has suffered

Check

gap and heat range.

one heat range colder

using the recommended

engine mechanical conditions such as low compression, worn

damage must be

f.

loose, improperly torqued

piston rings, worn valves, worn camshafts and related parts.

h.

Check the operation

is

pipes, or internally restricted mufflers or catalytic converters.

A

torque specification. for

a spark plug that

install

defective sensors or control units.

is hot,

decrease spark advance and reduce power

Replace defective knock sensors and

Check

e.

Compare

the inlet

If

restricted.

loose or defective knock sensor.

or defective knock sensor

g.

the spark plugs for the correct type, electrode

Replace worn or damaged spark plugs. For severe or continuous high

ages. e.

Check

11-7

failure.

Most

alternators utilize internal voltage regula-

which cannot be adjusted and must be replaced individually or as a unit

disassemble the

fuel additive or

with the alternator. cylinder head to

remove

the carbon. Ignition

f.

Check

the operation of the engine fuel

management system and

agement system. Similar rely

g.

Check

the engine operating temperature for overheating

and repair as

the octane rating of the fuel used during refilling,

octane rated b.

Check the

Use

a

ignition advance.

and use a higher

fuel.

ignition timing

Check the engine ber.

engine

fuel

man-

system, these ignition systems

determine the optimum ignition

Some

sensors provide information to the control unit

and adjust

for

to

recommended

components and replace

excessive carbon build-up

recommended decarbonizing

cylinder head to

On

these systems,

remove the carbon.

in

settings.

for

defective.

if

the

Check

combustion cham-

fuel additive or

disassemble the

if

ignition

nents.

Make sure

systems no longer

failed electrical

component

components,

electrical connectors to the related

If

necessary clean the

electrical contacts

compoand not

using electri-

cleaner The use of cleaning agents not specifically designed for

electrical contacts

damage

determine the amount of

the electrical connectors are fully connected, clean

physically damaged. cal contact

and

to

a failure occurs the tailed

must be replaced. Before replacing suspected carefully inspect the wiring

defective sensors or related c.

for information to

allow the ignition timing to be adjusted. Feedback from low voltage electrical

Engine l(nocks and pings during heavy acceleration, and on steep hills Check

by, or linked to, the

to the fuel injection

on electronic sensors

timing for a given engine speed and load.

necessary 5.

a.

systems may be controlled

replace

defective sensors or control units.

should be avoided, as they could leave a surface film or

the insulation of the wiring.

TROUBLESHOOTING

11-8

Check

b

1-C. Engine Noises, Odors and Vibrations

the fuel

ness and, 1.

Engine makes a knocking or pinging noise when acceleratCheck

Depending on the type

the octane rating of the luel being used.

driving or driving conditions,

it

may be necessary

system operation and

Check

the spark plug gap, heat range

operated

and condition.

severe operating conditions or

in

Check

If

recommended

ufacturer's

the igni-

the vehicle

man-

a.

Check

a

replace b.

Check

starter pinion

the starter

damaged

or

if

gear and the engine ring gear for damage, and

parts.

for a dark, rich

mounting bolts and housing.

If

the housing

cracked

is

a.

Check the accessory

drive belts for looseness

Check the accessory

drive belt tensioners for seizing or excessive bearing

noises and replace

loose, binding, or excessively noisy

may be

the bearing

and adjust as necessary

A

lean mixture

mounting area with

pump. The pump may not be

leaking; however,

and jammed. Replace the

faulty or the impeller loose

vice,

9. a

Engine makes a growling noise for a loose or failing water pump

pump and

Replace the

engine

5. a.

b.

trol

oil

and top

On

vehicles with hydraulic lash adjusters, check for collapsed

relief

On

oil

and

restricted oil

repair the

the alternator is

to crack, swell or bulge,

repair as

damaging or

has occurred, neutralize the bat-

this

soda and water mixture or

and replace

if

necessary

seal, gasket or

radiator cap, loose

cooling system hose

needed

valve or under the dashboard from the heater core, and replace the

worn engine

as necessary

ol white,

lor

white

smoke

in

addition to a sweet odor.

steamy smoke with a sweet odor indicates coolant

chamber Possible causes include

this condition include a white paste build-up

on the inside

a failed

ol the oil litter

cap, and softened, delormed or bulging radiator hoses lifters

and 10.

filter,

If

filter.

components

vehicles with hydraulic lash adjusters, check lor low

caused by a

d.

replace the engine

exhaust temperatures,

Check and

head gasket, cracked engine block or cylinder head. Other symptoms of

vehicles with hydraulic lash adjusters, check for low or dirty engine off or

ttie

and replace

alternator or voltage regulator. Inspect, ser-

test the battery,

leaking into the combustion

Engine makes a ticking or tapping noise

On

If

a suitable baking

Check the engine's exhaust

c

The presence

On

replace tailed c.

drive belt tensioners for excessive bearing noises

loose or excessively noisy

it

light

Vehicle has a sweet odor when driven Check for an engine coolant leak caused by a seeping

failed part

and replace

test

b Check lor a coolant leak from the radiator, coolant reservoir, heater con-

Check

Check the accessory

and

leak causing a lean running

result in increased

hose clamp, weeping cooling system

coolant b.

vacuum

gasket or

may

and replace the

and load

and replace or

a.

igni-

has a rotten egg odor when driven

equivalent,

water pump.

4.

an

Check

light.

overcharging, the battery electrolyte can be boiled Irom the battery,

tery

b.

for a seizing water

to

may become contaminated

condition or verily the condition by testing the

and the battery casing may begin

Engine makes a screecliing noise

Check

due

the fuel is not properly ignited

also trigger the check engine warning

shorting the battery internally

c.

or repair as

consumption has increased due

b Check the vehicle's alternator and battery condition

replace the starter motor and check the mounting bolts for

if

luel

may also trigger the check engine warning vacuum leaks as necessary

tightness

3.

and replace

or seals,

If

causing the catalytic converter to run hotter than normal This condition

motor grinds wiien used

damaged

may

for a leaking intake

condition

Examine the

filler

and

components as necessary

failed

8. Vehicle

spark plugs.

2. Starter

luel delivery

vehicle's emissions. Replace luel fouled spark plugs,

and replace worn or damaged

specification

economy

component, or

spark plugs

is

to the

components

the vehicle's luel

This condition

continuous high speeds,

at

use a colder heat range spark plug. Adjust the spark plug gap

tight-

noted, replace the

Is

damaged

tion related failure, the catalytic converter

components as needed.

adjust, or replace

seepage

It

loose hose clamps, cracked or

for

to a tailed

component, such as a l(nock sensor, may cause

the ignition timing to advance excessively or prematurely tion

Check

system settings and operation. Improperly adjusted

Ignition timing or a failed

looseness or seepage Check the cap

lor

necessary.

d

b. Verity the ignition

cap

return lines, or leaking

ot

use a higher octane

to

fuel.

c.

Check

c

ing a.

filler

loose, properly secure

if

cap.

oil

pump,

oil

pressure

valve

Engine vibrates when idling

Check

a.

or oil pressure

and

vehicles with manually adjusted valves, check lor excessive valve

tor loose, collapsed, or

damaged engine

or transmission

mounts

repair or replace as necessary.

Check

b.

for

loose or

damaged engine covers

or shields

and secure or

replace as necessary.

clearance or worn valve train parts Adjust the valves to specification or

11.

replace worn and defective parts. e.

Check

for a

loose or improperly tensioned timing belt or timing chain and

f.

Check

for a

6. a

Remove

the engine

Check

tial

replace.

bent connecting rod caused by a hydro-lock condition is

necessary to inspect

for

a.

is

tor

lor

adequate clearance or poten-

check

excessive engine rod bearing wear or

also associated with low engine

disassembly

Battery goes dead while driving Check

to inspect for

oil

will require

damaged and needed replacement

tails

Replace the battery

a battery load test

It

an overcharging condition

il

the battery will not hold

the battery loses lluid while driving, If

the alternator

built into the atternalor. necessitating alternator

engine

parts.

tor

is

overcharging,

replace the alternator or voltage regulator (A voltage regulator

damage This condition

pressure and

the battery condition

a charge or

damaged and needed

replacement parts

Check

lit

rubbing; repair or adjust as necessary

1-0. Engine Electrical System I.

bolt(s) to specification

Engine disassembly

c.

damaged exhaust system hangers and

loose crankshaft pulley or flywheel; replace and torque the

for a

lor a

missing, loose or

b Check the exhaust system routing and

Engine makes a heavy knocking noise Check

mounting b.

and

for

mounts; replace or repair as necessary

bent or sticking exhaust or intake valve.

cylinder head to access

Engine vibrates during acceleration

Check

a

adjust or replace parts as necessary.

b

Check

the battery cable condition

is typically

replacement or overtiaul

Clean or replace corroded cables and

clean the battery terminals 7.

a

Vehicle has a fuel odor Check

the fuel

that the

odor

gauge

is

level

If

when driven the fuel

caused by being

filled

gauge

c

registers

beyond

lull,

capacity, or

occurred during refueling The odor should clear

it

is

some

alter driving

twenty miles, allowing the vapor canister to purge.

possible spillage

an hour, or

Check

the alternator

tem

over or undercharging, replace the alternator or voltage regulator,

is

and voltage regulator operation

If

the charging sys-

or both

d

Inspect the wiring and wire connectors at the alternator for looseness, a

missing ground or detective terminal, and repair as necessary

TROUBLESHOOTING Inspect the alternator drive belt tension, tensioners and condition. Prop-

e.

weak

erly tension ttie drive belt, replace

the drive belt

2. Battery

Check

a.

Check

worn

or broken tensioners,

off

and replace

or cracked.

goes dead overnight fails

Check

if

the battery will not hold

Check tor

if

if

Some

a.

the alternator for an internally failed diode,

and replace the alterna-

System

Check

off the

Pressure

On

Check

Check

for

for a coolant leak

the insulation of the wiring.

Engine Exhaust System

failed coolant hoses,

1.

defective parts

and

fill

a.

and cooling system

Check

for

the blockage

Check

in

failed

c.

is

Another symptom of a restricted exhaust

Remove

impeller.

If

Flush the radiator or replace

if

d.

is

is

2. a.

cooling system and radiator cap for leaks. Check for

seepage caused by loose hose clamps,

failed coolant

b.

making contact with the vehicle

and water pump. Replace defective parts and

fill

the exhaust system clearance, routing

components and

radiator,

the cooling

the exhaust hangers, brackets

damaged mounts.

Check

c.

Check

in the

failed

head gasket, or a porous

damage

to

and alignment.

any manner, check

replace, then loosen

for internal

than the one which

cylinder head or engine block. Replace defec-

Another symptom

as necessary

Remove

Engine temperature remains cold when driving Check

the thermostat operation. Replace the thermostat

if

it

On

3.

vehicles with electrically controlled cooling fans, check the cooling

Check

fan operation.

and replace

failed

for defective

of the

a.

temperature sensors and stuck relays,

components.

b.

Check temperature gauge operation

if

equipped

is

damaged

may

travel in the direction of the

exhaust

is

in

a

component other

low engine manifold vacuum.

system and carefully remove any loose or broken

any

failed or

damaged

parts as necessary.

Exhaust system hangs too low Check

the exhaust hangers, brackets

ing or

damaged mounts.

and mounts. Replace broken, miss-

Check the exhaust routing and alignment. Check and replace bent or

damaged components.

proper operation

to verity

the exhaust

mufflers and catalytic converters. The broken

of a restricted

the exhaust

If

bent or

causing engine running and stalling problems.

failed,

pieces, then replace

for

and reposition the exhaust system.

sticks in the

open position.

c.

in

and mounts. Replace broken, miss-

exhaust flow and collect and/or create a blockage

caused by a

broken

the exhaust

Exhaust system vibrates when driving ing or

pieces from the defective component

for a coolant leak

If

any manner, loosen and reposition

Check

tive parts

b.

in

or

parts as necessary

system with the recommended coolant mixture.

water jacket casting

a.

low engine manifold vacuum.

remove any loose

Check

making contact with the vehicle

hoses, and cooling

system components such as the heater control valve, heater core, radiator cap,

is

damaged

the exhaust system.

poor, check for

Engine loses coolant test the

component other

in a

loose, replace the water

pump.

Pressure

The bro-

travel in the direction of the

Check the exhaust system clearance, routing and alignment. is

coolant circulation

If

the impeller

catalytic converters.

may

the exhaust system and carefully

pieces, then replace any failed or radiator.

and

than the one which failed, causing engine running and stalling problems.

head gasket, or a porous

too severe for flushing.

pump

to mufflers

ken pieces from the defective component

exhaust flow and collect and/or create a blockage

the cylinder head or engine block. Replace defec-

damaged water pump.

for a

or wear.

damaged mounts. Check for internal damage

components.

failed

damage

Check the exhaust hangers, brackets and mounts. Replace broken, missing or

mixture.

caused by a

Exhaust rattles at idle speed

b.

the cooling system

blown fuses or defective fan motors, temperature

an internally restricted

a loose water

3.

con-

fully

Check the engine and transmission mounts and replace mounts showing signs of

as necessary.

tive parts

b.

blown fuses,

necessary, clean the electri-

using electrical contact cleaner. The use of cleaning agents

1-F.

check

heater control valve, heater core, radiator, radiator

recommended coolant

water jacket casting

a.

for

connections are If

bleed the cooling system and inspect for leakage.

sensors and relays, and replace

2.

temperature sensors and relays to operate

diagnosing these systems, check

verify that the electrical

damage

vehicles with electrically controlled cooling fans, check the cooling

fan operation.

f.

hot and

cooling system and radiator cap for leaks. Check for seep-

pump. Replace

cap, and water

with the

full

cooling system with the correct coolant mixture.

test the

components such as the

e.

In

not specifically designed for electrical contacts could leave a film or

the coolant level. Set the heater temperature to

age caused by loose hose clamps,

d.

and result

Engine overiieats

Top

c.

electrical

When

damaged wires and

nected, clean and not physically damaged.

defective.

for internal air pockets,

b.

and use

the cooling fan.

1-E. Engine Cooling

of coolant

cooling systems rely on electrically driven cooling fans to cool

the radiator

cal contacts

1.

Once the engine

as needed.

off

engine block or cylinder head could cause a loss

or glove box

light, interior light

switch position and operation, and replace

defective. c.

and top

test.

such as a trunk

light

the cooling system with the correct coolant mixture. cool, recheck the fluid level

engine overheating.

a battery load

for a voltage draw,

light staying on.

is

NOTE: The engine cooling system can also be affected by an engine's mechanical condition. A failed head gasket or a porous casting in the

the battery condition. Replace the battery

a charge or b.

if

11-9

If

the exhaust

is

not routed properly, loosen and

reposition the exhaust system.

gauge. Check the sensors and wiring for defects, and repair or

replace defective components.

4.

4. a.

Engine runs hot Check

for

the blockage b.

Check

a.

an internally restricted

for a

is

c.

loose or slipping water if

brittle,

drive belt. Inspect the drive belt

belt.

Check

the sensors

equipped

and wiring

to verify

for defects,

proper operation

and

repair or

Check

internally

broken baffles or worn packing material.

Check

missing mufflers and silencers that have been replaced with

lor

straight pipes or with non-original

have a loss

full

system and inspect

hot,

check

for

for leakage.

Top

due

of efficiency

to

equipment silencers.

rattles, vibration

or missing exhaust hangers

and proper alignment should not

and misalignment may cause sur-

face cracks and broken welds, creating exhaust leaks or internal

the coolant level. Set the heater temperature to

internal air pockets, bleed the cooling

that

be overlooked. Excessive vibration caused by collapsed engine mounts,

damaged

replace defective components. e.

Check and replace exhaust silencers

NOTE: Exhaust system if

looseness and leaks. Check the exhaust pipes,

c.

the cooling fan operation. Replace defective fan motors, sensors or

Check temperature gauge operation of the gauge.

lor

b-

cracked or damaged. Check the pul-

relays as necessary d.

Exhaust sounds loud Check the system

clamps, flange bolts and manifold fasteners for tightness. Check and

if

replace any failed gaskets.

pump

condition and properly tension the

Check

Flush the radiator or replace

too severe for flushing.

condition. Replace the belt ley

radiator.

to

exhaust components such as the catalytic converter, creating a

tion to exhaust flow

and loss

of

power.

damage restric-

TROUBLESHOOTING

11-10

DRIVE TRAIN

2.

»atw:nrTa

2-A. Automatic Transmission

Transmission shifts erratically

1.

Check and

a.

sion

b.

il

Front

recommended

not within the

range, add or

fluid to obtain the correct fluid level. Alw/ays

fluid type

when adding transmission

Check the

fluid level

condition

If

filter

exhibits

Check gasket,

Check

d.

a burning odor indicates

and

ture;

that the

fluid.

A

fluid

Check

transmission has been slipping

nail or glass in the tire or tire tread.

inter-

rarely

however, a sharp object should be removed carefully

b Check

at

cause a punca

facility

capa-

tire repairs.

damaged

for a loose,

replace or missing

filter,

filter

2.

repair as necessary.

or

worn ConstanI Velocity (CV)

joint

and

defective

if

pressure lines and

and

fittings,

Rear wheel makes a Check

a.

for loose or leaking gaskets,

repair

clicking noise

debris such as a pebble, nail or glass

lor

in

the

remove the debris Small rocks and pebbles

Carefully

tire

or tire tread.

rarely

cause a

puncture; however, a sharp object should be removed carefully

loose or disconnected shift and throttle linkages or

for

clicking noise

such as a pebble,

remove the debris Small rocks and pebbles

ble of performing

which

fluid

or replace as necessary. e.

for debris

Carefully

fatigued

future repairs

an improperly installed transmission

for

makes a

Front wheel Check

a

become contaminated,

using the recommended type and amount of

and may require

nally c.

1.

fluid,

the fluid has

from excessive heat or exhibits a burning odor, change the transmission

and

Wheel Drive Vehicles

remove transmis-

use the recommended

vacuum

capable

of

performing

tire

at a facility

repairs

hoses, and repair as necessary

2-H. Other Drive Train Conditions

Transmission will not engage

2.

Check the

a.

shift linkage for

looseness, wear and proper adjustment, and

1.

repair as necessary. a.

Check

b.

for a loss of

ommended c.

If

transmission fluid and top

as needed with the rec-

fluid.

and the proper

engage with the

fluid level, internal

shift

damage has

likely

occurred,

units

On

and

repair or replace defective

linkage adiustment or leaking l\nany

vacuum

vacuum hoses

and solenoids

c.

to control

cal connectors are fully connected, clean

or servo units.

transmission shitting.

When

2. a.

contacts could leave a film or

and not physically damaged.

damage

On

number

lor

9.

change the

and

fluid

b.

filter

using the recommended If

the odor persists, trans-

be necessary.

vehicles with a manual transmission, check for a slipping or

On

causes and additional information

damaged

refer to section

1,

vehicles with an automatic transmission, check the fluid level and

condition Top

the insulation of the

will

Engine accelerates, but vehicle does not gain speed On

oft

or

change the

and

fluid

filter

replacement parts, lubricant type and amount. will

using the recommended If

the slipping continues.

be necessary.

BRAKE SYSTEM d

System Troubleshooting

Check face

a.

Check wheel

Check rotor

if

lug nut torque

and tighten evenly

the brake rotor for trueness it

is

too thin, warped, or

if

tion.

Some

tions

and recommendations before using

e

to specification.

and thickness

a

machined brake

3.

rotor.

a

caliper or caliper bracket

mounting

inspect for looseness Torque the mounting bolts

bolt torque

and inspect

and

for

Check

the brake

wear or

b Check

the bearing

is

pad or shoe mounting areas

is

not smooth

for a tack of lubricant or the

Clean and lubricate with a recommended high

rust.

the brake linings

and brake surface areas

for a seized or partially seized

for

severe wear or

dam-

loose, adjust

brake causing prerrature or uneven

brake wear, excessive heat and brake rotor or drum defective parts

If

or rotor sur-

Brakes make a grinding noise Check

pins.

the wheel bearing for looseness.

drum

the surface

age Replace worn or damaged parts

any looseness, including worn mounting brackets, bushings and sliding

Check

if

temperature brake grease

beyond specifica-

rotors can be machined; consult the manufacturer's specifica-

Check the brake

Inspect the brake

replace, along with the brake linings,

presence of surface

variations. Replace the

the thickness varies

the brake linings for glazing

and

or even.

Brake pedal pulsates or shimmies when pressed

b.

d.

off or

transmission removal and disassembly

3-A. Brake

c.

number

1.

2-C. condition number

wiring.

1.

and measure

vehicles with an automatic transmission, check the fluid level and

clutch. For possible

cleaner. The use of cleaning agents not specifically designed for elec-

3.

a brake caliper

rust,

vehicles with a manual transmission, check for a slipping clutch. For

mission removal and disassembly

necessary, clean the electrical contacts using electrical contact

II

On

replacement parts, lubricant type and amount

servos, check for proper

troubleshooting a vehicle with this type of system, be sure the electri-

trical

damage such as

related odors, refer to section 3-A. condition

condition. Top

automatic transmissions use an electronic control module,

electrical sensors

on brake

tion

components.

vehicles with kickdown linkages or

NOTE:

a seizing brake hydraulic

possible causes and additional information, refer to section 2-C, condi-

Transmission will not downshift during heavy acceleration On computer controlled transmissions, check for failed sensors or control

b.

the caliper piston lor surface

tion b.

a.

component such as

for

Check

linkage correctly

requiring transmission removal and disassembly.

3.

Burning odor from center of vehicle when accelerating Check

out-ol-round wear and caliper-to-piston clearance For additional informa-

the transmission does not

installed

off

if

damage Replace

and inspect the wheel bearing condition, which could have

been damaged due

to

excessive heal

possible, otherwise replace the bearing

2. a

4.

Brakes make a squealing noise Check

the brake rotor for the presence of a ridge

a

on the outer edge:

Vehicle pulls to one side during braking Check

for air in the

if

seals, fluid lines

present, b.

Check

remove the ridge

tor debris in the

or replace the brake rotor

and brake pads

fluid that c.

Check the brake

linings for wear

approaching the lining wear

and replace the brake linings

if

wear

brake hydraulic system Inspect the brake hydraulic

and related components

for fluid leaks

Remove

the air

from the brake system by bleeding the brakes Be sure to use iresh brake

brake lining material, clean and reinstall is

b

Check

for

meets the manufacturers recommended standards an internally restricted

flexible brake hydraulic

limit.

the

hose and flush the brake system

hose Replace

TROUBLESHOOTING Check

c.

brake hydraulic component such as a brake caliper

for a seizing

Check the

such as

caliper piston for surface dannage

rust,

the brake system using fresh brake fluid that meets the manufacturer's

recommended

replace failed parts and flush the brake system,

Check the

d.

vehicle's alignment

worn bushings,

and inspect

for

and set alignment

ball joints

vi/ear.

Replace

hydraulic seals.

to the manufacturer's

If

flush the brake

the brake system uses

drum brakes

front or rear,

brake fluid level and brake

fluid level. Inspect the If

the fluid level

and the brake hydraulic system

ok,

is

check the brake

is

master cylinder, then bleed and

free of hydraulic leaks, replace the brake

specifications. e.

standards,

Check the brake

b.

suspension

components, then bleed and flush

for leakage. Repair or replace leaking

and measure

out-of-round wear and caliper-to-piston clearance. Overhaul or

for

11-11

system using fresh brake

meets the manufac-

fluid that

recommended standards.

turer's

adjustment. Inspect for seized adjusters and clean or replace, then

Brakes produce a burning odor

9.

properly adjust.

a.

Brake pedal feels spongy or has excessive travel

5. a.

Check

the brake fluid level

and condition.

If

the fluid

is

contaminated or

and bleed and flush the brakes using fresh brake manufacturer's

Check

for a

damaged

or

fluid that

meets the

the brake system uses

If

Replace the

Check

b.

front or rear,

erly adjust.

a.

Check

Check brake or

0.

damaged

Check

brakes lack sufficient stopand brake booster check

valve.

and brake surface areas

for glazing

A

parts.

and linkages, and clean or replace as

Check

end dive or locks rear brakes

and

rear brakes,

brake pedal that

for

worn, failed

disconnected or missing spring or linkage

for the

brake proportioning valve. Replace missing parts or repair as necessary.

Pump

up a.

through the brake pedal while

most

is

is

ment.

fluid level

and inspect the

fluid lines

and seals

in

caused by brake

the front brakes, or both

very likely

pumps up or,

if

may be

with repeated use can be caused by air

the vehicle

in

the

rear drum brakes, A quick test for brake pump the brake pedal sev-

equipped with

is

seized or out of adjustment.

the brake pedal several times

is

to

and continue

If

the brake pedal

Do

to

apply pressure

pumped

up, the rear brakes are in need of adjust-

not compensate for the rear brake adjustment by adjusting the park-

ing brake, this will cause premature brake lining

vacuum brake

with the vehicle's engine start the

Check the brake hydraulic

likely

both the brake pedal and steering

If

brake pedal. With pressure being applied to the brake pedal, engage the

To test a

Brake pedal goes to floor when pressed and will not pump

8.

and

parking brake. Release the brake pedal and quickly press the brake pedal again.

for a seized,

or cable,

times with the vehicle's engine not running and the parking brake

released. to the

or seized brake proportioning valve and replace the

valve.

Check

brakes.

in the rear

adjustment on vehicles with rear drum brakes

Vehicle has excessive front

too easily a.

is felt

the steering wheel,

felt in

the brake adjusters

eral

b.

brake vibration which

wheel vibrate during braking, a surface variation

and replace worn

needed. 7.

A

brake hydraulic system

for seized hydraulic parts

mechanism, seized linkage

Brake vibrations or pulsation can often be diagnosed on a safe and care-

braking, but not

front

failed parts.

linings

for

necessary

surface variations

the operation of the brake booster

Replace worn or b.

firm, but

and measure

an internally restricted flexible brake hydraulic hose. Replace

the parking brake release

ful test drive.

Brake pedal feel is ping power or fade

rust,

BRAKE PERFORMANCE TROUBLESHOOTING HINTS

check the brake

adjustment. Inspect for seized adjusters and clean or replace, then prop-

6.

lor

Check

c.

repair as

drum brakes

damage such as

and flush the brake system.

the hose and flush the brake system.

flexible brake hydraulic hose.

hose and flush the brake system. c.

the caliper piston for surface

parts

recommended standards.

weak

for

Check

out-of-round wear and caliper-to-piston clearance. Overhaul or replace failed

has not been flushed every two years, clean the master cylinder reservoir,

b.

a seizing brake hydraulic component such as a brake caliper.

Check

booster,

off.

pump

engine. The brake pedal should

wear

the brake pedal several times

Apply pressure

to the brake pedal

and then

move downward about one

inch

(25mm),

WHEELS. TIRES. STEERING AND SUSPENSION 2. Tires a.

1.

b.

Front

Wheel Drive Vehicles

Torque lug nuts and axle nuts

b.

Wheel bearing worn or damaged. Replace wheel bearing.

c.

Wheel bearing out still

to specification

of adjustment. Adjust

wheel bearing

to specification;

3. Tires a.

Wheel Drive Vehicles

Wheel bearing out

of

still

Check Check

the

for

tire

Check

Wheel bearing worn

adjustment. Adjust wheel bearing to specification;

to specification

or

and recheck

for

Tires

if

worn

or defective tires

necessary. failed

and check the alignment; adjust

Check and

if

components, worn or necessary.

set tire pressures

Check

for

and properly

worn, damaged or defective suspension components. Replace

for a toed-out condition.

Excessive play in steering wheel Check

Check and

set tire pressures

Check

toe.

failed

for

to specification.

the steering gear free-play adjustment

and properly adjust

to

remove excessive play b.

and properly adjust the

and adjust the alignment

BWKfffffliBl

a.

worn on inside tread

Check alignment Check

balance. Replace

looseness.

damaged. Replace wheel bearing.

1.

b.

tire

the alignment settings.

defective parts

Torque lug nuts

c.

a.

pressure and

worn shock absorbers. Replaced

loose, replace.

b.

1.

and adjust the alignment.

adjust the alignment to specification, d.

if

set tire pressures

toe,

worn unevenly

defective tires c.

a.

Check and

for a toed-in condition.

worn, damaged or defective suspension components. Replace

and check the alignment; adjust

loose, replace.

Rear wheel or wheel bearing loose

Front

for

for looseness.

b.

2.

Check

defective parts

and recheck

a.

if

worn on outside tread

Check alignment

and properly adjust the

Front wheel or wheel bearing loose

worn, damaged or defective suspension components. Replace c.

Check

the steering linkage for worn,

components and perform a for a

defective parts and adjust the alignment. ing gear

damaged

front

or defective parts. Replace

end alignment.

worn, damaged, or defective steering box, replace the steer-

and check the

front

end alignment.

TROUBLESHOOTING

11-12

wheel shakes at cruising speeds

2. Steering

Check

a.

for

(or a

Check

b.

bent (ront wheel. Replace a

Stones rarely cause a

damaged wheel and check

the

objects

tire

an unevenly worn Iron!

for

Replace the

tire.

tire,

adjust

tire

Check

puncture and are easily removed Other

tire

create an air leak

when removed Consider having these

If

the front tires lor hidden internal

may have

the clicking noise varies with throttle input

worn Constant Velocity (CV-|Oint)

damage. Tires which have

encountered large pot holes or suffered other hard blows

sus-

damage and should be replaced immediately. front tires for an out-of-balance condition Remove, spin

punc-

tire

tures

pres-

sure and balance, c

may

obiects removed immediately at a facility equipped to repair

possible internal dannage

and

steering, check for a

universal (U- joint) or flex loinl

loinl.

makes a clunking or knocking noise over

2. Vehicle

i

tained internal

Check

d.

the

ance and

mended Check

e.

reinstall.

Torque

the wheel bolls or lug nuts to the

all

bal-

a.

A clunking ment

recom-

soft,

bumps

noise over

damaged

cracked,

most

is

caused by excessive move-

often

suspension component Check the suspension

or clearance in a

worn bushings Replace

or

the bushings

lor

and

specification.

for a loose

wheel bearing.

check the vehicle's alignment.

possible, adjust the bearing, or

If

b.

replace the bearing

if

it

a non-adjustable bearing.

is

Check

lor

loose suspension mounting bolts. Check the tightness on sub-

Irame bolts, pivot bolts and suspension mounting bolts, and torque to 3.

when braking

Steering wheel shakes

Refer to section 3-A, condition

a.

number

specification,

c

1

Check the vehicle

for a

Some wheel

loose wheel bearing.

adjusted lor looseness, while others must be replaced

4. a.

b.

Steering wheel

when turned

stiff

Check

the steering wheel free-play adjustment

Check

for a

damaged

and perform a

Check

c

becomes

for

front

damaged

and

replace the bearings as

reset as needed.

d.

assembly Replace the steering gear

steering gear

front

components Replace

defective

a

A low

Vehicle pulls to one side

b. Tires

pressure to

tires

recommended

and check alignment

settings.

settings.

noise

Align front end and check thrust

of specification

for a

dragging brake and repair or replace as necessary

2. Vehicle is very

Check

a.

for

worn

which has

will

b Check

shock absorbers or

strut

when

vary

may

turning Left hand turns increase the load on the

and

A

right turns load the fefl side.

wheel

failed front

also cause a slight steering wheel vibration

when

turning.

A

bearing which exhibits noise must be replaced

bouncy over bumps

or leaking

usually caused by a drive tram related

is

often associated with a wheel bearing

most

is

vehicle's right side,

bearing

Check

create noises over

temperatures or physical contact with a pot hole or curb. Sometimes the

angle. d.

slightly loose, or the latch

may

been damaged or worn The damage can be caused by excessive brake

tire

worn unevenly Replace

Alignment out

c.

is

makes a low pitched rumbling noise when driven

pitched rumbling noise

bearing and

pressure uneven Adjust

the door

surfaces Properly adjust the door latches to secure the

door,

3. Vehicle

a. Tire

If

bearings can be

loose Adjust or

end alignment.

4-D. Suspension 1.

adjustment

latch

if

the manufacturer,

not centered, the door assembly

is

bumps and rough

or seized suspension

components and perform a

Check the door adjustment

end alignment,

recommended by

cause

assemblies and

the tire condition failure

purposes,

symptoms a

try

and balance An

internally

damaged

tire

may

similar to failed suspension parts For diagnostic

known good

and replace detective

set of tires

tires.

replace as necessary.

Check

b.

for seized

shock absorbers or

strut

assemblies and replace as nec-

essary.

4. a.

NOTE: When one shock

fails,

it

is

recommended

Vehicle Check

for

3.

Vehicle leans excessively in turns Check

a.

for

b.

worn or leaking shock absorbers or

strut

assemblies and

Check

lor

c.

missing, damaged, or worn stabilizer links or bushings, and

4. Vehicle ride quality

Check

for seized

Check

b

for

excessively high

tire

pressures and adjust pressures

Vehicle Check check

lor

5.

seems law or leans a damaged, broken or

for a

Check

b.

to

weak

one side

Check

spring. Repface defective parts

and

b

needed alignment.

seized shock absorbers or strut assemblies and replace as nec-

for

worn or feaking shock absorbers

if

worn

thin layer of sus-

Check the

tire

Roads which have rough or uneven surfaces may

failure

An

condition and balance

symptoms

try a

internally

damaged

lire

may

similar to failed suspension parts For diagnostic

known good

set of tires

and replace defective

tires

imme-

diately.

or strut assemblies

and

c

for a

Check

worn Constant Velocity (CV-|oint) and replace

loose,

if

for a loose, bent, or

damaged

Noises

or failed

if

when coasting

it

or with steering or throttle input

ing noise frequency changes with road speed

and

if

the noise If

the click-

ttiorougli test drive

glass, nail or another hard object

tire

treads lor a stone, piece of

imbedded

or binding

out-of-balance axle or drive shaft Replace

to wtieelt. tires, steering

and

tlie

Bearing noises are isolated by noting whether the

noises or symptoms vary

not affected by the right, placing

steering or throttle input, check the

universal (U- joint)

suspension system can often limes be accomplished with a careful and

when

ing a straight line. During a is

damaged

joint,

components.

NOTE: Diagnosing failures related

Vehicle makes a clicking noises when driven Check the noise to see vanes with road speed Verify present

Check

or flex joint

d

is

bushings and replace

when driven

the road surface

purposes,

replace as necessary

a

of the

where the bushings wrap around the bar and

bushing brackets.

Vehicle vibrates Check

cause

for

4-E. Drivina Noises and Vibrations

1.

bushings which wrap

damaged. Remove the bushing bracket and apply a to the area

that are

afignment

cause unusual vibrations

essary.

c

for

stabilizer bar

to vehicle

a.

a

leaking, or the

Vibrations

recommendations 5.

or leaking boots.

damaged and

bushings Replace bushings

presence of sway bar or

for the

reinstall the

assemblies and replace as nec-

essary,

is

replacing suspension parts, check the vehicle

for seized or deteriorated

Check

pension grease

seems excessively harsh strut

loose, the boot

is

alignment

Check

or

shock absorbers or

it

When

around the bar Inspect the condition

replace or install as necessary

a

if

worn or damaged and check the vehicle

replace as necessary.

b

ball joint

ball joint is binding.

units as pairs.

damaged

the vehicle's ball joints for wear,

Replace a

to replace front or rear

makes a squeaking noise over bumps

into the tire or tire tread

right side

more

turning

left

hand

left or right,

or occur while driv-

lurn. the vehicle's

weight shifts to

force on the right side bearings, such that

wheel bearing

is

worn

or

damaged, the noise

if

or vibration

a

TROUBLESHOOTING should increase during lighl-to-heavy acceleration. Conversely, on right to lean to the left, loading the left side

hand turns, the vehicle tends

Knocking noises

such as bushings,

when

the suspension

in

roads, railroad tracks

bearings.

and speed bumps

ball joints or tie

the vehicle

is

11-13

driven over rough

worn suspension components

indicate

rod ends, or a worn steering system.

ELECTRICAL ACCESSORIES

5.

battery voltage

5-A. Headlights

and ground are present, replace the bulb.

present, check the interior light fuse for battery voltage. 1.

Check

a.

missing, replace the fuse.

One headlight only works on high or low beam is

voltage

for battery

headlight electrical connector.

at

assembly or bulb

present, replace the headlight

if

diagram

battery voltage is not present, refer to the headlight wiring

2.

for battery voltage

battery voltage for

at

to trou-

beam

headlight electrical connector

present, check the headlight connector

is

a proper ground.

light

and ground

If

If

battery voltage or

ground

is

if

at

Check

the head-

trical

present, trace the

is

for loose,

is

damaged

Check the door and

is

filament,

and replace

damaged.

if

and clean or replace the

for corrosion,

light

or corroded wires

and

electrical terminals;

switch operation, and replace

if

necessary.

very dim

the bulb and bulb socket for corrosion, and clean or replace the

Check

at

headlight electrical connector.

ground

diagram

check

to troubleshoot

voltage

If

for loose,

is

at the

bulb socket positive terminal or a poor

low, or the

damaged

ground marginal, trace the wiring and

or corroded wires

and

to,

electrical terminals;

repair as necessary,

the voltage at the

If

low voltage

for

ground.

If

headlamp elec-

circuit for the

significantly less than the voltage at the

battery, refer to the headlight wiring

Check

b.

connector, then clean and repair as necessary.

headlight electrical connector

not present, check the door switch

bulb and socket.

Headlight(s) very dim Check for battery voltage and ground battery voltage

is

repair as necessary.

a.

a.

the bulb for a

Check

c.

defective or operates intermittently.

3.

damaged

Check the bulb and bulb socket

d.

the switch

is

works intermittently

Check

3. Interior light if

ground

If

a.

available sepa-

not present, refer to the headlight

the headlight switch operation. Replace the switch

not

is is

bulb and socket.

wiring diagram to troubleshoot. b.

circuit.

b.

ground terminal

and ground are present

battery voltage

connector, replace the headlight assembly or bulb

rately

If

voltage

the fuse

contacts and clean or repair as necessary.

2. Interior light

Headlight does not work on high or low Check

a.

open or shorted

II

bleshoot.

If

If

battery voltage

if

present, refer to the wiring diagram to troubleshoot the cause for an

battery voltage

If

available separately.

the fuse has blown, or

If

Check the door and

c.

light

switch operation, and replace

if

necessary.

and locate

the voltage drop.

5-B. Tail, Running and Side

1.

Marker Lights

1. a.

Tail light,

Check If

and ground

battery voltage

is

at light's electrical

for a

proper ground.

If

age or ground

connector.

present, check the bulb socket and electrical

connector ground terminal

2.

battery voltage

at the light

connector, but not

clean the socket and the ground terminal connector.

in

If

the socket,

battery voltage or to

troubleshoot

ground

for

is

an open

in

Check

necessary

not present, refer to the wiring diagram

2. Tail light,

and replace

if

necessary.

running light or side marker light works Inter-

3.

the bulb for a

damaged

filament,

and replace

if

damaged,

for loose,

or corroded wires

and

Check

a.

One or both braku

electrical terminals,

and replace

if

necessary.

for

low voltage

for

ground.

voltage

If

is

at the

check

ground marginal, trace the wiring

5-E.

to,

and 1.

check

for loose,

damaged

or corroded wires

and

Check the

light

switch operation and replace

if

necessary. a.

1.

b.

and

position(s),

and

set the a.

b.

Check

for battery voltage

is

to

If

the

for a

ground

remove the

diagram

dim at the

brake light bulb

close to the battery voltage, check for

is

electrical

wire, terminal,

bolted to a painted surface,

it

may

connector and clean the mounting

mounts on bare

metal.

poor connection caused by either a

If

battery voltage

is

low,

faulty brake light switch,

Warning Lights

Warning

light(s) stay

on when the engine

is started

Check

the alternator output

Warning Light

the correct position.

and ground

Check

and voltage regulator operation, and replace

the warning light wiring for a shorted wire.

Check Engine Light

the interior light switch location in

refer to the wiring

circuit.

as necessary.

Interior light inoperative

switch

lights very

measured voltage

Ignition, Battery or Alternator

mCHSl a. Verify

an open

electrical terminals;

repair as necessary. c.

of

Refer to the wiring diagram to troubleshoot the cause of a voltage drop.

corrosion and clean or replace the

bulb socket positive terminal or a poor

low, or the

battery voltage

a loose, damaged, or corroded wire, terminal or electrical connector.

running light or side marker light very dim

Check the bulb and bulb socket Check

the

be necessary

bulb and socket, b.

If

surface, so the connector

the light switch operation

3. Tail light,

If

properly adjusted, and battery volt-

not present at the bulb sockets, or at the bulb elec-

cause

bulb or bulb socKet.

damaged

and repair as necessary. d.

is

is

a poor ground caused by a loose, damaged, or corroded

bulb and socket.

Check

voltage and ground at the

connector with the brake pedal pressed,

socket.

b Check the bulb and bulb socket for corrosion, and clean or replace the

c.

for battery

present, replace both bulbs.

Press the brake pedal and measure the voltage

a.

Check

If

the brake light switch

to troubleshoot the

mittently a.

If

age or the ground

circuit.

the light switch operation

at the

either battery volt-

If

not present, check the brake light switch adjustment and adjust as

If

trical

b.

and ground

for battery voltage

present, replace the bulb.

Both brake lights inoperative

battery volt-

the bulb socket, replace the bulb.

If

not present, refer to the wiring diagram to troubleshoot.

brake light bulb socket. is

age and ground are present

is

Press the brake pedal and check

a.

and ground are present

light inoperative

brake light bulb socket.

running light or side marker light inoperative

for battery voltage

One brake

Press the brake pedal and check

a

Check

the engine for routine maintenance

and tune-up

status.

engine tune-up specifications and verify the spark plug, at the interior light

bulb socket.

If

engine

oil

Note the

air filter

condition; replace and/or adjust items as necessary.

and

TROUBLESHOOTING

11-14

the fuel tank lor low fuel level, causing an intermittent lean fuel

Check

b.

mixture Top

Check

c.

tank and reset check engine

off fuel

disconnected engine

for a tailed or

and

Check the

and vacuum hoses

intake manifold

Check

and repair as

Check the engine

a.

the engine's mechanical condition for excessive oil

oil

consumption

the wheel sensors

for debris,

and clean as nec-

Check

c.

Check

Check the

the brake master cylinder for fluid leakage or seal failure

and

d.

the

ABS

pump and

control unit,

proportioning valves for proper

and the ABS

Check

a

and check

hydraulic lines and seals. Top

possible leakage from the

for

Check

b

brake fluid and repair leakage as neces-

off

b.

Check

the brake linings lor wear

c.

Check

for a

Check Check

d

change the

oft or

oil

and

oil level

oil filler

con-

nect the wire from the

oil

pressure sensor and with the ignition

position, but not running, the

oil

pressure

light

in

ON

the

should not be working.

If

being shorted to ground. Check the wire routing

to

make sure

the wire

d.

the

oil

Check the brake Check

pan and check

lor a

clogged

oil

Oil

oil lilter lor internal restrictions

or leaks,

for a

oil

operated with

oil

the engine bearings,

pressure relief valve,

oil

oil

pump

or

oil

Check the

oil loss,

such as leaking

oil lines

or oil pressure sensor

measure the engine's for the oil

damage to pump drive

If

oil

or a loose,

damaged,

the engine

oil level

oil loss,

pressure sensor operation by substituting a known good

oil

pressure sensor wire for being shorted to ground. Discon-

light to function

when

oil

pressure

of operating

an engine with low

oil

the brake release

light

in

the

ON

should not be working

II

damage Repair

is

pressure

is

the presence of

Check

verify the parking brake

has been

released

Check

the parking brake light switch for looseness or misalignment.

c.

Check

lor a

for a

or a loose or shorted brake light switch wire,

Warning Check

off

when

or repair as

or replace the wire

the alternator output

tent condition

may

indicate

pick-up tube screen

verify the parking brake

has been

switch lor looseness or misalignment

or a loose or shorted brake light switch wire.

necessary

llght(s) Inoperative with Ignition on,

for a defective

c

and engine

bulb by installing a known good bulb

sending unit by removing and then grounding the

Check

for a defective

wire

the sending unit

at

11

the light

wire, replace the

comes on

with the ignition on wtien

sending unit

driving 5-F. Turn Signal

Ignition, Battery or Alternator

light

damaged switch

grounding Ihe

on and

oil

b Check for a defective wire using the appropriate wiring diagram(s)

repair as necessary.

llghl(s) flickers

clogged

for a

not started a

damaged switch

pan and check

Check the parking brake and replace

b.

and replace or

oil

fully released,

3.

mechanism and

the

Check the brake release mechanism and

a

the engine is run-

Parking Brake Warning Light

Check

pressure sensor and with the ignition

Parking Brake Warning Light

c

a

oil

restricted, or leaking oil filter

and condition are acceptable,

pressure using a pressure gauge, or determine the

pressure warning

Remove

severe knocking and tapping noises

Warning

for a

oil

not pinched and check for insulation

d

symptom

2.

and check

or oil pressure sen-

being shorted to ground. Check the wire routing to make sure Ihe wire

b

fully

oil level

oil line

the light works with the wire disconnected, check the sensor wire for

ning, before operating the engine for an extended period of time. Another

Check

such as a leaking

as necessary and recheck before starting the engine

Belore starting the engine, check for possible causes of rapid

a

wear and replace as necessary

position, but not running, the

mechanism,

cause

possible leakage from the

and repair or replace as necessary.

Check the

could occur

pressure can be caused by excessive internal wear or

for

brake fluid and repair leakage as neces-

sensor.

and replace as neces-

damage

off

Pressure Warning Light

sor,

pressure below the manufac-

severe (and costly) engine

turer's specification,

Low

is

and check

linings for

nect the wire from the

the engine

unit for

loose or shorted brake warning light sensor or wire, and

sudden and rapid

pick-up tube screen.

sary. If

and the ABS control

repair as necessary.

Stop the engine immediately Check the engine

c.

WARNING:

and

fluid level

c

b.

Check the

and

proportioning valves lor proper

the sensor wiring at the wheel sensors

b.

a

sensor. e.

pump and

control unit,

sary,

pressure sensor operation by substituting a known good

oil

and clean as neces-

is

not pinched and check lor insulation damage. Repair or replace the wire

Check the

for debris,

replace or repair as necessary.

as necessary and recheck belore starting the engine.

Remove

ABS

hydraulic lines and seals. Top

the light works with the wire disconnected, check the sensor wire for

c.

the

Check the brake

a

as necessary

pressure sensor wire for being shorled to ground. Discon-

oil

and sensor rings

the brake master cylinder for fluid leakage or seal failure

Brake Warning Light

Pressure Warning Light

the

the wheel sensors

a loose or shorted wire

Stop the engine immediately Check the engine

Check

pinched or damaged wire

light wiring for a shorted,

operation, and replace as necessary

and replace as necessary.

loose or shorted brake warning light sensor or wire, and

replace or repair as necessary.

and top

and

repair as

replace as necessary.

c

dition,

and

sary

the brake fluid level

sary

Oil

for air leaks,

Anti-Lock Braking System (ABS) Light

Brake Warning Light Check

and vacuum hoses

fuel

replace as necessary

unit; repair or

control unit for

a loose or shorted wire, and repair as necessary.

a.

light.

disconnected engine

failure or partially

and repair as necessary

the sensor wiring at the wheel sensors

Check

tank and reset check engine

intake manifold

Check the warning

e

operation, replace as necessary d.

oft luel

an intermittent

necessary

replace as necessary.

Check

and engine

fuel level causing an intermittent lean fuel

component, sensor or control

ignition

c.

b.

lor

essary b.

a.

the fuel tank for low

mixture Top

LIglit

and sensor rings

air filter

condition: replace and/or adjust items as necessary.

Check

b.

Check

a.

required maintenance and tune-up status Verity

for

engine tune-up specifications, as well as spark plug,

Anti-Lock Braking System (ABS)

wire

necessary

Check Engine Light

for air leaks

necessary. e.

damaged

the warning light wiring for a shorted, pinched or

repair as

component,

sensor or control unit and repair or replace as necessary. d.

Check

b

light.

fuel or ignition

and 4-Way Hazard Lights

Warning Light

and voltage regulator operation An

worn brushes, an

intermit-

internal short, or a defective

voltage regulator Replace the alternator or failed

component

1.

a

Turn signals or hazard lights Check

lor a detective flasher unit

come

on, but

do not flash

and replace as necessary

TROUBLESHOOTING 2. Turn signals or

Check

Check the

if

circuit, short circuit or

If

known good

a.

Check

for failed

b.

Check

for

component, open

poor ground.

a.

a.

On

single horn systems, replace the horn.

On

dual horn systems, check the operation of the second horn. Dual horn

b. c.

for a failed

Check

for

Check

for a

Check

c.

for debris or

ward

corrosion

in

the bulb socket, and clean and repair as necessary.

poor ground

the bulb socket,

at

Check fuse and replace as necessary. Check switch operation and

c.

Check

bulb(s).

down-

prevent debris build-up.

to

Check

for installation of the correct flasher unit

Four-way hazard flasher indicator

and replace

if

bulb(s).

if

warning flasher switch and replace

if

ground

circuit for the

wiper switch or motor and repair as nec-

Windshield wiper motor makes a

2.

defective.

the

essary.

humming

noise, gets hot

or blows fuses

so, replace indicator

bulb. of the

Check

d.

incorrect.

light inoperative

Verify that the exterior lights are functioning and,

Check the operation

repair or replace as necessary.

corroded, loose, disconnected or broken wires and clean or

for

repair as necessary.

Check signal bulb(s) wattage and replace with higher wattage

b.

a.

b.

signals flash too fast

a.

7.

adequate drainage and

Windshield wipers do not operate

1.

b.

a.

the horn has a single opening, adjust the opening for

.lIllMHWHHUifflBI

signals flash too slowly

6. Turn

horn and verily the horn

in

and clean and repair as nec-

Check signal bulb(s) wattage and replace with lower wattage

a.

If

allow

to

condensation build-up

bulb and replace as necessary

essary.

5. Turn

time

at a

and recheck operation. Replace the horn which does not function.

does not work

light

Check

circuit information.

b.

positioning.

One signal

4.

and

systems have a high and low pitched horn. Unplug one horn

both housings and repair as necessary.

in

not present, refer to Chassis Electrical coverage for

Horn has an unusual tone

2.

bulbs and replace as necessary.

poor grounds

is

flasher unit.

signals or hazard lights only work on one side

3. Turn

voltage or ground

additional troubleshooting techniques

defective.

flasher unit by substituting a

the turn signal electrical system for a defective

Check

c.

hazard lights do not function on either side

the fuse and replace,

a. b.

11-15

a.

Wiper motor damaged

b.

Wiper linkage

bent,

internally; replace the

damaged

wiper motor.

or seized. Repair or replace wiper linkage as

necessary.

signal indicator light(s) do not work in either direc-

8. Turn

Verify that the exterior lights are functioning and,

a.

Windshield wiper motor operates, but one or both wipers

3.

tion if

so, replace indicator

fail to

b.

Check

9.

One

a.

Check

for a defective

b.

Check

for a defective flasher unit

for a defective ffasher unit

by substituting a known good

linkage as necessary.

unit.

Windshield wiper arms loose on wiper pivots. Secure wiper arm

b.

does not work

turn signal indicator light

move

Windshield wiper motor linkage loose or disconnected. Repair or replace

a.

bulb(s).

or replace both the wiper

by substituting a known good

unit.

Check

the wiper switch operation

rupts the b.

If

Horn does not operate

a.

Check

for a defective fuse

b.

Check

for battery voltage

pressing the horn switch.

6.

has

and replace as necessary.

and ground If

voltage

at

is

failed.

least

horn electrical connections when

power supplied

the wiper switch

is

to the

and

verify that the switch properly inter-

wiper motor.

functioning properly the wiper motor parking circuit

Replace the wiper motor assembly. Operate the wiper motor

one time before

installing the

arms and blades

tioning, then recheck using the highest wiper

present, replace the horn assembly.

arms and blades do not contact

make sure

the

Check

speedometer cable

b.

Speedometer Cable Operated

the

damaged, replace the

Speedometer does not work Check and

verify that the

speedometer cable

is

properly seated into the

speedometer assembly and the speedometer drive

3.

gear.

Check

the

speedometer cable

where the cable seats

for

into the

breakage or rounded-off cable ends

for

adequate lubrication. Remove the cable,

speedometer drive gear and

speedometer assembly. rounded

d. Install

tuted

2.

off,

into the

a

If

damaged, broken

or the cable

known good speedometer

to test for

proper operation.

If

the substi-

speedometer functions properly, replace the speedometer assembly

Speedometer needle fluctuates when driving

and the fasten-

wear and rounding, and replace as necessary.

at steady

1.

Speedometer

(Electronically Operated)

Speedometer does not work

a.

Check the speed sensor pickup and replace as necessary.

b.

Check the wiring between the speed sensor and the speedometer

for cor-

roded terminals, loose connections or broken wires and clean or repair as

necessary

Check speedometer cable routing

or sheathing for sharp

bends or kinks. c.

Route cable

for

and replace as necessary.

speeds. a.

intermittently

verify that the cable is fully installed

Check the cable ends

6-B.

drive gear condition

the cable has been

ends are

replace the cable.

Check speedometer

If

ers are secure. b.

c.

to

cable.

Speedometer works Check the cable and

a.

b.

at

ensure correct posi-

the windshield trim.

inspect for damage, clean, lubricate and reinstall. 1.

to

speed on a wet windshield

INSTRUMENTS AND GAUGES

6-A.

a

to pivot

pivot assembly.

Windshield wipers will not park

4. a.

1.

arm and

bulb and replace as necessary.

to

minimize sharp bends or kinks.

If

Install a

the sheathing has been stituted

damaged, replace the cable assembly. bly.

known good speedometer

to test for

proper operation.

If

the sub-

speedometer functions properly, replace the speedometer assem-

TROUBLESHOOTING

11-16 2.

Speedometer works Check

a.

intermltlently

the wiring between the speed sensor

Gauge operates

2.

and the speedometer

for cor-

a.

Check

necessary,

Check gauge sending

b.

Gauge operates

3.

Gauges

6-C. Fuel. Temperature and Oil Pressure 1.

damaged

wiring and repair as necessary

Check the speed sensor pickup and replace as necessary

b

erratically

lor loose, shorted,

roded terminals, loose connections or broken wires and clean or repair as

Gauge does not register missing or blown fuse and replace as necessary

a.

Check

for a

b.

Check

for

c.

Gauge sending

an open

circuit in the

unit defective.

pegged

fully

a

Sending unit-to-gauge wire shorted

b.

Sending

c.

Gauge

or sending unit not properly grounded,

d

Gauge

or sending unit improperly installed. Verify installation

and

gauge wiring. Repair wiring as necessary,

Replace gauge sending

or corroded electrical connections or

and replace as necessary.

units

unit defective; replace

ground.

to

sending

unit,

and wiring,

repair as necessary

unit.

d Gauge or sending unit improperly installed Verify installation and wiring,

and

7.

repair as

necessary

CLIMATE CONTROL

7-A. Air Conditioner 1. a.

No

air

Check

b. Air

coming from

air conditioner vents

the air conditioner fuse

1.

and replace as necessary

conditioner system discharged Have the system evacuated, charged

and leak tested by an

MVAC

certified technician, utilizing

c.

e.

Check blower motor fuse and replace as necessary. Check blower motor wiring

approved c

Air conditioner low pressure switch defective. Replace switch.

conditioner Ian resistor pack defective. Replace resistor pack,

Loose connection, broken wiring or defective air

air

d

conditioner relay

damaged

lor loose,

Check blower motor switch and repair or replace as

necessary

Check blower motor

for internal

resistor

pack

damage and

2. a.

necessary.

a. Air

conditioner system

is

air

b

Check the engine coolant

certified technician, utilizing

c.

approved recovery/recycling equipment. Repair as necessary, b. Air

compressor

clutch,

and

level.

If

the coolant level

Water collects on the used

for a

vacuum hose

for

when

is

low, top off

and check If

and

and

for

the air condi-

and

hose going

into

the other

much

is

is

or stuck thermostat

Check the heater control valve

proper installation.

full

and bleed

coolant leaks

coolant temperature

and

Move

the heater temperature

verify the operation of the heater

control valve. With the engine at normal operating temperature

heater temperature control in the

interior floor

damaged

control valve operation

control from hot to cold several times

repair

or replace as necessary,

3.

Check the heater cable or

conditioner compressor clutch not engaging. Check compressor

clutch wiring, electrical connections and

circuits,

repair or replace as necessary.

Check engine coolant operating temperature. below specification, check

discharged. Have the system evacuated,

charged and leak tested by an IVIVAC

open

Heater blows cool air the air from the cooling system as necessary

blows warm

for

in

conditioning electrical circuit. Repair wiring or replace relay as

2. Air conditioner

or corroded contacts

repair as necessary

recovery/recycling equipment. Repair as necessary

d. Air

Blower motor does not operate

a.

b

and the

hot position, carefully feel the heater

exiting the control valve,

II

one heater hose

is

hot and

cooler, replace the control valve,

tioner Is a. Air

conditioner evaporator drain hose

where

it

exits the

b. Air conditioner

hose

is

blocked. Clear the drain hose

passenger compartment.

evaporator drain hose

to the evaporator

is

3. a.

drainage tray under the dashboard.

Heater steams the windshield when used Check

for a

loose cooling system hose clamp or leaking coolant hose

near the engine firewall or under the dash area, and repair as necessary,

disconnected. Secure the drain b.

Check

for the existence of

a sweet odor and

heater floor vents, indicating a failed or

4. Air conditioner a.

The

air conditioner

stricted, allowing

has a moldy odor when used evaporator drain hose

condensation

to build

blocked or partially

re-

up around the evaporator and

drainage tray Clear the drain hose where

ment.

is

test the

it

exits the

check

fluid

damaged

cooling system with the heater set to the

for fluid

leakage from the floor vents

If

dripping from the heater core Pressure fully

leakage

warm

position and

is verified,

remove

and replace the heater core assembly

passenger compart-

NOTE: On some vehicles, the dashboard must be disassamblad and removed to access the heater core.

GLOSSARY

AIR/FUEL RATIO: The ture

drawn

ratio ot air-to-gasoline

by weigtit

in

the fuel mix-

into the engine.

AIR INJECTION: One method

of

reducing harmful exhaust emissions by

injecting air into each of the exhaust ports of an engine.

The fresh

can

of water

vapor and unburned

past the piston rings into the crankcase during normal engine

removed by the PCV system

buildup of harmful acids

the crankcase.

in

to

prevent the

BRAKE PAD: A

brake shoe and lining assembly used with disc brakes.

BRAKE SHOE:

The backing

exit the tailpipe.

ALTERNATOR: A trical

Combustion gases, composed

operation. These gases are

air enter-

ing the hot exhaust manifold causes any remaining fuel to be burned before it

BLOWBY:

fuel, that leak

11-17

device used for converting mechanical energy into elec-

for the brake lining.

The term

is,

however,

usually applied to the assembly of the brake backing and lining.

energy.

BUSHING: A

AMMETER:

An instrument,

flow of an electrical current

calibrated in amperes, used to

a

in

Ammeters

circuit.

measure the

are always connected

used

series with the circuit being tested.

electrical

The

flow of electrical current present

rate of

pressure

is

applied against one

ohm

ANALOG COMPUTER:

Any microprocessor

gous)

make

electrical signals to

when one

volt of

that

hydraulically activated device in a disc brake system, which

mounted straddling

electrical

a magnetic

in

a generator.

field,

it

CAMSHAFT: A

uses similar (analo-

shaft in the engine

operate the valves. The camshaft

in

a motor or relay.

changes mechanical energy

at

one

caliper contains at least

on which are the lobes (cams) which driven by the crankshaft, via a

is

half the crankshaft

When

into electrical

belt,

speed.

rotated

CAPACITOR: A

device which stores an electrical charge.

energy as

CARBON MONOXIDE

(CO): A colorless, odorless gas given

normal byproduct of combustion.

ATMOSPHERIC PRESSURE: by the weight

The

laminated, soft iron core wrapped by a wire that converts

energy to mechanical energy as

in

the brake rotor (disc).

one piston and two brake pads. Hydraulic pressure on the piston(s) forces

chain or gears,

ARMATURE: A

usually removable, for a bearing; an anti-friction liner

the pads against the rotor

of electrical resistance.

calculations.

its

liner,

place of a bearing.

CALIPER: A is

AMPERE:

in

in

of the air in the

The pressure on the

atmosphere. At sea

Earth's surface

level, this

pressure

caused

in

It

is

off

as a

poisonous and extremely dangerous

confined areas, building up slowly to toxic levels without warning

quate ventilation

can be

engine, which mixes the

is

if

ade-

not available.

is

14.7psiat32°F(101kPaatO°C).

CARBURETOR: A ATOMIZATION: The suspended

down

breaking

of a liquid into a fine mist that

AXIAL PLAY:

device, usually air

and

mounted on

fuel in the

the intake manifold of an

proper proportion

to

allow even

combustion.

in air

CATALYTIC CONVERTER: A

Ivlovement parallel to a shaft or bearing bore.

device installed

in

the exhaust system, like

a muffler, that converts harmful byproducts of combustion into carbon diox-

BACKFIRE: The sudden combustion system

of

gases

ide in the intake or

exhaust

and water vapor by means

heat-producing chemical reaction.

of a

that results in a loud explosion.

CENTRIFUGAL ADVANCE: A BACKLASH: The clearance

or play

between two

parts,

such as meshed gears.

timing by using flyweights

in

mechanical method

of

advancing the spark

the distributor that react to centrifugal force

generated by the distributor shaft rotation.

BACKPRESSURE:

Restrictions in the exhaust system that slow the exit of

exhaust gases from the combustion chamber

CHECK VALVE: or

BAKELITE: A

heat resistant, plastic insulator material

printed circuit boards

commonly used

vacuum

in

Any one-way

one direction

valve installed to permit the flow of

air,

fuel

only.

in

CHOKE: A

and transistorized components.

device, usually a

moveable

valve, placed in the intake path of a

carburetor to restrict the flow of air

BALL BEARING: A

bearing

between which hardened

made up

of

hardened inner and outer races

CIRCUIT: Any unbroken path through which an electrical to describe fuel flow in some instances.

steel balls roll.

current can flow.

Also used

BALLAST RESISTOR: A voltage after the engine

is

resistor in the primary ignition circuit that lowers

started to reduce

wear on

ignition

components.

CIRCUIT BREAKER: A

switch which protects an electrical circuit from over-

load by opening the circuit

Some

BEARING: A

friction reducing,

a stationary part and a

moving

circuit

when

the current flow exceeds a predetermined level.

breakers must be reset manually, while most reset automatically

supportive device usually located between

part.

COIL (IGNITION): A

transformer

in

the ignition circuit which steps up the

voltage provided to the spark plugs.

BIMETAL TEMPERATURE SENSOR: Any dissimilar types of metal that bend

sensor or switch made

when heated

or cooled

due

of

two

to the differ-

ent expansion rates of the alloys. These types of sensors usually function

COMBINATION MANIFOLD: An intake

as an on/off switch.

and exhaust manifolds

in

assembly which includes both the

one casting.

GLOSSARY

11-18

COMBINATION VALVE: A fuel

vapors

device used

some

in

systems

fuel

thai routes

charcoal storage canister instead of venting ttiem into the

!o a

atmosphere. The valve relieves

fuel tank

pressure and allows fresh

DISTRIBUTOR: A

mechanically driven device on an engine which

responsible for electrically firing the spark plug

at a

is

predetermined point

of

the piston stroke.

air into

the tank as the fuel level drops to prevent a vapor lock situation.

DOWEL COMPRESSION

RATIO: The comparison

der and combustion

of the total

chamber with the piston

volume

BDC and

at

of the cylin-

the piston at

DRUM CONDENSER:

An

1

tem

in

which

device which acts to store an electrical charge,

electrical

preventing voltage surges. 2.

A

radiator-like device in the air conditioning sys-

gas condenses

refrigerant

Any

pin, inserted in

mating holes

two

in

different parts allow-

BRAKE: A

braking system which consists of two brake shoes and

one or two wheel cylinders, mounted on a fixed backing drum, mounted on an

and a brake

plate,

which revolves around the assembly

axle,

into a liquid, giving off heat.

DWELL:

CONDUCTOR:

PIN: A

ing those parts to maintain a fixed relationship.

TDC.

material through which an electrical current can be

The

measured

rate,

cycles on and

trical circuit

in

degrees

of shaft rotation, at

which an elec-

off.

transmitted easily.

ELECTRONIC CONTROL UNIT (ECU): CONTINUITY: Continuous

complete

or

Can be checked with an

circuit.

fier

See Module

or igniter.

Ignition

module, module, ampli-

for definition.

ohmmeter.

ELECTRONIC IGNITION: A

COUNTERSHAFT: An and transmits,

intermediate shaft which

CRANKCASE:

The lower

engine

part of an

is

rotated by a mainshaft

spark plugs

a working part.

in turn, that rotation to

END-PLAY: The measured amount

which the crankshaft and

in

system

in

which the timing and

firing of the

controlled by an electronic control unit, usually called a

is

module. These systems have no points

or condenser.

of axial

movement

in

a shaft

related parts operate

ENGINE: A

CRANKSHAFT:

The main driving

shaft of an engine

rocating motion from the pistons and converts

device that converts heat into mechanical energy

which receives recip-

to rotary

it

motion.

EXHAUST MANIFOLD: A

set of cast

passages or pipes which conduct

exhaust gases from the engine,

CYLINDER:

an engine, the round hole

In

the engine block in which the

in

piston(s) ride.

FEELER GAUGE: A thickness, used to

CYLINDER BLOCK:

The main

member

structural

found the cylinders, crankshaft and other principal

of

an engine

in

which

parts.

FIRING ORDER: The of

CYLINDER HEAD:

The detachable portion

to the top of the cylinder block tion

of the engine, usually fastened

and containing

chambers. On overhead valve engines,

operating parts.

On overhead cam

engines,

all

or

most

parts.

order

an engine Also the order

in

in

which combustion occurs

which spark

is

in

the cylinders

distributed to the plugs by

the distributor.

combus-

of the

contains the valves and their

it

contains the camshaft as well.

it

blade, usually metal, or precisely predetermined

measure the clearance between two

is

FLOODING: The

presence

of loo

much

combustion chamber which prevents the

fuel in the intake

manifold and

mixture from

air/luel

firing,

thereby causing a no-start situation.

DEAD CENTER:

The extreme top

or

bottom

of the piston stroke.

FLYWHEEL: A DETONATION: An unwanted

explosion of the air/fuel mixture

in

the

com-

bustion chamber caused by excess heat and compression, advanced timing, or

an overly lean mixture. Also referred

DIAPHRAGM: A vacuum advance

thin, flexible wall

Around

separating two cavities, such as

in

a

unit.

starting

initial

FOOT POUND or

aflixed the ring gear

is

ring gear, turning the flywheel,

imparting the

to as "ping

disc shaped part bolted to the rear

the outer perimeter

engages the

work needed

motion

lbs. or

(ft.

to raise

end The

of the crankshaft starter drive

which rotates the crankshaft,

to the engine.

sometimes,

ft.lb.):

The amount

an item weighing one pound, a distance

of of

energy

one

foot

DIESELING: A cause the engine

condition to run

on

in

which hot spots

after the

key

is

the combustion

in

turned

chamber

FUSE: A

oft.

protective device in a circuit

breaking the circuit

DIFFERENTIAL: A geared assembly which

allows the transmission of

motion between drive axles, giving one axle the

is

ability to turn faster

than

DIODE: An

designed

fuse

the other.

electrical device that will

allow current to flow

in

one direction

when

a specific

which prevents

amperage

structed around a strip or wire of a lower

is

to protect

present

in

GEAR RATIO:

When

is

circuit

overload by

present The device

amperage

is

con-

rating than the circuit

an amperage higher than

that

stamped on the

the circuit, the strip or wire melts, opening the circuit

The

ratio

between the number

of teeth

on meshing gears.

only

GENERATOR: A DISC BRAKE: A rotor,

hydraulic braking assembly consisting of a brake disc, or

mounted on an

axle,

device wtiich converts mechanical energy into electrical

energy

and a caliper assembly containing, usually two

brake pads which are activated by hydraulic pressure The pads are forced

HEAT RANGE:

against the sides of the disc, creating friction which slows the vehicle

from

Its tiring

The measure

of

a spark plug's

ability lo dissipate heal

end The higher the heal range, the

hotter the plug fires

It

GLOSSARY HUB: The

OVERHEAD CAMSHAFT

center part of a wheel or gear.

camshaft

HYDROCARBON carbon.

A major

(HC): Any chemical compound made up

pollutant

of

formed by the engine as a byproduct

hydrogen and

of

is

by means

of the cylinder

of rocker

configuration

in

which the

head and operates the valve

arms.

combustion.

OVERHEAD VALVE HYDROMETER: An

(OHC): An engine

mounted on top

either directly or

11-19

instrument used to measure the specific gravity of a

the cylinder block.

solution.

(OHV): An engine configuration

the valves are located

in

which

the cylinder head and the camshaft

in

The camshaft operates the valves

is

via lifters

all of

located

in

and

pushrods.

POUND

INCH

(inch lbs.;

sometimes

in. lb.

or in. lbs.): One twelfth

OXIDES OF NITROGEN (NOx):

pound.

of a foot

duced as a byproduct

Chemical compounds

of nitrogen pro-

combustion. They combine with hydrocarbons

of

to

produce smog.

INDUCTION: A means magnetic

Principle used

field.

energy

of transferring electrical in

in

the form of a

the ignition coil to increase voltage.

OXYGEN SENSOR: of

INJECTOR: A

device which receives metered fuel under relatively low

pressure and

activated to inject the fuel into the engine under relatively

is

high pressure

at a

oxygen

Use with

the feedback system to sense the presence

exhaust gas and signal the computer which can reference

in the

the voltage signal to an air/fuel ratio.

predetermined time.

PINION: The smaller

INPUT SHAFT: The

which torque

shaft to

is

two meshing gears.

of

applied, usually carrying the

PISTON RING: An open-ended

driving gear or gears.

INTAKE MANIFOLD: A

casting of passages or pipes used to conduct

air

ring with

fits

Most automotive pistons have

compression sealing; one

groove on the outer

into a

form a seal between the pis-

of the piston. Its chief function is to

diameter

ton and cylinder wall.

three rings: two for

for oil sealing.

or a fuel/air mixture to the cylinders.

PRELOAD: A

JOURNAL:

The bearing surface within which a shaft operates.

KEY: A small block usually

by adjustment.

a notch between a shaft and a hub to

fitted in

prevent slippage of the two parts.

PRIMARY

CIRCUIT:

the low voltage side of the ignition

system which

consists of the ignition switch, ballast resistor or resistance wire, bypass, coil,

MANIFOLD: A

predetermined load placed on a bearing during assembly or

casting of passages or set of pipes which connect the

electronic control unit

and pick-up

coil

as well as the connecting wires

and harnesses.

cylinders to an inlet or outlet source.

PRESS

MANIFOLD VACUUM: Low formed

just

below the

pressure

in

Manifold vacuum

throttle plates.

is

FIT:

The mating

of

two parts under pressure, due

diameter of one being smaller than the outer diameter

an engine intake manifold highest at idle

versa; an interference

to the inner

of the other, or vice

fit.

and drops under acceleration.

RACE: The

MASTER CYLINDER: hydraulic system.

clutch systems and

The primary

automotive use,

In

is

found

in

or, in

a power brake

system, through the power booster.

MODULE:

surface on the inner or outer ring of a bearing on which

t

needles or rollers move.

brake and hydraulic

pedal activated, either directly

is

balls,

fluid pressurizing device in a it

REGULATOR: A els of a circuit at

Electronic control unit, amplifier or igniter of solid state or

RELAY: A

device which maintains the amperage and/or voltage lev-

predetermined values.

switch which automatically opens and/or closes a circuit.

integrated design which controls the current flow in the ignition primary circuit

based on input from the pick-up

primary

circuit,

high secondary voltage

coil. is

When

induced

the

module opens

the

RESISTANCE: The in

opposition to the flow of current through a circuit or

the coil. electrical device,

and

is

measured

in

ohms. Resistance

is

equal to the volt-

age divided by the amperage.

NEEDLE BEARING: A large

number)

bearing which consists of a

number

(usually a

of long, thin rollers.

RESISTOR: A of resistance in

OHM:

(i2)

trical flow.

The

unit

One ohm

one ampere

in

used is

the

to

measure the resistance

amount

device, usually

an electrical

made

of resistance that limits current

in

an

An instrument used

for

which

offers a preset

amount

flow to

RING GEAR: The name

a circuit with one volt of pressure.

given to a ring-shaped gear attached to a differ-

ential case, or affixed to a flywheel or

OHMMETER:

of wire,

circuit.

of conductor-to-elec-

measuring the resistance,

in

as part of a planetary gear

set.

ohms,

ROLLER BEARING: A

bearing

made up

of

hardened inner and outer

electrical circuit.

races between which hardened steel rollers move.

OUTPUT SHAFT:

The

shaft

which transmits torque from a device, such

as a transmission.

ROTOR:

1

.

The disc-shaped

part of a disc brake assembly,

the brake pads bear; also called, brake disc. 2.

upon which

The device mounted atop

the distributor shaft, which passes current to the distributor cap tower con-

OVERDRIVE: A

which produces more shaft revolutions

gear

than that transmitted to

it.

tacts.

GLOSSARY

11-20 SECONDARY

CIRCUIT: The high voltage side

TORQUE:

system,

of the ignition

The twisting force applied

an obiect

to

usually at)ove 20.000 volts The secondary includes the ignition coil, coil

cap and

wire, distributor

SENDING

rotor,

spark plug wires and spark plugs.

UNIT: A mechanical,

electro-magnetic

electrical, hydraulic or

device designed to measure engine operating conditions or

operate as a simple on/off switch or they

may

member

to a driven

and torque.

In

automotive use,

changes

in

engine to the automatic transmission.

TRANSDUCER: A

provide a variabie volt-

TRANSISTOR: A

device used to change a force into an electrical signal.

semi-conductor component which can be actuated by a

small voltage to perform an electrical switching function,

TUNE-UP: A

regular maintenance function, usually associated with the

replacement and adjustment

SHIM: Spacers

of precise,

predetermined thickness used between parts to fuel

establish a proper working relationship.

SLAVE CYLINDER:

In

SOLENOID: A

coil

ol parts

of a vehicle tor the

and components

purpose

of attaining

in

and

the electrical

optimum

perfor-

mance.

automotive use, a device

in the

hydraulic clutch

TURBOCHARGER: An

activated by hydraulic force, disengaging the clutch

is

systems

and forces

it

into the

used to produce a magnetic

field,

the effect of which

is

exhaust driven

pump which compresses

combustion chambers

pressures The increased

to

power from a driving

finks the drivepfate at the rear

a potentiometer) as conditions or measured parameters

(like

system which

it

nature and

in

designed to send a voltage signal to an on-board computer, some sensors

may

via hydraulic action, providing

of the

ambient pressures and temperatures. Usually electronic

age signal

turbine used to transmit

member

drive ratio

device which transmits information to a gauge.

SENSOR: Any

TORQUE CONVERTER: A

air

at

intake air

higher than atmospheric

pressure allows more

fuel to

be burned and

horsepower being produced

results in increased

produce work.

VACUUM ADVANCE: SPARK PLUG: A

device screwed into the combustion chamber of a spark

The basic construction

ignition engine

ceramic insulator, mounted

in

an outer conductive base. An

electrical

charge from the spark plug wire travels along the conductive core and

jumps

a preset air

ductive base.

The

gap

to a

response

to increased

A

device which advances the ignition timing

In

engine vacuum.

a conductive core inside of a

is

grounding point or points

at

VACUUM GAUGE: uum

in

An Instrument used

to

measure the presence

of vac-

a chamber.

the end of the con-

resuftant spark ignites the fuel/air mixture in the

combus-

VALVE: A

tion chamber.

device which control the pressure, direction of ffow or rate of

flow of a liquid or gas

SPLINES: Ridges machined

or cast onto the outer diameter of a shaft or

VALVE CLEARANCE:

inner diameter of a bore to enable parts to mate without rotation.

The measured gap between the end

stem and the rocker arm, cam lobe or foflower

TACHOMETER: A shaft, gear, etc

.

which

is

device used to measure the rotary speed of an engine,

VISCOSITY: The

usually in rotations per minute

THERMOSTAT: A

of the valve

that activates the valve.

valve, located in the cooling

closed when cold and opens gradually

system in

heating, controlling the temperature of the coofant

of

an engine,

response

and

to

rate of

engine

coolant

VOLTMETER: An

rating of a fiquid's internal resistance to flow.

instrument used for measuring electrical force in units

called volts Voltmeters are always connected parallel with the circuit being tested

flow.

WHEEL CYLINDER: TOP DEAD CENTER top of

its travel

(TDC): The point

at

on the compression stroke

which the piston reaches the

Found

in the

automolive drum brake assembly,

it

a device, actuated by hydraulic pressure, which, through internal pistons,

pushes the brake shoes outward against the drums.

is

AIR BAG (SUPPLEMENTAL RESTRAINT SYSTEM) 1-15 AIR CLEANER REMOVAL & INSTALLATION 1-15 6-10 AIR CONDITIONING COMPONENTS 1-29 AIR CONDITIONING SYSTEM 1-30 PREVENTIVE MAINTENANCE SYSTEM INSPECTION 1-30 SYSTEM SERVICE & REPAIR 1-29 ALTERNATOR 2-10

REMOVAL & INSTALLATION TESTING

6-7

2-10

2-10

ALTERNATOR PRECAUTIONS

2-10

ANTENNA 10-6 REPLACEMENT 10-6 ANTI-LOCK BRAKE SYSTEM

AUTOMATIC TRANSAXLE

9-27

7-2

AUTOMATIC TRANSAXLE (FLUIDS AND LUBRICANTS) DRAIN AND REFILL

1-36

1-37

CHECK 1-36 AUTOMATIC TRANSAXLE ASSEMBLY ADJUSTMENTS 7-9 REMOVAL & INSTALLATION 7-5 FLUID LEVEL

7-5

AVOIDING THE MOST COMMON MISTAKES AVOIDING TROUBLE 1-2 BASIC ELECTRICAL THEORY

1-2

6-2

HOW DOES ELECTRICITY WORK: THE WATER ANALOGY OHM'S LAW 6-2 BASIC FUEL SYSTEM DIAGNOSIS 5-2 BASIC OPERATING PRINCIPLES 9-2 9-2 DISC BRAKES DRUM BRAKES 9-2 POWER BOOSTERS 9-2 BAHERY 1-18 BAHERY FLUID

1-18

CABLES 1-19 CHARGING 1-20 GENERAL MAINTENANCE PRECAUTIONS 1-18 REPLACEMENT 1-20

BAnERY CABLES BELTS

1-18

6-7

1-20

ADJUSTING INSPECTION

1-21

1-20

REMOVAL & INSTALLATION 1-21 BLEEDING THE ABS SYSTEM 9-40 BLEEDING THE BRAKE SYSTEM 9-7 BRAKE BLEEDING

9-7

BLOWER MOTOR 6-9 REMOVAL & INSTALLATION BODY LUBRICATION 1-39 DOOR HINGES 1-39 HOOD LATCH AND HINGES PARKING BRAKE LINKAGE BOLTS, NUTS

6-9

1-39 1-39

AND OTHER THREADED RETAINERS

BRAKE CALIPER (FRONT DISC BRAKES)

9-9

OVERHAUL 9-11 REMOVAL & INSTALLATION 9-9 BRAKE CALIPER (REAR DISC BRAKES) 9-22 OVERHAUL 9-24 REMOVAL & INSTALLATION 9-22 BRAKE DISC (FRONT DISC BRAKES) 9-1 INSPECTION

9-12

REMOVAL & INSTALLATION 9-12 =>BRAKE DISC (REAR DISC BRAKES) 9-24 " .

.

INSPECTION

9-25

REMOVAL & INSTALLATION BRAKE DRUMS 9-13 INSPECTION

9-24

9-13

REMOVAL & INSTALLATION BRAKE LIGHT SWITCH 9-3 REMOVAL & INSTALLATION

9-13

9-3

1

-7

6-2

MASTER INDEX

11-22

BRAKE OPERATING SYSTEM

9-2

BRAKE PADS (FRONT DISC BRAKES) INSPECTION

TESTING 9-8

9-9

REMOVAL & INSTALLATION 9-8 BRAKE PADS {REAR DISC BRAKES) 9-20 INSPECTION

INSPECTION

OPERATION

9-17

SYSTEM) 2-4 CRANKSHAFT POSITION SENSOR (DISTRIBUTORLESS IGNITION SYSTEM) 2-9 CRANKSHAFT POSITION SENSOR (ELECTRONIC ENGINE CONTROLS) 4-17

9-14

9-41

ADJUSTMENT 9-27 REMOVAL & INSTALLATION

OPERATION

9-25

CV-BOOTS IGNITION

IGNITION

POSITION SENSOR (ELECTRONIC ENGINE CONTROLS) 4-17 OPERATION 4-17

REMOVAL & INSTALLATION

1-22

1-22 INSPECTION CYLINDER HEAD (ENGINE MECHANICAL)

REMOVAL & INSTALLATION

3-16

3-16

INSPECTION

4-17

4-22

REMOVAL & INSTALLATION 8-17 COMPONENT LOCATIONS ELECTRONIC ENGINE CONTROL COMPONENT LOCATIONS—4.6L NORTHSTAR ENGINE 4-18 FRONT SUSPENSION COMPONENT LOCATIONS— DEVILLE CONCOURS 8-4 FRONT SUSPENSION COMPONENT LOCATIONS— SEVILLE TOURING SEDAN (STS) 8-5 MAINTENANCE COMPONENT LOCATIONS-^.BL NORTHSTAR 1-15 ENGINE REAR SUSPENSION COMPONENT LOCATIONS— DEVILLE

8-14

REAR SUSPENSION COMPONENT LOCATIONS— SEVILLE TOURING

SEDAN (STS) 8-15 CONSOLE 10-10 REMOVAL & INSTALLATION 10-10 CONTROL ARMS/LINKS 8-21 REMOVAL & INSTALLATION 8-21 CONTROL MODULE (ANTI-LOCK BRAKES) 9-36 REMOVAL & INSTALLATION 9-36 CONTROL PANEL (HEATING AND AIR CONDITIONING) 6-10 REMOVAL & INSTALLATION 6-10 COOLANT TEMPERATURE SENSOR (ELECTRONIC ENGINE CONTROLS) 4-13 4-13

REMOVAL & INSTALLATION

4-14

4-13

COOLANT TEMPERATURE SENSOR (SENDING UNITS AND 2-15

3-32

CYLINDER HEAD COVERS 3-4 DASH PANEL AND PAD 10-6 DASHBOARD AND PAD 10-6 DETERMINING ENGINE CONDITION 3-26 COMPRESSION TEST 3-26 OIL PRESSURE TEST 3-26 DIAGNOSIS AND TESTING (DISTRIBUTOR IGNITION SYSTEM) COMPONENT TESTING 2-2 VISUAL INSPECTION 2-2 DIAGNOSIS AND TESTING (DISTRIBUTORLESS 2-5 IGNITION SYSTEM) DIAGNOSIS AND TESTING (TROUBLE CODES) 4-19 CIRCUIT/COMPONENT REPAIR 4-19

INTERMinENTS

4-19

VISUALVPHYSICAL INSPECTION

DISCONNECTING THE CABLES DISTRIBUTOR

INSTALLATION

2-4

REMOVAL & INSTALLATION DISTRIBUTOR CAP AND ROTOR INSPECTION

4-19

6-7

2-3

2-4 1

-27

1-27

REMOVAL & INSTALLATION 1-27 DISTRIBUTOR IGNITION SYSTEM 2-2 DISTRIBUTORLESS IGNITION SYSTEM DO S 6 1

DONTS 1-6 DOOR GLASS AND REGULATOR REMOVAL & INSTALLATION DOOR LOCKS 10-15 REMOVAL & INSTALLATION DOOR PANELS 10-12 REMOVAL & INSTALLATION DOORS 10-2 ADJUSTMENT 10-2 DRUM BRAKES 9-13 ELECTRIC FAN SWITCH

ELECTRIC FUEL

PUMP

10-20 10-20

10-15

10-12

2-16

REMOVAL & INSTALLATION

2-15

REMOVAL & INSTALLATION

3-31

REFINISHING & REPAIRING

2-10

CHASSIS GREASING 1-39 6-47 CIRCUIT BREAKERS RESETTING AND/OR REPLACEMENT 6-47 CIRCUIT PROTECTION 6-40 CLEARING CODES (ELECTRONIC ENGINE CONTROL) 8-17 COIL SPRINGS

3-28

ASSEMBLY 3-33 DISASSEMBLY 3-29

4-17

CHARGING SYSTEM

TESTING

6-11

CYLINDER HEAD (ENGINE RECONDITIONING)

2-9

CAMSHAR

SENSORS)

4-17

4-17

CRUISE CONTROL

CAMSHAFT POSITION SENSOR (DISTRIBUTORLESS

OPERATION

4-17

REMOVAL & INSTALLATION TESTING

2-4

CONCOURS

4-2

4-2

PCV SYSTEM TESTING 4-2 REMOVAL & INSTALLATION 4-3 CRANKSHAFT DAMPER 3-18 REMOVAL & INSTALLATION 3-18 CRANKSHAFT POSITION SENSOR (DISTRIBUTOR IGNITION

9-13

CAMSHAFT BEARINGS AND LIFTERS 3-23 REMOVAL & INSTALLATION 3-23 CAMSHAFT COVER 3-5 REMOVAL & INSTALLATION 3-5 CAMSHAFT POSITION SENSOR (DISTRIBUTOR

TESTING

1-37

CRANKCASE VENTILATION SYSTEM

BRAKE SPECIFICATIONS BUY OR REBUILD? 3-26 CABLES 9-25

SYSTEM)

1-37

LEVEL CHECK

9-21

REMOVAL & INSTALLATION

SYSTEM)

1-37

RECOMMENDATION

FLUID

REMOVAL & INSTALLATION 9-20 BRAKE ROTOR (FRONT DISC BRAKES) 9-12 BRAKE ROTOR (REAR DISC BRAKES) 9-24 BRAKE SHOES 9-13

ADJUSTMENTS

2-15

COOLING SYSTEM 1-37 DRAIN, FLUSH AND REFILL

5-9

2-16

2-5

2-2

MASTER INDEX REMOVAL & INSTALLATION TESTING ELECTRIC

10-24

REMOVAL & INSTALLATION ELECTRICAL COMPONENTS

CONNECTORS GROUND 6-3 LOAD

FOG/DRIVING LIGHTS 6-36 REMOVAL & INSTALLATION

5-9

5-12

WINDOW MOTOR

4.5

10-24

4.6

6-2

4,9

6-3

6-2

PROTECTIVE DEVICES SWITCHES & RELAYS

6-3 6-3

WIRING & HARNESSES 6-3 ELECTRONIC ENGINE CONTROL COMPONENT LOCATIONS—4.6L NORTHSTAR ENGINE 4-18 ELECTRONIC ENGINE CONTROLS 4-10 EMERGENCY BRAKE 9-25

EMISSION CONTROLS

4-2

ENGINE (ENGINE MECHANICAL) REMOVAL & INSTALLATION ENGINE BLOCK 3-34

ASSEMBLY 3-36 DISASSEMBLY 3-34 GENERAL INFORMATION

FUEL INJECTOR(S) 5-6 REMOVAL & INSTALLATION

FUSES

1-12

3-27

3-27

DAMAGED THREADS

3-28

3-27

3-28

ENGINE RECONDITIONING 3-26 ENGINE START-UP AND BREAK-IN 3-38 BREAKING IT IN 3-38 KEEP IT MAINTAINED 3-38 STARTING THE ENGINE 3-38 ENGINE TUNE-UP SPECIFICATIONS 1-29 ENGINE VEHICLE IDENTIFICATION 1-11 ENTERTAINMENT SYSTEMS 6-12 EVAPORATIVE CANISTER 1-18 SERVICING

6-40

4-3

DIAGNOSTIC AIDS 4-4 OPERATION 4-3 EXHAUST GAS RECIRCULATION SYSTEM COMPONENT TESTING 4-5 OPERATION 4-5

REMOVAL & INSTALLATION EXHAUST MANIFOLD 3-10 REMOVAL & INSTALLATION

4-5

GRILLE

(SEQUENTIAL MULTI-PORT FUEL INJECTION

(TROUBLE CODES) 4-19

3-24

EXTERIOR 10-2 FASTENERS, MEASUREMENTS AND CONVERSIONS

7-2

1-7

10-4

7-10

REMOVAL & INSTALLATION

3-10

7-10

HEADLIGHT SWITCH 6-27 REMOVAL & INSTALLATION 6-27 HEADLIGHTS 6-28 AIMING THE HEADLIGHTS 6-28 REMOVAL & INSTALLATION 6-28 HEATER CORE 6-10 REMOVAL & INSTALLATION 6-10 HEATING AND AIR CONDITIONING

HOOD

2-2

(DISTRIBUTORLESS IGNITION

10-4

HALFSHAFTS

9-27

(DISTRIBUTOR IGNITION SYSTEM)

REMOVAL & INSTALLATION

4-8

FIRING ORDERS 2-10 FLASHERS 6-47 REPLACEMENT 6-47 1-34 FLUID DISPOSAL FLUID PAN (AUTOMATIC TRANSAXLE) REMOVAL & INSTALLATION 7-2 FLUIDS AND LUBRICANTS 1 -34 FLYWHEEL/FLEXPLATE 3-24 REMOVAL & INSTALLATION 3-24

6-40

6-47

TEVESMKII 9-27 TEVESMKIV 9-28 GENERAL INFORMATION GENERAL INFORMATION SYSTEM) 2-5 GENERAL INFORMATION SYSTEM) 5-3 GENERAL INFORMATION ELECTRICAL TOOLS SCAN TOOLS 4-19 GENERATOR 2-10

1-18

EVAPORATIVE EMISSION CONTROLS COMPONENT TESTING 4-4

5-8

1-34

REPLACEMENT 6-47 GAUGE CLUSTER 6-22 GAUGE PANEL 6-22 GAUGES (INSTRUMENTS AND SWITCHES) 6-25 REMOVAL & INSTALLATION 6-25 GENERAL ENGINE SPEICIFICATIONS 1-13 GENERAL INFORMATION (AIR BAG) 6-7 ARMING THE SYSTEM 6-7 DISARMING THE SYSTEM 6-7 SERVICE PRECAUTIONS 6-7 GENERAL INFORMATION (ANTI-LOCK BRAKE SYSTEM) BOSCH ANTI-LOCK BRAKE SYSTEM 9-28 PRECAUTIONS 9-28

3-2

ENGINE NUMBER (SERIAL IDENTIFICATION)

ENGINE PREPARATION

5-2

5-9

REPLACEMENT

3-13

FUSIBLE LINKS

ENGINE OVERHAUL TIPS CLEANING 3-27

1-16

5-7

5-6

FUEL TANK

3-36

EXHAUST SYSTEM

1-16

FUEL RECOMMENDATIONS

ENGINE MECHANICAL

TOOLS

8-5

(STS)

REMOVAL & INSTALLATION

FUEL RAIL ASSEMBLY 5-8 REMOVAL & INSTALLATION

3-14

REPAIRING

3-41

FUEL PRESSURE REGULATOR 5-8 REMOVAL & INSTALLATION 5-8

3-13

OVERHAUL TIPS

SEDAN

FUEL FILTER

FUEL LINES AND FIHINGS

3-34

REMOVAL & INSTALLATION TESTING

3-40

9-8

FRONT SUSPENSION 8-4 FRONT SUSPENSION COMPONENT LOCATIONS— DEVILLE CONCOURS 8-4 FRONT SUSPENSION COMPONENT LOCATIONS— SEVILLE TOURING

TESTING

3-2 3-2

3-34

REFINISHING

ENGINE FAN

3-39

FRONT HUB AND BEARING 8-12 REMOVAL & INSTALLATION 8-12

POWER SOURCE

INSPECTION

6-36

ENGINE MECHANICAL SPECIFICATIONS ENGINE MECHANICAL SPECIFICATIONS ENGINE MECHANICAL SPECIFICATIONS

FRONT DISC BRAKES

6-4

11-23

10-2

ALIGNMENT 10-3 REMOVAL & INSTALLATION 10-2 HOSES (COOLING SYSTEM) 1-21

6-9

4-1

MASTER INDEX

11-24 INSPECTION

1-21

OPERATION

REMOVAL & INSTALLATION

THIS BOOK 1-2 HUB & BEARINGS 8-24 REMOVAL & INSTALLATION 8-24 HYDRAULIC CONTROL UNIT (ANTI-LOCK BRAKES) REMOVAL & INSTALLATION 9-38 IDENTIFICATION (AUTOMATIC TRANSAXLE) 7-2 IDLE AIR

CONTROL VALVE

OPERATION TESTING IGNITION COIL

TESTING

4-13

FLUID LEVEL

1-38

RECOMMENDATION

FLUID

2-2 2-3

2-3

2-9

REMOVAL & INSTALLATION

2-8

OIL

LOCK CYLINDER 8-31 REMOVAL & INSTALLATION 8-31

IGNITION

MODULE (DISTRIBUTOR IGNITION SYSTEM) 2-3 REMOVAL & INSTALLATION 2-3 MODULE (DISTRIBUTORLESS IGNITION SYSTEM) REMOVAL & INSTALLATION 2-9 8-30 IGNITION SWITCH REMOVAL & INSTALLATION 8-30 IGNITION

IGNITION

2-9

PUMP

OPERATION

4-11

1-28

REMOVAL & INSTALLATION

ADJUSTMENT

1-28

TESTING

MIRROR

10-25

REPLACEMENT 3-25 INSTRUMENT CLUSTER 6-22 REMOVAL & INSTALLATION 6-22 INSTRUMENT PANEL AND PAD (DASHBOARD) REMOVAL & INSTALLATION 10-6

INSTRUMENTS AND SWITCHES

6-22

INTAKE AIR TEMPERATURE SENSOR

4-14

OPERATION

PC V VALVE

10-6

4-14

REMOVAL & INSTALLATION

4-14

4-14

TESTING

INTAKE MANIFOLD

3-8

REMOVAL & INSTALLATION INTERIOR 10-6 JACKING 1-40

3-8

REMOVAL & INSTALLATION LEAF SPRING

8-12

LOWER BALL JOINT INSPECTION

8-38

REMOVAL & INSTALLATION 8-35 POWERTRAIN ASSEMBLY 3-3 REMOVAL & INSTALLATION 3-3 POWERTRAIN CONTROL MODULE (PCM) OPERATION 4-0 REMOVAL & INSTALLATION 4-10 PRECAUTIONS (BAHERY JUMP STARTING)

8-17

PROPORTIONING VALVE (BRAKES)

8-8

8-8

RADIATOR

1-15

MAINTENANCE INTERVALS 1-41 MAINTENANCE OR REPAIR? 1-2 MANIFOLD AIR PRESSURE SENSOR

1

-39

5-2

3-12

REMOVAL & INSTALLATION

3-12

RADIO RECEIVER/TAPE PLAYER/CD PLAYER 6-12 REMOVAL & INSTALLATION 6-12 READING CODES (ELECTRONIC ENGINE CONTROLS) OBD-I OBD-II

SYSTEMS SYSTEMS

4-20

4-20 4-21

REAR DISC BRAKES 9-20 REAR MAIN SEAL 3-23 REMOVAL & INSTALLATION

4-15

4-10

9-6

REMOVAL & INSTALLATION 9-6 QUICK-CONNECT FITTINGS (FUEL LINES)

REMOVAL & INSTALLATION 8-8 LOWER CONTROL ARM 8-10 CONTROL ARM BUSHING REPUCEMENT 8-11 REMOVAL & INSTALLATION 8-10 MACPHERSON STRUTS 8-6 OVERHAUL 8-7 REMOVAL & INSTALLATION 8-6 MAINTENANCE COMPONENT LOCATIONS^ 61 NORTHSTAR ENGINE

9-25

1-17

8-12

8-17

REMOVAL & INSTALLATION LIGHTING 6-28

4-11

REMOVAL & INSTALLATION 1-17 PNP SWITCH REPLACEMENT (AUTOMATIC TRANSAXLE) 7-4 REMOVAL & INSTALLATION 7-4 POWER BRAKE BOOSTER 9-5 REMOVAL & INSTALLATION 9-5 POWER DISTRIBUTION BOX 6-40 POWER STEERING GEAR 8-33 REMOVAL & INSTALLATION 8-33 POWER STEERING PUMP (FLUIDS AND LUBRICANTS) 1-38 FLUID RECOMMENDATION 1-38 LEVEL CHECK 1-38 POWER STEERING PUMP (STEERING) 8-35 BLEEDING

JACKING PRECAUTIONS 1-40 JUMP STARTING 1-39 JUMP STARTING PROCEDURE 1-39 KNUCKLE AND SPINDLE (FRONT SUSPENSION)

4-12

4-11

OXYGEN SENSOR PARKING BRAKE

REMOVAL & INSTALLATION 10-25 INSPECTION (EXHAUST SYSTEM) 3-24

2-16

3-18

(ENGINE)

REMOVAL & INSTALLATION 3-18 OIL RECOMMENDATIONS (ENGINE) 1-34 CHANGING OIL & FILTER 1-35 OIL LEVEL CHECK 1-35 10-5 OUTSIDE MIRRORS REMOVAL & INSTALLATION 10-5 4-11 02 SENSOR

IGNITION TIMING INSIDE REAR VIEW

1-38

NEUTRAL SAFETY SWITCH 7-4 REMOVAL & INSTALLATION 7-4 OIL PAN (ENGINE) 3-17 REMOVAL & INSTALLATION 3-17 OIL PRESSURE SWITCH (ENGINE) 2-16

IGNITION COIL

TESTING

4-15

4-15

MASTER CYLINDER (BRAKE OPERATING SYSTEM) 9-4 REMOVAL & INSTALLATION 9-4 MASTER CYLINDER (FLUIDS AND LUBRICANTS) 1-38

1-29

PACK 2-8 REMOVAL & INSTALLATION

4-14

OPERATION 4-14 REMOVAL & INSTALLATION

9-38

4-13

REMOVAL & INSTALLATION TESTING

4-15

4-15

MASS AIRFLOW SENSOR

4-13

ADJUSTMENT

IDLE SPEED

TESTING

4-13

REMOVAL & INSTALLATION

4-15

REMOVAL & INSTALLATION

1-22

HOW TO USE

3-23

REAR SUSPENSION 8-14 REAR SUSPENSION COMPONENT LOCATIONS—OEVILLE CONCOURS 8-14

MASTER INDEX REAR SUSPENSION COMPONENT LOCATIONS— SEVILLE TOURING

SEDAN

8-15

(STS)

RELIEVING FUEL SYSTEM PRESSURE

TESTING

THERMOSTAT 3-7 REMOVAL & INSTALLATION

THROHLEBODY

5-3

6-30

1-27

1-22

1-11 ENGINE VEHICLE IDENTIFICATION ENGINE MECHANICAL SPECIFICATIONS

ENGINE MECHANICAL SPECIFICATIONS ENGINE MECHANICAL SPECIFICATIONS

3-39 3-40 3-41

REMOVAL & INSTALLATION

2-13

1-33

8-32

TRUNK LID 10-4 ALIGNMENT 10-4 REMOVAL & INSTALLATION TURN SIGNAL SWITCH 8-27 REMOVAL & INSTALLATION

VALVE LASH

8-25

STRUTS (FRONT SUSPENSION) 8-6 SWAY BAR (FRONT SUSPENSION) 8-9 REMOVAL & INSTALLATION 8-9 SWAY BAR (REAR SUSPENSION) 8-23 REMOVAL & INSTALLATION 8-23 TANK ASSEMBLY (FUEL SYSTEM) 5-9 REMOVAL & INSTALLATION 5-9 TEST EQUIPMENT (UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS) 6-4 JUMPER WIRES 6-4 MULTIMETERS 6-5 6-5

TROUBLESHOOTING ELECTRICAL SYSTEMS 6-5 TESTING (UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL

10-4

4-23

3-4

1-29

WATER PUMP 3-15 REMOVAL & INSTALLATION WHEEL ALIGNMENT 8-13 8-13

CASTER 8-13 TOE 8-13 WHEEL CYLINDERS

9-18

OVERHAUL 9-18 REMOVAL & INSTALLATION WHEEL LUG STUDS 8-3 REMOVAL & INSTALLATION

WHEELS WHEELS

1-11

3-15

9-18

8-3

8-2 8-2

INSPECTION

8-2

REMOVAL & INSTALLATION 8-2 WHERE TO BEGIN 1-2 WINDSHIELD WASHER PUMP 6-21 REMOVAL & INSTALLATION 6-21 WINDSHIELD WIPER BLADE AND ARM REMOVAL & INSTALLATION 6-18 WINDSHIELD WIPER MOTOR 6-20

6-18

-8

4-19

8-27

1-29

1

3-41

UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS 6-2

VACUUM DIAGRAMS

CAMBER

8-25

REMOVAL & INSTALLATION STOP LIGHT SWITCH 9-3

1-34 1-33

TRANSMISSION/TRANSAXLE ID NUMBER 1-12 TROUBLE CODES (ELECTRONIC ENGINE CONTROLS) TROUBLE CODES (ANTI-LOCK BRAKE SYSTEM) 9-29 CLEARING CODES 9-32 READING CODES 9-29

VEHICLE IDENTIFICATION PLATE

2-13

STEERING LINKAGE 8-32 REMOVAL & INSTALLATION

6-6

1-32

STORAGE

ADJUSTMENT

2-13

STARTING SYSTEM STEERING 8-25

3-19

1-32

TIRE ROTATION

VALVE COVERS

2-13

SYSTEMS)

3-21

3-19

TORQUE ANGLE METERS 1-9 TORQUE WRENCHES 1-8 TORQUE SPECIFICATIONS (ENGINE AND ENGINE OVERHAUL) TRAILER ViriRING 6-40

GENERAL ENGINE SPECIFICATIONS MAINTENANCE INTERVALS 1-41 TORQUE SPECIFICATIONS (ENGINE AND ENGINE OVERHAUL) 3-41 SPEED SENSORS (ANTI-LOCK BRAKES) 9-32 REMOVAL & INSTALLATION 9-32 STANDARD AND METRIC MEASUREMENTS 1-10

TEST LIGHTS

3-20

TOOLS AND EQUIPMENT 1-3 TORQUE (FASTENERS, MEASUREMENTS AND CONVERSIONS)

1-13

STEERING WHEEL

3-20

REMOVAL & INSTALLATION SEHING CAMSHAFT TIMING

TIRE

4.5

TESTING

4-16

4-16

TIRE DESIGN

SPARK PLUG HEAT RANGE 1-23 SPEAKERS 6-15 REMOVAL & INSTALLATION 6-15 SPECIAL TOOLS 1-4 SPECIFICATIONS CHARTS BRAKE SPECIFICATIONS 9-41 ENGINE TUNE-UP SPECIFICATIONS 1-29

STARTER

REMOVAL & INSTALLATION TESTING

TIMING CHAIN AND GEARS

REMOVAL & INSTALLATION 1-32 TIRES AND WHEELS CARE OF SPECIAL WHEELS INFLATION & INSPECTION

6-30

1-25 INSPECTION & GAPPING REMOVAL & INSTALLATION 1-23

4.9

5-4

4-15

4-15

TIMING CHAIN COVER AND SEAL

SIGNAL AND MARKER LIGHTS REMOVAL & INSTALLATION SPARK PLUG WIRES 1-26 REMOVAL & INSTALLATION 1-26 TESTING

4.6

OPERATION

3-7

5-4

REMOVAL & INSTALLATION THROHLE POSITION SENSOR

8-20

SPARKPLUGS

6-6

RESISTANCE 6-6 SHORT CIRCUITS 6-6 VOLTAGE 6-6 VOLTAGE DROP 6-6

5-4

REMOTE RADIO RECEIVER 6-14 REMOVAL & INSTALLATION 6-14 RIMS 8-2 ROCKER ARMS AND VALVE COVERS 3-4 REMOVAL & INSTALLATION 3-4 ROUTINE MAINTENANCE 1-14 SENDING UNITS AND SENSORS 2-15 SEQUENTIAL MULTI-PORT FUEL INJECTION SYSTEM SERIAL NUMBER IDENTIFICATION 1-11 SERVICING YOUR VEHICLE SAFELY 1-6 SHOCKS (REAR SUSPENSION) 8-19 SHOCK ABSORBERS 8-19 REMOVAL & INSTALLATION 8-19

OPEN CIRCUITS

11-25

11-26

MASTER INDEX

REMOVAL & INSTALLATION 6-20 WINDSHIELD WIPER SWITCH 6-27 REMOVAL & INSTALLATION 6-27 WINDSHIELD WIPERS (ROUTINE MAINTENANCE)

ELEMENT

1-30

(REFILL)

CARE & REPLACEMENT

WINDSHIELD WIPERS AND WASHERS WIRE AND CONNECTOR REPAIR 6-7 WIRING DIAGRAMS 6-48

1-30

6-18

...for

Total

The Do-lt-Yourselfer

Car Care

is

the most

complete, step-by-step automotive repair manual

ever use. All repair procedures are supported by you'll

detailed specifications,

exploded views, and photographs.

Here are just a few of the Items in this manual that

make your •

•

• • • •

repair jobs easier:

General Information •Routine

Maintenance

&

Tune-Up -Engine

Engine Overhaul •Driveability

&

&

Expanded index to quickly locate information

Emission Controls •Trouble Codes

Vacuum diagrams

Diagnostics -Fuel System