Chilton's SUV Repair Manual 1998-2002 - Perennial Edition [Perennial Edition] 0801993652, 9780801993657

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REPAITR

MANUAL

CHILTON SUV REPAIR MANUAL| 1998-2002 Edition

THOMSON) (fo 2 8”) ae DELMAR

LEARNING

Chilton SUV Repair Manual 1998-2002 Vice President, Technology and Trades SBU: Alar Elken

Channel Manager: Beth A. Lutz

Production Editor:

Elizabeth Hough

Custom Publishing Coordinator:

Executive Director, Professional Business Unit:

Greg Clayton

Brian McGrath

Claudette Corley

Publisher, Professional Business Unit: David Koontz

Production Director: Mary Ellen Black

Technology Project Manager: David Porush

Editorial Assistant: Kristen Shenfield

Larry Main

Production Manager:

Editors: Rich Rivele Christine L. Sheeky Tim Crain Thomas A. Mellon

ALL RIGHTS RESERVED. No part of this work covered by the copyright hereon may be reproduced in any form or by any means— graphic, electronic, or mechanical, including photocopying, recording, taping, Web distribution, or information storage and retrieval systems— without the written permission of the publisher

ISBN: 0-8019-9365-2

COPYRIGHT 2003 by Delmar Learning, a division of Thomson Learning, Inc. Thomson Learning‘ is a trademark used herein under license. Printed in the United States of America 12345 XX 05 04 03

For more information contact Delmar Learning Executive Woods 5 Maxwell Drive, PO Box 8007, Clifton Park, NY 12065-8007 Or find us on the World Wide Web at : www.chiltonsonline.com, or www«trainingbay.com

For permission to use material from the text or product, contact us by Tel.

Fax

(800) 730-2214

(800) 730-2215

www.thomsonrights.com

NOTICE TO THE READER

Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein. Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer.

The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions.

‘

The publisher makes no representation or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the readers' use of, or reliance upon, this material.

Table of Contents Unit Repair Sections

Specifications

1

Specifications, Scheduled Maintenance Interval and Scheduled Maintenance Labor Time Charts

Heater Cores

2

Heater Core Removal and Installation Procedures

Timing Belts

3

Timing Belt Removal and Installation Procedures

Brakes

4

Brake System Component Service Procedures

SUV Sections

Acura

MDX

Acura

SLX

BMW

X5

Chrysler Corp.

Ford Motor Co. and Mazda

+

Durango

Escape, Tribute

Ford Motor Co.

Explorer, Explorer Sport, Explorer Sport Trac, Mountaineer

Ford Motor Co.

Excursion, Expedition, Navigator

Geo/Chevrolet and Suzuki

Tracker, Sidekick, Sidekick Sport, X-90, Vitara, Grand Vitara

General Motors

Blazer, Bravada, Envoy, Jimmy, Trailblazer, Xtreme

General Motors

Denali, Denali XL, Escalade, Suburban, Yukon, Yukon XL

Honda Hyundai

Isuzu and Honda Jeep

Kia

Land Rover Mercedes-Benz Mitsubishi

Nissan and Infiniti

Subaru

CR-V Santa Fe Amigo, Passport, Rodeo, Rodeo Sport, Trooper, Vehicross

Cherokee, Grand Cherokee, Liberty, Wrangler Sportage Discovery, Discovery Series Il, Range Rover

ML320, ML430 Montero, Montero Sport Pathfinder, Xterra, QX4 Forester

Toyota and Lexus

ARunner, Highlander, RAV4, RX300

Toyota and Lexus

Land Cruiser, LX470, Sequoia,

a

ie

ee ee tiie).

Model Index Section No.

Model 4

Model

Grand Vitara

4Runner

A

Highlander

B

Jimmy

C

Land Cruiser Liberty LX470

Amigo Blazer

Bravada Cherokee CR-V D Denali Denali XL

Discovery Discovery Series II Durango E Envoy Escalade Escape Excursion Expedition Explorer ~ Explorer Sport Explorer Sport Trac F

Forester

G Grand Cherokee

Section No.

Section No.

12-1

Santa Fe Sequoia Sidekick Sidekick Sport SLX Sportage Suburban

16-1 26-1 hey Tal 6-1 Tech 14-1

MDX ML320 ML430 Montero Montero Sport Mountaineer

Tracker Trailblazer Tribute Trooper

Taq 1a 9-| We)

Vehicross Vitara

I 122]

Navigator

Wrangler

Passport Pathfinder

X-5 X-90 Xtreme Xterra

Qx4 Range Rover RAV4 Rodeo Rodeo Sport RX300

Yukon Yukon XL

EDITORIAL POLICY &

gz

Manufacturer and Model Coverage _ This Manual does not seek to cover every make and model that is currently available on the market. Rather, the Chilton Editorial Staff makes judicious decisions as to which makes and models warrant coverage. Those that are included herein represent Chilton’s judgement as to the Me a models that make up 90% of vehicles that will be presented to the average technician for diagnosis and repair. In general, this Manual oes not cover: e Exotics (¢.g. Rolls-Royce, Dodge Viper; Alfa Romeo, etc.) e OEM's with no U.S. presence (e.g. Fiat) ¢ OEM's that have not sold enough units to be a factor in the repair market,

Model Year Information Every effort is made to gather current data for use in this Manual. Data is acquired from manufacturers at the time when each OEM chooses to

release it. Different manufacturers choose to release their new model information at different times of the year. Indeed, the same manufacturer can be early one season with information, and then late the next season. As a result, not all models are equally current when each edition of this Manual goes to press. You will note that the Editorial Staff has taken care to indicate the currency of coverage for each model.

Safety Notice Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles, as well as the personal safety of those performing the repairs. This manual outlines procedures for servicing and repairing vehicles using safe effective methods. The procedures contain many NOTES, WARNINGS and CAUTIONS which should be followed along with standard safety procedures to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety. It is important to note that repair procedures and techniques, tools and parts for servicing vehicles, as well as the skill and experience of the individual performing the work vary widely. It is not possible to anticipate all of the conceivable ways or conditions under which vehicles may be serviced, or to provide cautions as to all of the possible hazards that may result. Standard and accepted safety precautions and equipment should be used when handling toxic or flammable fluids, and safety goggles or other protection should be used during cutting, grinding, chiseling, prying, or any other process that can cause material removal or projectiles. Some procedures require the use of tools specially designed for a specific purpose. Before substituting another tool or procedure, you must be completely satisfied that neither your personal safety, nor the performance of the vehicle will be endangered.

Although information in this manual is based on industry sources and is as complete as possible at the time of publication, the possibility exists that some vehicle manufacturers made later changes which could not be included here. Information on very late models may not be available in some circumstances. While striving for total accuracy, the Publisher cannot assume responsibility for any errors, changes, or omissions that may occur in the compilation of this data.

LOCATING AND USING INFORMATION Organization The Table of Contents, located at the front of the book, lists each Unit Repair Section and Model Specific section in this manual.

To find where a particular model specific section is located in the book, you need only look in the Table of Contents. Once you have found the proper section, you may wish to find where specific procedures are located in that section. Turn to the Index at the front of the model specific section. At the upper left-hand side is a listing of the main topics within that section and the page number on which they may be found. Following the main topics is an alphabetical listing of all of the procedures within the section and their page numbers. The Model Index, located just after the Table of Contents in the beginning of this manual, may also be used to locate the specific section for any vehicle model covered in this manual.

SS

Sos ie PG ae , , a f a z

Specifications Specifications charts for all models covered in this book are located in Chapter 1. They include: Vehicle and Engine Identification, General Engine Specifications, Engine Tune-Up Specifications, Capacities, Valve Specifications, Crankshaft & Connecting Rod Specifications, Piston & Ring Specifications, Engine Fastener Torque Specifications, Brake Specifications, Maintenance Interval Specifications, Ball Joint Specifications, Wheel & Tire Specifications, and Wheel Alignment Specifications.

Unit Repair Sections The three Unit Repair Sections are written to cover all applicable models for the specific system or component, unless specifically noted otherwise. The procedures covered in the URS are not repeated in the model specific sections, therefore, refer to the URS for the service procedures for the applicable systems or components. Refer to the Table of Contents for URS coverage.

Model Specific Sections The model specific sections are grouped by manufacturer and arranged in alphabetical order. The text and illustrations that comprise the service procedures in each model specific section are arranged in the following order of systems and components: Engine Repair (Gasoline, then Diesel if applicable), Fuel System (Gasoline, then Diesel if applicable), Drive Train, Steering and Suspension. All illustrations are located as close as possible to the applicable procedure. Procedures are for all models in the particular section unless specifically noted otherwise. ji

Part Numbers Part numbers listed in this book are not recommendations by the Publisher for any product by brand name. They are references that can be used with interchanges manuals and aftermarket supplier catalogs to locate each brand supplier's discrete part number.

Special Tools Special absolutely priate part let. Before

tools are recommended by the vehicle manufacturer to perform their specific job. Use has been kept to a minimum, but where necessary, they are referred to in the text by the part number of the tool manufacturer. These tools may be purchased, under the appronumber, from your local dealer or regional distributor, or an equivalent tool can be purchased locally from a tool supplier or parts outsubstituting any tool for the one recommended, read the previous Safety Notice.

ACKNOWLEDGMENTS This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the expressed written permission from Ford Motor Company.

Portions of the material contained herein have been reprinted with permission of General Motors Corporation, Service Technology Group.

og

SPECIFICATIONS AGURAGIIOIEM .ccicicvcscatseeee 1-2 NA chine AH rosin lence aha 1-2 aah ee a te ae alee i a 1-10 PLY cee 4 4a a ae 1-18 I hi itee Sark, VAR 1-18 CHRYSLER CORP............... 1-25 DOOGE DUFANGO skis sccierssndcunratbinss 1-25 Jeep Cherokee © Grand Cherokee Wrangler.¢ Liberty ccs 1-38 FORD MOTOR CO.............. 1-55 FOLOMESCAPCS.nce ee scsi 1-55 Ford Explorer © Mercury MOUPNQIAGEL Sis. uittsteasushusaestronss 1-65 Ford Full-Size ¢ Expedition Excursion @ Lincoln Navigator.....1-81 GENERAL MOTORS............ 1-95 Cadillac Escalade @ Chevrolet Suburban ¢ Tahoe GMC Denali ¢

Chevrolet Blazer © Trail Blazer © Xtreme ¢ GMCe Envoy Jimmy ¢ Oldsmobile Bravada....1-115 GEO CHEVROLET/SUZUKI ...1-127 Geo Chevrolet © Tracker @ Suzuki ¢ X90 © Sidekick ¢ Sidekick Sport © Vitara ¢ Grand Mitare métiar pa Ys cm os aeoaerReseen:.081-127 HOND Aisi cescoernnsepervcriwess 1-140 GHEYedie ake etna mace 1-140 PASSPORT RSIS noe

1-148

HYUNDAI ...................68 1-157 DATSLOswack asta Neath vst daosnahagasail 1-157 ISUZU eit tates ee 1-163 Amigo © Rodeo © Trooper ¢ Be ROSS shidmeeivascteonanavnmaie 1-163 KLAR cette os xee Mee ees 1-177 OPOTAG PDA cid ah eRe 1-177 LAND ROVER.................- 1-185

Discovery® Discovery Series || ¢ Range ROVClS ccirocrcunenennee 1-185 MAZDA fi eoncccesed eee 1-195 THD UTC. sti, Wes eaketeesecctonee eee 1-195 MERCEDES-BENZ............. 1-204 ML320:¢ ML430 0 cs. cnctie 1-204 MITSUBISHI................... 1-210 Montero © Montero Sport........... 1-210 NISSAN .ccvesovrrrieoernivengiis 1-220 Nissan ¢ Pathfinder « QX4 e PAGE biplanes ie EN Se 1-220 SUBARU .............2:20000005 1-228 Foresters yy oe od scaeetiiitaag ames1-228 TOYOTA/LEXUS ............... 1-236 ARunner @ RAV4 © RX300 e Highlander... ccc. cee 1-236 Land Cruiser ¢ Sequoia © LX470:pees ee eee 1-256

hhah

: Ses a ipa

a =

.

A

ACURA

ki

bh

MDX

ENGINE AND VEHICLE IDENTIFICATION CHART Liters (cc 3.5 (3471

Cu. In. . 212

Engine Code Cyl. Fuel Sys. 6 SMFI

Engine Type SOHC

Eng.Mfg. Honda

La Code® 1

3‘SOHC:"SingleOverhead Cam

Model Year “Wevear 2001

2

2002

MFI: Sequential Multi-port Fuel Injection

.

me1m position of VIN 5

93551001

GENERAL ENGINE SPECIFICATIONS eee, ane Lear

Model

_ Engine Displacement Liters (cc

3.5 casi SMFI: Sequential Multi-port Fuel Injection

Engine —

Fuel ig Typ

Net Horsepower @ rpm

SMFI_|_210@5200_}

Net Torque @ rpm ft. Ibs.

Bore x Stroke in.

Compression Ratio

Oil Pressure @ rpm

229@4300 |3.50x3.66_| 94:1 | 71@3000 . 93551002

3

3

SBEETIE AMES

1 57

ENGINE TUNE-UP SPECIFICATIONS Engine siieaigyieey

ae

Spark Plug ri

Ignition Timing

ae _

Idle Speed en)

Fuel jae

Valve Clearance (in.) n. Ex.

NOTE: The Vehicle Emission Control Information label often reflects changes made during production and must be used ifthey differ from this chart.

NOTE: The fuel pressure readings are given with the vacuum hose connected to the regulator and the engine running B: Before top dead center 93551003

9308MG32

3.5L Engine Firing order: 1-2-3-4-5-6 Distributorless ignition system (One coil per cylinder)

For complete service labor times, order the Chilton Labor Guide

.

SPECIFICATIONS

1» 4

ACURA

CAPACITIES Engine

Year

Model

Engine Displacement Liters(cc

3.5 (3471

Oil with Filter ats.

=

SSeS

Drive Transmission (pts.La “Spd

ST

Transfer Case ots.

OS

Axle Abe ie

Fuel Tank

Cooling sini

I.

EL

0

NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained. 93551004

VALVE SPECIFICATIONS Engine Displacement

Engine

‘Seat ph

Face a

IDVIN

2

g

Spring Spring Test _ Installed Pressure Height i

Stem-to-Guide Clearance (in.) Intake

Exhaust

Stem Diameter in. Intake

Exhaust

NA: Not Available

© Valve spring free length: Intake: 1.9713 in.

Exhaust: 2.1060 in. 93551005

ian | £

Year 2001

AND CONNECTING ROD SPECIFICATIONS

All measurements are given in inches - Engine Displacement Liters (cc 3.5 (3471)

Engine ID/VIN J35A3

Crankshaft Main Brg. = Main Brg. Oil Shaft Journal Dia. _ Clearance End-pla 2.8337~ 0.00080.00402.8346 0.0017 0.0140

—-Thrust on No.

Journal Diameter 2.16442.1654

Connecting Rod Oil Clearance 0,00080.0017

: Side Clearance _

99551006 Pe

PISTON AND RING SPECIFICATIONS

Year

Engine Displacement

Engine

Liters (cc

ID/VIN

All measurements are given in inches Ring Gap Piston Top Bottom Oil Clearance

Compression

Compression

Control

Top

Ring Side Clearance Bottom

Compression

Compression

5

Oly Control

Y

93551007

Please visit our web site at www.chiltonsonline.com

=

1-6 ~ SPECIFICATIONS ACURA

TORQUE SPECIFICATIONS All readings in ft. lbs.

Year

2001

Engine Displacement Liters (cc

3.5 (3471

Cylinder Head Bolts

Engine ID/VIN

BOATS.

f=

Main Bearing Bolts

Rod Bearing Bolts

@ SO]

Crankshaft Flywheel Damper Bolts Bolts

AO]

4

Manifold Exhaust Intake

6

Spark Plugs

Lug Nut

2G

NOTE: Dip main bearing bolts and crankshaft damper bolt in clean engine oil prior to tightening.

® Step 1: 29ft.bs. Step 2: 51 ft.Ibs. Step 3: 72ft.Ibs.

@ 11mm bott56f.tbs. 10mm bolt 36ft.Ibs. @Step 1:14ft.Ibs. Step2:90 degrees 93551008

BRAKE SPECIFICATIONS Acura MDX All measurements in inches unless noted

Year

2001

Model

Original Thickness

Brake Disc Minimum

Thickness

pM YE ee GE Ee

Maximum Runout_

Brake Drum Diameter Original Max. Maximum Inside Wear Machine

Diameter

_Limit

Eee Eee Ee i ee

Diameter

Minimum Lining Thickness Front Rear

Brake Caliper Bracket Mounting Bolts Bolts

(ft.lbs.)

ee ee [ie 0.413] aeai

_(ft. Ibs.)

ee

F: Front R: Rear 93551009

WHEEL ALIGNMENT Caster

Year

Preferred

Setting

Range

Setting

Toe-in

(Deg.)

(+/-Deg.)

(Deg.)

(in.)

E

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS OEM Tires Tire Pressures (psi) Year

Model

2001

Standard

PepsesAi7-

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch

Sena Axis

Camber

Preferred

tof

Optional

Front

tL ub: Nope ech | 92

Rear

ae ee

Inclination

Wheel

“a Ball Joint —

Size

Inspection_

Noe

Nee

‘

STD: Standard OPT: Optional

NS: Not specified by manufacturer

93551011 st

7

’ -

>

he

a

Timing belt service is covered in Section 3 of this manual

q - __SPECIFICATIONS ACURA

SCHEDULED MAINTENANCE INTERVALS Acura—MDX VEHICLE MILEAGE INTERVAL (x1000

TO BE SERVICED Accessory drive belts

SERVICE 75|15[225]a0|s75]6| oe67.5] ead Scr bias giao tageboo

Air cleaner element

sr

75

aa97.5

feed lit ERG

8 jin Ua ee le Le oe HF A dnc BB ihAa ed LAedeAA cd Soaere as

Brake fluid

Every 3 years

ABS

Engine coolant ©

Enaine oil

TR fall coleeboolly |v’ |

Engine oilandcoolantlevels

|

Engine oilfilter Exhaust system Fidieveb andcondtion” Front and rear brakes Fuellines & connection Halfshatt boots idle speed Parking brake system Rear differential fluid Rotate andinspect tires Spark plugs rll

“je ean Timing belt & boots

| |

a

a ee eS ae

ee

A

We edal Me ee a

Water pump

ae |: Inspect

| wily | vo) ee isveieee

SAE AT \ SASS

ESS SPAS

Inspect the SRS 10 years after production

Transmission fluid

R: Replace

joven

Inspect at each fuel stop

CER) a es a

Valve clearance

|

a: es Se ae ea eet it TL ald. [ees cohen bese fol fie le | ok fot Le fa vel Le ee ERR SI 7 0 MOS A | a AY PO Re es en Ee ee ee | Ae ee eRe 9 fs a A a A ee el ed A GS eed ck LY eadMonae el aa AD Vie had Wd ce EO le Peed Bw Ee re ee ee eae eer ea I eee oR Pee vw feeb hp ts — a ad ot as ES ESE ee ea see ee eae Cs es a EP Pee

Restart sysiem Dae

Suspension components

v

| 1S)S88
65 pao &S/5 alS 6/5 S15 & Sb Sig 6/6

93551040

aa ;

i

es) ln hie

se

mt

he

a

eee i.e

i

es

2) (

a

a

ae

|

ra.ar

“tunvsuen cone I7O1 CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS All measurements are given in inches.

Year

Engine Displacement Engine Liters(cc) ID/VIN

Crankshaft Main Brg. Main Brg.Oi Shaft Journal Dia. Clearance End-play

Thrust onNo.

fees Bea Peale: | aaee|ons|ooo {eens [-on-| ‘com eee |eae |eens|oc eT |as |tere|com| eee Tae |tare|ooo

Connecting Rod Journal Oil Side Diameter Clearance Clearance 2.1240- | 0.0005-

3.9 (3916) | xX

2.4995- | 0,0005- | 0.0020-

5.2(5211) | Y

2.4995- | 0,0005- | 0.0020-

2.1240- | 0.0005-

Z

2.8095- | 0.0005- | 0.0020-

2.1240- | 0.0005-

|X

2.4995- | 0.0005- | 0.0020-

2.1240- | 0.0005-

5.2(5211) | Y

2.4995- | 0.0005- | 0.0020-

2.1240- | 0.0005-

5.9 (5899) | Z

2.8095. | 0.0005- | 0.0020- vga 2.1240- | 0.0005-

3.9 (3916)

i

4.7 (4701)

eae

5.2(5211) | Y

5.9 (5899) | Z

2.4996- | 0.0002- | 0.00210,00050.0015 0.0005-

2.0076- | 0.0004-

2

0.0022 0.0005-

2

:

0.0022

2001-02

5.9 (5899) | Z ee

2.5005 | 0.0021 | 0.0112 2.8095® | 0.00202.8105 0.0070

2.0082 | 0.0022 2.1250 | 0.0022

@ No. 1: 0.0005-0.0015 Nos. 2-5: 0.0005-0,0020 93551041

Heater Core replacement is covered in Section 2 of this manual

eae Lae oF,

R02)

ie

me

> = 2s fr.

;

e~_f s

=.

ie

Ae,

oe

Oe

ens

ae

eee

‘ my

5)

SPECIFICATIONS

1 -32

ee

CHRYSLER CORP.

‘

PISTON AND RING SPECIFICATIONS All measurements are given in inches.

Year

Engine Displacement Liters (cc) 3.9 (3916)

Engine VIN X

Piston Clearance 0.00050.0015

5.2 (5211)

Y

0.0005-

Top Compression 0.01000.0200

Ring Gap Bottom Compression 0.01000 0.0200

Oil Control 0.00200.0080

0.0100-

0.0100-

0.0100-

0.0120-

0.0220-

Ring Side Clearance Bottom Top Compression Compression 0.00150.00150.0030 0.0030

Oil Control

0.0015-

So

5,9 (5899)

pT

0.0005S

[tons | tooo | oto | oro | como |oon 0.0005Ss 0.0005-

0.0100-

0.0100-

0.0020-

0.0015-

0.0015-

0.0100-

0.0100-

0.0100-

0.0015-

0.0015-

0.0005-

0.0120-

0.0220-

0.0150-

3.9 (3916)

X

5.2 (5211)

Y

5.9 (5899)

Z

4,7 (4701)

N | 0.00080.0020 Y

5.2 (5211)

4,7 (4701)

2001-02

Zz

0.0016-

0.00200.0041

0.00

0.0015-

so

0.0220-

0.0150-

0.0016-

0.0016-

0.0146-

0.0099-

0.0020-

0.0016-

0.0220-

0.0150-

0.0016-

0.0016-

0.0310

0.0550

0.0033

0.0033 93551042

BRAKE SPECIFICATIONS All measurements in inches unless noted Brake Drum

Brake Disc Minimum Maximum

Year

2001-02

Original Model ___ Thickness Thickness

Minimum

Original Inside

Max. Wear

Maximum Machine

_Run-out_Diameter

_—Limit

Diameter

Lining Thickness Front

Rear

| Durango | 0.900 | 0890 | 0.004 | 100 | © [ O | Durango | 0.900 | 0890 | 0004 | 110 [| O | © [Oo] |__Durango | 0.900 | 0.890 | 000 | 11.00 [ © [| O |

Brake Caliper

Bracket Bolts

Mounting Bolts

((ft.lbs.)

(ft. Ibs.)

a7

NA: Not Available @ Maximum allowable drum diameter, either

from wear or machining, is stamped on the drum.

@) Riveted brake pads: 0.0625 in. Bonded brake pads: 0.1875 in.

@ Riveted brake shoes: 0,031 in. Bonded brake shoes: 0.0625 in.

93551643

SPECIFICATIONS CHRYSLER CORP.

1 -3

WHEEL ALIGNMENT Caster

Camber

Preferred

Year

Model

Range

Setting

(+!-Deg,)

(Deg,)

Steering Axis

Preferred

Range

Setting

(4/-Deg.)

Toe-in

(Deg.)

(in.)

Inclination

[ew [0s [at SC*C*«dSC

Rear

| |

35 35 a

| |

Wheel

Ball Joint

Size

Inspection 0.060 in. © 0.060 in. © 0.060 in. © 0.060 in. ©

65d 65JJ

fon)on E

[

NA: Information not available OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch

STD: Standard OPT: Optional

@ Both upper and lower 93551045

Brake service is covered in Section 4 of this manual

:

i

93551044

Year

‘ei

..1 -3A ~ SPECIFICATIONS CHRYSLER CORP.

SCHEDULED MAINTENANCE INTERVALS 1998-99 Durango

os] = [=] @ [os] mesorl raw [=] [os] « [as] @ [ee] a a VEHICLE MILEAGE INTERVAL (x1000)

TO BE SERVICED

TYPE OF

Engine oil & filter Steering linkage (2wd)

Balljoints Sadaes ed Baa Ca Front wheel bearings SE ied SO a Se ee Brake linings DESERET FA TP MS Ree Aricleonercioment OQuorR |fo fck] i] vate te |) osha] Bote i Sais Sparkplugs ‘ae SS HW | eT as ane

Auto trans tuidiéthere cor |[oavsbsb | i). saey IL Utcede [Ea i ae Ring wensbends sor) [Fad fovends Fs bY sag ae ee ee aretencase fui) |b Re foto Pimorda EY ofa | cps | ind |S Engine coolaft ORO TAPS pew ope [aor[s EL aivee TP ria bi ae Spek phigcables |) REPO Yel Re aes ieee |e i ee Recebsoly divebet@. [FSA sper] | ey ee base [te | a ee PCV valve @ BTR cso LE Need I ace eal aa lh oes I R: Replace

S/I: Service or Inspect

L: Lubricate

Adj: Adjust

® Replace every 36 months, regardless of mileage 2) Inspect and replace if necessary.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle is operated under any of the following conditions it is considered severe service: - Extremely dusty areas.

- 50% or more of the vehicle operation is in 32°C (90°F) or higher temperatures, or constant operation in temperatures below 0°C (32°F). - Prolonged idling (vehicle operation in stop and go traffic. - Frequent short running periods (engine does not warm to normal operating temperatures). - Police, taxi, delivery usage or trailer towing usage. Oil & oil filter change: change every 3000 miles. Air filter/air pump air filter: change every 24,000 miles. Engine coolant level, hoses & clamps: check every 6,000 miles. Exhaust system: check every 6000 miles. Drive belts: check every 18,000 miles; replace every 24,000 miles. Crankcase inlet air filter (6 & 8 cyl.): clean every 24,000 miles. Oxygen sensor: replace every 82,500 miles. Automatic transmission fluid, filter & bands: change & adjust every 12,000 miles. Steering linkage: lubricate every 6000 miles, Rear axle fluid: change every 12,000 miles.

tunvstencone 1-0 SCHEDULED MAINTENANCE INTERVALS 2000-02 Durango

SERVICED

sence 78

TO BE

TYPE OF

Engine oil & filter Frontwheelbearing Brake linings Aircleaner element Spark plugs Transfer casefluid Engine coolant ©

VEHICLE MILEAGE INTERVAL (x1000)

as

|8

a ca a ac cc ca Z FE RR HP er Pe ee Dea Pe ae aa Pe EGA a[ob i 20 a phen seennmt og aH IN A wa oe | | Lia ee)Es ld iid ee | aE PE ? Pee Fare id Ee Ba Be | a connie] ov | i kosrai git fet |ia [Rf DRE rd A eh ede) Ped oe

PCV valve Cees Eat eal aes eS | Drive belitencioner@ >" | isn [ep ee Automatic transmissionfluid | OR {| {| {| =f | | | | Automatictransmissionbands| Ad. | | | | { | | R: Replace

S/l: Service or inspect

@ Replace every 36 months, regardless of mileage. ® Replace if necessary FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) if a vehicle is operated under any of the following conditions it is considered severe service: - Extremely dusty greas.

= 50% or more of the vehicle operation is In 32°C (90°F) or higher temperatures, or constant operation in temperatures below 0°C (32°F). - Prolonged idling (vehicle operation in stop and go traffic. - Frequent short running periods (engine does not warm to normal operating temperatures).

- Police, taxi, delivery usage or trailer towing usage.

Oil & oil filter change: change every 3000 miles. Air filter: change every 24,000 miles. Engine coolant level, hoses & clamps: check every 6,000 miles. Exhaust system: check every 6000 miles.

Drive belts: check every 18,000 miles; replace every 24,000 miles. Oxygen sensor. replace every 82,500 miles.

Automatic transmission fluid, filter & bands; change & adjust every 12,000 miles. Rear axle fluid: change every 12,000 miles. 93551047

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

|

fap SPeCREATIONS =” i CHRYSLER CORP.

ae

a

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pi

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SCHEDULED MAINTENANCE INTERVALS DAIMLERCHRYSLER CORPORATION

|

ae i

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ee Ks

DODGE DURANGO 1998-99

ir

The following should be used as a guide when determining the amount of work required for a particular service.

a

In estimating how long a particular Scheduled Maintenance Service should take, please observe the following: @ Labor Time is time based on field research and data supplied by the vehicle manufacturer.

ak

@ Labor time operations are given in hours and tenths of an hour.

i

@ All labor operations are to be used as a guide.

ie Pt t. ae.

Mechanic Skill Level Codes: (A) PRECISION: Highly skilled with multiple certification. (B) GENERAL: Normally skilled with certification. (C) MAINTENANCE: Semi-skilled working on certification.

ee is

|

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LABOR TIME 7500 Mile Service (C)

ih

45000 Mile Service (B)

anti ties cost

5

Alt Models Meer sic ecsctact

0

e

service

on -cccvdsccsocesssesesavenves

30000 Mile Service (B)

AN MOdGlS: fijevicestencacessaBedouetes 52500 Mile Service

pitas

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PRA OOGNS oyecoacesiesuvesstacas sateasncs

75000 Mile Service (B)

37500 Mile Service (B)

3.2

:

All Models... Syren ewes bos 3.5

All MOIS «a.ecssssssssssssseecsseeeeeee 2.2

eae Service (C)

WiMOGOIS prsszhapcadtics.cusincs ccseesers PUR TIOGONS 5.00 iano

ea racaaraes

LABOR TIME 82500 Mile Service (C)

1.7

nr (B) Te 60000 Mile Service

22500 Mile Service (C) PA MOGGIS

LABOR TIME

'

Sy

8

All Models@20

222"

#2

2

5

20000 Mile Service {F) All Models. iscscsccdssecscasnssetsacvass =1.9 1 97500 Mile Service (C)

AllM

isn oldsglare

105000 Mile Service (C)

All, Model Swiyees.ctsiat getwendeestecs

a 2

3.5 93551048

a ra

:

|

—

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‘

—

*

tnevsenconr, SCHEDULED MAINTENANCE INTERVALS DAIMLERCHRYSLER CORPORATION

:

1-O7

DODGE DURANGO 2000-02 The following should be used as a guide when determining the amount of work required for a particular service. In estimating how long a particular Scheduled Maintenance Service should take, please observe the following: ®@ Labor Time is time based on field research and data supplied by the vehicle manufacturer.

‘

@ Labor time operations are given in hours and tenths of an hour. @ All labor operations are to be used as a guide.

Mechanic Skill Level Codes: (A) PRECISION: Highly skilled with multiple certification. (B) GENERAL: Normally skilled with certification. (C) MAINTENANCE: Semi-skilled working on certification.

LABOR

TIME

7500 Mile Service (C) BAU MOGOINS 7. fotertichcns.. ar.veenes ont

5

6

All Models

8

3

Sree. anint...2.4....3

30000 Mile Service (B)

1.7

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67500 Mile Service (C)

ON adslA gop aa as Ml Models “eG ees |

Tet 1.2

TA Modbts ied snaoaee 75000 Mile Service (C) AIL MOGGIS

All Models! 9.......8.2......22e

5

90000 Mile Service (B)

All MOGEIS .......cssssscecsseeseesseeees tok

TIME

82500 Mile Service (C)

All Models ........cccccesseesseseseenee

All Modelo

LABOR

TIME

52500 Mile Service (C)

All MOdeIS ........s.sseseesesseesteesees

37500 Mile Service (B)

LABOR

2

45000 Mile Service (B)

15000 Mile Service (C)

;'

vccsssactecscncravnstawwcetenses

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Ali Models’...

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5

100000 Mile Service (B) 3 All MOGEIS «.....ssssssssssssssssssesscee 1

1.2 93551C48A

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

; CHRYSLER CORP. Jeep Cherokee ° Grand Cherokee « Wwihigier ° hiperty

3 at

7 -

ENGINE AND VEHICLE IDENTIFICATION Be.

a cero

Liters(cc)

*

4.7 (4701) 2.5 (2458)

; 2.4L (2429

Engine

__Cu.In,__—Cyl._—Fuel'Sys.__EngineType 287 150

8 4

148

6 8 8 6 4

Model Year

Eng. Mfg.

Code@

MFI MFI

SOHC OHV

Chrysler Chrysler

W X

Chrysler Chrysler Chrysler Chrysler Chrysler

y 1 2

MFI MFI

OHV OHV OHV SOHC DOHC

pe he

1998 1999

2000 2001 2002

MFI: Multi-port Fuel Injection OHV: Over Head Valve SOHC: Single Overhead Camshaft OFT position of VIN

@ 10th position of VIN 93551049

Lod | J

SPECIFICATIONS

4-39 ;


ENGINE TUNE-UP SPECIFICATIONS

. Year

Engine Displacement Liters (cc

Engine ID/VIN

4.0 (3966) 47 (4701

N

Spark Plug Gap in.

Ignition Timing deg.

Fuel Pump psi

Idle Speed rpm

Valve Clearance Intake Exhaust

| (2458) 2.5 |sae P ocpore.0es lp@es@ | rim [4758 | eae

| NDOT Re io See ORR CM ETT ae | se ene eve Pt (6214) Se eeae Yb peo) Cane @ 1 ie arse [eon OR a ae ee a | _5.9(5899)__| ie Ser Tae (a eS SO 2 ON a Cec ae BS a es | (2458) 2.5 SOR a | _4.0(3966)|a ay OS SONG Ts SS RS eS ee | (4701) 4.7 —_—|PT ea a ae Ee Ta | (2458) 2.5 |Fa ae ES Be os ae De a STON Ee | 4.0 (3966) | aa 4.7 (4701 | (4701) 47 |Ra RO RB 2.5 (2458 (a a Es a SON a Re RO a a | (2458) 2.5 Re Oa eee ee eS) | -4.0(3966) ae 4.7 (4701 CS CS PONG 2 a el 2.4 (2429) OE OE RS ee ee ee CR SR ESOS Te a CS ee | (2458) 2.5 3.7 (3701) Sd ee OG a ee a

2000 2001

2002

CCR

SOE

0,040 Ov Peosi@:A

PR

i47-5t

ee

ee

|Gos@es [ HyvOm@iW]

HYD

HYD

NOTE: The Vehicle Emission Control Information label often reflects specification changes made during production. The label figures must be used ifthey differ from those in this chart. HYD: Hydraulic ® Ignition timing and idle speed are controlled by the PCM. No adjustement is necessary. 93551051

FIRING ORDER: 15362 CLOCKWISE ROTATION

of the Vehicle

4

79243652

79243643

2.5L Engine Firing order: 1-3-4-2 Distributor rotation: Clockwise

1998 4.0L Engine Firing order: 1-5-3-6-2-4 Distributor rotation: Clockwise

SPECIFICATIONS — 1-4 CHRYSLER CORP.

==

(6) (5) (4) Gp &) C1) |

or

CLOCKWISE ROTATION

1-8-4-3-6-5.7-2

COIL PACKS

eS

GODS 79243614

1999-02 4.0L Engine Firing order: 1-3-4-2 Distributorless ignition system

5.2L and 5.9L Engines Firing order: 1-8-—4-3-6-5-7-2 Distributor rotation: Clockwise

93023G01

4.7L Engine Firing order: 1-8-4-3-6-5—7-2 Distributorless ignition system (one coil on each cylinder)

79244642

Accessory serpentine belt routing—Jeep Grand Cherokee 4.0L engine

For Wheel Alignment specifications, see Section 1 of this manual

CIFICATIONS: -AQ SPE CHRYSLER CORP.

1. 2. 3. 4. 5.

2. Alternator 3. Water Pump 4, Power Steering 5. Crankshaft 6. Drive Belt Tensioner 7. A/C Pulley 8. Drive Belt

Alternator pulley Belt idler pulley Power steering pulley A/C compressor pulley Water pump

We. We 6. 7. 8. 9.

Crankshaft pulley Belt idler pulley Drive belt tensioner Drive belt 79244619

79244G86

Accessory serpentine belt routing—Ford 4.6L engines with A/C

Accessory serpentine belt routing—Ford Explorer/Mercury Mountaineer 5.0L engine

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SPECIFICATIONS

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FORD MOTOR CO.

1-69

CAPACITIES Engine Oil with

Engine a

: Model

Displacement

Engine

Filter

Liters (cc)

IDVIN

(qts.)

Transmission

—_(pts.) 5-Spd

Auto. ©

Transfer

Drive Axle

Case

Front. Rear

(pts.) — (pts.)

;

(pts.)

Fuel

Cooling

Tank

—‘System

(gal.)

(qts.)

9 8 | ExplorerSpot| 40(3950) | X | 50 | 66 | 20 | 30 |30 | 55 | 175] [Ewiowr |—a0unoo) |e | 70| 86 | mo | a0|axe] ee [ate [Explorer | socao) [Pp [|50 | — | 278 | @ | oa | 55 | 210 | [Mounizineer | 40(4000) | E [70 | — | 00 | 80|aa | s5 | 210 | | Mountaineer | 5.0(4049) | P| 50 | — | 27s | @ | 32 | 55 | 210 | 1999 |ExplorerSpor| 40(0050) [x | 50 | 66 | 00 | 30 | 325 | 56 | 175 | [Explorer 4.0(4000) [| 70 | 56 | 20 | 30 |aa | 55 | 210 | [Explorer | 50(4o) | P| 50 | — | 278 | @ | aa | 55 | 210 | |Mountaineer | 40(4000) | — [70 | — | 20 | 30 | 325 | 55 | 210 | [Mountaineer { 5.0(4949) | P| 50 | — | 278 | © | 395 | 55 | 210 | 2000 | ExplorerSpor|_40(0960) | x | 50 | 56 | 200 | 80 | 325 | 55 | 75 | i SIS es as aE 209° | 40 [ss | 210 | Eplorer | _60(409) |P|50| SSECe Seer Mountaineer | 40(4000) | € | 70 | — | 0 | 30 | 325 | 55 | 210 | ; Mountaineer | sosaa) | P| 50 | — | 278 | © | 325 | 55 | 210 | 2007 |ExporerSpon |_40(@950)_| x | 50 | 56 | 20 | 26 | 36 | 55 | 175 | 5.0 (4949)

| Mountaineer |—40(4000) | © | 70 |—_

_ |Mointaineer | s0(eoa) | P| 50 |—_

2002

Explorer

Mountaineer

4.0 (4000)

4.6 (4601)

— @

30 @

5.0

3.0

:

Pa

i

5.0

a

se

[tao 160

160 160 160 160 160 160 160 120 140 140 157 120 We

140

P55 | 210 | 157

@

3.0

2.75

oO)

©

2.75

22.5

®

©

:

NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained.

® Dr fill @ Part time: 3.0 Full time: 2.6

@ 4-door Explorer: 21.0 Explorer sport Trac: 20.5 ®

4-door Explorer: 22.5

Explorer Sport: 17.5 Explorer Sport Trac: 20.5

© w/o auxiliary heater: 16.3 w/auxiliary heater: 18.3 ©wlo auxiliary heater: 18.6 w/auxiliary heater: 20.1

93551079

For complete service labor times, order the Chilton Labor Guide

;

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85

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SPECIFICATIONS

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FORD MOTOR CO.

VALVE SPECIFICATIONS

Year

1998

Engine Displacement Liters (cc) 4.0 (3950)

Engine _

Seat Angle (deg.)

4.0 (4000) lee 5.0 (4949) 1999

2001

Spring Test Pressure (Ibs. @ in.) 138@ 1.22

202-225@ Puen, oe 1.413-1.445 a ae .20

Spring _Installed Height (in.) 1.580-

Stem-to-Guide Stem Clearance | Diameter (in.) (in.) Intake Exhaust Intake Exhaust 0.0008- } 0.0018- | 0.3159- | 0.3149-

1569-

0.0010- | 0.0010- | 0.27400.27300.0020 0.2748 0.2740 0.00100.0015- | 0.3415- | 0.3410-

4.0 (3950)

om 22

1.580-

0.0008-

4.0 (4000)

Bie

1 569-

0.0010- | 0.0010- | 0.2740-

0.2730-

0.0010-

0.0015:

0.3415:

0.3410-

5.0 (4949) 2000

Face Angle (deg.)

ape

2006120

0.0018-

0.3159- | 0.3149-

4.0 (3950)

138@ 1.22

1.580-

0.0008-

0.0018- | 0.3159.

0.3149-

4.0 (4000)

202-225@

1.569-

0.0010-

0.0010-

0.2740-

0.2730-

0.0027

0 a

2 ==

0.3418 0.3149-

4.0 (3950)

X

4.0 (4000)

E

45

5.0 (4949)

P

44

4.0 (4000)

E

45

202-225@

0.3156 0.2730-

1.413-1.445

0.2740

200@ 1.20

0.3410-

202-225@ 1.413-1.445 162-180@ 1.134

0.27300.2740

0.3418 2002

4.6 (4601)

0.2736-

0.2740

@ Intake: 1.75-1.81 in. Exhaust: 1.59 in. 93551080

- SPECIFICATIONS

FORD MOTOR CO.

5

|

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

All measurements are given in inches.

ss

Displacement Liters (cc)

Crankshaft

mg

Engine Year

Main Brg. Journal Dia.

Engine ID/VIN

2.2433-

Main Brg. Oil Clearance

Connecting Rod Shaft End-play

Thrust on No.

er |#9 sl: Ea 4.0 (4000)

ete

0

(39

4.0 (3950)

Side

.

Clearance

0.0003- | 0.0060-

2.7252-

0.0003- | 0,0036-

2.1228-

0.0008- | 0.0010-

2.1252-

0.0003- | 0.0002-

X

0.0020 0.00020.0025

E

0.0036-

X

4.0 (4000)

2.24822.2490

5.0 (4949)

2002

2.1252-

Oil Clearance

0.0010-

“ 5.0 (4949) 2001

Journal Diameter

0.00360.0106

5.0 (4949)

2000

4

4.0 (4000)

E

4.6 (4601)

W

0.0106 0.00100.0020 0.00020.0025 0.00360.0106 0.00100.0020 0.00360.0106 0.0059 0.0177 93551081

Please visit our web site at www.chiltonsonline.com

4-72

SPECIFICATIONS

:

FORD MOTOR CO.

|

Oe

ny

ee

PISTON AND RING SPECIFICATIONS

Year

Engine Displacement Liters (cc)

1998

4.0 (3950)

All measurements are given in inches. Ring Gap Piston Top Bottom Oil Clearance Compression Compression Control

— Engine ID/VIN

X

/

4.0 (4000) 5.0 (4949) 4.0 (3950) 4.0 (4000)

5.0 (4949) 4.0 (3950)

baie

ier ber xd x

4.0 (4000)

E

5.0 (4949)

P

4.0 (3950)

X

4.0 (4000)

E

5.0 (4949)

P

4.0 (4000)

E

0.000800019 0.00080,0019 0.0020 0.0008-

Ring Side Clearance Top Bottom Oil Compression Compression Control

0.0150.023 0.0150.023

0.0150.023 0.0150.023

0.0150.055 0.0150.055

0.00200.0033 0.00100.0030

0.0100.020

0.0180.028

0.0100.040

. 0.00130.0033

|

0.00200.0033 0.00100.0030

|

0.0013-

0.0020-

0.0008-

0.0010-

0.0012-

0.020

0.018-

0.010-

|. 0.0013-

0.0013-

0.015-

0.015-

0.0020-

0.0020-

0.015-

0.015-

0.0010-

0.0180.028

0.0100.040

0.00130.0033

SNUG

4.6 (4601) 93551082

|

aes Ie TORQUE SPECIFICATIONS All readings . Engine Displacement Liters (cc)

Engine _

Cylinder =Main Head Bearing Bolts _—_Bolts

Rod Bearing Bolts

in ft. lbs. Crankshaft Damper Flywheel Bolts —_ Bolts

Manifold Intake* Exhaust

Spark Plugs

Lug Nut

)00) )

* NOTE: Applies to Lower Manifold only. @ Step 1: 25 tt. ibs.

® Step 1: 15 ft. lbs.(20 Nm)

Step 2: 53 ft. Ibs.

Step 2: +90 degrees

Step 3: Plus 90 degrees

® Step 1: 44 ft. Ibs. Step 2: +90 degrees

@ Step 1: 154. Ibs. Step 2: +90 degrees

© Step 1: 28 ft. Ibs.

@ Step 1: 46-49 ft. Ibs. Step 2: +90 degrees

Step 2: Plus 90 degrees Step 3: Plus 90 degrees

@ Step 1: 22 tt. Ibs.

® Step 1: 20-28 ft. Ibs.

Step 2: +85 degrees

Step 2: Loosen two turns

© Step 1: 71 inch Ibs.

Step 3: 20-25 ft. Ibs.

Step 2: 107 inch Ibs. Step 3: 143 inch Ibs.

® Step 1: 89 inch Ibs. (10 Nm) Step 2: 24 ft. Ibs. (32 Nm)

© 12mm bolts:

@ Step 1: 24 ft. Ibs.

Step 1: 26 ft. Ibs. (35 Nm)

Step 2: plus 90 degrees

Step 2: +90 degrees

® Step 1: 37 ft. Ibs.

Step 2: +90 degrees

Step 2: plus 90 degrees

8mm bolts: 24 ft. Ibs. (32 Nm)

® Step 1: 30 ft. bs. Step 2: +90 degrees

® Step 1: 30-37 ft. Ibs. Step 2: +80-90 degrees

Step 3: back off 1 full tum

Step 1: 19-25 ft. Ibs

Step 4: 30 ft. Ibs.

Step 2: +90 degrees © Step 1: 25-35 ft. Ibs.

@

Step 3: Plus 90 degrees Step 1: 33 ft. Ibs. Step 2: Turn 90 degrees

@ Step 1: 27 inch Ibs.

Step 2: 89 inch Ibs. Step 3: 10 ft. Ibs. Step 4: 12 ft. Ibs.

:

,

Step 5: +90 degrees Step 6: +90 additional degrees

Bolts 1-20: 106 inch Ibs. Bolts 1-10: 20 ft. Ibs. Bolts 11-20: 30 ft. Ibs.

Cross-mounted bolts: Step 1, 30 ft. Ibs.; Step 2, plus 90 degrees

@ Step 1: 17 ft. Ibs. Step 2: 32 ft. Ibs. Step 3: +90-120 degrees

@ Step 1: 66 ft. Ibs. Step 2: back off 1 full tum Step 3: 37 ft. Ibs. Step 4: +90 degrees 93551083

Timing belt service is covered in Section 3 of this manual

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SPECIFICATIONS FORD MOTOR CO.

BRAKE SPECIFICATIONS All measurements in inches unless noted Brake Drum Diameter Brake Disc Original Max. Maximum Year

Original Thickness

Model

Minimum Thickness

Maximum Runout

Inside Diameter

Wear Limit

Machine Diameter

Minimum Lining Thickness

; Brake Caliper Bracket Mounting Bolts (ft.Ibs.)

1998 Peas Sree eee 00005 |oh=v | | fe, [onto era ie| Jo.ggo"S. J0.440: ||ong! |Te Pe Th = Lose || ao |PeeerSrot Pet tao} nei |aoe ff ee

Bolts (ft. Ibs.)

Siat20 120 21-26

1000 |1009 |1006 | oos9 | eo | 20

jNenereer FY tom | oaso_{ogo {=f ff on 21-26 7 2 a ee a ae Be 1999 pees 0,980.--| $-0,06005 [joie |tyes | ine al) 0.100 tree ies | @.4AD-~|-) 0.0024} foi |b mses |e 030] Pa ae29

oso |oone | — | — | — | oso | veg | ove oso | ooze |1000 | 1009 | 1006 | o0sa | a0 | 20

2000

2

rai cmaleaeee =.

a

ee

,

Be Cen

ee ae a Be esis ett Ee ee ler. Paced OB res EE eee ete ales a a i oo ee eiee

Bacon A CE72:97 | 21.26 = asec Eas OE

=

|

—

|

— | o100 | 7297 | 21-26

eee Meas

ss

Pe

72-97

21-26

80

20

72-97 | 21-26

80

2002

1.020

|

:

Beside BR

0.480

:

;

1.020

;

,

:

:

: :

a

20: a

21-26

pi

ve 24 91-26

80

20

72-97 | 21-26 .

; d

80

20

72-97

21-26

80

20

NOTE: Due to changes made during production, refer to manufacturer's specifications if they differ from those in this chart 93551084

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1-75

SPECIFICATIONS

FORD MOTOR CO.

WHEEL ALIGNMENT Caster |

Year

Model

Camber

Range

Preferred Setting

Range

Preferred Setting

(+/-Deg.)

(Deg.)

+/-Deg.

_ (Deg.)

Steering Axis Toe-in

Inclination

(in.)

Deg.

1998 [Explorer | [| 100 | +40. ‘| 060 | 050 | OfewO2s | — |_ExplorerSpot | | 4.00 | |__Mountaineer | | 100 |

®t +420 =| oso |

1999 | Explorer | [| 100 | +420 +«+| Eiplorerspot | [100 | © | |__Mountaineer | | 100 | +420 | 2000 | Exporer | | 100 | +420 +| [BiplorerSpod | | 100 | o | | Mountaineer | | 1.00 [| +420 | 201 | Exper | | 100 | 420 | Explorerspot | [100 | o@ | [Explorer SportTrac] | 00 |-Mountainesr

||

| FO

1.00. |]

420-0

050 | o7 | oso | 050 | 07 | oso] 080 | om |

To

050

050 | eos | 050 | avo |

050 050 050 050 050 050 050 05

To

|

| otowors | |o1awoas | | o1aw025 | | Oavoas | | otewoas | | tao25 | | O1evoas | | atovoas |

— —

— — — — — — — —

|

| Woes | —

.

050) | 012-025 |

2002 | Explorer [F] 10 | © | 08 | 050 | o1owos | — aie eee enema eae aes aon = PExplorerspor | | 10 | © | 070 | 050 | o1amozs | — [ExplorerSport Trac] [| 100 | ==95O | 70 a ——eEe———E Wy

et

et

ef

| 050 | 0.1241-0.25 0.50 0.104/-0.25 08

= =

=

® Left side: +3.95 Right side: +4.45 @ Lett side: +5.1

Right side: +5.3 93551085

Heater Core replacement is covered in Section 2 of this manual

Mi

2

ee

4c7 - —SPECIFICATIONS

|

FORD MOTOR CO.

jis,

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS OEM Tires Year

Model

Standard

1998

Explorer

P225/70R15

Tire Pressures (psi) Optional

na

Front

Rear

Explorer Mountaineer

P235/75R15SL

aj aeeae tT

P255/70R16 P235/70R15 P255/70R16

2001

Explorer Sport

2002

P225/70R15

Size

Inspection

0.030 in. ©

TJ

dsaul 0.030 in.©

7-JJ

P255/70R16

2000

Ball Joint

Poe

tS ee a ee P255/70R16 P235/75R15SL P255/70R16

Wheel

35

7-JJ

26

7-JJ

35 26

7-JJ

0.030 in. ©

0.030 in.©

0.030 in. ©

30

0.030 in.©

Todd 0.030 in.©

7-JJ

P235/70R15

P255/70R16

P235/70R15 P225/70R15

P255/70R16 P235/70R15

;

P255/70R16 P245/70R16 P255/70R16 P255/70HR16

7-JJ

0.030 in.O 0.030 in. 0.030 in. ©

Explorer

P225/70R16

Explorer Sport Explorer Sport Trac

P235/70R15 P235/70R15

P255/70R16 P255/70R16

0.030 in. ©

Mountaineer

P225/70R16

P245/70R16

0.030 in. ©

P255/70R16 P255/70HR16

0.030 in.©

0.030 in.®

oloole loool ae +

z sey 5

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch

STD: Standard OPT: Optional @® Both upper and lower @ See placard on vehicle

9355186

;

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17

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hop > em a Pek De te nna a

ee ee ee

c

SPECIFICATIONS

FORD MOTOR CO.

SCHEDULED MAINTENANCE INTERVALS 1998-00 Ford Explorer, Explorer Sport; Mercury Mountaineer

:

cia [ise «TwTe[aT] =[ool «[o[a[ole VEHICLE MILEAGE INTERVAL (x1000)

TOBE

.

TYPE OF

Engine oil & filter

Driveshatt fittings Y Exhaust system ain kanaeananauauauaeananaee % Coogee ies Fol fis. i. Le i Cee ie ee it to eee Coolant strength se onal end aed i cs Sa Oe eed Seed GE eee Brake caliper rails fan el cl (tenia Deel a eta Focal mae ed aE Aircleaner filter Hs ead inci Seema Gta ed “es 7 ss aa ar dae Gi pa ° ZO SN ie a a aes ie ec al ee ee Med ee ee ee Fuel filter ® i el a We I a ee ed Ba Kee ee PCV valve Se Scales ae a Ga eed ere Ri Accessory drive belts Sil Hie End ae Pee i ed ie mi Spark plugs

ee makes

Transfer case fluid Manual trans. fluid Coolant @

ia aakoeal Ming [rears per Seren Pa pod Mee ea (ia: asd niceties lane eer oesanmrcie eee onal a mae ea Jb Walk Hatieee Paani Oeil Beas ered ned ee ee abe

Differential fluid @

(esate

Clutch reservoir level Brake hoses Paneirene ecient R: Replace

every 100,000 miles

every 100,000 miles

ma ed a a or a Dal i eis ae thor [Cea nt Le eal Le fo I |

S: Service

|: Inspect

ea ee | ee en ae eee cr ee | ee

ele

L: Lubricate

@ Recommended, but not required in Calif, @ Change at 50,000 miles, then every 30,000 miles or 36 months

® Except synthetic FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) Ifa vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier. - Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than 10 miles in any temperature.

- Extensive idling or low-speed driving for long distance as in heavy commercial use, such as delivery, taxi or police cars. - Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads.

- Driving in extremely hot (over 90°) conditions. Engine oil & filter: replace every 3000 miles. Air cleaner filter: service or inspect every 6000 miles.

Exhaust system: check every 6000 miles. Rotate tires every 9000 miles. (City delivery vehicles & other unique applications that require constant turning may need frequent tire rotation.) Automatic transmission fluid & filter: change every 21,000 miles. 93551087

Brake service is covered in Section 4 of this manual

4 ‘ -

[=[e[o

VEHICLE MILEAGE INTERVAL (x1 000)

TO BE

TYPE OF

Engine oil& filter Tires Auto trans. fluid

eee Rotate

Brake pads/shoes Coolant hoses

ee ee < van Uae eae

eS

BS SS

S/I Ss

Steering linkage ~ Cabin air filter Ball joints (2wd) Exhaust system Engine air filter

fa BY

Fuel filter© Auto trans fluid (4-speed) Green coolant @ Wheel bearings (2wd Manual trans. fluid Spark plugs PCV valve Orange coolant Auto trans fluid (5-speed)

DEREEREEEERER BRESERSSEGRESEE every 100,000 miles every every every every every every

Differential fluid

Accessory drive belts Transfer case fluid R: Replace

S: Service

I: Inspect

@

Recommended,

@

Change every 30,000 miles or 36 months thereafter

100,000 150,000 150,000 150,000 150,000 150,000

miles miles miles miles miles miles

L: Lubricate

but not required in Calif.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier. - Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than 10 miles in any temperature. - Extensive idling or low-speed driving for long distance as in heavy commercial use, such as delivery, taxi or police cars. - Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads. - Driving in extremely hot (over 90°) conditions. Engine oil & filter: replace every 3000 miles. Air cleaner filter: service or inspect every 6000 miles. Exhaust system: check every 6000 miles. Automatic transmission fluid & filter: change every 30,000 miles.

,

Transfer case fluid: change every 60,000 miles Fule filter: change every 15,000 miles Spark plugs: change every 60,000 miles 2wd front wheel bearings: lubricate every 30,000 miles 93551088

FORD MOTORCO.

&

:

SCHEDULED MAINTENANCE INTERVALS FORD MOTOR COMPANY FORD EXPLORER, EXPLORER SPORT (1998-2000) MERCURY MOUNTAINEER (1998-2000) The following should be used as a guide when determining the amount of work required for a particular service. In estimating how long a particular Scheduled Maintenance Service should take, please observe the following: @ Labor Time is time based on field research and data supplied by the vehicle manufacturer. @ Labor time operations are given in hours and tenths of an hour. ®@ All labor operations are to be used as a guide.

Mechanic Skill Level Codes:

(A) PRECISION: Highly skilled with multiple certification. (B) GENERAL: Normally skilled with certification.

(C) MAINTENANCE: Semi-skilled working on certification.

30000 Mile Service (B)

5000 Mile Service (C) All models

.........

10000 Mile Service (C) All models

.........

15000 Mile Service (C) All models

.........

20000 Mile Service (C) All models

.........

25000 Mile Service (C) All models

.........

Allmodels

............

35000 Mile Service (C) All MOGEIS Hs, 0:ercbarc: av'cesys Oe

40000 Mile Service (C) All models

............

45000 Mile Service (C) All models

............

50000 Mile Service (C) All models

2

22. ses 700

55000 Mile Service (C) All models”:

tpn gingeun-ee

60000 Mile Service (B) All:models”..

3" for... sc

2.0

65000 Mile Service (C) All models

...........

9 93551090

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

‘

1-80 _sgmearass

ibis

SCHEDULED MAINTENANCE INTERVALS FORD MOTOR COMPANY FORD EXPLORER, EXPLORER SPORT, EXPLORER SPORT-TRAC (2001-02) MERCURY MOUNTAINEER (2001-02) The following should be used as a guide when determining the amount of work required for a particular service. In estimating how long a particular Scheduled Maintenance Service should take, please‘ observe the following: @ Labor Time is time based on field research and data supplied by the vehicle manufacturer. @ Labor time operations are given in hours and tenths of an hour. @ All labor operations are to be used as a guide.

Mechanic Skill Level Codes: (A) PRECISION: Highly skilled with multiple certification. (B) GENERAL: Normally skilled with certification. (C) MAINTENANCE: Semi-skilled working on certification.

LABOR TIME 5000 Mile Service (C)

30000 Mile Service (B)

Alimodels ..........+++..

RawnGdech eee

9

< 4Su axes Sat

20000 Mile Service (C) PIR EOGIONS |5 ea

3 wn ek Shy

25000 Mile Service (C) MU MOdeS

i.

ac

or Peps

Allimodels)

1.0 9

9

ass oxestnavieiats eee

1.4 9

40000 Mile Service (C)

9

45000 Mile Service (C) oC SS

5.

-

-

All models ©... hot dooie oe

9

All models:

9

55000 ble serie (a

. 7% mcd Stine

60000 Mile Service (B)

All. MOdGIS: «earradewens ir SME t All’ models

LABOR TIME 50000 Mile Service (C)

All Models —coiiey: «»«:«5 OOP

9 35000 Mile Service (C)

15000 Mile Service (C)

All models

LABOR TIME

All Models 1...aries ers 2.2

65000 Mile Service (C) ee

1.2

All modele

=

Tee

9 93551C90A

Pr

SPECIFICATIONS

‘

fal

s

FORD MOTOR CO.

n!

!

i

, s

gg a

ENGINE AND VEHICLE IDENTIFICATION Code® 5 6 F L W

Engine

Liters (cc) 6.8 (6802) 4.6 (4588) 7.3 (7292) 5.4 (5409) 4.6 (4588)

Cu. In. 415 280 445 330 280

Cyl. 10 8 8 8 8

Model Year

Fuel Sys. MFI MFI DI MFI MFI

Type SOHC SOHC OHV SOHC SOHC

Eng. Mfg. Ford Ford Navistar Ford Ford

Code @ W X y 1 2

Year 1998 1999 2000 2001 2002

MFI: Multi-port Fuel Injection DI: Direct Injection Turbo-Diesel

OHV: Overhead Valve ,

SOHC: Single Overhead Camshaft @eth digit of the Vehicle Identification Number (VIN)

@ 10th digit of the Vehicle Identification Number (VIN) 93551091

GENERAL ENGINE SPECIFICATIONS Engine

Year

Model

Displacement Liters (cc)

Expedition | 4.6 (4588) Expedition | 4.6 (4588) 5.4 (5409) Excursion | 6.8 (6802) Excursion | 7.3 (7292)

6/W

Fuel System Type MFI

Net Horsepower @ rpm

Net Torque @rpm (ft. Ibs.)

Bore x

Stroke (in.)

Compression Ratio

210@4400 | 290@3250 | 3.55x3.54 | 9.0:

MFI | 210@4400 | 290@3250 | 3.55x3.54 | 9.0:1

Oil Pressure @ rpm 20-45@ 1500 40-70@ 1500 20-45 @ 1500

40-70@ 40-70@ 40-70@ 20-45@

6.8 (6802) Excursion | 7.3 (7292) Expedition | —4.6 (4588) Expedition | 5.4 (5409)

3.55X4.17 265@4250 | 410@2750 | 4.09X4.17 210@3000 4.11x4.18 290@3250 | 3.55x3.54 210@4400 330 @3000 3,.55X4.17 235 @4250 260@4250 | 330@3000 | 3.55xX4.17 330@3000 | 3.55X4.17 235 @4250 265@4250 | 410@2750 | 4.09X4.17 210@3000 | 425@2000 | 4.11x4.18 210@4400 | 290@3250 | 3.55x3.54 235@4250 | 330@3000 | 3.55X4.17

Navigator

260@4250

40-70@ 1500

Expedition

4.6 (4588)

Expedition | 5.4 (5409) 5.4 (5409) 2001

Engine VIN

5.4 (5409)

5.4 (5409)

DI MFI MFI MFI

| 330@3000

3.55X4.17

1500 1500 3000 1500

40-70@ 1500

40-70@ 1500 40-70@ 1500 40-70@ 1500 40-70@3000 20-45@ 1500 40-70@ 1500

MFI: Multi-port Fuel Injection DI: Direct Injection Turbo-Diesel 93551094

For Accessory Drive Belt illustrations, see Section 7 of this manual

a I £

FORD MOTOR CO. Ford Full-Size * Expedition * Excursion ¢ Lincoln Navigator

|

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ae

ee we ee

Te

VP

SPECIFICATIONS

1-8

FORD MOTOR CO.

GASOLINE ENGINE TUNE-UP SPECIFICATIONS

Year

Displacement Liters (cc)

1998

4.6 (4588)

‘Ignition Timing

Spark Plug

Engine

— Engine ait

4.6 (4588)

Gap (in.)

(deg.) © MT

Idle Speed

Fuel

AT

Pump (psi) ©

Valve

(rpm) MT

0.052-0.056'|)"

iets 0B |v 6045. SNS

0.052-0.066{

— | 1B | 24

AT

Clearance In. Ase

op’ @ —oe] HYD

HYD

[| — | @ | HYD

HYD

[0052-0056 [7 — | 1B | 3045 | — | @ | HYD |

5.4 (5409)

sa —|5 —fonsonss| =n [6 [=| gm |__46(4se8) | w [ooseoose[ — | 1p | v4 | — | @ | HO | 46 (4588) | 6 | 0,0520,056] 00520056 —— | top | 045 | — | @ | HYD | 5.4 (5409) |.10B | 245 |. — | @ | HYD saree) |S [ooszacss [ios [aes | @ | vo | zo00 | 4614580) | Ww | ooseoosef — | tos | 94 | — | @ | HYD | 4.6 (4588) 0.052-0.056 oe 10B 30-45 =O}

foo

|

2001

5.4 (5409)

L

4.6 (4588)

0.052-0.056

10B

0.052-0.056|

— | 108

0.052-0.055

4.6 (4588)

6

5.4 (5409)

L 0.052-0.056 5 | 0.052-0.055]

108

0.052-0.056 - =~

28-45

HYD

mene

HYD

HYD HYD

HYD

HYD

io HYD HYD HYD

HYD | _HYD HYD

10B

@

HYD

HYD

10B — | 108

@

HYD HYD

HYD HYD

+=

NOTE: The Vehicle Emission Control Information label often reflects specification changes changes made during production. The label figures must be used if they differ ‘ni those in this chart. B: Before top dead center

HYD: Hydraulic NA: Not Available

Owith engine running @idie speed and timing are electronically controlled and cannot be adjusted

93551092

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by

SPECIFICATIONS 4.89 FORD MOTOR CO. IU

DIESEL ENGINE TUNE-UP SPECIFICATIONS

Year

oF 2001

Engine ID/VIN

Engine Displacement cu. in. (cc)

Valve Clearance Intake Exhaust (in.) (in.)

Intake Valve Opens (deg.)

Injection Pump Setting (deg.)

tape Tw | WO] — | © wo [ wo] —- | ©

Injection Nozzle Pressure (psi) New Used

Cranking Compression Idle Speed Pressure (rpm) (psi)

| ster |1s | OT | ws | wl © | ©

NOTE: The Vehicle Emission Control Information label often reflects specification changes made during production. The label figures must be used if they differ from those in this chart HYD: Hydraulic

B: Before top dead center NA: Not Available

@ PCM controlled @ See underhood emission label @ Compression pressure in the lowest cylinder must be at least 75% of the highest cylinder

Minimum pressure: 195 psi Maximum pressure: 440 psi 93551093

79243G29

79243G58

4.6L Engines Firing order: 1-3-7—2-6-5-4-8 Distributorless ignition system

5.4L Engines Firing order: 1-3-7-2-6-5—4-8 Distributorless ignition system (one coil on each cylinder)

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

1-84 Poiomovonces

la

Front of the Vehicle 2. Alternator

3. Water Pump 4. Power Steering 5, Crankshaft 6. Drive Belt Tensioner 7. Drive Belt '

79243G57

79244G87

6.8L Engine

Firing order: 1-6-5-10-2-7-3-8—4-9

Accessory serpentine belt routing—Ford 4.6L, 5.4L, and 6.8L

Distributorless ignition system (one coil on each cylinder)

engines without A/C

2. Alternator 3. Water Pump

4. Power Steering 5. Crankshaft 6. Drive Belt Tensioner

7. A/C Pulley

79244G84

8. Drive Belt 79244G86

Accessory serpentine belt routing—Ford 4.6L, 5.4L, and 6.8L

engines with A/C

Accessory serpentine belt routing—Ford 7.3L turbo diesel engine

vate

NS SPECIFICATIO

__FORD MOTOR CO.

a a7"

i

CAPACITIES .

Engine

Year

Model

Engine Displacement Liters (cc)

Engine ID/VIN

5.4 (5409)

L

Drive

Oil with Transmission Filter — (pts.) (qts.) 5-Spd Auto.

Transfer Axle Case Front. Rear pts.) — (pts.) (pts.)

Fuel ‘Tank (gal.)

Cooling — System (qts.)

1998 [_Expediion [46 (45ee) | ow | 60] — | o | 40] 37 | 58 [2450] 179 | Expedition | 5.4(640) | ot | 70 | ~ | o@ | 40 | 37 | 55 | sal 208 1999 asusse) | ow [60 | — | o | 40] 37 | 55 | aso] 179 Expedition 5.4 (5409) 7.0 eee 24.5@| 20.8

7000

z001

546.8 (5409) (6802)

Excursion Expedition Expedition Navigator

7.3 (7292) 4.6 (4588) 5.4 (5409) 5.4 (5409)

5

7.0

ail

40 [i 37 |) 55

“sede@]) 20s

7770 [| o | | 80 | 60 | 440 mo || 230 198 | — | @ | 42 | 600] 600]

aw pt} 28 6.0 @|60@| 440 | 230 “BW 6.0 @ | 40 | 37 | 55 | 245@| 179 eS Pe para 245@| 208 L 70 | — | @ [| 40 | 37 | 55 | 245@] 208

Excursion

5450 | 5t | pet 70 | =— |Po @ | 42] 60 | 60 | «0 | 23.0 198 6.8 (6802) 6.0 @| 60 ©

Excursion

7.3 (7292)

4.6 (4588) 5.4 (5409)

6/W 8

6.0 Pen Eh hel ea ao

Navigator

5.4 (5409)

et

Ae etSeoe

Expedition Expedition

F

14.0

®

6.0 @}

3.7

60 @]

440

23.0

17.9 20.8

20.8

NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained.

@ With 4R70W: 28 pts.

i

With E40D: 32.0 pts. @ Also available with a 30 gallon tank with 8 ft. box

@ Heavy duty: 7.5 pts.

99551095

For Wheel Alignment specifications, see Section 1 of this manual

Ee

Migr

ia rs

.

|

SPECIFICATIONS |

1-8

as

4

EES

a

a

i

;

FORD MOTOR CO.

:

Sh

VALVE SPECIFICATIONS

Year

Engine Displacement Liters (cc)

4999

2000

2001

Engine IDVVIN W

Seat Angle _—(deg.)

Face Angle (deg.)

Spring Spring Test _ Installed Height Pressure (in.) (Ibs. @ in.)

Stem-to-Guide Clearance (in.) Exhaust Intake 0.0008 0.00180.0027 0.0037

Stem Diameter (in.) Exhaust Intake

0.2750- | 0.27400.2746 0.2736

4.6 (4588)

6

45

45.5

[email protected]

1.570 | 0.0008- | 0.0018- | 0.2750- | 0.2740-

5.4 (5409)

L

45

45.5

[email protected]

1.570 | 0.0008- | 0,0018-

0.275- | 0.274-

6.8 (6802)

5

44.50- | 45.25-

[email protected]

1.570 | 0.0008 | 0.0018-

0.274-

4.6 (4588) | 6/W

45

45.5

132@ 1.100

1.570 | 0.0008- | 0.0018 | 0.2750- | 0.2740-

5.4 (5409)

L

45

45.5

[email protected]

1,570

6.8 (6802)

5

44.50 45.25

[email protected]

1.570

4.6 (4588)

6/W

45

[email protected]

1.570

5.4 (5409)

L

[email protected]

1.570

6.8 (6802)

5

[email protected]

1.570

7.3 (7292)

F

4.6 (4588)

6/W

[email protected]

5.4 (5409)

L

[email protected]

6.8 (6802)

5

[email protected]

7.3 (7292)

F

200@ 1.38

45

44.5045,25

0.00180.0037 0.00180.0037

0.2750.2746 0.2750.2746

0.2740.2736 0.2740.2735

0.0008- | 0.0018- | 0.2750- | 0.27400008

0.2740.2736 0,2740.2735

®

0.3119-

|

0.0018-

0008-

0.3126 0.2750- | 0.27400.2740.2736 0.2740.2735 0.31190.3126

@ Intake: 30 degrees Exhaust: 37.5 degrees

@ Intake: 1.767 in. Exhaust: 1.833 in. 93551096 ‘

FORD MOTOR

co.

a 7

i. | fo

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS Engine Displacement Liters (cc)

4.6 (4588)

PSE 1999

Engine

ID/VIN

(iain eedeoc

2001

Journal

Diameter

Oil — Clearance

Side Clearance ©

0.0051-

2.0870-

0.0011- | 0.0006-

2.6500-

0.0011-

0.0051-

2.0870-

0.0011- | 0.0006-

2.6568-

0,0009-

0.0015-

2.0859-

0,0010- | 0,0006-

Poh — FUaden - 0,0009-

0.0015-

2.0859-

0.0010- | 0.0006-

ee

L

Tew [sows |ooo|| | |sone | ones] comm 2.6500-

0.0011-

0.0051-

2.0870-

0.0011- | 0.0006-

2.6568-

0.0009-

0,0015-

2.0859-

0.0010- | 0,0006-

2,0859-

0,0006-

2.65682000

Connecting Rod

0.0011-

4.6 (4588)

5,4 (5409)

All measurements are given in inches. Crankshaft Main Brg. Main Brg. Oil Shaft Thrust Journal Dia. Clearance _ End-play on No.

|° 0.0009- | 0.0015- eh

4.6 (4588)

6/W

2.6500-

0.0011-

0.0051-

2.0870-

0.0011- | 0.0006-

5,4 (5409)

L

2.6568-

0.0009-

0.0015-

2.0859-

0.0010- | 0.0006-

5

2.0859-

0.0010- | 0.0006-

4

2.49802.4990

0.0015- | 0.01200.0240 0.00060.0177 0.00060.0177 0.00060.0177 0.01200.0240

4.6 (4588) 5.4 (5409)

L

Kids 5

6.8 (6802)

5

5

7.3 (7292)

F

4

93551097

For Maintenance Interval recommendations, see Section 1 of this manual

say , Py ¢

1-8

CO

_ SPECI FORD FICAT MOTOR IONS CO.

ae

en

PISTON AND RING SPECIFICATIONS

Year 1998

Engine Displacement Liters (cc)

Engine ID/VIN

4.6 (4588) 4.6 (4588)

W

5.4 (5409)

L

All measurements are given in inches. Ring Gap Piston Top Bottom Oil Clearance Compression Compression Control 0.00050.0100.0100.006-

0.010-

Ring Side Clearance Top Bottom Oil Compression Compression Control 0.00160.0012-

0.006-

0.0016-

0.0012-

0.006-

|}° 0,.0012-

0.0012-

0.026 0.006-

0.0037 0.0016-

0.0037 0.0012-

0.0012-

0.0012-

- 0.00120.0037

0.00120.0037

6.8 (6802) 4.6 (4588)

6/W

5.4 (5409)

L

6.8 (6802) 4.6 (4588)

6/W

0.00050.0010 0.00000.0010 0.00000.0010

0.010-

0.010-

SNUG

SNUG

6.8 (6802)

SNUG

7.3 (7292)

SNUG

4.6 (4588)

5.4 (5409)

SNUG

6.8 (6802)

SNUG

7.3 (7292) 93551098

SPECIFICATIONS FORD MOTOR CO. TORQUE SPECIFICATIONS All readings Engine Displacement Liters (cc)

Engine ID/VIN

Cylinder Head Bolts

Main Bearing Bolts

in ft. lbs.

Rod = Crankshaft Bearing Damper Bolts Bolts

Flywheel Bolts

Manifold Intake*

Exhaust

Spark Plugs

Lug Nut

ate} ®

83-113

egies ®

18 * NOTE: Applies to Lower Manifold only. @ Step 1: 88 ft. Ibs. Step 2: Loosen bolt

0) Step 1: 29 ft. Ibs. Step 2: 36 ft. Ibs. Step 3: Loosen, and torque one at a time

Step 3; 39 ft. Ibs.

Short bolts to 32 ft. Ibs.

Step 4: Plus 90 degrees

Long bolts to 36 ft. Ibs. Step 4: Tur each bolt 135 degrees

@ Jack screws: Step 1: 45 inch Ibs. Step 2: 98 inch Ibs.

Cross-mounted cap bolts: Step 1: 24 ft. Ibs.

@® Step 1: 30-33 ft. Ibs. Step 2: 90-120 degrees

Step 1: 18 inch Ibs. Step 2: 71-106 inch Ibs.

@ Step 1: 18 inch Ibs.

@ Step 1: 65 ft. lbs.

Step 2: 96 inch Ibs.

Step 2: 85 ft. Ibs.

© Step 1: 27-32 inch Ibs.

Step 3: 105 ft. Ibs.

Step 2: Plus 90 degrees Step 3: Plus 90 degrees

© Step 1: 27-32 ft. Ibs,

Step 2: Plus 90 degrees

Step 2: Plus 90 degrees 93551099

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

4.07 ~~ SPECIFICATIONS { 1-90 FORD MOTOR CO.

UE BRAKE SPECIFICATIONS All measurements in inches unless noted Brake Drum Diameter Original Max. Maxinum

Brake Disc Year

Model

ag I

Original

Minimum

Thickness

Thickness

Eee

Maximum _ Inside

Runout

Diameter

Ie

Brake Caliper Minimum _— Bracket Mounting

Wear

Machine

Lining

Bolts

Bolts

Limit

Diameter

Thickness

((ft.Ibs.)

(ft. Ibs.)

ee

a a aR Be ee ———eE—e—e—E——e

rR] 0700 | oes | ooo | — | — | —. | oo | 120| heme ali Bibee wae ee ee ee Ry 0700 | oasr | oo | — | — | — | oa | 120 | “Excursion [| 1200 [1.180 |oo02s | 1200 | 209 | 1206 | 0030 | 166 py (ical ns es eee 125-168 | Ry 0700 | 0657 [ooo | — | — | — | 0% | 12 See Re se Se ks. PA 0700 | 0657. |"0.0280 |

Excursion

/R|

1.220

1.180

0.700 1.023

0.657 0.964

LR} 0.700__| 0.657

=

ea

ed

Pe

0.080"

to

0.030 0.030

| 125-168

bh

NOTE: Due to changes made during no}roduction, refer to manufacturer's specifications ifthey differ from those in this chart F: Front

R: Rear 93551CA1

—

6x

SPECIFICATIONS

4

FORD MOTOR CO.

eT i VG

A ay

La

WHEEL ALIGNMENT Caster

E Year

Model

: Preferred

Camber

Steering Axis

Preferred

Range

Setting

Range

Setting

Toe-in

Inclination

+/-Deg.

Deg.

+/-Deg.

Deg.

in.

Deg.

fawoar| io | veo [ov | 000 ‘|oomiaas | — fwobase| co [sto | avo | oa «| omwoas | — [anoar| 100 | smo [ow | 04 | oamwors | —

1999

co Me aE REA CE awd 10 [sto [075-020 | ooo | | Expeciion [2WDbase| 1100 | 46.10 [070 «| a0 «| onew-o25 | fawoair [100 [vio [070 [030 |00evoas | fawObase| 100 [810 [ovo [020 | aaow-o25 | jawDair [700 [500 | oma [0a | o0voas | Tig WE a dL Ta

iia

ae Sa

a

— — = — =

edee

2000 | Excursion [2 |200 |P40+4. «|~—1.00~=«Y=Ctsiwe~—=«Coos | +8 basse |4WD ||200 |aso | 100 «| oas| omwozs | — Expedition

Navigator

| 400 | tO |pores 70 |080 | 0.0641-0.25 2WD ait | 00 | . Fe as ae 064-025 |20Dair| WD base ey 070 |020 | 0.304/-0.25 OO |e Bab Oe | LY COD |awDair AWDair| 100 | +500 | 040] 0.40 | (0.204/-0.25 W eis sad 075 asd|033 | 0.064/0.25 eicot 0.20+/-0.25 | [02041035 a Oe FST Ae a) Ea | _2W ee oe400 [100m | ooavrazs | WD base

(=)

zo01 | Excursion Expodiion |base [WD 2WD base] ivaa1.00OOaad[610 |wWDai 20Dair | 100 | vio wObase| 100 | 510 war | 100 | 500 Navigator | 2WD

NOE LOVER GERISAO)

| 070 | | 070 | [07 | [040 | Poa

030 | o0ewo2s | 90 | ocewo2s | 020 | oaowoas | | 020028 | 020-025 | [04002001025

7 a

3

ic i _

— : — — _— — z —

93551CA2

For complete service labor times, order the Chilton Labor Guide

iS

f

OF CUIFIVATIUNGD

1-9Z

va

2

ANE) Oe Ce

FORD MOTOR CO.

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS OEM Tires Year

Model

| | | | |

| |

Standard

pass7oni6 Passronié Passvonié Paasrsrig Passvonté Padsvsrié

Tire Pressures (psi) Optional

Front

Rear

Wheel

Ball Joint

Size

Inspection

| _paesvori7_ | 35 | S858 | NK | | P2esv7oRi7_— | 0 ||SH] 75 | | Paesont7 | =35 | 85 | S| | Pasev7eri7_ | 0 | S| 75 | =| =Paeeoni7,_ | = 35 | 85 | | Passveri7_ | 30S | S88 | S75 |

0.030in. @ __ Navigator | (0.080. __ Expedition | (0.030in.© __Navigator | (0.080. __ Expedition | W080i.© _ Navigator | (0.030in.@ 0.030 in, © __ Excursion —_—s|_—Passvori6 | _—paesvont7 | 35 | 3 | 7wW | 0.030in@ _ Navigator | Paasrsrig —[Passvsri7_ | 30 S| S85 S| S75 | (0.030in.@

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch STD: Standard

OPT: Optional

@ Both upper and lower 93551043

een

:

ae

Oe

oe TS oP oe

5

as

ply

ees

Ne

a

roumeronce, 1-93

SCHEDULED MAINTENANCE INTERVALS EXCURSION

TO BE

VEHICLE MILEAGE INTERVAL (x1000)

TYPE OF

SERVICED

ca

60 6570]75

Automatic transmission fluid @

(i(naanaldada ic ha dca ie iia afGoa i.euhalillaBid Bl

Engine coolant

=

Accessory drive belt Air cleaner filter O@

ls Be

Engine cooling system hoses,

Y

Engine oil& filter

MEv TeTSH He CHG Bs Ra KakAKA Y

= v Exhaust system Eos needeelna seca als elt Frontwheelbearings | sat | | | | [| [| Frontirearaxelubricant | oR | | | | | | Fuelfiter © PAS TR PETES TT PES | a

Rotate tires Sparkplugs

redaaal Ean

ia RR E1608 0

SN

v KAKA Pale

Ve

lo

SN

clamps & coolant ©

PCV valve

bc

ia

aa

v

"i

ae Pal ealen mal [imal a (imahae Litt Beem es Raia aloe fs et ES Prembesetbtn ae | Ko PT Fs) PTE TTcs Terly aed | aa [a A Ba Ee Every 120,000 miles

EE AA EAA AEROS « GS SAN EG i oa oad

driveshaft U joints ssa

R: Replace

‘Ue

ett

STR

GEINGEEEIacE

dcr

| ;

S/I: Service or Inspect

© Perform this at the mileage shown or every 30 months, whichever occurs first.

@7.31 DIT Diesel engine: the air filter should be replaced when the restriction gauge is in the red zone.

@ Except the E40D transmission. O)Drain, flush and refill the cooling system initially at 50,000 miles or 48 months, whichever occurs first, then every 30,000 miles or 30 months thereafter. ©7.3L DIT Diesel engine: add 4 pints of FW-15 each time the coolant is replaced. ©7.3L DIT Diese! engine: add 8-10 oz. of FW-15 to the engine coolant every 15,000 miles. @ The axle lubricant must be replaced every 100,000 miles of if the axle has been submerged under water. Otherwise the lube should not be checked or changed unless a repair is required. 7.3L DIT Diesel engine: the fuel filter should be replaced when the restriction lamp is illuminated.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier.

- Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than 10 miles in any temperature. - Extensive idling or low-speed driving for long distances as in heavy commercial use, such as delivery, taxi or police cars. - Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads. Engine oil & filter: replace every 3000 miles. Tires: rotate and inspect every 6000 miles.

Steering linkage, suspension, U-joints: lubricate every 6000 miles. Exhaust system: inspect for leaks or damage every 12,000 miles. Fuel filter: replace every 15,000 miles. Automatic transmission fluid: change ever 21,000 miles. Front wheel bearings (2WD): inspect and repack every 30,000 miles.

Rear axle lubricant (E-Super Duty only): replace every 30,000 miles. Spark plugs (except 4.2L engine): replace every 60,000 miles. PCV valve: replace every 60,000 miles.

Accessory drive belt: inspect every 60,000 miles. Spark plugs: replace every 99,000 miles. 98551CA4

Please visit our web site at www.chiltonsonline.com

1

OP LUT IUAITIUING FORD MOTOR CO.

34

SCHEDULED MAINTENANCE INTERVALS

(see rece Accessory drive belt =eeeeer SERVICED

Expedition and Navigator VEHICLE MILEAGE INTERVAL (x1000

fll fmf saa

SERVICE

PEE

Aircleanerfiter ©

aN

v

Ss

x

SN

v

SN

SS S AEE

Brake caliper, slide rail a Tastee Ta

mrae4

LR papers Eaniciatennacneial XS

XM

aN SLI

lines

‘SS

i

SN Stee

coolant @

saeahe Engine oll& fiter

hoses, clamps & coolant

Exhaust system

Front wheel bearings

Front/rear axle driveshaft slip yoke

Hite tTaaee iaTtiti caaaaie a caaa a a a a aaa Rak RAS ara

Bn

qe

eee

2

RSIRS ERN ESE BEea Bk-| Sa | |. eds BesaePetes BB eeHa i BeFe aa Bs BePay en nas neorReaeie aesEZBtSeaESBSE Be

ee

| Sal | | | | | |v

ERE

Dak

ee

SS SN TAESENT

Frontrearaefuid® | 8 [ [ TT TT TTT Te tty ttt tt it ft Fue! fiter ED BE AR ee Parking brakeeyoties | Sh [at Ts leh MP ee PCV valve PEs SP A BS ON RB 0 Rotate tires Ne ee

ev pa | lee ee eee a aed tea er se dc sl os ee eee rararara -

Spark plugs

Steering linkage, suspension, driveshaftU |] SI&L

[VY IV IVY IY IY IM IY iv iv iv

viv iv iv iv iv iv iv

vv

vw

joints R: Replace

S/l: Service or Inspect

@ Perform this at the mileage shown or every 30 months, whichever occurs first. @ Drain, flush and refill the cooling system initially at 50,000 miles or 48 months, whichever occurs first, then every 30,000 miles or 30 months thereafter.

@ The axle tubricant must be replaced every 100,000 miles or if the axle has been submerged under water. Otherwise the lube should not be checked or changed unless a repair is required.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier.

- Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than 10 miles in any temperature. - Extensive idling or low-speed driving for long distance as in heavy commercial use, such as delivery, taxi or police cars.

- Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads. - Driving in extremely hot (over 90°) conditions. Engine oil & filter: replace every 3000 miles. Tires: rotate and inspect every 6000 miles.

Clutch reservoir fluid level: inspect every 6000 miles. Automatic transmission shift linkage: lubricate every 6000 miles.

Steering linkage: suspension, U-oints: lubricate every 6000 miles. Exhaust system: inspect for leaks of damage every 6000 miles. Fuel filter: replace every 15,000 miles. Automatic transmission fluid: ehange every 21,000 miles.

Crankcase emission air filter: replace every 60,000 miles. PCV valve: replace every 60,000 miles. Accessory drive belt: inspect every 60,000 miles. Spark plugs: replace every 99,000 miles. 93551CA5

-

ceuemacorons 1-99. GENERAL MOTORS

,

Cadillac Escalade « Chevrolet Suburban e Tahoe GMC Denali ¢ Yukon

ENGINE AND VEHICLE IDENTIFICATION Engine

Code® _ Liters (cc) J R S IS U V G

7.4 5.7 6.5 5.3 6.0 4.8 8.1

(7440) (5735) (6473) (5327) (5966) (4802) (8128)

CPC: Chevrolet/Pontiac/Canada

Cu. In.

Cyl.

454 350 395 325 364 293 496

8 8 8 8 8 8 8

Model Year

Fuel Sys. _Engine Type MFI MFI DSL MFI MFI MFI MFI

OHV OHV OHV OHV OHV OHV OHV

Eng. Mfg. CPC CPC CPC CPC CPC CPC CPC

Code @

Year

Ww X Y 1

1998 1999 2000 2001

.

DSL: Diesel MFI: Multi-port Fuel Injection

© 8th position of VIN @ 10th position of VIN © 7

93551CBB

Timing belt service is covered in Section 3 of this manual

1 -U6 ;

OF CUIPIUATIUNGS

Soe).

|

GENERAL MOTORS

GENERAL ENGINE SPECIFICATIONS All measurements are » Engine Engine Displacement _ Series Year

Model

Liters (cc

(IDIVIN)

1998

Denali

5.7 (5735)

R

Denali Escalade Escalade

6.5 (6374)

S R S

Suburban Suburban 1999

Denali Escalade

2000

2001

Suburban Suburban Suburban Tahoe/Yukon Denali Denali Escalade Escalade Suburban Suburban Suburban Tahoe/Yukon Denali Denali XL Suburban Suburban Suburban Tahoe Tahoe Yukon Yukon Yukon XL Yukon XL Yukon XL

®

rpm

- 180@3400

Bore x Stroke n

Net Torque@rpm ft. Ibs.

Compression

Oil Pressure @ rpm

18@2000 30-43@2000 18@2000 30-43@2000

360@1700

R J

Suburban Tahoe/Yukon Denali

Fuel System

given in inches.

Net Horsepower

18@2000 40@2000

S

30-43@2000

R 5.7 (9735) “1 Rew 1 ||

255@4600

335@2800

18@2000 18@2000

6.5 (6374) 5.7 (5735)

S R

180@3400 255@4600

360@1700 335@2800

30-43@2000 18@2000

6.5 (6374)

S

360@1700

30-43@2000

5.7 (5735) 7.4 (7440) 6.5 (6374) ' 5.7 (5735) 6.5 (6374) 5.7 (5735) 6.5 (6374) 5.7 (5735) 7.4 (7440) 6.5 (6374)

R J S R R S R S R J S R U U i U G V T V T a U G

255@4600 290@4200 180@3400

335@2800 410@3200 360@1700

255@4600 180@3400 255@4600

335@2800 360@1700 335@2800 360@1700 335@2800 410@3200 360@1700

18@2000 40@2000 30-43@2000 18@2000 18@2000 30-43@2000 18@2000 _ 30-43@2000 - 18@2000 40@2000 30-43@2000 18@2000 18@2000 18@2000 18@2000 18@2000 10@2000 18@2000 18@2000 18@2000 18@2000 18@2000 18@2000 10@2000

MFI

255@4600 290@4200 180@3400 300@4400 300@4400 285@4000 300@4400 340@4200 270@5200 285@4000 270@5200 285@4000 285@4000 300@4400

360@4000 360@4000 360@4000 360@4000 455@3200 285@4000 360@4000 285@4000 360@4000 360@4000 360@4000 455@3200

| | | | | | | | |

4.00x3.62 4.25x4,37 3.78x3.27 3.78x3.62 3.78x3.27 3.78x3.62 3.78x3.62 4.00x3.62 4.25x4.37

DSL: Diesel MFI: Multi-port Fuel Injection 93551CB9

5

ipiillalialal tie "SPE FICATIONS 197 $ r $ r CIGENERAL MOTORS Oe e

Engine Displacement Liters (cc

Year

GASOLINE ENGINE TUNE-UP SPECIFICATIONS

|

Ignition Timing (deg.)

Idle Speed (rp a

Spark Plugs Ga i 5

Engine IDIVIN

1998 | 5.7(5735) | OR | 0.060 1999

Fuel P ay

M

Valve Ch f 7

;

[57067057 | [7a raay |

NOTE: The Vehicle Emission Control Information label often reflects specification changes made during production. The label figures must be used if they differ from those in this chart. HYD: Hydraulic

@ Ignition timing is preset and cannot be adjusted Q@with key ON and engine OFF

°

@ Over 8500 GVW @® Idle speed is maintained by the Powertrain Control Module (PCM) 93551CBO

DIESEL ENGINE TUNE-UP SPECIFICATIONS njection

Year

Engine Displacement cu. in. (cc)

6.5 (6473) 656473) 6.5 (6473)

Engine ID/VIN

| Sf

Valve Clearance Intake Exhaust (in. in.

Intake _—Injection Valve Pump Opens __ Settin

Nozzle Pressure (psi)

Idie Speed (rpm

1800_| 1700 | © | HYD |) HYD | 2 Oemfon © [1800] 1700 JOO | © | © | 1800 | 1700

Cranking Compression Pressure si)

NOTE: The Vehicle Emission Control Information label often reflects specification changes made during production. The label figures must be used if they differ from those in this chart.

HYD: Hydraulic NA: Not Available _

@Reter to Vehicle Emission Control Information label

Heater Core replacement is covered in Section 2 of this manual

ae

1 -§ §

SENERAL MOTORS

Front of the Vehicle

YOE),.. CO@] - v 79243G61

4.3L Engines Firing order: 1-6-5—4-3-2 Distributor rotation: Clockwise

4.8L, 5.3L and 6.0L Engines Firing order: 1-8—7-2-6-5-4-3 Distributorless ignition system (one coil on each cylinder)

79243G62

5.0L, 5.7L and 7.4L Engines Firing order: 1-8-4-3-6-5-7-2 Distributor rotation: Clockwise

IDLER PULLEY GENERATOR TENSIONER PULLEY

POWER STEERING A/C COMPRESSOR

CRANKSHAFT PULLEY 93024611

Accessory serpentine belt routing—GM 4.8L, 5.3L, 6.0L engines

SPECIFICATIONS

7

1-99

GENERAL MOTORS St

Sl

GENERATOR PULLEY IDLER PULLEY

~

on o

IDLER PULLEY

TENSIONER PULLEY

WATER PUMP PULLEY

C/SHAFT PULLEY

WITHOUT A/C 79244631

Accessory serpentine belt routing—GM 5.7L engines without A/C

A/C COMPRE SSOR PULLEY

C/SHAFT PULLEY WITH A/C 79244632

Accessory serpentine belt routing—GM 5.7L engines with A/C

Brake service is covered in Section 4 of this manual

1-1 0

SPECIFICATIONS GENERAL MOTORS A/G COMPRESSOR PULLEY 7.4 L ENGINE WITHOUT K19

IDLER PULLEY

P/S PUMP

PULLEY

GENERATOR PULLEY

IOLEE PULLEY

IOLER PULLEY

P/S PUMP PULLEY

GENERATOR PULLEY WATER PUMP PULLEY

TENSIONER PULLEY

WATER PUMP PULLEY

C/SHAFT PULLEY

WITH A/C

TENSIONER PULLEY C/SHAFT PULLEY WITHOUT A/C

A/C COMPRESSOR PULLEY

7.4L ENGINE WITH K19 IOLER PULLEY GENERATOR PULLEY

TENSIONER PULLEY

P/S PUMP PULLEY

GENERATOR PULLEY WATER PUMP PULLEY

TENSIONER PULLEY

P/S PUMP PULLEY

WATER PUMP PULLEY A.1.A. PUMP PULLEY

WITHOUT A/C Accessory serpentine belt routing—GM 7.4L engine

C/SHAFT PULLEY 79244633

-

ers

is

ue

|

:

em

bois >

spgeoatos 1 101

93551GMM

Accessory serpentine belt routing—GM 8.1L engine

GENERATOR TENSIONER

A/C COMPRESSOR IDLER PULLEY (IF NOT EQUIPPED WITH A/C) WATER PUMP PULLEY

A/C COMPRESSOR

POWER STEERING TENSIONER

{OLER PULLEY

GENERATOR

C/SHAFT

E

GENERATOR

P/S PUMP

WITHOUT SECOND GENERATOR

VACUUM PUMP WATER PUMP PULLEY

C/SHAFT

P/S PUMP

WITH SECOND GENERATOR 79244634

Accessory serpentine belt routing—GM 6.5L Diesel engines

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

fa 1-102 SPECIFICATIONS GENERAL MOTORS

CAPACITIES

Denali Denali Escalade Escalade Suburban Tahoe Tahoe Yukon Yukon Denali Denali Escalade Escalade Suburban Suburban Tahoe Tahoe Yukon Yukon Denali Denali Escalade Escalade Suburban Suburban

Tahoe Tahoe Yukon Yukon

Engine Displacement Liters (cc 5.7 (5735) 6.5 (6473) 5.7 (5735) 6.5 (6473) 5.7 (5735) 5.7 (5735) 6.5 (6473) 5.7 (5735) : 5.7 (5735) 6.5 (6473) 5.7 (5735) 6.5 (6473) 7.4 (7440) 5.7 (5735) 5.7 (5735) 6.5 (6473) 5.7 (5735) 5.7 6.5 5.7 6.5 7.4 5.7 5.7 6.5 5.7

Engine

Engine Oilwith Filter .

Transmission — Transfer (pts.) Case Auto. (pts.

Drive Axle Front

Rear pts.

Fuel Tank gal.

Cooling System ;

|

1 1\®|

(5735) (6473) (5735) (6473) (7440) (5735) (5735) (6473) (5735)

|©|@|@/O/©|@|@|@|@ os —)

A) —| 7} 2a] 2} BW] 2) 2d] DW «| ||) || |!

O}1/O} @O]1 |O) O}1 JO} [OP /O}1 el1 TL OHO} JOH 1| ©) ©} Of] JO} /O;L /O}1 |O} O}LOFl |@) 1© ©|O|@|O/O©|©|O|O©/O|O/O|O |S/O@/O|@|O|@O|@|@|O|OlsF ©/©/@/@|@ 93551002

Tie 2

SPECIFICATIONS GENERAL MOTORS

CAPACITIES

Year 2001

Model Denali Denali XL

Engine Displacement Liters (cc

Engine

6.0 (5967) 6.0 (5967)

U U

Suburban

| 5.3 (5327)

Suburban Suburban Tahoe Tahoe Yukon Yukon Yukon XL

6.0 (5967) 8.1 (8128) 4.8 (4802) 5.3 (5327) 4.8 (4802) 5.3 (5327) 5.3 (5327)

6.0 (5967) Yukon XL

Engine Oilwith Filter qts.

ail

Transmission (pts.) 5-Spd Auto

@®

Transfer Case pts. 2 2)

T

Drive Axle Front pts.

Rear pts.

Fuel Tank (g

Cooling }

@ ©)

2)

@

U G V T V 1. T

@® @ @ ©) ©) @ @

2) 2) 2) @ 2) @ @

2) ©) ©) ©) @ ©) ©)

U

®

@

©)

G

@

@

2)

NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained. @ AL6OE trans.: 10.0 pts.

;

4L80E trans.: 14.5 pts.

8.25 in ring gear: 3.5 pts.

9,25 ring gear: 3.7 pts.

@NV241 and NV243: 4.5 pts.

® 8.6 in. ring gear: 4.8 pts.

4401 and 4470: 6.6 pts.

9,5 & 10.5 in. ring gear: 5.5 pts.

@K2 models: 3.5 pts.‘

11.5 in. ring gear: 7.7 pts.

K3 models: 4.5 pts.

@ 1500 XL: 32.5 gallon tank

@8.5 in. ring gear: 4.2 pts.

2500 XL: 38.5 gallon tank

9.5 in. ring gear: 6.6 pts.

® With optional oil cooler: 15.4 qts.

F

9.75 in, ring gear: 6.0 pts.

© With optional A/C: 14.9 ats.

:

10.5 in. ring gear: 6.5 pts.

With front A/C: 14.4 qts.

i

© Std, available with 25 and 34 gallon tanks Chassis cab available with 22, 30 and 34 gallon tanks

© Optional 31 and 40 gallon tanks

With front and rear A/C: 15.8 qts. ® With optional oil cooler; 15.4 ats.

© With front AIC: 14.4 ats.

@ AL60E trans.: 10.0 pts.

AL80E trans.: 15.4 pts.

93551063

For Accessory Drive Belt illustrations, see Section 7 of this manual

: j -104 SPEcIFicaTions GENERAL MOTORS VALVE SPECIFICATIONS

Year

Engine Displacement Liters (cc

Seat Angle deg. 6

Engine ID/VIN

Face Angle (deg.

Spring Test Pressure (Ibs. @ in.)

Spring _Installed Height in.

[email protected] | 1.69-

Sees

Ce eteieee 0.0027

[email protected] | 1,69Lit [email protected] 1.80

Peaeali

238-262@ 1.34 45

ethene | ar 7.4 (7440)

2001

Stem-to-Guide Clearance in. Intake Exhaust

[email protected] | 1.691,71 230@ 1.40 [email protected] | 1.83

8 (4802)

V

5.3 (5327)

uf

46

220@ 1.32

1,80

6.0 (5966)

U

46

[email protected]

1.80

220@ 1.32

ee

216-236@ 1.34

0.00100.0027 0.00100.0027 0.00100.0029 @} 0.00100.0027 0.00100.0027 0.00100.0029 @{ 0.00100.0026

Stem Diameter in. Intake Exhaust NA

NA

NA

0.0027

0,00100.0027 0.00100,0027 0.00120.0031 @® 0.00100.0027 0,00100.0027 0.00120.0031 @ 0.00100.0026 0.00100.0026

NA Fe>

NA

NA NA

0.31320.3140 0.31320.3140 0.31320.3140

| | | | } |

0.31320.3140 0.31320.3140 0.31320.3140

0.3715- | 0.37130.3722 | 0.3720

NA: Not Available

@ Sewice limit: Intake: 0.0037 MAX Exhaust: 0.0049 MAX 93551004

e ee

—

a

2 ee en

TT

ee

a

ae,

ee

SPECIFICATIONS 4-405

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

Year 1998

Engine Displacement Liters (cc 5.7 (5735)

Engine ID/VIN

All measurements are given in inches. Crankshaft Main Brg. = Main Brg. Oil Shaft Thrust Journal Dia. Clearance End-play _onNo.

6.5 (6473) 1999

5.7 (5735)

2000

2001

Connecting Rod Oil Side Clearance Clearance

0.0013-

0.0060-

2.0998

0.0035

0.0140

eae

0.0018-

0.0067-

2.09782.0998

6.5 (6473)

7.4 (7440)

—_Journal Diameter

J

costo|Veeen | 2.1996 2,0978- | Fasttp- Aoaeeke|

5.7 (5735) 6.5 (6473)

S

7.4 (7440)

J

4.8 (4802)

V

5.3 (5327)

T

6.0 (5966)

U

8.1 (8128)

G

psn

2.1996

2.55802.5593

0.0007 0.0021 0.0007-

0.00150.0078

0.00180.0039

0.00670.0248

: Pel

0.00180.0039 0.00110.0029

0.00670.0248 0.00130.0230

0.0011- | 0.00130.0029 0.0230 0.0013- | 0.00600.0035 0.0140

2.1000

0.0030

0.0200

2.0990-

0.0006-

0.0043-

2.1000 2.09902.1000

0.0030 0.00060.0030

0.0200 0.00430.0200

0.0008-

0.0151-

0.0025

0.0270

®No.1, 2, 3, 4: 0.0018 in.-0.0033 in. No. 5: 0.0022 in.-0.0037 in. © 2.399 in.-2.400 in. (Green) 2.400 in.-2.401 in. (Yellow)

Nos. 2, 3, 4: 0.0009 in.-0.0024 in.

© No. 1: 0.0017 in.-0.0030 in.

No. 5: 0.0010 in.-0.0027 in.

No. 2, 3, 4: 0.0011 in.-0.0024 in.

@No. 1, 2, 3, 4: 2.9517 in.-2.9520 in. (Blue)

No. 5: 0.0025 in.-0.0038 in.

2.9520 in.-2.9524 in. (Orange/Red) 2.9524 in.-2.9527 in. (White)

DNo. 1, 2, 3, 4: 0.0008-0.0020 in. No. 5: 0.0014-0.0026 in.

No. 5: 2.9515 in.-2.9518 in. (Blue) 2.9518 in.-2.9522 in. (Orange/Red)

2.9522 in.-2.9525 in. (White) 93551005

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

;

2 4 *

NA: Not Available

® No. 1: 2.4484 in.-2.4493 in. Nos. 2, 3, 4: 2.4481 in.-2.4490 in. No. 5: 2.4479 in.-2.4488 in. @ No. 1: 0.0007 in.-0.0021 in.

7f

0.0039 0.0248 0.0013- | 0.00600.0035 0.0140

2.0990- | 0.0006- | 0.0043-

2.1996

re ’

|

J 1-1 0

SPECIFICATIONS

GENERAL MOTORS

PISTON AND RING SPECIFICATIONS Engine Displacement

Engine

Year

Liters (cc

ID/VIN

1998

1999

All measurements are given in inches. Ring Gap Piston Top Bottom Oil

Top

Clearance

Compression

Compression

Control

5.7 (5735)

0.0007-

0.010-

0.018-

0.010-

0.020

0.0031

0.0007-

0.020 0.010-

0.039

5.7 (5735)

0.026

0.030

0.0032

Ring Side Clearance Bottom

Compression

Oil

Compression

Control

0.0012-

0.0020-

0.0031 0.00120.0032

0.0035 0.00200.0070

6.5 (6473)

7.4 (7440) 2000

J

5.7 (5735) 6.5 (6473)

0.020

0.039

0.020

0.0031

0.0031

0.0035

0.00180.0030

0.0100.0180

0.0160.0240

0.0100.030

0.00120.0029

0.00120.0029

0.00500.0065

0.0021

0.020

0.026

0.030

0.0032

0.0032

0.0070

0.020

0.039

0.020

0.0031

0.0031

0.0035

0.0030

0.0180

0.0240

0.030

0.0029

0.0029

0.0065

0.0024

0.015

0.025

0.027

0.0031

0.0087

0.0024 0.015 0.00100.0024 0.015 Glace || 0.0120.018

0.025 0.0170.025 0.0170.025

0.027 0.0070.027 0.0100.030

0.0031 0.00160.0031 0.00120.0029

0.0087 0.00040.0087 0.0020.008

J 2001

4.8 (4802)

V

5.3 (5327)

T

6.0 (5966)

U

8.1 (8128)

G

0.0033 0.00160.00120.0029

@ 1-6: 0.0037-0.0047 in. 7-8: 0.0042-0,0052 in. ®

interference fit (coated piston)

93551CC6

‘cenerac morons 1-107 TORQUE SPECIFICATIONS

ae

:

Year

1998 1999

2001

Engine Displacement Liters (cc

Engine IDIVIN

All readings

Cylinder Main Head _ Bearing Bolts Bolts

in ft. Ibs.

Rod Bearing Bolts

Crankshaft Damper Flywheel Manifold Bolts Bolts Intake* Exhaust

TPG PemcR pkg Fue four Vapi zs 5.7 (5735) 6.5 (6473) 7.4 (7440 5.7 (5735 ) 6.5 (6473) 4.8 (4802)

5.3 (5327) 6.0 (5966)

Spark Plugs

Lug

S

110

® @ fee 100 45

R S

741

© 30

V in U

G

Step 1: 22 ft bs.

* NOTE: Applies to Lower Manifold only. ® Step 1: 20 ft. Ibs.

@ Step 1: 15 ft. Ibs.

Step 2: 90 degrees

Step 2: 37 ft. Ibs.

Step 2: 50 ft. Ibs.

Step 3: 90 degrees,

Step 3: 74 ft. Ibs.

Step 3: 50 ft. Ibs.

(except medium length bolts at front and rear)

Step 4; Plus 90-100 degrees

Step 4: Tighten medium length bolts,

@ Outer bolts on cap§ 2-4: 67 ft. Ibs.

at front and rear an additional 50 degrees

© Step 1: 22 ft. Ibs.

All others: 74 ft. Ibs.

Step 2:

@ Tighten all bolts t6 20 ft. Ibs.

Short bolt: Plus 55 degrees

Retorque to 50 ft. Ibs. ® Lower intake manifold: 1st pass: 27 in. Ibs.

2nd pass: 106 in. Ibs.

plus 120 degrees

Upper manifold bolts:

Step 3: 90 degrees,

1st pass: 44 in. Ibs.

(except medium length bolts at front and rear)

2nd pass: 88 in. Ibs.

Step 4: Tighten medium length bolts, at front and rear an additional 50 degrees

©aAll5 &6 stud single rear wheels: 110 ft. Ibs.

All 8 stud single rear wheels: 120 ft. Ibs.

@® Outer bolts: 100 ft. Ibs. Inner bolts: 111 ft. Ibs.

@ Inner bolts; Step 1: 15 ft. Ibs.

® Step 1: 15 ft. Ibs. Step 2: 60 degrees

® Use a new bolt

. “ 2 7

2nd pass: 22 ft. Ibs., Final pass:

Step 2: 90 degrees

; va

® 1st pass: 22 ft. Ibs.

Long bolt: Plus 75 degrees (©)Step 1: 22 ft. Ibs.

Retorque to 22 ft. Ibs.

Step 2: 89 in. Ibs.

®© Nuts: 39 ft. Ibs. Stud: 16 ft. Ibs.

Medium bolt: Plus 65 degrees

Final pass: 11 ft. Ibs.

© Tighten bolts to 12 ft. Ibs.

® Step 1: 44 in. Ibs.

Short bolt: Plus 60 degrees Medium bolt: Plus 45 degrees Long bolt: Plus 30 degrees

® 22 ft Ibs., plus 90 degrees ® 1st pass: 30 ft. Ibs. 2nd pass: 59 ft. Ibs.

3rd pass: 70 ft. Ibs. @ ist & 2nd pass: 44 inch Ibs.

3rd pass; 89 inch Ibs, 4th pass: 106 inch Ibs. @) Center bolt: 26 ft. Ibs.

Step 1: 37 ft. Ibs.

Nut: 12 ft. Ibs.

Step 2: 140 degrees

Stud: 15 ft. Ibs. 93551CC7

For Wheel Alignment specifications, see Section 17 of this manual

;

1-10 8 SPECIFICATIONS GENERAL MOTORS BRAKE SPECIFICATIONS All measurements in inches unless noted Brake Drum Diameter

Brake Disc Minimum Thickness Thickness

Original

Year

1998

1999

2000

Model

Original Maximum _ Inside Runout

Diameter

Maximum Machine Diameter

Minimum _Lining Thickness

Brake Caliper Mounting Bracket Bolts Bolts ft. Ibs. (ft. Ibs.

TF] 1500 | 1480 | 004 | — [| — | — | 0030 | NA | a ee aa aa eS OC Co Tahoe |F] 1500 | 1480 | 004 | — | — | -— | 0030 | NA | NAGS | Lc OF lye Sloe 1O pape COT Slee ao Rilo tO jYukon Pe[1500 feo | 0008 ft ee ee Ys as ae Ee es na | tS }Dera PE temo_f 10 foot ft Oo ey (ee ed a ee oe eS ee ee ee Envoy |F| 1.090 | 0965 | 008 [| — | — | — | 00: | S& | rR { o7e7 | 0728 | 0004 | 950 | 950 | 956 | 0030 [ NA | Escalade | F] 1500 | 1.480 | 0004 [ — | — | — | 003 | NA | Rie ee OT IS OP Os | 0.000) Nae: | Suburban| F[ 1.500 | 1480 | 000 | -— [| — | — | 003 [| NA _| Ril ys el — ee ee O [ee Owl Org eet aie [Tatoo TF} 1800 fat tO ff TO 2 ey eee es Oe Ee ee a eee

38 = 38 ieee 38

: 0. NA GOCE MULLET IRRLLN Aiea PSOE We eee Re Cue ee |Ewey Let oe Rota tae tas Ta ta PR{ 0.787 | 0.728 | 0.004 | 950 | 959 | 0,030. |NA | Escalade | F{ 1500 | 1.480 | 0.004 [| — | — | 0.030 |NA | 2 ee ee a ee a OS POR

38 %

Fey RnR

J

1; aaa) (es ee a )Toe LF} 1st 418) | 900 eee es PO

oooe [=|

2001

Max. Wear Limit

9

a

Pes re a tA ie PE OM SE

=

a a

| = [00% [NA

WS Se ea ao eed Dak ald a SE ae ge } eral FE ee | ==} = 4 | 3 wecil Calpe ® > |. 0.005 | ee eT ee Dera eeYF} @ ff fee {= 0.030 @ Pie Re OR Ei a eae ©

0.005 ea i }Tame [FL @ | _@_ 0.005 | = ER | On| 0.006 = tee |Yon FEL _@ 1 © _} 99 { = [= Oa aa Ba

ore A ee me me eae Ue il

ROR

(Ora

ey

® © ® © ae Bs ea

38

© — 38 aos 38 eee 38 38 = @

38

38

88 80 ee 80 @

@ 80 ® 80 ®

80 Ie

NA: Not Available @ Available with 1 in., 11.15 in. and 13 in. drums

@ 40 in. drum: 10.05

11.15 in. drum: 11.24 1 in. drum: 13.09

@1 in. drum: 10.09 11.95 in. drum: 11.21

1 in. drum: 13.06 @ 2w0: 38 tt. Ibs.

© Vacuum: 1.14 in.

Hydraulic: 1.50 in.

© Vacuum: 1.10 in. Hydraulic: 1.46 in.

@® 15 series: 129 ft. bs. 25 series: 221 ft. Ibs.

Vacuum: 0.787 in, Hydraulic: 1.14 in.

@ Vacuum: 0.748 in.

Hydraulic: 1.10 in.

© Vacuum: 148 ft. Ibs. Hydraulic (9000 Ibs.): 122 ft. Ibs.

Hydraulic (12,000 Ibs.): 221 ft. Ibs, @) 415 series: 31 ft. bs

25 series: 80 ft. Ibs.

4WD: 77 ft. Ibs. 93551008

> v=

——

er © ber sBae

pa OL ee|

i>

Pe |

cs ad

a

id

yr

.\4 6@

-

=

5

"

.

a

F re

1 ¢

‘ae ae)

coraiee 1708 “eee

WHEEL ALIGNMENT Caster

Year

Model

Camber Preferred Setting Deg.

Range +/-Deg.

Range +/-Deg.

Preferred Setting Deg.

Toe-in in.

Steering Axis Inclination Deg.

TSPB RS) AWD gt |g 1.00.) at 48.75) salle! O80 prizhects +050 ag Wake 200 | 2WDHD | notadjustable | notadjustable [| 0.50 | +1.25 [| Otew-0.12 | pose} AWN J 0001.00} [sie 43.00_atria ANS 050, AER AN 40.85. lh 02a Oe0T | | AWOHD | 100] 3.00 | 050 0.24H/-0.20 19990) few | 8.00 85 O50 4050 Sef OdO207 [| | 2WDHD | notadjustable | notadjustable | 0.50 | 41.25 | Ot2W-0.12 |

Se

COON

a

ET

a

ES

A

a

= — Fil =

| 4 |

—

per aWOHD Lt fs 11,00 Ff} 43.00} i] GL) LoS 1) 50.20 0208 ae Paget AWD kf 11.00. LAB al Pd OOS ST 40,50.) PAO 26H 200.| | 2WDHD | notadiustable | notadustable | 050 | +1.25 | 0.124012 | pent AWE ste far 1:00fpr |aol D08 eae DOO, res|esent lOo ret |SOeaeercOen|

2001

ae Salhi — mages = 1.00 p88 eget [0 S0E reps|ar tO25 See oraheo tae ae

1.00

npr

ONO a fone ORS |PMO Oe

1.00 @ ere ryt 25spony rer0.10020 eH oP AWDHD 5 [—0 1.00 + |e? @ Fees 5—0.50

:

ape

ees =

|

® Lett side: 3.90 Right side: 4.70

® Lettside: 4.50

”

Right side: 4.75

@ Left side:3.50

*

Right side: 4.50 93551CC9

For Maintenance Interval recommendations, see Section 1 of this manual

ur

‘pote

Choe

9° Pere aa ee See ee

4-110 SPECIFICATIONS

|

GENERAL MOTORS

°

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS OEM Tires Optional Standard

Model

Year

Tire Pressures (psi) Rear Front

Wheel Size

Ball Joint Inspection L: 0.090 in.

Tahoe/Yukon, 2wd

.

P235/75R15

Nae

| Tahoe/Yukon, 4wd | —P245/75R16 | P2657sRi6 | | 1500 Suburban 2wd | P235/75R15XL_| LT24575RI6E | 1999

2500 Suburban Denali

LT245/75R16E P265/70R16

Tahoe/Yukon, 2wd

P235/75R15

|None |

ase ee

36 36 36 36

| |

36 | 36 | ~ 36

U® L: 0.090 in

) L®

3

L® U® L: 0.090 in U@

36

ina. ae

36 36 36 36 36

Pre 36 36 36 36

36

36

P245/75R16 P265/75R16 P235/75R15XL_ | LT245/75R16E P245/75R16C | LT245/75R16E

36 36 36

36 36 36

® OL OL

2500 Suburban

LT245/75R16E

None

36

36

U: 0.125 in.

Denali

P265/70R16

None

36

36

L@® U®

Tahoe/Yukon, 2wd

P235/75R15

None

36

36

36 36 36 36

36 36 36 36

L: 0.090 in.

2000

Tahoe/Yukon, 4wd 1500 Suburban 2wd 1500 Suburban 4wd 2500 Suburban Denali

Tahoe/Yukon, 2wd

P245/75R16 P235/75R15XL | LT245/75R16E P245/75R16C_ | LT245/75R16E LT245/75R16E None P265/70R16

P235/75R15

©) L® L® L® U@ L: 0.090 in. U®@ L: 0.090 in.

Tahoe/Yukon, 4wd 1500 Suburban 2wd 1500 Suburban 4wd 2001

Tahoe/Yukon, 4wd 1500 Suburban 2wd 1500 Suburban 4wd 2500 Suburban

P245/75R16 P265/75R16 P235/75R15XL | LT245/75R16E P245/75R16C | LT245/75R16E LT245/75R16E None

L: 0.090 in.

U @ L: 0.090 in. ® OL OL U: 0.125 in. L@

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch

STD: Standard OPT: Optional L: Lower U: Upper @® Do not lift truck. Inspect the boss into which the grease fitting is threaded. Replace if the boss is flush or receded below the surface of the ball joint 2) Replace if any movement is noted or if stud can be moved by hand @ Ball joint is adjustable, refer to manual for procedure

935510G0

i.

"(ore ‘

.

=> »

me |

a

=

*

*"

é

4

“

7

4

ol

7

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.

SPECIFICATIONS

‘ or

GENERAL MOTORS

SCHEDULED MAINTENANCE INTERVALS DENALI, DENALI XL, SUBURBAN, TAHOE, YUKON, YUKON XL—DIESEL

eeesh oy:

VEHICLE MILEAGE INTERVAL (x1000)

senvice| §|#|10|15|20] 23]2s|20]35] ao]a5]50]53]55]co]60] 70]75]20]a]a5|oo]05| TYPE OF

Air intake system

FRSA

8 2

FA

A

Automatic transmission fluid ®

Brake system

a

Every 50,000 miles

Sn

a

Chassis & suspension

RR

v

Viviv

grease points

ae

eee

Cooling fan operation Crankcase depression regular valve system hoses

CV jit boos& ale seasPa PCE EGR system@ Engine coolant Engine al

pb

-

eee

-+ fe Every 150,000 miles

cooli t 2 fiedi

,

fp el ka ef lt due sla |Soda Wala ett ee

Rear/front axlefluidlevel

ec

RO CE

SS

te

eee

Initially at 100,000 miles, then every 50,000 miles

Engine oil& filter Front wheel bearings © Fuel filter

aaa

TN YP

ee

HY

ee

PNA FS ES

bac Et

a Pe

bic ed

ee

see TAM

Rotate tires

insulation ©

R; Replace

S/l: Inspect and service, if necessary

L: Lubricate

C: Clean

@ Vehicles with a GVWR of 8500 Ibs or more only. @ itequipped. @ 2-wheel drive models only. FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) if a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier. - Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than 10 miles in any temperature. - Extensive idling or low-speed driving for long distances as in heavy commercial use, such as delivery, taxi or police cars. - Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads.

- Driving in extremely hot (over 90°) conditions. Engine oil & filter: replace every 2500 miles.

Chassis and suspension grease points: lubricate every 2500 miles Rear/tront axle fluid level: inspect initially at 5000 miles, then every 2500 miles thereafter. Rotate tires: every 7500 miles.

Air cleaner filter: inspect every 15,000 miles. Front wheel bearings (2-wheel drive only): clean, inspect and repack every 15,000 miles. 93551CD1

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

1-112 feienalnorons SCHEDULED MAINTENANCE INTERVALS

warms

DENALI, DENALI XL, SUBURBAN, TAHOE, YUKON, YUKON XL—GASOLINE

(S| =[=Fo ll ol»

VEHICLE MILEAGE INTERVAL (x1000

TYPE OF

Accessory drive belt

Mii DEE SLAW

Automatic transmission fluid ©

os Re

Brake system

rel

bowebe LM

NAS

as RE

ado) a

tt very

Mal Malet |: par

a

miles

a

ro [am

Se Be

ee

az

ee ve

Chassis & suspension greasepoints | tc |v |v [v[v[v[v[v[v|v [viv [v[v|v |

viv

Cooling fan operation CVjoint boots & axle seals EGR system

¥

160

|

Sa

OB

NW

Te

2 | a) PN eS Mn

ee

Engine coolant

pd RAD

Engine oil & filter EVAP system Front wheel bearings @ Fuel filter Fuel system Rear/front axlefluid level Rotate tires

MBean aa RY A a Ya | a ea ed BCS a BS EE ee ee ae ee ace Le uaesean aeae med BS ce es kU | dB | eames on, Mead um oe noel EMMMLLD PONKORE CPs GN Mec 71Sea Ue Mn cA DM Nae | | LAAN! ces an?Oe =| Soart 1pashalEoeheal Coosa iSiamed ioe! Saeed Kina Gee CoeZaed booed fee eee em) Races weeps horsey cece RCO GI oe eet ato On| Tt et | ee Par a te ana a Sv ee Fran soe Pamcl Out AEN mca brn cach tandd Ons WaneG ca fate! | ce pndca ar al Sa

Every 150,000 miles

Sis & nod saon © cia alae Ea aie SA a Spark plugs

Every

Spark plug wires R: Replace

S/\: Inspect and service, if necessary

Is

7

100,000 miles

Every 100,000 miles L: Lubricate

@ Vehicles with aGVWR or 8500 Ibs. or more only. @ 2-wheel drive models only.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier. - Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than 10 miles in any temperature. - Extensive idling or low-speed driving for long distances as in heavy commercial use, such as delivery, taxi or police cars. - Operating on rough, muddy or sait-covered roads. - Operating on unpaved or dusty roads. - Driving in extremely hot (over 90°) conditions. Engine oil & filter: replace every 3000 miles or 3 months, whichever occurs first. Chassis and suspension grease points: lubricate every 3000 miles. Rear/front axle fluid level: inspect every 3000 miles. Rotate the tires ever 6000 miles. Brake system components: inspect ever 6000 miles. Front wheel bearings (2-wheel drive only): clean, inspect and repack every 15,000 miles. Shields & underhood insulation (vehicles w/GVWR over 8500 Ibs. only): inspect every 15,000 miles. Cooling fan system hoses & connections: inspect every 15,000 miles.

Fuel filter: replace-every 30,000 miles. Air cleaner filler: inspect every 45,000 miles, Automatic transmission fluid & filter; replace every 50,000 miles. Accessory drive belt: inspect every 60,000 miles.

Fuel system tank, cap and lines: inspect every 60,000 miles. EVAP system: inspect every 60,000 miles. EGR system: inspect every 60,000 miles. PCV system: inspect every 100,000 miles. Engine cooling system components: inspect and clean every 150,000 miles.

‘ 93551CD2

SPECIFICATIONS 1 113 GENERAL MOTORS

SCHEDULED MAINTENANCE INTERVALS GENERAL MOTORS CORPORATION DENALI, DENALI XL, SUBURBAN, TAHOE, YUKON, YUKON XL (GASOLINE) The following should be used as a guide when determining the amount of work required for a particular service. In estimating how long a particular Scheduled Maintenance Service should take, please observe the following: @ Labor Time is time based on field research and data supplied by the vehicle manufacturer. @ Labor time operations are given in hours and tenths of an hour, @ All labor operations are to be used as a guide.

Mechanic Skill Level Codes:

(A) PRECISION: Highly skilled with multiple certification. (B) GENERAL: Normally skilled with certification. (C) MAINTENANCE: Semi-skilled working on certification.

7500 Mile Service (C)

45000 Mile Service (C)

All Models. ..............0cc000 W/AWD Ad) ........cccecceceeeees

1.5 1

15000 Mile Service (C) All Models ..:..........+ss000 ery W/AWD Add) 00... ..ccesseseeseees 22500 Mile Service (C)

1.6 1

All Models y..........ccccceeee Lest WAWDiadG eal

1.5 |

All Models ...........ccccceesseeeeee W/AWD Add) .....ccccscececcccceeeseces

52500 Mile Service (C)

All MOCEIS. ....rseassecsenrsntbnes WWD BOG wrscassseisransssuspsestes

60000 Mile Service (B) All Models ........cccccccsesseccecseceece W/AWD Ad

..........00ceeeceeceeevees

30000 Mile Service (B)

67500 Mile Service (C)

All Models ..............cc0008 W/AW Dia aiiiee ceiver: coos 37500 Mile Service (C) All Models .................006 aise Ad. WAWD Gd 522 h.kiiccane

All Models .........cccccccsseeeseees W/AWD Add ..i.c.cccseeeseccesnsceees

75000 Mile Service (C) 1.5 Ps|

All Models ..............ccccsseeeees W/AWD Add 2.....cccscsesecececesscees

82500 Mile Service (C)

90000 Mile Service (B) AlleModels \2.¢.::..ccccccecesssesdestarat W/AWD A uu...ccccccescseeesnseesssnseees 97500 Mile Service (C) AlliModels: «.....:::.,00+-+seesesalesnyeas W/AWD A .......csecsccccesssressecervees

105000 Mile Service (B) All Models W/AWD Add. 112500 Mile All Models. W/AWD A 120000 Mile All Models WAWD.add

...........:.sscscscessseeceeee eee oy ecera cates earn Service (C) ..............ssssseesseeeceeee ......ccscsccenceesectcecereenes Service (B) *7.228.23.5. 2 eeeee ...223. cabins cee:

All: Models iy .c eeeee WAWD add ..i23\.cahsne. ae 93551CD3

For complete service labor times, order the Chilton Labor Guide

1-114 Siena norons SCHEDULED MAINTENANCE INTERVALS GENERAL MOTORS CORPORATION DENALI, DENALI XL, SUBURBAN, TAHOE, YUKON, YUKON XL (DIESEL) The following should be used as a guide when determining the amount of work required for a particular service. In estimating how long a particular Scheduled Maintenance Service should take, please observe the following: @ Labor Time is time based on field research and data supplied by the vehicle manulseiirer, @ Labor time operations are given in hours and tenths of an hour. @ All labor operations are to be used as a guide.

Mechanic Skill Level Codes: (A) PRECISION: Highly skilled with multiple certification. (B) GENERAL: Normally skilled with certification. (C) MAINTENANCE: Semi-skilled working on certification.

LABOR TIME

5000 Mile Service (C) AllModels

.............

35000 Mile Service (C) 1.5

8000 Mile Service (C)

AN MODIS hes steecs aren FISK 10000 Mile Service (C)

Al MOGGIS..

occ.csenc.n ce. ROLY

LABOR TIME

Al Models

ert

68000 Mile Service (C)

ee

8

38000 Mile Service (C)

1.0

8

All Models’

iso 72". fo.

1.0

75000 Mile Service (C)

All Models.-.:6.00. 6.5 60% 40000 Mile Service (C)

All Models

LABOR TIME

.............

8

8

All Models sec ee 80000 Mile Service (C)

AllModels

1.5

.............

8

15000 Mile Service (C) AiodeIg= Soro

8

sy aye Service (C) ; ROE Senate: + .s:72.4 “abst 5

83000 Mile Service (C) All Models.s:.-.vua +, BABDP!

1.0

20000 Mile Service (C) miviccde 23000 Mile Service (C)

‘tpi

Tee Service (C) ta aahe tea. aR i ty cde |(OL (C)

85000 Mile Service (C) All Models ...........0. 90000 Mile Service (B)

8

All Models

als batch

25000 Mile Service (C)

PAU MOCG See ie ao. oiuid uote exe

30000 Mile Service (B)

reiky eariege aan en rte

-

55000 Mile Service (C)

8

60000 Mile Service (B)

/Au ayo m9 siaceeaaedt 2.4

lone

AllModels ...........-. AlModels

6...

hea

65000 Mile Service (C) Al Models:

6 19

oho. 0ccnsune

8 2.5

All Modéls:

...... 22 5.a5.

2.4

Alt Models)",

yah rates d We oa.

8

95000 MileSenieetc

tenes perce se)

Ps

es

8 93551004

SPECIFICATIONS GENERAL MOTORS

1-115 bi| LPT.

GENERAL MOTORS Chevrolet Blazer ¢ Trail Blazer « Xtreme « GMC e

:

Envoy e Jimmy e Oldsmobile Bravada ENGINE AND VEHICLE IDENTIFICATION Engine

e

Liters (cc)

Cu. In.

Cyl.

Mode! Year

Fuel Sys. _Engine Type

Eng. Mfg.

e

S

4.2 (4200)

256

6

MFI

DOHC

CPC

Ww

4.3 (4293)

263

6

MFI

OHV

W

X

CPC

4.3 (4293)

Xx

263

6

MFI

OHV

CPC

Y

CPC: Chevrolet/Pontiac/Canada

1

MFI: Multi-port Fuel Injection

2

@® 8thposition ofVIN @® 10th position ofVIN 93551CT1

Please visit our web site at www.chiltonsonline.com

1-116 ecm Horons GENERAL ENGINE SPECIFICATIONS

Model

Year

1998

Bradava

Engine Displacement Liters (cc)

All measurements are given in inches. Net Net Engine Horsepower Torque Brpm Fuel Series (ft. Ibs.) @ rpm System (ID/VIN)

|43(4203) | W

| MI |

Compression Ratio

Oil Pressure Brpm

|

@

| 400x348 | 9.24 | 18@2000

|

@

| 4.00x3.48 | 9.2:1__| 18@2000

a | agen | PMN Laswa LX Leana]| 9.4 | 1e@2000 -43(azeay_| Ww | MFI | 230@4600 | 285@2800 | 400c48 gam 02t_| | atone t t xb -[ swes te@2000 | 921 | -400048 | @ | o [wil w Jim t8@2000 |” 921 | 400348 | @ | ro x ro | _@ | 400348 | 924 | te@2000 W Blazer PF @

x

1999

2000

@

Bore x Stroke (in.)

Bradava

4,3 (4293)

W

MFI

4.00x3.48

@

|92:1 | 18@2000

Envoy | 434293) | W | MFI| 230@4600 | Za5@280 | 40048 | 941 | 18@2000 ge sa toon |ot |teen | Jimmy | 4303) | W | wl o | @ 400x348 |924 | 16@2000 400348 |924 | 16@2000 Cee Pre aes eran oor ea 8 | 16@2000 ME 7e5@2800 |40004 | 941 4.3 (4293) xX | mi] @ | © | 400348 | 9.21 | 18@2000 _@ | @ | 40048 | 927 | 18@2000 MT [we x | | t8@2000 ooa48 |921 230@4600 Envoy 9.4:1 4.3 (4293)

xX

®

Jimmy

4.3 (4293)

W

O)

Blazer

4,3 (4293)

W

190@4400

4.00x3.48

4.3 (4293)

W Ww

@ 230@4600

4.00x3.48

A:

4.00x3.48

4

3.66x4.02 3.66x4.02 3,66x4.02

10.0:1 10.0:1

2001

4.3 (4293) Xtreme

4,3 (4293)

Blazer 2002

Bradava Envoy TrailBlazer

MFI: Multi-port Fuel Injection @ 2w0: 245@2800 4WD: 250@2800

@ 2wo: 17084400

9

x

W

3

W

W 4,2 (4200) 4.2 (4200) 4.2 (4200)

;

S S S

2:

190@4400 MFI MFI MFI

270@6000 270@6000 270@6000

18@2000 275@3600 275@3600 275@3600

12@1200 12@1200

10.0:1 | 12@1200

@® Below 15,000 GVWR: 18083400 Above 15,000 GVWR: 190B3400 @ 2wo: 18084400 4WD: 19084400

AWD: 18084400 93551072 4

SPECIFICATIONS 4 _4 17 GENERAL MOTORS

GASOLINE ENGINE TUNE-UP SPECIFICATIONS .

Engine Displacement Lite:rs (cc

- Engine DIVIN

Spark Plugs Gap in.

Ignition Timing (deg.)

AT

Fuel Pump psi

Idle Speed (rpm)

MT

AT

Valve Clearance ; Ex.

NOTE: The Vehicle Emission Control Information label often reflects specification changes made during production. The label figures must be used ifthey differ from those in this chart. HYD: Hydraulic @) Distributoriess ignition, cannot be adjusted

@vwith key ON and engine OFF ® Distributorless ignition, cannot beadjusted @ idle speed is maintained by the PCM

s 93551CT3

Front of the Vehicle

79243661

4.3L Engines

Firing order 1-6-5-4—3-2 Distributorless ignition system

Timing belt service is covered in Section 3 of this manual

f

WET 16 teem

) WITHOUT AIR CONDITIONING 1. Pulley, Idler

ee

) WITH AIR CONDITIONING 5. Pulley, Crankshaft

2. Pulley, AC Compressor

6. Pulley, Water Pump

3. Belt, Drive 4. Pulley. Power Steering Pump

7. Pulley, Drive Belt Tensioner 8. Pulley, Generator 79244624

Accessory serpentine belt routing—GM 4.3L engines

a

PR a SPECIFICATIONS 1-11 9.

-

"4

‘=

GENERAL MOTORS

CAPACITIES

a

Model

Engine Displacement

Engine

Engine Oil with Filter

Liters (cc

ID/VIN

gts.)

fe

Transmission (pts.)

_5-Spd_

Auto.

— Transfer Case

ots.

Drive Axle Front Rear

nts.

ots.

‘

Fuel Tank

Cooling System

gal.

gts.)

tee

tee

Blazer | 4.3(4203) | W | 50 | 44 | 100 | 26 | 26 | 39 noe a [aigsl cries eco MRO MRE POPS EIS) 113.6 a Dok ol ee eee SE an i | 4.3(4203) | xX | 50 | — | 100 | 26 | 26 | 39 | 20 | ft9 ; Pap Se ae ae ese ae ee ass) [xX If 50 | | 00 | 26) [26 |ise.) 20 [tic Helis ha ee es Sa [43 (4289) [x [50 | | too | 2628 39 | 0 [is 1999 Bravada 93 (4203)=— [EW Hhoce One cay ae fe 10 ae. y + 32 11.9 iccit i tacete ncas GMa AAWOE bae 9, aa eS aN a ete Ze ee ia 43 azeay | x | 50 | — | 110 | 26 | 26 | 39 | 200 | 19 Speer aas HEROES at epg oe SO ee 43 (azeay | x | 50 | — | 10 | 26 | 26 | 39 | 200 | 119 Be od ee a“ hn aE | 4.3(4293) | xX | 50 | — [ 1410 | 26 | 26 | 39 | 20 | 19 2000 Pee ar ee ee 19 agama [ok [760 | — [tio | 260) zen] a0) | ee epeme Ewoy | 43(420) | w | s0 | — | 10 | 26 119 ee is ee town teense le 00 | 119 Jimmy | 43283) | W | 50 | — | 10 | 26 | 26 | 39 | 200 | 119 Yass) | x | s0_| — [10 |-26 | 26 | a9 | 20 | 119 Blazer | 43am) | w | 50 | 44 | 110 | 26 | 26 | 39 i139 Pea Pere ee ene Lee 26 | 39 | 20 | 119 2001

2002

4.3 (4293)

X

edo | 20 | 20 | oo

[_dimmy | 43azea) [wf 50 | — | 26 | 26 | 39 | 20 ee Craa ra 0 w io [| 26 | 26 | 39 |20 [ 26 [40 | 106 | 26 | — | too | 70 42(4%00) |[ Ss |4.2(4200) || Braveda Envoy —s |] S 7.0 a 10.0 2.6 26 40 | 186 4.2 (4200)

S

10.0

26

26

NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained.

Heater Core replacement is covered in Section 2 of this manual

4.0

| 119 | 119 | 119 | 139

| 139

186 | 13.9 ee

ee Cee

|

eR,

nT

We

TLE aN

ERM

;

|

1-1 20 SPECIFICATIONS GENERAL MOTORS

VALVE SPECIFICATIONS Engine Displacement

— Engine

Seat

Face

Angle

Angle

— Spring Test Pressure

Spring

Stem-to-Guide

Stem

_Installed

Clearance

Diameter

Height

(in.)

n.

(in.)

Intake

Exhaust

_Intake _Exhaust

1998

4.3 (4293) 4.3 (4293)

4.3 (4293)

4.2 (4200) NAC

Avalatye

93551CT5

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

1998

All measurements are given in inches. Crankshaft

Engine Displacement

Engine

Main Brg.

Main Brg. Oil

Liters (cc

ID/VIN

Journal Dia.

Clearance

4.3 (4293)

Shaft

Thrust

Journal

Connecting Rod Oil

Side

on No.

Diameter

Clearance

Clearance

0.0140 0.00600.0140

4.3 (4293)

4.3 (4293)

0.0140: 0.00600.0140

4.3 (4293)

4,3 (4293)

0.0140

4.3 (4293)

0,00080.0025 ® No. 1: 2.4488-2.4495

® No. 1: 2.4484-2.4493

Nos. 2, 3: 2.4485-2.4494

Nos. 2, 3: 2.4481-2.4490

No. 4; 2.4480-2.4489

No. 4: 2.4479-2.4488

@® No. 1: 0.0008-0.0020 Nos. 2, 3: 0.0011-0.0023 No, 4: 0.0017-0.0032 93551CT6

SPECIFICATIONS

GENERAL MOTORS

1-121

PISTON AND RING SPECIFICATIONS

Year

Engine Displacement Liters (cc)

Engine ID/VIN

4.3 (4293)

All measurements are given in inches. Ring Gap Piston Top Bottom Oil Clearance Compression Compression Control

0,00070.0017

0,O100.030 0.0100.030

Ring Side Clearance Top Bottom Oil Compression Compression Control

0.O18. 0.026

0018. 00017 0.00040.0017

4.2 (4200)

00118.

a i

wa

0.001793551CT7

TORQUE SPECIFICATIONS All readings Engine sy Tapa

e3+ a283) 43nee

* NOTE: Applies to Lower Manifold only. M 1st pass: 22 ft. Ibs. 2nd pass:

Engine

ae

Cylinder Head

Bolts ® @

Main ie

Rod Ss

in ft. Ibs. Crankshaft ae pee

sone

ist pass: 22 ft.Ibs.

Medium bolt: Pius 65 degrees

2nd pass: Plus 155 degrees

Long bolt: Plus 75 degrees

)

2 short end bolts; 15 ft.ibs. 1 long end bolt: 13 ft. Ibs.

2nd pass: 106 inch Ibs.

© 18 ftlbs., plus 155 depress @ 18 ftIbs., plus 110 degrees 111 ft. Ibs., plus 180 degrees

Final pass: 11 ft. Ibs.

@ 18 ft. Ibs., plus 50 degrees

Upper manifold bolts:

© 1st pass: 18 ft. Ibs.

@ Lower intake manifold: 1st pass: 27 inch Ibs.

Lug

Exhaust

@ Tighten bolts to 12 ft. Ibs. Retorque to 22 ft. ibs. (©) Cylinder head bolts (14)

Short bolt: Plus 55 degrees

@ 20ftIbs. plus 70 degrees

Manifold Intake *

1st pass: 44 inch Ibs.

2nd pass: 18 ft. Ibs.

2nd pass: 88 inch Ibs.

3rd pass: 18ft. Ibs. 93551CT8

Brake service is covered in Section 4 of this manual

hTERT 8 Mer ane cee | Ay CMA ne aana Oe ee ee 1-12 SPECIFICATIONS Al

5

'

°

u]

.

.

¥

ois

vt

fi

*

ee

GENERAL MOTORS

BRAKE SPECIFICATIONS All measurements in inches unless noted

Brake Drum Diameter Year

1998]

Model

Original

Brake Disc Minimum

Maximum

Original Inside

Max. Wear

Maximum Machine

Thickness

Thickness

Runout

Diameter

Limit

Diameter

0.965

0.003

Bravia |F] 1090 | 0% | 003] — Envoy

F

Ty di R

0.787

& 0.985 0.728

PRI o7e7__| 0.728 | 0.004 | FI] 1.030 | 0.965 FR{ over | 0728 |

1999

[0986 | PF] 4.030 0787 F

Envoy

; TrailBlazer

0.965

0.787

Bracket Bolts

Mounting Bolts

Thickness

(ft.lbs.)

_(ft. Ibs.

P0030 | NAT 0.030

3

)

| NA | = 0030 [000 [2 | o_— 0.030 i a 0.030 | NA 0.030 | NA

38 =

Teen lio 27S [0090 [NA @ 0.030 0.030 — 0020:

|52.

=

@ ~

R

NA

2s

F

52

®

R

NA

Sd

F

52

@

@=

F

=

@

R

NA

a

F R F R F

52 NA 52 NA 52

@ v @

iad Bravada

1,030

R

R i

2001-02

0.965

0.787

F

2001-02

1.030

R|

Brake Caliper Minimum _Lining

= ®

=)

2 | @

R

NA

F

NA

59

®

a

NA59

©

R

NA

ah,

F

i

ts

es

NA: Not Available ® 2W0: 38 ft bs. 4WD: 77 ft. Ibs. 93551CT9

SPECIFICATIONS 4.493 WHEEL ALIGNMENT Caster

Camber

Preferred

Year

Range

Model

(#!-Deg.)

Setting

Range

(Deg,)

;

Preferred

sf

Setting

+1-Deg.

Toe-in

(Deg.)

(in.)

1998 |BlazerlimmyrEnvoy[2WO] 100 | +800 | 10 | 0 | o10uo0e | — jawof 100 [+20 «| Sito ~S«d|SCiSSC*dY«C tO | Co Ea ee eee oe AWD | 59,00] 0 4.00. Lo otowotb T= 1999 ee ae Se eee Lo eee ee = jawol 100 | 200 —«Y~StooSdYS*d CO | fe are ee ee EN BE Re RAT = 2000 | BlazeriJimmy/Envoy|2WO}

| Bde 2001

AWD} —4 1,00] jt 00+ | STO 1.00 | 43.00 | 100

jawof 100 | +20 ~+| 10 | 0 Lt

Sf

AWO] 1 100 PN Peo BlazerJimmy/ [2WD] 4.00) | * @ | Envoy/Bravada [4wo] 4.00 | OT

eS CO] OC a Na)

2002 er

TrailBlazer

Lt 0 aD AOD | OWS |

ee

[4wot

100

| O10w005 | —

or 00 tO

ee oe 0 0010 a | OH | O00 |

ST

Fa

ee

—

re A

| 850TH

|

=

aes

oa: ia

=

—

© Left Side:+2.80. Right Side: +3.30

@ Left Side: +4.70 Right Side: +5.20 93551CT0O

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

‘

5

;

ida

Se

ee,

© eR

rae

een

a

ey 1

re

oe

va494 SPECIFICATIONS GENERAL MOTORS

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS Year

Model

Blazer/Jimmy/Envoy

OEM Tires “parigiert _ ~*~ ~ Standard Standard ‘Optional

P205/70R15

P235/70R15

P235/70R15

None

Blazer/Jimmy/Envoy

P205/70R15

P235/70R15

Bravada Blazer/Jimmy/Envoy

P236/70R15 P205/70R15,

ee eee

Ee Relea) Front ear

Wheel

Ball Joint

Size

Inspection U: 0.125 in. L®

aa

Remain

te nak

a

U: 0.125 in.

L®

= ole

Sg

P235/75R15

Bravada Blazer/Jimmy/

P2STORIS ob P205/70R15

Envoy

None P235/70R15

[I BS

| eat

rape aree Tae

aN

z

P235/75R15

Bravada

P235/70R15

Envoy/TrailBlazer

P205/70R15

Bravada

P235/70R15

P= Nones 9] ee Sos ee

ate

P236/70R15 eR

Pe rig a

fae som Sonia ary Poa el

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch

STD: Standard OPT: Optional L: Lower U: Upper ® Do not lift truck. Inspect the boss into which the grease fitting is threaded, Replace if the boss is flush or receded below the surface of the ball joint

@ Replace ifany measurable movement is found, 93551CS1

aeue”

ey

Cl

SPECIFICATIONS

|

GENERAL MOTORS 1 “1 2 4)

“

_

SCHEDULED MAINTENANCE INTERVALS GM—Blazer, Jimmy, Bravada, Envoy, Xtreme, Trail Blazer VEHICLE MILEAGE INTERVAL (x1000)

TO BE SERVICED

TYPE OF a

Accessory drive belt Air cleaner filter

SE

Automatic transmission fluid | R |

Brake system©

Ea

120

as

+++ HH HHH

Every 50,000 miles

Bad Wi BR FSR ca WS ca Ke

+114 eet

2

vi v

odbn

CV-joint boots &axle seals Engine coolant system @

Engine oil&fiter

Front wheel bearings Fuelfilter Fuel tank, cap & lines

eenRAS TY eee ae [aes [NS ee

Sil

Rotate tires

v

Every 100,000 miles

| _st_ | v¥| v |v |v iv |v i[vi[vi|vivivi[v[vi[v[vie

Spark plug wires. Spark plugs R: Replace

|ae

vd ol A, TS Ve Pa Le HZ ee ae ee ieslath fe Pe Toledo] Pe er itebend ia

PCV valve

Rearfrontaxiefluidlevel

Every 150,000 miles

ior uh VO WER. ENCT WH [Py inlay pe] Sil ieee

S/\: Inspect and service, ifnecessary

bole

heal

Every 100,000 miles Every 100,000 miles L: Lubricate

© This should beperformed when thetires areremoved forrotation. ® Drain, flush and refill the cooling system, inspect the system hoses, and clean the radiator and condenser.

@ 2-wheel drive models only. FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) if a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier. - Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than 10 milesin any temperature. - Extensive idling or low-speed driving for long distances as in heavy commercial use, such as delivery, taxi or police cars.

- Operating on rough, muddy or salt-covered roads. + Operating on unpaved or dusty roads.

- Driving In extremely hot (over 90°) conditions. Engine oil & filter: replace every 3000 miles or 3 months, whichever occurs first.

Chassis and suspension grease points: lubricate every 3000 miles. Rear/front axle fluid level: inspect every 3000 miles. Rotate the tires ever 6000 miles. Brake system components: inspect ever 6000 miles. Front wheel bearings (2-wheel drive only): clean, inspect and repack every 15,000 miles. Air cleaner filter: inspect every 15,000 miles.

Automatic transmission fluid & filter: replace every 15,000 miles.

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

93551¢S2

|

aT

iy,

Pas

ee

¥

AE

eS

eee

ee rts

eva

©

tee eee a

rw,

&,

SCHEDULED MAINTENANCE INTERVALS GENERAL MOTORS CORPORATION BLAZER, JIMMY, BRAVADA, ENVOY, XTREME, TRAIL BLAZER The following should be used as a guide when determining the amount of work required for a particular service. In estimating how long a particular Scheduled Maintenance Service should take, please observe the following: @ Labor Time is time based on field research and data supplied by the vehicle manufacturer. @ Labor time operations are given in hours and tenths of an hour. @ All labor operations are to be used as a guide.

Mechanic Skill Level Codes: (A) PRECISION: Highly skilled with multiple certification. (B) GENERAL: Normally skilled with certification. (C) MAINTENANCE: Semi-skilled working on certification.

LABOR TIME

7500 Mile Service (C) PUIMOGOIS oi. 8 os stiaueter te sys WAV Daddeters tt sree cis sees

15000 Mile Service (C) AMMO ES warsnemtve~nreedreremendp ame WAWD add .* .. ve. Oo” W/AIMAOGe. orgie ake ke cline 22500 Mile Service (C) AllamMOdOlS ssesroneamncctedartertesne VORA DAC ie ans rag ok 30000 Mile Service (B) UTOUGIS aay amists wise s ote 3 WIAWI' AOC "icine coches e & oe W/ATLAOG mae ote neater etetice cokesas

45000 Mile Service (C) i 2

7 2 5 of 2

11 2 5

37500 Mile Service (C) PANLEIMOC GIS tae samc tailed. WAWD Addl. 1c stonekl,

LABOR TIME

YT 2

LABOR TIME

90000 Mile Service (B)

AN MOCEIS bana fooneiic breve turns WAWDIAdG Sica cies vslbie eie

yf 2

WAL 400 Seay te oes bit Pot 52500 Mile Service (C) All’models |. 28) 0/0003 s scce ade WAWD add os. cece es 60000 Mile Service (B) All: MOdEIS»ssiaaes’irers tesrstereet WAWDiadd~ Wien tia. ease W/ATTAGG A ea snk isots sheen 67500 Mile Service (C) Ail; models. ss are eicce sons bee W/AWD add si eee oe one 75000 Mile Service (C) All models . .. . aivwnenveniey WAWDiaddy ae ee CLAN Bit:(o[6 ER, 5° RRP 82500 Mile Service (C) AIINMOGGIS ae seecattre verse tte WAWD adds ¥ etre. eee

Bo PYf 2 3 2 5 ey4 2 7 2 5

All:smodelst.. 2... 0c eneeaeeeshe W/4WDAdd toc civics cee ae WAT add . 4. . « + ine hala 97500 Mile Service (C) All. mOdelSi 2 W...ccacucwousuanteaweere w/4WDiadd}. . 0. «+ 2 See 105000 Mile Service (C) All- models errrcrsrorsert: WAWD add ............... WAT: AU cand Ga towerDexreRieg TaN 112500 Mile Service (C) All modelSv.. 5%. 830 ee W4WD add. eee ee 120000 Mile Service (B) All models ............... WAWD. adds « 2x0ne2.0 seteu. wit WAT ACC a ese oe ee

1.1 2

5 7 2 sh 2 5 7 2 1.3 2 5

ff 2 93551CS3

: i

es }

tl

SPECIFICATIONS 4.497 GEO/CHEVROLET

GEO CHEVROLET/SUZUKI Geo Chevrolet ¢ Tracker ¢ Suzuki * X90 « Sidekick « Sidekick Sport ¢ Vitara ¢ Grand Vitara ENGINE AND VEHICLE IDENTIFICATION CHART

Code 0/6 2 a 5 6/1 C

Liters (cc) 1.6 (1590) 1.8 (1843) 2.0 (1997) 2.5 (2494) 2.0 (1997)

Cu. In. 97 112.5 121.8 152 122

Engine Code Cyl. Fuel Sys. __Engine Type 4 MFI SOHC 4 MFI DOHC DOHC MFI 4 6 MFI DOHC 4 MFI DOHC

Model Year

Eng. Mfg. Suzuki Suzuki Suzuki Suzuki Suzuki

Code W X Y 1 2

>

Year 1998 1999 2000 2001 2002

MFI: Multiport Fuel Injection

DOHC: Dual Overhead Cam

,

SOHC: Single Overhead Cam ‘

93551Cl6

GENERAL ENGINE SPECIFICATIONS Model

Engine Displacement Liters (cc)

X90

1.6 (1590)

Year

Sidekick

1.6 (1590) 1.8 (1843) 1.6 (1590)

Engine ID/VIN

pe OT 0

Tracker 6 Vitara |1.6(1590) | 0 | Eee 2.0 (1997) 5 6 Grand Vitara 2.5 (2494) 6 Tracker 1.6 (1590) 2.0 (1997) C Vitara 1.6(1590) | Oo | Grand Vitara Tracker Vitara

Grand Vitara Tracker Tracker

2.0 (1997) 2.5 (2494) 1.6 (1590)

2.0 (1997) 1.6 (1590) 2.0 2.5 1.6 2.0

(1997) (2494) (1590) (1997)

Fuel System Type

Net Horsepower @ rpm

Net Torque @ rpm (ft. Ibs.)

Bore x Stroke (in.)

Compression Ratio

98 @4000

2.95x3.54

5:

47-61 @3000

MFI MFI MFI

95@5600 | 98@4000 120@6500 95@5600 98@4000

MPI MFI

95 @5600

98 @4000

2.95x3.54

47-61 @3000

127@6000

134@3000

3.31Xx3.54

55-67 @ 4000

140@6500

151 @4000

3.31x2.95

55-67@4000

95@5600

98 @ 4000

2.95x3.54

47-61 @ 4000

134@3000 98 @ 4000 134@3000 151 @4000 98 @ 4000 134@3000 98 @ 4000 134@3000 151@4000 98@ 4000 134@3000 151 @4000

3.31x3.54 2.95x3.54 3.31X3,54 3.31x2.95 2.95x3.54 3.31x3.54 2.95x3.54 3.31x3.54 3.31x2.95 2.95x3.54 3.31x3.54 3.31x2.95

55-67 @ 4000 47-61 @ 3000 55-67 @ 4000 55-67 @4000 47-61 @4000 55-67 @ 4000 47-61 @3000 55-67@4000 55-67 @ 4000 47-61 @ 4000 55-67@4000 55-67 @ 4000

MFI MFI MFI

127 @6000 95@5600 127 @6000 140@6500 95@5600 127@6000 95@5600 127@6000 140@6500 95@5600 127@6000 140@6500 ]|31/O/DID|AlLOlLO!|A/|a\n

2.95x3.54 3.31x3.27 2.95x3.54

Oil Pressure @ rpm

47-61 @3000 55-67@4000 47-61@4000

MFI: Multi-port Fuel Injection NA: Not available

93551C17

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

Nea

ies SN)

ek

eRe CRA MAD GT eas Nie ie

1-128 separ

the n

°

fal a

ae

'

ENGINE TUNE-UP SPECIFICATIONS

Year

Bee

Displacement Liters (cc)

acme

Ignition Timing (deg.)

Spark Plugs

Engine

Gap in. 0.029

Engine ID/VIN

MT

Fuel Pump (psi)

AT

& 1999

1.6 (1590)

Pe

Idle Speed

Valve

(rpm)

Clearance

In.

MT

=) f=

S588 8)

=g

i

Ss si2 S

Ssiss 8) g|8 3] 3 ile sip S22 co

88

700700800 800 800-850 | 800-850

3 3

igntaae

| 20(i907) | Cc | 0.04 | 2001

°

1.6 (1590) 2.0 (1997

5

S

oO

E

Esta | ae oleae pete | 0.041 0,040

3

Ss

oO

HYD 0.0050-

5

pel

noir_| oso HYD HYD

800 800 700-- | 700800 800 700700-

0.0070 =231-12 Shae

800-850 | 800-850

0.00500.0070 HYD

HYD

32

1.6 (1590)

2.5 (2494)

= is]

|

2.0 (1997)

9

Ex.

C

ae ef

a

s

ea

800

sis 800

~

HYD

S38as Siaie& rie

800 Meo a800 a | 0.0070 ||ooo 0.0070 | cao 35-43 | 700-800 | 700-800 HYD

HYD: Hydraulic 93551C19

Front

q{—

of the Vehicle

79243634

93023G05

93023603

1998 1.6L engine Firing order: 1-3-4-2 Distributor rotation: Counterclockwise

1999-02 1.6L engine Firing order: 1-3-4-2 Distributorless ignition system (coils over No. 2 and 4 cylinders)

2.0L engine

Firing order: 1-3-4-2 Distributorless ignition system (one coil over each cylinder)

|

eae

-

iS %

eas

!

Of

ai

2 ie

7

SFecocuevaoes 1-129 A/C COMPRESSOR WATER PUMP A/C COMPRESSOR WATER PUMP

GENERATOR

POWER STEERING

GENERATOR

CRANKSHAFT PULLEY

CRANKSHAFT PULLEY 93024G03

Accessory V-belt routing— 1.6L engine with A/C

93024604

Accessory V-belt routing—1.6L engine with A/C and P/S

IDLER PULLEY WATER PUMP

POWER STEERING

WATER PUMP

GENERATOR

POWER STEGRING

GENERATOR

A/C COMPRESSOR

IDLER PULLEY

CRANKSHAFT PULLEY

CRANKSHAFT PULLEY 93024G05

Accessory V-belt routing—1.6L engine with P/S

93024G07

Accessory serpentine belt routing—1.8L and 2.0L engines

¥

FAN CLUTCH PULLEY

IDLER PULLEY

FAN CLUTCH PULLEY is POWER STEERING

CRANKSHAFT PULLEY

CRANKSHAFT PULLEY 93024609

93024608

Accessory V-belt routing—2.5L engine with P/S

Accessory V-belt routing—1.8L and 2.0L engines

FAN CLUTCH PULLEY IDLER PULLEY

Ge

GENERATOR

POWER STEERING

CRANKSHAFT PULLEY

A/C COMPRESSOR 93024610

Accessory V-belt routing—2.5L engine with A/C and P/S

For Wheel Alignment specifications, see Section 1 of this manual

1-130 SPECIFICATIONS GEO/CHEVROLET CAPACITIES

Year

1998

1999

2000

Sd

Model

Engine Displacement Liters (cc

Engine Oil with Filter its,

Engine ID/VIN

[xo _f1e(tse) fo f | Sidekick | 1.6(159) | o | [Sidekick Spot | 1.8(1843) [ 2 | [Tracker | _4.6(1500) [6 | Vitara [_(1.6(15900) | 0 [ Pe eeNg eric ee ced |GrandVitara | 25(2404) [ 6 |

Transmission (pts.) §-Spd Auto.

Transfer Case pts.

Drive Axle Front pts.

| @ } 36 { et | | @ | 36 [ 21 | 46 | @ | 36 | 21 | 46 [| 16 [ 36 | 24 | 46 | @ | 36 | 21 | 46 MARE RRC [| @ | 36 [| 21 | 46 | Tracker | 1.6(159) | 6 | 475 | 32 | 106 [| 36 | 24 | 46 | Tracker | 20(1907) [| Cc | 59 | 32 | 106 [| 36 | 24 | 46

Vitara | 1.6(159) Bh edec [Grand Viera | 25(aom) Tracker | _1.6(1590) |__Tracker | 20(1907) RI | 207) |GrandVitara | 2544)

47 [ @ 475 [| @ 55 | @ 475 | 32 475 [ @ OF MN 6 [| 55

Fuel Tan gal.

Rear nt

Cooling System ats.

2 5. 55 55 55 5.5 | 185 | 55

| | | |

@ 185 110 11

| | | |

| 110 | 55 | 110 | 65

| 0 | 47 | @ | @ | 96 | 21 | 46 [| 11 | econ eacd (MO Ta BCE MPR GEA St | 6 | 6 | 55 | @ | 36 | 21 | 46 | 105 | | 6 | 475 | 32 | 106 | 36 | 24 | 46 | 110 | | C [| 590 [ 32 | 106 | 36 | 24 | 46 | 110 | A TBE TM, gE | 5 | 59 | © | @ [| 36 | 21 [| 46 | @ J | 6 | 6 | 55 | @ | 36 | 21 | 46 | 185 |

55 55 55 55

65 69

85

| Tracker | 1.6(1590) | 6 | 475 | 32 | @ | 36 | 24 | 46 | © JT 58 | Tracker | 20(1907) | Cc [ 59 | 32 [| @ | 36 | 24 [ 46 [ © J 69 pe Trackers] 12.5 (2404) Pt

6

6s]

as | 365] itt

48 [oy

aes

Note: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained.

© 2-wheel drive model: 4.0 pts. 4-wheel drive model: 3.2 pts, 2)3-speed transmission: Fluid drain, and filter and pan removal only: 5.9 pts. After complete transmission overhaul: 10.8 pts.

4-speed overdrive transmission:

Fluid drain, and filter and pan removal only: 5.3 pts. After complete transmission overhaul: 14.6 pts.

@2-door model: 11 gals, 4-door model: 14.5 gals. @ 2wn: 6.0 pts AWD: 5.2 pts. © 2dr. 14.8 Adr: 17.4 93551C10

ee %

ie

= a ees

a

Le

Cele

VALVE SPECIFICATIONS Engine Displacement Liters (cc

Engine ID/VIN

Seat Angle deg.

Face Angle deg.

SpringTest Pressure Ibs. @ in.

Spring Installed Height in.

Stem-to-Guide Clearance (in.) Intake Exhaust

Stem Diameter in. Intake Exhaust

jn ili ii eA por [ee ey ee | as |ae|Se i a a a da

Year

1999

pe

irertie

t &

1.24 24-28@ 1.24

al OG OA i a i a

1 24

2000

1.6 (1590)

2.0Mae

0.0018

0.0028

0.0018

0.0028

ABee

0.2344

0.0027

0.0035 0.0018-

0.2157 0.2152-

0.2148 0.2142-

1.245

‘Boi

a

0.0035

5oe

"mae

0. 0035

0.2354

:er

0.0035

0.2167

==

0.0035 0.0018-

0.2354 0.2152-

24-28@ 1.24

5

a

0.2148

0.0008-pte

Sa

0. 0027

0.2354

Hol ne a a ea ee ig ee 16 (1590)

Spats 2.5 (2494)

23,.6-27.5@

0.0008-

ee

0.0027

0. 0035

0.2344

.

0.2148

fa

0.2344 0.2142-

0.2339-

0.2344

0.2142-

0.0035

0.0187

0.2148

0.0035

0.2354

0.2344

a 2157

0.2148

0.2354

0.2344

foae! [toa a 45 a

ozost_| ozs 0.23390.2354

1.6 (1590)

= a 0.2344

0.2344

45

0.2142-

45

0,2339-

0.2148

2.0 (1997)

0.2344 @ inner: 13.6-17.4@ 1.08 Outer: 30.4-39.2@ 1.25

@ Inner spring: 1.08 Outer spring: 1.25 93551CJ1

For Maintenance Interval recommendations, see Section 1 of this manual

1-132

A\

Ls

my ve ote).

1?

.

4

has

i

GEO/CHEVROLET

-

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS All measurements are

|

Year 1998

Engine Displacement Liters (cc

Engine ID/VIN

MainBrg. Journal Dia. 2.04652.0472

given in inches.

Crankshaft Main Brg. Oil Shaft _ Clearance End-pla 0.00060.00440.0023 0.0149

1.8 (1843)

1.6 (1590)

2.0 (1997)

1.6 (1590)

0.0023

0.0165

1.9709

2.0472 2.04652.0472

0.002 0.00060.0023

0.0149 0.00440.0149

* 1.7322

0.00080.002 0.00080.0023 0.00060.0023 0.00080.0023 0.

0.00390.0165 0.00440.0149 0.00440.0149 0.00390.0165

2.04652.0472 2.28282.2834

2.0 (1997)

2001

Connecting Rod Oil Side Clearance _Clearance

1.7322

2.2834

2.5 (2494)

2000

Journal Diameter

0.0031

ints

1.6 (1590) 1999

Thrust onNo.

|

0.0031 0.0031

1.7322

0.0031

1.96601.9709 1.96781.9685 1.73161.7322 1.96781.9685

0.00080.0031 0.00160.0031 0.00080.0031 0.00160.0031

NA NA NA

0

2.0 (1997)

5

2.5 (2494)

6/1

1,6 (1590)

6

2.0 (1997)

iC

1,6 (1590)

0

2.0 (1997)

5

NA

2.5 (2494)

6/1

NA

1.6 (1590)

6

NA

2.0 (1997)

C

0.0149 0.00390.0165 0044-

0.00080.0031

NA

1.6 (1590)

0.00060.0023 0.00080.0023

1.73161.7322 1.96601.9709 1.96781.9685 1.7316-

a a ~ r

NA NA NA NA NA NA

NA: Not Available 935510J2

SFieonevnot I-1dd PISTON AND RING SPECIFICATIONS All measurements are given in inches. Year 1998

Engine Displacement Liters (cc

Engine ID/VIN_

Piston Clearance

0.0015 0.00080.0015

Top — Compression

Ring Gap Bottom Compression

Oil Control

0.0709 0.00390.0669

Ring Side Clearance Oil Bottom Top Compression Compression Control

0.0027 0.00120.0027

0.0023 0.0023

2.0 (1997)

NA

2.5 (2494)

NA

1.6 (1590) 0.0023

2.0 (1997) 1.6 (1590)

0.0027

0.0023

2.0 (1997) 0.0023

2.5 (2494) 1.6 (1590)

NA

2.0 (1997)

NA

1.6 (1590)

2.0 (1997) 2.5 (2494)

NA

1.6 (1590)

NA

2.0 (1997)

NA

NA: Not Available

93551CJ3

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

we

¥ :

1-1 1%

a

ue

3 4 SPECIFICATIONS

ee

GEO/CHEVROLET

TORQUE SPECIFICATIONS

Year

1998

Engine Displacement Liters (cc

[tie

Cylinder Engine ID/VIN

To

ToT

| 1.8 (1843) |nC

1999

Y,4,6(1590) | 6c] 0 | 2.0.(1997) | RbCHe)

All readings in ft. lbs. Main Rod = Crankshaft Bearing Bearing Damper Flywheel Bolts Bolts Bolts Bolts

se

ae fe

oe

eee

@

erase.

tet

Spark Plugs

te

@aelnge® [ines “| s4@ig | 158 soot eee EO@oed|

|

ead TA ees eo TUG (1500) bine | T@ee| 5SOO [pre hT "S4Gyn [oe gn

SO ECC) RO 2000 ~~[1.6(1590) [ 0 | © | 3641 2.01097) S| Ol @ Fe (2664 | Osta Oo | 1.6(1590) [| 6 | © | 39@ eee os) eas Rs eee 2001 {| 1.6(1590) | 0 | © | 3641

|

Be |24-26 | 4@ | 57 |13-20| fons [085 | 551 se att-20 | Leg Se nara | 758 ee ipOS | 25 | 4®© | 8 | PE a ee | 2426 | 81@ | 57 | 13-20 | |

Coe 2hUTA eke kOe ei Od ee ee8EL (er et ea a ee Eo | 1.6(1590) | 6 | © | 2 | EO I on ee BRA

| ed BLO el a OI bate a 9A

® Step 1: 26 ft.Ibs. Step2:41 ft. Ibs,

Step 3: 52ft.Ibs.

@ Value shown is for crankshaft timing belt sprocket

® Step 1: 38ft.Ibs. Step 2: 64 ft. Ibs.

ed BE Ee ikSG Sa el

Step2: 41 ft. Ibs.

Step 3; Loosen inreverse orderto 0 ft. Ibs,

Step 4: 26 ft. tbs.

Step 5:62ft.Ibs. © step 1: 38 ft. Ibs. Step 2: 61 ft. Ibs.

Step4:27 ft.Ibs.

Step 3: Loosen in reverse order to 0ft. Ibs.

Step5:76ft.Ibs.

Step 4:38ft.Ibs.

@ 10mm: 43.5ft.Ibs. 8mm: 19.5ft.Ibs.

Nut

58-80 58-80 70 58-80 58-80 69 70 70 58-80 58-80 69 70 70 70 70 70 70 70

© Step 1: 26 ft.tbs.

Step 3: Loosen in reverse order to0ft.Ibs.

Step6:Tighten 6mm bolt to 8ft.Ibs.

Bay

Lug

Step 5: 76ft.Ibs.

Step6:Tighten 6mm bolt to8ft.Ibs. ® Use multiple passes to arrive at final torque. Value shown is for crankshaft timing belt sprocket 935510J4

—

as.

na

GEO/CHEVROLET

Ge Lay

BRAKE SPECIFICATIONS All measurements in inches unless noted

Year

1998

1999

Model

| X90 {| 0.304 T0315 | Sidekick® | 0.670 | 0.590 | Sidekick@ | 0.670_| 0.590 pot | 0.866 | 0787 Tracker® __ |_0.670 | 0.590 | Tracker@ _|_0.670_{ 0.590 Grand Vitara Tracker©

2000

2001

Original Thickness

Brake Disc Minimum Thickness

:

Maximum Runout

[0006 | 0.006 | 0.006 | 0.006 | 0.006 | 0.006 0.006

;

0.670

0.590

0.670

0.590

Brake Drum Diameter Original Max. Maximum Inside Wear Machine Diameter Limit Diameter

Brake Caliper Bracket Mounting Bolts Bolts (ft. Ibs. (ft. Ibs.

[ 866 | a74 | 874 | 008 | 004 |iehot=72 51-72 ||| | 866 | 874 | 874 | 008 | 004 |Saree 51-72 | [ 10.00 | to07 | 1007 | 008 | 004 | 51-72 | | 1000 | 1007 | 1007 | 008 | 0.04 || 51725 51-72 | | 866 | 874 | 874 | 008 | 004 |rao 51-72 | | 866 [| 374 | 874 | 008 | 0.04 | 51-72 | 8.66

0

8.66

8,74

8.66

0.006

Minimum Lining Thickness Front Rear

866

51-72 Eee

0

1921 19:21 19-21 @ 19-21 19-21 19-21

4

8.74

8.74

0.08

0.04

19-21

| 874 | 874 | 008 | 004 |pet 51-72 1.72 5 4|

19-21

={| Vitara =| 0670 | 0590 | 0.006 | 66 | 874 | 874 | 008 |004 | 615 8.66 61.5 PI 8.66 61.5 1 ntelS 8.66 0.08 0.670 0.866 0.670

0.590 0.787 0.590

0.670__|__0.590 @a2-doormodel @ 4-door model

,

0006 0,006 0,006

8.66 8,66 8,66

8.74 8.74 8.74

8.74

0.08 | 0.04 0. 08 0 4 0.08 | 0.04

19-21 @ 19-21 19-21

61.5 F| 19-21 hee 61.5

0)

becclemee 19-21 8.66 | 38.74 {| 874 | 0.08 | 0.04 |erik wal 19-21

© 10mm: 37 ft. Ibs.

@ 10mm: 37 tt. Ibs.

12mm: 42 ft. Ibs.

412mm: 62 ft. Ibs. 93551CJ5

WHEEL ALIGNMENT Caster

Camber Preferred Settin

Year

Model

1998

De

Range g.

Preferred Setting Deg +3.00

Toe-in i 0.16+/-0.08 0.16+/-0.08 0.32+/-0.16

Steering Axis Inclination

0.16+/-0.08 0.16+/-0.08

1999

Vitara Grand Vitara Tracker Vitara Grand Vitara. Tracker Grand Vitara Tracker

foe

sata

cere!

0+/-0.08 0+/-0.08 0+/-0.16 0+/-0.08 0+/-0.08 0+/-0.16 0+/-0.08 0+/-0.08 0+/-0.16

_

—

— 93551CJ6

For complete service labor times, order the Chilton Labor Guide

SPECIFICATIONS

at

|

Be

i 1-1 36 GEO/CHEVROLET

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS

OEM Tires Year

1998

1999

Model

Standard

__Tire Pressures (psi) __Wheel

Ball Joint

Size

Inspection

Front

Optional

Rear

SB | none [28 Pres7snis | | S| | | Sidekick awd ss|—sP2057SRI5 | ~—s none «Ss | Sidekick Spot |= PatsesRiG =| none, || S28 | BO | [Tracker Qwd |= Ptgsv75nis =| ~—SsNone =| S23 | 3 Toe tracker 4nd 1.98] P2O5P5R15 YT Neonode ce| 23-8 | ies Foe be Sale eee X00 CL odPASS65R15- =" ee” foned) co] 428k] ae oe [Vitara 2-door2wd_ | PI9S/75SR15 | PateessRIG | 26 | 2 | bw | | Vitara 2-door 4wd | P20S/75R15 | =~ none S| S65 | S| CC | Vitara4-door | PaisesRis = | none | 26 | | | 2SGrand Viera (up P2sgessRie-< Ff anone) ef) 26 i] p26 | 7A ar Tracker2wd | waft |PIS6/75R15 2 #| E aNone} ©eof) 23 oat] pea | 6Sam Tracker dwd j"go[ -)P2OS75R15 of mate

Ale

eeSil eal eb acl icallie S/|

al Sil

AREAS

Ge el ee ES

ra

baat oe lain a

¢ “i v ss

SAAS

ST fons Sc |vl earner |i te oa PER Ei I Fae a kB a

"

|

ee

ick ea me ce dl Ge a OL aDriveshaft flangeae torquea @ i Hines Jia edenFea BA sc Rs See Comal ada icga bone olscree Gnd bean Ee’ oad acnh cas Paid ow de clevis pin®

Drum anddisc brakes ©

Seiad

Oe Wace ea akce es cles ines eee So alOs Ogee ese

Engine coolant

[a oe a

Front and rear axle lubricant

SE

Engine coolant level © Engine oil& filter @ Exhaust system @

Front and reardriveshafts © Front wheelbearings

Fuel ines & tank cap ©

Inspect forfluid leaks @ Key lock cylinder Manual transmission and transfer

Parking brake system @

ee

ee

Se en ein ec

Sil PROS | MEL [cv [ae] aa [ov Votieeew [| at secre | Si Sil PR

SES

Sil nae

La

ee

a

Pd

ee

eee

eee

eee adome

EY PE

Wd

7:

Ci

|

ES

Peewee

Power steering fluid

ee

ee (ae —

Bl RARE

Ting be

Throttle linkage@

Be feel FA (as Ee fumes acts vec. 3

uid

aE

=

Ra

ue

v

-

=

v

v

2

||| 1+ 7 ana

Every 100,000 miles

v

Se a Ge oe BE) Bet

oe

EEE EEE

ar BR

S/|

ra Ek.

ge

| RS

see PE Suspension & steetng @ =

arter safety swit

ee

ee

Radiatorcoreand NC condenser |smac | | | | ||| |v| || | Rotateres 7 See lugs

vi ee @.

a

Swe

TS

we

oS ee

v

Es

v ieee

v

ECAR

SAR

Sarr

7 93551CM4A

SPECIFICATIONS 4_4

tts 1-1

SCHEDULED MAINTENANCE INTERVALS Honda—Passport

sre|=]5[2s][5]5[2s] 95][as] |m VEHICLE MILEAGE INTERVAL (x1000)

TYPE OF

TO BE SERVICED Tires and wheels @ Valve clearance R: Replace

5

a

a

—_L: Lubricate

A: Adjust

ed ce Aad Rk

a

a

I

favhih etfern odebizasr brevefertonrfoer saltneeda a}pe |r alint-w!

S/l: Service or Inspect

ag

C: Clean

@ Perform this atthe mileage indicated or every 6 months, whichever occurs first.

@ Perform this at the mileage indicated or every 24 months, whichever occurs first. @ Perform this atthe mileage indicated or every 12 months, whichever occurs first.

® 321 V6 engine. FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) lfa vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier.

- Repeated short trips of less than 5 miles in temperatures below freezing. - Extensive idling or low-speed driving for long distances as in heavy commercial use, such as delivery, taxi or police cars.

- Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads.

ome

Air cleaner element: replace every 15,000 miles

Engine oil and filter: replace every 3000 miles or 3 months, whichever occurs first. Automatic transmission fluid: replace every 20,000 miles. Rear axle lubricant: replace every 15,000 miles. 93551CM4B

7

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

oa 4-156 SPECiFications HONDA & SCHEDULED MAINTENANCE INTERVALS HONDA PASSPORT

1 ee

The following should be used as a guide when determining the amount of work required for a particular service. In estimating how long a particular Scheduled Maintenance Service should take, please observe the following: @ Labor Time is time based on field research and data supplied by the vehicle manufacturer. ®@ Labor time operations are given in hours and tenths of an hour.

@ All labor operations are to be used as a guide. Mechanic Skill Level Codes: (A) PRECISION: Highly skilled with multiple certification.

(B) GENERAL: Normally skilled with certification. (C) MAINTENANCE: Semi-skilled working on certification.

LABOR TIME 7500 Mile Service (C) PaSSport: cts hfe tec eiscosbeeoe 15000 Mile Service (B) RASSDOMRs ree tics cecestacsssvessessesosd 22500 Mile Service (C) ELC)OE 0 os RR pal 30000 Mile Service (B) ECR Gag Ea ce Eon hee ae 37500 Mile Service (C) IRASSPOM pccecttees nescscscasuascccctsseas 45000 Mile Service (C) RBASSOONLE seer ee cote cs teeecceseeees

1.8 3.6

1.8 5.3 1.8 1.9

LABOR TIME 52500 Mile Service (C) PaSSport. x. treater tieeeeie 60000 Mile Service (B) RaSSPOMt -.....cerseccmutestressneee Adjust valves add 67500 Mile Service (C) Passports. .cosacr eieieecs noe 75000 Mile Service (B) PASSDOMl: ..ssaiscsntere ieetict ovaaacns Replace timing belt add 82500 Mile Service (C) Passport ..a2 eer en tact

1.8 5.3

1.8 2.7 1.8

LABOR TIME 90000 Mile Service (B) PASSPOMt. 5. .ciscccosss-csssetestecceseveee 97500 Mile Service (C) Passpont™ tense ee ee 105000 Mile Service (B) Passportiiexiithansus.sanitst Meese 112500 Mile Service (C) PASSPOF.d:.0: cca cee esis te 120000 Mile Service (B) Passport 7.52)... oe eee Adjust valves add

5.3 1.8

3.1 1.8 5.3

93551CM5

HYUNDAI Sante-Fe ENGINE AND VEHICLE IDENTIFICATION CHART ee ee ee ef eeEhging En Code Codewe )= | WEISS Ors fo ra Sole _Us(e)_—— Liters (cc) Cu. Guy In. cy Fuel Sys. Sk Engine EneType peng Eng. Mfg. ig Code @ BOA 2.4 (2351) (Cr Si 120 120 rt ot nednett oes beetMFI MFLi yin,ncxteu DOGS dhard wachlyundala aay aeei120. Th). Gy, AUP ROTRMIRI eipalae GsDOMGh nel acHyundai bvundalt nae 2 Bar t2gne\. (Ole.

Model Year Year 2001 2002

DOHC: Double Overhead Cam MFI: Multi-port Fuel Injection

@ 8th position of VIN 93551CX1

GENERAL ENGINE SPECIFICATIONS Model

Santa Fe

Engine Displacement Liters (cc) 2.4 (2351) 2.7 (2656

Engine ID/VIN

Fuel System Type MFI MFI

Net rete @ rpm 149@5500 181@6000

Net Torque @ rpm (ft. Ibs.) 156 @3000 177@4000

Bore x a 3. ii= 94 3.41x2.95

Compression Ratio 10:01 |10:01|

Oil Pressure @ rpm

MFI: Multi-port Fuel Injection

@ 11.6 Psi (80 kPa) @ idle. @7.3 Psi (50 kPa) or more @ idle. 93551CX2

For complete service labor times, order the Chilton Labor Guide

= 4 oT

-

Ae

’

at,

i 4-159 SPECIFICATIONS

ed

a

bP

ie

HYUNDAI

!

ENGINE TUNE-UP SPECIFICATIONS Ignition

Year

Engine Displacement Liters (cc

2001

2.4 (2351)

Timing

Spark Plug

— Engine

Fuel Pump (psi)

Idle

Valve

Speed m

Clearance (in.) In. Ex.

MT

AT

ess

NA

NOTE: The Vehicle Emission Control Information label often reflects changes made during production and must be used ifthey differ from this chart. NOTE: The fuel pressure readings are given with the vacuum hose connected to the regulator and the engine running B: Before top dead center HYD: Hydraulic

NA;: Not Availible 93551CX3

Power Steering oil pump pulley Engine coolant pump pulley

Tensioner

pulley

Alternator pulley

Crankshaft pulley Air conditioning compressor pulley Accessory V-belt routing—Hyundai 2.4L engines

9355LG04

sible Power steering pulley

ft 1 -1 59 Power steering pulley

Tensioner

9)

Alternator

|

eR

Air conditioner pulley

cas

Alternator

Crankshaft pulley

Crankshaft pulley

9355LG03

Accessory V-belt routing—Hyundai 2.7L engines

Please visit our web site at www.chiltonsonline.com

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1 =1 60 SPECIFICATIONS HYUNDAI

|

CAPACITIES Engine

Engine Model

Transmission

Transfer

(pts.)

Case

Displacement

Engine

Filter

Liters (cc)

ID/VIN

(qts.)

2.4 (2351) 2.7 (2656

Drive

Oilwith

SN | 476

Man.

Auto.

22 | 8

Axle Front

(pts.)

Fuel

Cooling

Rear

Tank

System

(pts.)

(gal.)

—_(qts.) 7.35 8.94

eS eee |e eee

NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained. 93551CX4

VALVE SPECIFICATIONS

Year 2001

Engine Displacement Liters (cc) 2.4 (2351)

2.7 (2656)

Engine ID/VIN

Seat Angle (deg.) 45

Face Angle _(deg.) 45

Spring Test Pressure (Ibs. @ in.) NA

Spring Free Length (in.) 1.804

45

45

NA

1.670

Stem-to-Guide Clearance (in.) Intake Exhaust

Stem Diameter (in.) Intake Exhaust

NA: Not Available 935510X5

SPECIFICATIONS 44164 SP

ee

cor

eer)

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ees

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

|

All measurements are given in inches

I

Engine

- Displacement Liters (cc

Year

|

Crankshaft

—_Engine ID/VIN

Main Brg. Journal Dia.

eh Gea

Rica

NA: Not Available

Connecting

Main Brg. Oil Clearance

Shaft

Thrust on No.

[toes | creme ue

Journal Diameter

Rod

Oil Clearance

Side Clearance

‘A

@® Nos. 1, 2, 4 and 5: 0.0007-0,0014

t

No. 3: 0.0009-0.0016

‘

4

93551CX6

PISTON AND RING SPECIFICATIONS

Year 2001

Engine Displacement Liters (cc

| we

Engine ID/VIN

All measurements are given in inches Ring Gap Piston Top Bottom Oil Clearance Compression Compression Control

Ring Side Clearance Top Bottom Oil Compression Compression _ Control

| toe |toe |ones | Stier | toe |tons | roe | tos | coms | Stes | Sous | ows | 0.0012

0.0138

0.0205

0.0276

0.0031

0.0028

NA: Not Applicable 93551CX7 ‘

TORQUE SPECIFICATIONS a

Year 2001

Engine Displacement Liters (cc

All readings Engine ID/VIN

Cylinder Head Bolts

Main Bearing Bolts

in ft. Ibs.

Rod Bearing Bolts

Crankshaft Damper Flywheel Bolts Bolts

Manifold Intake Exhaust

Spark Plugs

Lug Nut

24(5t) | Boo} © | @ | © | i422 | 4101 | @ | © | 1522 | 66-83 bic e ae e e 15-

NOTE: Dip main bearing bolts and crankshaft damper bolt in clean engine oil prior to tightening.

© If using used parts: Step 1: 14 ft. Ibs. (20 Nm).

@ Bolt (M8): 11-14 ft. Ibs. Nut: 22-30 ft. Ibs.

Step 2: plus an additional 90 degrees.

© Bolt (M8): 18-2 ft. Ibs.

Step 3: plus an additional 90 degrees.

Bolt (M10): 25-40

Ifusing new parts: Step 1: 46 ft. Ibs. (64 Nm) Step 2: Release the bolts.

Step 3: 14 ft. lbs, (20 Nm) Step 4: plus an additional 90 degrees.

Step 5: plus an additional 90 degrees.

@ 15 ft. Ibs. Plus 90degrees @ 14 ft.tbs. Plus 90degrees

© Step 1: 14 ft-lbs. Step 2: plus an additional 90 degrees. Step 3: plus an additional 90 degrees.

© Step 1: 18 ft. Ibs. Step 2: plus an additional 5862 degrees. Step 3: plus an additional 4347 degrees.

@ Bolt (M10); 10-12 ft. Ibs. Bolt (M7): 7-9 @y2-15 ft. lbs. Plus 90-94 degrees 93551CX8

Timing belt service is covered in Section 3 of this manual

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1 1 62 SPECIFICATIONS

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HYUNDAI

BRAKE SPECIFICATIONS

Hyundai Santa Fe All measurements in inches unless noted Brake Drum Diameter Maximum Max. Original Brake Disc Machine Wear Maximum _ Inside Minimum

Original Thickness

Thickness

Runout

Diameter

Diameter

Limit

Minimum Lining Thickness Shoe Pad

Brake Caliper Mounting Bracket Bolts Bolts.

93551CX9

VALVE SPECIFICATIONS Engine Displacement Liters (cc

1998

Engine IDIVIN

el A

Seat Angle deg.

Face Angle (i g.)

1.654 @

0.0024

0.0026

Stem Diameter in. Intake Exhaust 0.23430.2348 0.2348

1.654 @

0.0024

0.0026

0.2348

0.2348

1,654 @

0.0024

0.0026

0.2348

0.2348

1.654 @

0.0024

0.0026

0.2348

SpringTest Pressure (Ibs. @ in.)

Spring Installed Height in.

Stem-to-Guide Clearance (in.) Intake Exhaust

De ae PT temo | nous 9ene il eae be he || el ee eee We |renee teams ee ‘O)Refacing angle: 90 degrees

@ 102-118 tbs. @ 1.315 in, @ Free length: 1.8913 in. @ Weer limit: 0.0059 in. 93551CX0

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS

e

e

OEM Tires

Year

2001

Model

Standard

P225/70R16

Optional

Tire Pressures (psi) Front Rear

Wheel Size

6.5Jx16

Ball Joint Inspection

NS

OEM: Original Equipment Manufacturer

‘

PSI: Pounds Per Square Inch NS: Not specified by manufacturer 93551CY1

én

SPECIFICATIONS 1= 6: i ISUZU Amigo ¢ Rodeo ¢ Trooper * VehiCROSS ENGINE AND VEHICLE IDENTIFICATION Code

Liters (cc)

Cu. In.

Engine Cyl.

Fuel Sys. _ Engine Type

_Eng. Mfg.

‘Coda

A eS WE Geer SZ) eea YT ac8” ce NET fT, DONC peeled amp X X 3.5 (3494) 213 6 MFI DOHC

Isuzu

MFI: Multi-port Fuel Injection

Model Year tt ua weed

a

4 1 ee ee ees TA

ear

1999

2000 2001 me ei)

DOHC: Double Overhead Camshaft

:

SOHC: Single Overhead Camshait

|

© 10th position of VIN

| 93551CM7

&

GENERAL ENGINE SPECIFICATIONS Year

1998

1999

2000

x ‘ - Model

Engine Displacement Liters (cc

Engine Series ID/VIN)

Fuel System

Net Horsepower @ rpm

Net Torque @ rpm ft. Ibs.

Bore x Stroke in.

22@800

| 2.2(2198) | D | MFI | 130@5200 | 144@4000_ | 3.39x3.72

| A azgisy [wwe aisesi00 |—ziseano | sepans [ant | aaneonm Rodeo | 2.2(2198) | D | MFI | 130@5200 | 144@4000 | 330x372 | 96:1 | 22@800 ee mccma ce MFI_| 205@5400 | 214@3000 | 368x303 | ai:1_| 60-8063000

|_ Trooper | 3.5(3494) |X | MFI | 215@5400 | 230@3000__ | 3.68x3.35 | 9.1:1_| _60-80@3000

Amigo | 22(2198) | D | Mri | 190@5000 | 144@4000_ | 3.3072 | 961 | 220800

| -3.2(3165) | W | Mri | 205@5400 | 214@3000__ | 3.68.03 | 91:1 | a I | D) | MFI | 130@5200 be Rodeo |22/2198 Feasts [wwe |aosesi00 |—2iveatno — 3.68x3.03 Trooper | 3.5(3494) [| X | MFI | 215@5400 | 230@3000 | 368x325 | 91:1 | MFI_ | 215@5400 | _230@3000__ | 3.68x3.35_| 9.1:1_| VehiCROSS

3.2 (3165) | _W 9.11 32 (3165)_| _W__|_MFl 9.41 3.66135 | att a8 2t5@5400 | 29063000 | 36005 | 9.11 iCROS| osA|— 35(0494) | x | MFI] MFI | 130@5200 | 144@4000_ | 3.39x3.72 | 10.0:

:

ca s =p)

(dp)

2.2 (2198) 3.2 (3165)

Rodeo Sport | 2.2 (2198)

Troope VehiCROSS ; =

60-80@3000 22@800 60-80@3000 60-80@3000 _60-80@3000

| 22(2198) | D | MFI_| 190@5200 | 144@4000_ | s39a72 | 961 | 220800

igo

3 aro) F

Rodeo

2001

Oil Pressure @ rp

Compression Ratio

| 60-80@3000 226800 | 60-806 3000 | 608003000 | 60-8003000 236800

MFI | 205@5400 | 214@3000 | 368x303 | 91:1 | 60-80@3000 22@800 10.0:1 MFI 130@5200

ag | radX ea MFI | 215@5400 MFI

3.68x3,03 3.68x3.35 3,68x3.35

9.4:1 9.1:1 9.1:1

60-80@3000 60-80@3000 60-80@3000

MFI: Multiport fuel injection 93551CM8

Heater Core replacement is covered in Section 2 of this manual

41-164 SPECIFICATIONS

ES ENGINE TUNE-UP SPECIFICATIONS

Engine

Displacement

i Engine

Spark Plug

Ignition Timing

Fuel

Gap

(deg)=

Pump

Idle Speed

rpm) a, a

Valve

Clearance ee

ae 2.2 (2198

3,2 (3165)

ee Di pul

Po 3.5 (3494) 2.2 (2198)

ron |ae

ae

3.5 (3494) NOTE: The Vehicle Emission Control Information label often reflects specification changes made during production. The label figures must be used ifthey differ from those in this chart. B: Before top dead center

HYD: Hydraulic @® Controlled by the PCM 93551CM9

Front of the Vehicle

v

Front of the Vehicle

v

79243668

2.2L (VIN D) engine Firing order: 1-3-4-2 Distributorless ignition system

79243650

3.2L DOHC and 3.5L engines Firing order: 1-2-3-4-5-6 Distributorless ignition system (one coil on each cylinder)

SPECIFICATIONS 4.465

AIR PUMP ORIVE BELT

~ A/C COMPRESSOR DRIVE BELT 79244G37

79244G39

Accessory V-belt routing—2.2L engines

9355NG99

Accessory serpentine belt routing—3.5L engines

Brake service is covered in Section 4 of this manual

4

ee

ey Chen ies

G SPECIFICATIONS

(Sl

Bae

. 7, «t

CAPACITIES

Year

1998

Model

Amiao

OAM Rodeo |

ee

7999

2000

2001

Engine Displacement Liters (cc

Be

Engine ID/VIN

el

ee

Oil with Filter (qts.

Engine Transmission (pts.) Auto. Man.

Transfer Case

Drive Axle Front

ee

Rear

Fuel Tank

Cooling System gts.)

3.7

ATT.

73

11.2 | wert ceo Tee | =P a0 een Fear | 22(2198) | OD | 48 | 45 | 182] 30 | 30 | 37 { 21.1 | 73

rr aeaoe LT

Ps Trooper — (" 9.5:43404)- fe

| 50d 8.8] 18.2] 8004

Amigo |( 22ete)) [Dna lo48-1 | 45) abn]

I Rodeo

errs | 22(21%) raz gies) | VehicROsS | 35(3404)

SON Mo Seis 222 8.

30) eee

pene)

ne

ea ea a ae ka 11.2 | D | 48 | 45 | 182] 30 [..30 [| 37 | 211 [ 73 [Wik [5.010 62 wee | So To aoe tr [eee | xX | 50 | ~— | 182 | 300] 30 | 64 [| 25 | ©

(2198 cd ardpe2.2 rr aoe TY We Ew cipro

“ape3.7om 17.7

=

7.3

Reet caster ig Wt | cot pac eee nae 11.2 | Fedeo fe3te) fb} st 48 S27 130 220.) Sree ee ee be 82{3168)- fe We | 6.06 |~6.2 1182) 830 fe 26 Le) Site thle emtne 35(340) | X | 50 | 58 | 182 [ 30] 30+] 64 | 25 | © |_VehiCROss_| 3.5(3494) | xX | 50 | — | 12] 300 [ 30 | 64 | 225 | © Rodeo Sport |22(2198). | Di | 48 [62.1.— | 40 ]--22).|.47--| 117 ol 73 oe Mme a RC ae 11.2

ee Trooper

3,2 (3165 3.5 (3494

VehiCROSS | _3.5 (3494

5.0 5.0

Pe alMBETes

ae

CS a EE a ee 58 | 122 |300 | 30 | 64

es a

®@

7A

NOTE: All capacities are approximate. Add fluid gradually and check to ensure a proper level has been reached. M40 pts. ifequipped with Torque On Demand

Qam:7.4 qts. MTT: 7.0 qts. 93551CM0

SPECIFICATIONS 4_4 :

ISUZU 1-1

VALVE SPECIFICATIONS Engine Displacement

1998

Engine

Seat Angl (deg.

Face Angle deg. NA

Spring Test Pressure Ibs. @ in NA

Spring _Installed Height in.) NA

Stem-to-Guide Clearance (in.) Intake Exhaust 0.00120.00160.0022 0.0026

Stem Diameter (in.) Intake Exhaust NA

oa 41-44@ 0.00020.00120.2346ee ETE a | | toe |tts |as| Sesoe | saul 1 |IP oso olen 3.2 (3165)

NA

i

B

0.0025 0.0016-

0.2353 NA

0.0025

0.2353

Yoon. ||0.2346eee 0.0012-

2.2 (2198) 3.2 (3165) 55 (3494) NA: Not Available 93551CN1

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

4-168 SPEciFicaTions ISUZU

Be sag a

Te tal

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS

Year

me

Engine Displacement Liters (cc

Journal Diameter

Connecting Rod Oil Side Clearance _ Clearance

eT P| ease | ooots | too |” | ston |conte | onto

3.2 (3165) Fete

rae

1999

Engine ID/VIN

All measurements are given in inches. Crankshaft Main Brg. Main Brg. Oil Shaft Thrust Journal Dia. Clearance End-pla' onNo.

ot eee

fea 2.2 (2198)

3,2 (3165)

2.2610

0.0016

0.0008

2.5165-

0.0007-

0.0024-

2.5170

0.0017

0.0094

2.5170

eos

[erage |

eee

ooorr_|

0.0094 0.0004-

0.0007-

002

0.001

2.5170

0.0017

2.2610

0016

0.0012

ole:

0.0150

0.0050-

0.002

0.0150

0.0023

0.0150 0.0050-

cow | | arse | coos | _oten

0.001 0.0007-

2.5170

1.9100

BRR

3

2.5170

0.0017 0.00070.0017

.0094

|

0.0008

ti

0.0050;

0.0023

0.0150

1235

0.0023

0.0150

oot80 ae eis a (= ‘oro0 | _aoore | _ooten pe || zero | too |cose ares | omnes _| on 2.5170 0.0017 0.0094 Pee |ois Seem [ome vos ||| teat tLeter0.0150 2.51652.5170

cos

. 2.1235

0.0150

0.0150 0.00240.0094

0.00500.0150 93551CN2

>

°- @

tics.

4p

eae

2

i

eS

SPECIFICATIONS 4.46

,i

PISTON AND RING SPECIFICATIONS All measurements are given in inches. Engine Displacement Liters (cc

Engine ID/VIN

Piston __Clearance

Top Compression

3.5 (3494)

X

NA

0.01180.0157

1998

cali laa ali ear 3.2 (3165) W

ett

NA

Ring Gap Bottom Compression

Oil Control 0.0160.055

Ring Side Clearance Top Bottom | Compression Compression 0.00080.00080.0546 0.0546

Oil Control

NA 0.00080.0546

0.00080.0546

3.5 (3494) 2.2 (2198) 3.2 (3165) 3.5 (3494)

NA

2.2 (2198) NA

2 (3165) 3.5 (3494)

0.00060.0015

NA: Not Available

93551CN4

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

ae 1%

bs

ee

Oe

icarions 2470 scecin ISUZU

TORQUE SPECIFICATIONS Engine Displacement

© Step 1: 18 ft. Ibs. Step 2: Plus 90 degrees Step 3: Plus 90 degrees Step 4: Plus 90 degrees

@ Step 1: 37ft.Ibs. Step 2: Plus 45 degrees Step 3: Plus 15 degrees

@® Step 1:25 ft.lbs. Step 2: Pius 45 degrees

Step 3: Plus 15 degrees

Cylinder

All readings in ft. lbs. Main Rod Damper Bearing Bearing Bolts Bolts

@ Crankshaft sprocket:

Step 1: 94 ft. Ibs. Step 2: Plus 45 degrees Crankshaft balancer: Step 1: 14 ft. Ibs.

Flywheel

Manifold Intake

Exhaust

Spark

Lug

Plugs

Nuts

@® Step 1:21ft. Ibs. Step 2: 47 ft. Ibs. Step 1: 22 ft. Ibs. Step 2: Plus 55-65 degrees Step 3: Crankcase side bolts to 29 #t. Ibs.

Step 2: Plus 45 degrees

®Step 1: 48tt.tbs. Step 2: Plus 30 degrees Step 3: Plus 15 degrees

© Step 1: 112 inch Ibs. Step 2: 14 ft. Ibs. Step 3: 14 ft. Ibs. 93551CN5

SPECIFICATIONS 1-1 710 =

BRAKE SPECIFICATIONS

:

All measurements in inches unless noted Brake Drum Diameter

Brake Disc i

_

Model

Machine Thickness

Fi 1.020 | 0983

=Max.

Maximum

Minimum

— Bracket

‘Mounting

Maximum _ Inside Runout Diameter

Wear Limit

Machine Diameter

Lining Thickness

Bolts ft. Ibs.

Bolts ft. Ibs.)

=] a

5 32 4 32 54 32

J

|0969 || 000

|R{ o7io | 0668 | 0654 Rodeo | F{ 1.020 | 0983 { 0969 |R| o7io | 0668 { o654 Trooper | F{ 1.024 | 0.983 [| 0969 |R| o7io | 0668 | o654 YeMeROSS | tes 4 0M ON [R| o7io | 0668 | 0.654 Amigo Ej 1m) tosses TR]

0710 |

1.020 R| 0710 Trooper | F |1.024 | |R| 0710 | : 2001

Minimum Thickness

Brake Caliper

Original

Amigo [FI 1.020 | 0.983 |0.969 | 0.05 [| — [ — [| -— J Pea atic mapa ed) A a EE ee | Redeo LE1 1029_{o9e8_} ogee} oong_{ =| =| —_| |R{ o7io | 0668 | 0654 | 0.005 | 116 | 1167 | NA | Trooper | F} 1.024 | 0.983 | 0969 | 0005 | — [| — | -— | BA | i be go

2000

=

Original Thickness

~-|-1-- 0,75 3-+-| —— 4210 bef: £6.50" | peck Opes fee Oe wee a ee ee ee ee St Biiodeeruind Md i eee ad Peet Ce ad ee ee eee Ai ee aa iC a ee a a Ee peWehiCROSS hos [P O75 Tir t421007 ane 05080 |) aa ee Oe oie Rodeo Spot POR |) 4,00 | [14250 0G fim O50 [i eed Pe Ontos: am i ee ER Ce PS a Ee a Rodeo F #250 0hy [OR 0.500 [Tog] OT Oats aaapioriey |R = ieee) OO De 04+/-0.20 pi Troopet S| 075.) ie 4290 0 ep See | 0+/-0.08

.VehiCROSS 20). 1075 [dat 4210,

OST

|

04/-0.08

ad

= = =

2 = = = = = = = — = ~ = =

~ L-

>

93551CN7

SPECIFICATIONS 4.473 TIRE, WHEEL AND BALL JOINT SPECIFICATIONS OEM Tires * Year

|

Model

Standard

Optional

Tire Pressures (psi) Front Rear

Wheel Size

Ball Joint Inspection

6.5-JJ

U: 4-28©

L: 4-55

=

:

ipo]

n

4=

a

;

L: 4-55

z

’

L: 4-55

4

L: 4-55

;

=A

L: 4-55

29

=a

U: 4-28© L: 4-55

Std: 29

Std: 29

Opt: 26

Opt: 26

U: 4-28© Opt: 7JJ

26

ro)

L: 4-55

U: 4-28@ L: 4-55

Trooper

VehiCROSS

P245/70R16

35

T-JJ

26 26

TJJ TAN

TJ ml rm!oS oO] S|

VehiCROSS

P245/70R16

nr nm|S|

ce | ee =~]

NooD

:(et[o]= 86 SERVICE Tel

hash

eee eee eo a cd eg a PaesFa CG ea a Spe piel oi le acto || i

se see CECE

lines & hoses

~

Drive belts

ea

a

Sil

Engine coolant

A

Sania ladies ead ea mae Gd Sead Engine oil& fiter Exhaustpipes &mounts | si | | |v | |is |v]|rt SM a rh Fuel tank capgasket Cc ea 7S Halfshaft boots & flange bots) St | | |v[ ||[~|SM ist|ey SM Limited slip differential fluid [esaahiony ki. acs al Ba hc vied bei Manual transmission and

gee

v

Bee

differential fluid

Non-platinum spark plugs

Bim apank pugs

ea

ES

Ny) Reena |> [ES a

Propeller shaft (4WD)

caret

Propelshaft bots

eee

Rear wheel bearing

ee

Steering linkage

beige Sal aoe Le head

Valves

Gua

R: Replace

S/l; Service or Inspect

A

dE

ae a = ae

a PS

ie

bond a

ee

gud a ied we)

[sts 8 | [ss Ts [st tststststs

—_L: Lubricate

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) if a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier. - Repeated short trips of less than 5 miles in temperatures below freezing.

- Excessive idling or low-speed driving for long distances as in heavy commercial use, such as delivery, taxi or police cars. - Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads. Oil filter: service or inspect every 5000 miles or 4 months, whichever occurs first. Brake linings and discs or drums: service or inspect every 5000 miles or 4 months, whichever occurs first. Steering linkage: service or inspect every 5000 miles or 4 months, whichever occurs first. Ball joints and boots: service or inspect every 5000 miles or 4 months, whichever occurs first. Brake discs & pads (front): service or inspect every 6000 miles.

Halfshaft boots: service or inspect every 5000 miles or 4 months. Retighten the flange bolts, whichever occurs first. Body chassis bolts and nuts: service or inspect every 5000 miles or 4 months, whichever occurs first.

Transmission and differential fluid: replace every 15,000 miles or 12 months, whichever occurs first. Transfer case and differential fluid: replace every 15,000 miles or 12 months, whichever occurs first. Timing belt: replace every 60,000 miles or 48 months, whichever occurs first. 93551CAY

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SPECIFICATIONS 4_94Q SCHEDULED MAINTENANCE INTERVALS Toyota—Highlander

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Brake linings & drums

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Brake line pipes & hoses Brake pads & discs (front & rear) Propeller shaft grease

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Steering knuckle & chassis grease

Steering linkage

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Air cleaner filter

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Fuel lines & connections

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Charcoal canister. Fuel tank cap gasket

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Heated oxygen sensors (except Calif.)® R: Replace

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@ Heated oxygen sensors (except Calif.): replace every 80,000 miles. ® Platinum plugs are replaced at 100,000 mile intervals

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) Ifa vehicle is operated under any of the following conditions it is considered severe service: - Extremely dusty areas. - 50% or more of the vehicle operation is in 32°C (90°F) or higher temperatures, or constant operation in temperatures below 0°C (32°F). - Prolonged idling (vehicle operation in stop and go traffic). - Frequent short running periods (engine does not warm to normal operating temperatures).

- Police, taxi, delivery usage or trailer towing usage. Air cleaner filter: service or inspect every 3750 miles

Engine oil & filter: replace every 3750 miles. Ball joints & dust covers: service or inspect every 7500 mites.

Bolts & nuts on chassis & body: service or inspect every 7500 miles. Brake pads & discs (front & rear): service or inspect every 7500 miles. Steering knuckle & chassis grease: service or inspect every 7500 miles. Steering linkage: service or inspect every 7500 miles. Exhaust pipes & mountings: service or inspect every 15,000 miles. 93551CBZ

Timing belt service is covered in Section 3 of this manual

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; 1-250 SPECIFICATIONS

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SCHEDULED MAINTENANCE INTERVALS Lexus—RX300

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Engine oil & filter Ball joints & dust covers Bolts & nuts on chassis & body

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Brake linings & drums

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Use care not to spill the coolant remaining in the heater core during removal.

11. Remove the heater core. To install: 12. Install the instrument panel finish panel by performing the following procedure:

CAUTION Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. ->Verify that the 4-way locator on the left-hand side is properly seated.

a. Position the instrument panel on the center dash panel. b. Install the left-hand instrument panel bolts. c. Install the right-hand instrument panel bolts. d. Engage the antenna cable locators into the instrument panel and connect it to the radio. e. Connect the right-hand instrument panel cow! side wiring electrical connectors.

f. Connect the ECS module electrical connector by performing the following: ¢ Connect the connector. e Install the locking clip. g. Install the right-hand A-pillar lower trim panel. h. From inside the engine compartment, install the main wiring assembly/lower bulkhead connector by performing the following: Position the bulkhead connector. Secure the clips. Tighten the bolt. Install the coolant reservoir by performing the following: e Position the reservoir. e Install the bolts. j. Install the instrument panel dash brace by performing the following:

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m. Install the left-hand upper access panel. n. Connect the climate control vacuum harness connector. o. Install the upper center instrument panel access panel.

p. Install the instrument panel cow! top Screws. q. Install the engine cover. r. Position the engine cover in the vehicle and fasten the cover latches. s. Install the steering column. t. Install the driver’s side air bag module by installing or connecting the following items: e Driver's air bag module. e Air bag sliding contact electrical connector. e Horn electrical connector. e Both driver's air bag module screws. e Both back cover plugs. u. Install the passenger's side air bag modules by installing or connecting the following items: e The 6 offset fasteners used for retaining the air bag module door from the instrument panel. e Passenger’s air bag module electrical connector and module. e Passenger’s air bag module retaining nuts. e Instrument panel finish panel and reinforcement. 13. Connect the quick disconnect heater hose couplings at the heater core by performing the following procedure: a. Clean the tubes and lubricate them with rubber insulator lube. b. Install a new coupling retainer, spacer, and lubricated O-ring seals into the quick disconnect coupling housing. c. Push the heater water hose with a quick disconnect coupling onto the tube. d. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. 14. Refill the cooling system. 15. Connect the battery ground cable. 16. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Ford Expedition and Excursion; Lincoln Navigator

¢ Position the instrument panel dash © REMOVAL & INSTALLATION

brace. Install the 6 bolts. k. Install the AFCM.

|. Install the instrument panel cow! top nut.

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Expedition and Navigator 1. Disconnect the negative battery cable.

PM After disconnecting the negative battery cable, wait 1 minute for the SRS module to deplete its energy. 2. Drain the cooling system into a clean container for reuse. 3. Remove the instrument panel by performing the following procedure: a. If equipped, remove the floor console assembly. b. Remove the lower steering column cover bolts and the cover. c. Remove both front door scuff plates. d. Remove both side cowl trim panels. e. Disconnect the electrical connector from the Brake Pedal Position (BPP) Switch. f. Remove the radio ground and the GEM/CTM ground bolts. g. Disconnect the left side instrument panel main wiring harness connector. h. In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors. i. In the driver's compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instru-

ment panel. j. Disconnect the air bag diagnostic monitor electrical connector. k. Disconnect the inertia fuel shutoff switch electrical connector. |. Remove the right side ground bolts. m. Disconnect the right side instrument panel wiring harness connectors. n. Disconnect the electronic blend door actuator electrical connector. _0. Disconnect the climate control head vacuum harness connector. p. Remove the steering column opening cover reinforcement nuts and the cover reinforcement. q. At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors. r. Atthe steering column, disconnect the remaining electrical connectors. s. lf equipped with a transmission range indicator, remove the bolt and disconnect the cable. t. Remove the steering column-toinstrument panel nuts and lower the steering column. u. Remove the right side front fender

HEATER CORES — FORD MOTOR CO.

1. Instrument panel finish panel 2. Instrument panel defroster opening grille assembly 3. Instrument cluster panel 4. Instrument panel relay cover 5. Instrument panel

6. 7. 8. 9. 10.

Glove compartment Center instrument panel finish panel Instrument panel steering column cover Instrument panel fuse door Steering column opening cover 93113GM2

Exploded view of the instrument panel components—Ford Expedition and Lincoln Navigator

For complete service labor times, order the Chilton Labor Guide

2-24 NATE eanES

1. Digital audio compact disc player 2. Compact disc player mounting bracket 3. Compact disc player compartment trim panel

4. Radio and A/C integral control assembly

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5. A/C register (upper)

6. Blower assembly 7. Center console finish panel

8. Console finish panel mat 93113GM3

Exploded view of the floor console components—Ford Expedition and Lincoln Navigator

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splash shield screws and move the shield away from the panel.

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the antenna base. w. Remove the instrument panel relay cover and disconnect the autolamp sensor electrical connector and/or the sunload sensor connector. x. Remove the glove box. y. At the passenger's air bag module, remove the screws, disconnect the electrical connector and remove the air bag module.

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91190640

Remove the bulkhead electrical connectors from inside the engine compartment—Ford Expedition and Lincoln Navigator

91190641

Remove the audio unit ground and the GEM/CTM ground bolts—Ford Expedition and Lincoln Navigator

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Remove the instrument panel bolts through the steering column opening—Ford Expedition and Lincoln Navigator

with the front facing upward. a. Remove the right side assist handle screw covers, the screws and the handle. b. At both doors, pull back the weatherstrip seals and remove the windshield garnish moldings. c. Remove the instrument panel reinforcement bolt below the left side corner of the glove box. d. Through the air bag module opening, remove the instrument panel bolts. e. On Expedition, remove the upper instrument panel cowl covers and bolts. f. On Navigator, remove the instrument panel defroster grille assembly and the instrument panel cowl top bolts. g. At the relay bracket, remove the instrument panel bolt. h. At the lower left side of the cigar lighter, remove the instrument panel bolt. i. At the both sides, remove the instrument panel-to-cowl side nuts. j. At the steering column opening, remove the instrument panel bolts. k. Remove the upper instrument panel floor brace bolt. |. Using an assistant, remove the instrument panel. 4. |f equipped with the 5.4L 4V engine, remove the junction block splash shield. 5. lf equipped with the 5.4L 4V engine, remove the bolts and disconnect the cable ends from the starter relay. 6. If equipped with the 5.4L 4V engine, remove the junction block bracket. 7. Compress the holding tabs and disconnect the heater hoses from the heater core. 8. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter.

Please visit our web site at www.chiltonsonline.com

9. Disconnect the vacuum line.

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HEATER CORES

FORD MOTOR CO.

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91190644

Remove the passenger side ground bolt—Ford Expedition and Lincoln Navigator

Detach the passenger side instrument panel main harness connectors—Ford Expedition and Lincoln Navigator

91190646 91190645

Remove the instrument panel bolt on the relay bracket—Ford Expedition and Lincoln Navigator

Remove the instrument panel bolts through the passenger side air bag module opening—Ford Expedition and Lincoln Navigator

91190648 91190647

Remove the instrument panel reinforcement bolt below the driver’s side ) corner of the glove compartment—Ford Expedition and Lincoln Navigator

Position the carpet aside and loosen the instrument panel floor brace—Ford Expedition and Lincoln Navigator

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10. Remove the heater core bracket screws and the bracket. 11. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover. 12. Remove the blend door assembly from the heater housing. 13. Remove the heater core. To install: 14. Install the heater core. 15. Install the blend door assembly to the heater housing. 16. Install the 13 heater housing plenum camber cover and the heater housing 91190649

Remove the passenger side instrument panel cow! side nut—Ford Expedition and Lincoln Navigator

plenum chamber cover screws. 17. Install the heater core bracket and the bracket screws. 18. Connect the vacuum line. 19. Install the air conditioning plenum demister adapter and the air conditioning

plenum screw. 20. Connect the heater hoses to the heater core.

91190G50

On Navigator, remove the defroster grille assembly—Ford Expedition and Lincoln Navigator

91190651

Remove the cowl panel mounting bolts—Ford Expedition and Lincoln Navigator

21. Install the instrument panel by performing the following procedure: a. Using an assistant, install the instrument panel. b. Install the upper instrument panel floor brace bolt. c. At the steering column opening, install the instrument panel bolts. d. At the both sides, install. the instrument panel-to-cowl side nuts. e. At the lower left side of the cigar lighter, install the instrument panel bolt. f. At the relay bracket, install the instrument panel bolt. g. On Navigator, install the instrument panel cowl top bolts and the instrument panel defroster grille assembly. h. On Expedition, install the upper instrument panel cow! bolts and covers. i. Through the air bag module opening, install the instrument panel bolts. j. Install the instrument panel reinforcement bolt below the left side corner of the glove box. k. At both doors, install the windshield garnish moldings and the weatherstrip seals. |. Install the right side assist handle, the screws and the handle screw covers. m. At the passenger's air bag module, install the air bag module, connect the electrical connector and install the air bag module screws. n. Install the glove box. 0. Connect the autolamp sensor electrical connector and/or the sunload sen-

Timing belt service is covered in Section 3 of this manual

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ii. Install both front door scuff plates. jj. Install the lower steering column

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22. Refill the cooling system. 23. Connect the negative battery cable. 24, Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

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1. Drain and recycle the engine coolant. 91190G52 9 Etie coin,

Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in — sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

93113GM1

2. Disconnect the heater water hoses from the heater core. 3. Disengage the stops and lower the glove compartment door. 4. Remove the electronic blend door actuator and bracket assembly.

View of the heater core—Ford Expedition and Lincoln Navigator

sor connector; then, install the instrument panel relay cover. p. Connect the antenna cable to the antenna base, q. Install the right side front fender splash shield and screws. r. Install the steering column and the steering column-to-instrument panel nuts. Ss. lf equipped with a transmission range indicator, connect the cable and install the bolt. t. At the steering column, connect the remaining electrical connectors. u. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors. v. Install the steering column opening cover reinforcement and the cover reinforcement nuts. w. Connect the climate contro! head

vacuum harness connector.

x. Connect the electronic blend door actuator electrical connector. y. Connect the right side instrument panel wiring harness connectors. z. Install the right side ground bolts. aa. Connect the inertia fuel shutoff switch electrical connector. bb. Connect the air bag diagnostic monitor electrical connector. cc. In the driver’s compartment, install the bulkhead electrical connector to the instrument panel. dd. In the engine compartment, connect the bulkhead wiring harness connectors and the install wiring connector bolts. ee. Connect the left side instrument panel main wiring harness connector. ff. Install the radio ground and the GEM/CTM ground bolts. gg. Connect the electrical connector to the Brake Pedal Position (BPP) switch. hh. Install-both side cowl trim panels.

>The heater core cover must be raised vertically before removal to avoid damage to the heater core housing. 5. Remove the heater core cover screws and remove the cover. 6. Remove the heater core from the housing. To install:

Position the temperature blend door manually to properly align the actuator and the door. Do not power the actuator electrically. If it is not engaged with the temperature blend door, damage to the actuator may occur. eos oes e>Add gasket between housing and cover before installing cover.

HEATER CORES | FORD MOTOR CO.

7. The installation is the reverse of the removal.

Ford Explorer and Mercury Mountaineer REMOVAL & INSTALLATION 1998-00 1. Disconnect the negative battery cable.

ki CAUTION After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy. 2. Drain the cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core. 4. Remove the steering column by performing the following procedure:

a. Position the front wheels in the straight-ahead direction. b. At the both sides of the steering wheel, remove the cover plugs, the steering wheel-to-air bag module screws, disconnect the air bag electrical connector and carefully remove the air bag module.

*k< CAUTION Safely store the air bag module with the front side facing upward. c. Remove the steering wheel-tosteering column nut. d. Using-a steering wheel puller, press the steering wheel from the steering column. e. Remove the parking brake release handle screws and move the release handle aside. f. Remove the hood release screws and move the hood release aside. g. Remove the 2 instrument panel-tosteering column cover screws and the COVEr. h. Remove the instrument panel steering column opening reinforcement bolts and the reinforcement. i. Remove the ignition switch bolt and disconnect the ignition switch electrical connector. j. At the base of the steering column, disconnect the electrical connectors. k. If equipped with an automatic

transmission, remove the transmission range indicator bolt and the cable. |. If equipped with an automatic transmission, disconnect the shift cable from the steering column shift tube lever and the steering column bracket. m. Disconnect the brake shift interlock solenoid electrical connector. n. Remove the air bag sliding contact. 0. Remove the upper intermediate steering shaft-to-column shaft bolt and discard the bolt. p. Remove the lower steering columnto-instrument panel nuts and the steering column. 5. Remove the instrument panel by performing the following procedure: a. Disconnect the Brake Pedal Position (BPP) switch electrical connector.

b. Remove the push pins and remove both cowl side trim panels. c. At the right side cowl panel, disconnect the electrical connectors and ground wires. d. Remove both sides windshield garnish moldings. e. Disconnect the power distribution box from its bracket and move it aside. f. In the engine compartment, loosen the bulkhead wiring harness bolts and disconnect the electrical connectors. g. Pull the bulkhead electrical con-nector handle and disconnect the wiring harness. h. Remove the passenger's side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module. Store the air bag module in a safe location with the front facing upward. a. Disconnect the blend door actuator’s electrical connector. b. Disconnect the climate control vacuum harness connector. c. Disconnect the radio’s antenna connector. d. Remove the glove compartment. e. Remove the instrument panel defroster grille. f. Remove the upper instrument panel bolts. g. If equipped, remove the upper series floor console. h. Under the steering column, remove the instrument panel brace bolt. i. At both sides, remove the windshield side garnish moldings. j. Remove both the right and left instrument panel-to-cow! bolts.

k. Remove the fuse panel door. |. Pull the instrument panel away from the dash. m. Loosen the instrument panel-tobody harness bolt and disconnect the harness. n. Using an assistant, remove the instrument panel. 6. At the PCM, disconnect the electrical connector; then, remove the 2 PCM cover nuts, the cover and the PCM. >The PCM is located at the right side of the instrument panel. 7. Remove the evaporator core by perform the following procedure: a. Discharge and recover the air conditioning system refrigerant. b. Remove the refrigerant lines from the evaporator core. Discard the Orings. c. Disconnect the air conditioning cycling switch.

d. Disconnect the blower motor electrical connectors. e. Disconnect the speed control servo connector; then, remove the bolt and reposition the speed control servo. f. Remove the windshield washer reservoir/coolant recovery reservoir, and move it aside. g. Disconnect the air conditioning manifold and tube from the accumulator/drier. h. Disconnect the condenser-to-evaporator tube. i. Inside the vehicle, disconnect the air conditioning system vacuum harness and the evaporator housing mounting nut. j. In the passenger's compartment, remove the evaporator housing-to-chasSiS nut. k. In the engine compartment, remove the 3 evaporator housing-to-chassis nuts. |. Remove the air conditioning accumulator from the evaporator core. m. If equipped with a 5.0L engine, remove the evaporator housing heat shield screw, clips and the shield. n. Remove the evaporator housing cover screws and the cover. o. Remove the evaporator core from the housing. 8. Remove the PCM ground strap screw and the heat sink. 9. In the engine compartment, remove the heater housing air plenum nuts.

Brake service is covered in Section 4 of this manual

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10. Remove the heater core-to-air plenum cover screws and the cover. 11. Remove the heater core. To install: 12. Install the heater core. 13. Install the heater core-to-air plenum cover and the cover screws. 14. In the engine compartment, install the heater housing air plenum nuts. 15. Install the PCM ground strap screw and the heat sink. 16. Install the evaporator core by perform the following procedure: a. Install the evaporator core to the 93113GL7

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b. Install the evaporator housing cover and the cover screws. c. If equipped with a 5.0L engine, install the evaporator housing heat shield, clips and the shield screw. d. Install the air conditioning accumulator to the evaporator core. e. In the engine compartment, install the 3 evaporator housing-to-chassis nuts. f. In the passenger's compartment, install the evaporator housing-to-chassis nut. g. Inside the vehicle, connect the air conditioning system vacuum harness and the evaporator housing mounting nut. h. Connect the condenser-to-evaporator tube. i. Connect the air conditioning manifold and tube to the accumulator/drier. j. Install the windshield washer reservoir/coolant recovery reservoir. k. Install the speed control servo, the

View of the evaporator housing—Ford Explorer and Mercury Mountaineer

bolt and connect the speed control servo

connector. |. Connect the blower motor electrical connectors. m. Connect the air conditioning cycling switch. n. Using new O-rings, install the refrigerant lines to the evaporator core. 17. Install the PCM, the cover and the PCM cover nuts; then, disconnect the electrical connector. 18. Install the instrument panel by performing the following procedure: a. Using an assistant, install the instrument panel. b. Connect the harness and tighten the instrument panel-to-body harness bolt. c. Push the instrument panel away

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toward the dash. d. Install the fuse pane! door.

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

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2-382 _Harworonco, 90. Connect the heater hoses to the heater core. 21. Refill the cooling system. 22. Connect the negative battery cable. 93. Evacuate and charge the air conditioning system. 24. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

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View of the heater core—Ford Explorer and Mercury Mountaineer

e. Install both the right and left instrument panel-to-cowl bolts. f, At both sides, install the windshield side garnish moldings. g. Under the steering column, install the instrument panel brace bolt. h. If equipped, install the upper series floor console. i, Install the upper instrument panel bolts. j. Install the instrument panel defroster grille. k. Install the glove compartment. |. Connect the radio's antenna connector.

m. Connect the climate control vacuum harness connector. n. Connect the blend door actuator’s electrical connector. 0. Install the passenger's side air bag module, connect the electrical connector and install the air bag module-to-instrument panel screws. p. Connect the bulkhead electrical connector wiring harness. q. In the engine compartment, connect the electrical connectors and tighten the bulkhead wiring harness bolts. t. Connect the power distribution box to its bracket. s. Install both sides windshield garnish moldings. t. At the right side cowl panel, connect the electrical connectors and ground Wires. u. Install both cowl side trim panels and the push pins. v. Connect the Brake Pedal Position (BPP) switch electrical connector. 19. Install the steering column by performing the following procedure: a. Install the lower steering column

and the steering column-to-instrument panel nuts; then, torque the nuts to 10-13 ft. Ibs. (13-17 Nm). b. Using a new bolt, install the upper intermediate steering shaft-to-column shaft bolt and torque to 19-25 ft. Ibs. (26-34 Nm). c. Install the air bag sliding contact. d. Connect the brake shift interlock solenoid electrical connector. e. If equipped with an automatic transmission, connect the shift cable from the steering column shift tube lever and the steering column bracket. f. lf equipped with an automatic transmission, install the transmission range indicator cable and bolt. g. At the base of the steering column, connect the electrical connectors. h. Connect the ignition switch electrical connector and install the ignition switch bolt. . Install the instrument panel steering column opening reinforcement and the reinforcement bolts. j. Install the instrument panel-toSteering column cover and the 2 cover SCrews. k. Install the hood release and the hood release screws. |. Install the parking brake release handle and the release handle screws. m. Install the steering wheel to the steering column. n. Install the steering wheel-to-steering column nut and torque the nut to 20-34 ft. Ibs. (4-46 Nm). 0. At the both sides of the steering wheel, install the air bag module, connect the air bag electrical connector, install the steering wheel-to-air bag module screws and the cover plugs.

Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 3. Remove the steering column. 4. Disconnect the brake pedal position (BPP) switch electrical connector. 5. lf equipped, disconnect the clutch pedal position (CPP) switch electrical connector. 6. Remove the LH and RH cowl side trim panels. 7. Disconnect the electrical connectors and the ground wires on the RH cowl panel. 8. Disconnect the power distribution box from the bracket and position aside. 9. Disconnect the bulkhead wiring harness connectors from inside the engine compartment. 10. Remove the bulkhead connector insulator. 11. Unclip the bulkhead electrical connectors from the dash panel. 12. Remove the passenger side air bag module. 13. Disconnect the blend door actuator electrical connector. 14. Disconnect the climate control vacuum harness connector. 15. Disconnect the radio antenna cable in-line connector. 16. Raise the glove compartment. 17. Remove the instrument panel : defroster opening grille. 18. Remove the instrument panel cow! top bolts. 19. If equipped, remove the upper series floor console. 20. Remove the instrument panel brace bolt from under the steering column opening. 21. Remove the windshield side garnish mouldings. 22. Remove the RH instrument panel cowl side bolt.

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23. Remove the instrument panel fuse panel door. 24. Remove the LH instrument panel cowl side bolts. 25. Position the instrument panel away from the dash panel. 26. Disconnect the instrument panel to body harness. ->Two technicians are required to carry out this step.

27. Remove the instrument panel. 28. Recover the refrigerant. For additional information, refer to «Section 41200». 29. Disconnect the A/C cycling switch. 30. Disconnect the blower electrical connectors. 31. Position the speed control servo aside. 32. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside. 33. Disconnect the A/C manifold and tube from the suction accumulator/drier. 34. Disconnect the condenser to evaporator tube. : 35. Disconnect the A/C system vacuum harness and the A/C evaporator housing mounting nut inside the vehicle. 36. Remove the A/C evaporator housing. 37. Remove the powertrain contro! module (PCM). 38. Remove the PCM heat sink. 39. Remove the heater air plenum nuts from the engine side of the dash panel. 40. Remove the heater core cover to air plenum screws. 41. Lift off the cover. 42. Remove the heater core. 43. To install, reverse the removal procedure. Be sure to install a new oval foam seal around the heater core inlet and outlet tubes.

2002 1. Deactivate the supplemental restraints system (SRS). 2. Release the two floor console front clips (one each side). 3. On vehicles with manual transmission, remove the gearshift lever handle. 4. Remove the console finish panel mat. 5. On vehicles with automatic transmission: a. If equipped, remove the ashtray assembly.

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b. Disconnect the electrical connector. c. Remove the console finish panel SCIeW. 6. Remove the console finish panel by lifting up at the rear and sliding it rearward. Disconnect the electrical connector(s). 7. Remove the floor console front SCIeWs. 8. If equipped, disconnect the electrical connector and release the wiring harness locators. 9. Remove the floor console center bolts. 10. Remove the two floor console access covers (one each side). 11. Remove the two floor console rear bolts (one each side). 12. Remove the floor console by lifting up at the rear of the console and sliding it rearward. 13. Refhove the screws and remove the snow shield. 14. Crimp off the coolant hoses and disconnect from the heater core. ‘15. Remove the instrument panel center Support brackets. 16. Remove the assist handle bolt covers. 17. Remove the bolts and the passenger assist handle. 18. Remove the windshield side garnish moldings. 19. Remove the defroster opening grill. 20. Remove the upper instrument panel support bolts. 21. Remove the exterior cowl grill. 22. Remove the instrument panel support bolt. 23. Remove the two instrument panel side finish panels. 24. Lower the glove compartment. 25. Loosen the LH instrument panel side Support bolts until half the threads are exposed.

After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

Be sure the instrument panel is properly supported to avoid possible damage to the instrument panel wiring or components. To avoid damage to the instrument panel wiring or components, do not use excessive force when moving the instrument panel away from the dash panel. The instrument panel may be supported by installing threaded rods or equivalent, with the same diameter and thread pitch, in place of the instrument panel support bolts.

3. Drain the cooling system into a clean container for reuse. 4. Remove the instrument panel by performing the following procedure: a. If equipped with automatic transmission, move the shift lever to the 1 position to ease removal. b. At the lower driver's side instrument panel, release the electrical connector push button clip and move the connector aside. c. Remove the fuse panel door. d. Remove the hood latch release handle screws and move the hood release handle aside.

26. Properly support the instrument panel and remove the RH instrument panel support bolts to allow the instrument panel to be pulled away from the dash panel. 27. Remove the center console floor duct. 28. Remove the screws and remove the RH floor duct. 29. Remove the screws and remove the LH floor duct. 30. Disconnect the electrical connectors and detach the pin-type retainers. 31. Remove the screws and remove the heater core tube cover. 32, Remove the RH heater core cover SCreWs. 33. Remove the LH heater core cover screws and remove the heater core cover.

>The instrument panel will need to be moved to facilitate removal of the heater core.

34. Remove the heater core. 35. To install, reverse the removal procedure. Lubricate the coolant hoses with coolant hose lubricant or plain water only if needed. Top-off the engine coolant level. For additional information. Reactivate the supplemental restraints system (SRS). 1998-01 Ford F-Series

REMOVAL & INSTALLATION 1. If equipped with power seats, move the seats fully rearward. 2. Disconnect the negative battery cable.

+: CAUTION

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

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Steering Column Opening Cover Screw(s) 2.0-3.0 Nem (19.0-26.0 In-Lb) Screw(s) 2.0-2.4 Nem

(18.0-21.0 In-Lb)

rfid Description Cowl Side Panel (LH) Nut Insert (4 Req'd) U-Nut Cowl Side Panei (RH) Screw(s) 2.0-2.4 Nem (18.0-21.0 In-Lb) 88280613

Instrument panel installation—F-250HD, F-350 and F-Super Duty

HEATER CORES 99m FORD MOTOR CO. w. At the steering column, disconnect —

1. 2. 3. 4.

Instrument panel finish panel Instrument cluster panel Instrument panel relay cover Instrument panel

5. 6. 7. 8.

Center instrument panel finish panel Instrument panel steering column cover, lower instrument panel fuse door Steering column opening cover 93113GLO0

Exploded view of the instrument panel components—Ford F-150, F-250

e. Remove the parking brake release handle screws and move the parking brake release handle aside. f. If equipped, remove the 2 instrument panel floor duct panel push clips and release the expander clip. g. Remove the lower steering column cover bolts and the cover. h. Remove both front door scuff plates. i. Remove both side cowl trim panels. j. Disconnect the electrical connector from the Brake Pedal Position (BPP) Switch. k. Remove the radio ground and the GEM/CTM ground bolts. |. Disconnect the left side instrument panel main wiring harness connector. m. In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors.

n. In the engine compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instrument panel. 0. Disconnect the air bag diagnostic monitor electrical connector. p. Disconnect the inertia fuel shutoff switch electrical connector. gq. Remove the right side ground

bolts. r. Disconnect the right side instrument panel wiring harness connectors. s. Disconnect the electronic blend door actuator electrical connector. t. Disconnect the climate control head vacuum harness connector. u. Remove the steering column opening cover reinforcement nuts and the cover reinforcement. v. At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors.

the remaining electrical connectors. x. If equipped with a transmission range indicator, remove the bolt and disconnect the cable. y. Remove the steering column-toinstrument panel nuts and lower the steering column. z. Remove and disconnect the radio. aa. Remove the instrument panel relay cover and disconnect the autolamp sensor electrical connector. bb. Remove the glove box. cc. At the passenger's air bag module, remove the screws, disconnect the electrical connector and remove the air bag module. Place the air bag module in a safe place with the front facing upward. a. Remove the right side assist handle screw covers, the screws and the handle. b. At both doors, pull back the weatherstrip seals and remove the windshield garnish moldings. c. Remove the instrument panel reinforcement bolt below the left side corner of the glove box. d. Through the air bag module opening, remove the instrument panel bolts. e. Remove the upper instrument panel cowl covers and bolts. f. At the relay bracket, remove the instrument panel bolt. g. At the lower left side of the cigar lighter, remove the instrument panel bolt. h. At the both sides, remove the instrument panel-to-cowl side nuts. i. At the steering column opening, remove the instrument panel bolts. j. Remove the upper instrument panel floor brace bolt. k. Loosen the instrument panel brace bolts and nut. |. Using an assistant, remove the instrument panel. 5. Compress the holding tabs and disconnect the heater hoses from the heater core. 6. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter. 7. Disconnect the vacuum line. 8. Remove the heater core bracket screws and the bracket. 9. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover.

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

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View of the heater core—Ford F-150

10. Remove the blend door assembly from the heater housing. 11. Remove the heater core. To install: 12. Install the heater core. 13. Install the blend door assembly to the heater housing. 14. Install the 13 heater housing plenum camber cover and the heater housing plenum chamber cover screws. 15. Install the heater core bracket and the bracket screws. 16. Connect the vacuum line. 17. Install the air conditioning plenum demister adapter and the air conditioning plenum screw. 18. Connect the heater hoses to the heater core. 19. Install the instrument panel by per-

forming the following procedure:

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PLENUM ASSY

HEATER CORE

HEATER CORE ASSY

HEATER CORE TUBES

HEATER

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Heater core removal—F-250, F-350 and F-Super Duty models

a

HEATER CORES FORD MOTOR CO. a. Using an assistant, install the instrument panel. b. Tighten the instrument panel brace bolts and nut. c. Install the upper instrument panel floor brace bolt. d. At the steering column opening, install the instrument panel bolts. e. At the both sides, install the instrument panel-to-cowl side nuts. f. At the lower left side of the cigar lighter, install the instrument panel bolt. g. At the relay bracket, install the instrument panel bolt. h. Install the upper instrument panel cowl bolts and covers. i. Through the air bag module opening, install the instrument panel bolts. j. Install the instrument panel reinforcement bolt below the left side corner of the glove box. k. At both doors, install the windshield garnish moldings and the weatherstrip seals. |. Install the right side assist handle, the screws and the handle screw covers. m. At the passenger's air bag module,

connect the electrical connector and install the air bag module. n. Install the glove box. 0. Install the instrument panel relay cover and connect the autolamp sensor electrical connector. p. Install and connect the radio. q. Install the steering column-toinstrument panel and the steering column nuts. r. If equipped with a transmission range indicator, connect the cable and install the bolt. s. At the steering column, connect the remaining electrical connectors. t. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors. u. Install the steering column opening cover reinforcement and the cover reinforcement nuts. v. Connect the climate control head vacuum harness connector. w. Connect the electronic blend door actuator electrical connector. x. Connect the right side instrument panel wiring harness connectors. y. Install the right side ground bolts. z. Connect the inertia fuel shutoff switch electrical connector. aa. Connect the air bag diagnostic monitor electrical connector.

bb. In the driver's compartment, install the bulkhead electrical connector to the instrument panel. cc. In the engine compartment, install the bulkhead wiring harness connector bolts and connect the wiring connectors. dd. Connect the left side instrument panel main wiring harness connector. ee. Install the radio ground and the GEM/CTM ground bolts. ff. Connect the electrical connector to the Brake Pedal Position (BPP) switch. gg. Install both side cowl trim panels. hh. Install both front door scuff plates. il. Install the lower steering column cover and the cover bolts. jj. lf equipped, install the 2 instrument panel floor duct panel push clips and the expander clip. kk. fhstall the parking brake release handle and the parking brake release handle aside screws. ll. Install the hood latch release handle screws. mm. Install the fuse panel door. nn. At the lower driver's side instrument panel, install the connectors. 20. Refill the cooling system. 21. Connect the negative battery cable. 22. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

1998-01 Ford Ranger REMOVAL & INSTALLATION 1998-01 1. Disconnect the negative battery cable.

teste CAUTION. After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy. 2. Drain the cooling system into a clean container for reuse. 3. Remove the steering column by performing the following procedure: a. Position the front wheels in the straight-ahead direction. b. At the both sides of the steering wheel, remove the cover plugs, the steering wheel-to-air bag module screws, disconnect the air bag electrical connector and carefully remove the air bag module.

Safely store the air bag module with the front side facing upward. c. Remove the steering wheel-tosteering column nut. d. Using a steering wheel puller, press the steering wheel from the steering column. e. Remove the parking brake release handle screws and move the release handle aside. f. Remove the hood release screws and move the hood release aside. g. Remove the 2 instrument panel-tosteering column cover screws and the cover. h. Remove the instrument panel steering column opening reinforcement bolts and the reinforcement. i. Remove the ignition switch bolt and disconnect the ignition switch electrical connector. j. At the base of the steering column, disconnect the electrical connectors. k. lf equipped with an automatic transmission, remove the transmission range indicator bolt and the cable. |. lf equipped with an automatic transmission, disconnect the shift cable from the steering column shift tube lever and the steering column bracket. m. Disconnect the brake shift interlock solenoid electrical connector. n. Remove the air bag sliding contact. 0. Remove the upper intermediate steering shaft-to-column shaft bolt and discard the bolt. p. Remove the lower steering columnto-instrument panel nuts and the steering column. 4. Remove the instrument panel by performing the following procedure: a. Remove the parking brake release handle screws and move the release handle aside. b. Disconnect the Brake Pedal Position (BPP) switch electrical connector. c. Remove both front door scuff plates. d. Remove the push pins and remove both cowl side trim panels. e. At the right side cowl panel, disconnect the electrical connectors and ground wires. f. Remove both sides windshield garnish moldings. g. Remove the instrument panel fuse door.

For Wheel Alignment specifications, see Section 1 of this manual

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5 Instrument Panel Steering Column Cover 93113GL3

View of the instrument panel components—Ford Ranger

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HEATER CORES). 39 FORD MOTOR CO.

Store the air bag module in a safe loca-

tion with the front facing upward. a. Disconnect the blend door actuator’s electrical connector. b. Disconnect the climate control vacuum harness connector. c. Disconnect the radio's antenna connector.

View of the evaporator core—Ford Ranger

h. Disconnect the power distribution box from its bracket and move it aside. i. In the engine compartment, loosen

the bulkhead wiring harness bolts and disconnect the electrical connectors. j. Pull the bulkhead electrical con-

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nector handle and disconnect the wiring k. Remove the passenger's side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module.

d. Remove the glove compartment. e. Remove the instrument panel defroster grille. f. Remove the upper instrument panel bolts. g. Under the steering column, remove the instrument panel brace bolt. h. Remove both the right and left instrument panel-to-cowl bolts. i. Pull the instrument panel away from the dash. j. Loosen the instrument panel-tobody harness bolt and disconnect the harness. k. Using an assistant, remove the instrument panel. 5. Remove the evaporator core by perform the following procedure: a. Discharge and recover the air conditioning system refrigerant. b. Remove the refrigerant lines from the evaporator core. Discard the O-rings. c. If equipped, remove the air conditioning vacuum reservoir tank/bracket screws and reposition the tank. d. If equipped, disconnect the speed control servo connector; then, remove the bolt and reposition the speed control Servo. e. If equipped with a 3.0L or 4.0L engine, remove the support bracket. f. Disengage the windshield washer hose retainer and move it aside. g. Disconnect the vacuum hose and the retainer: then, move the hose aside. h. Remove the passenger's compartment nut. i. At the back of the engine, remove the hose support bolts. j. Remove the evaporator housing-tochassis nuts. k. Remove the air conditioning accumulator bracket screws. |. Remove the evaporator housing cover screws, clips and the cover. m. Remove the evaporator core from the housing. 6. Disconnect the heater hoses from the heater core.

View of the heater core cover—Ford Ranger

7. Remove the heater housing plenum chamber nuts and the plenum chamber.

For Maintenance Interval recommendations, see Section 1 of this manual

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FORD MOTOR CO. s. Install both cowl side trim panels © and the push pins. t. Install both front door scuff plates. u. Connect the Brake Pedal Position

(BPP) switch electrical connector. v. Install the parking brake release

handle and the release handle aside SCIeWS.

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93113GL5

View of the heater core—Ford Ranger

8. Remove the heater core-to-heater housing screws and the cover. 9. Remove the heater core. To install: 10. Install the heater core. 11. Install the heater core-to-heater housing cover and the cover screws. 12. Install the heater housing plenum chamber and the plenum chamber nuts. 13. Connect the heater hoses to the heater core. 14. Install the evaporator core by perform the following procedure: a. Install the evaporator core to the housing. b. Install the evaporator housing cover, clips and the cover screws. c. Install the air conditioning accumulator bracket screws. d. Install the evaporator housing-tochassis nuts. e. At the back of the engine, install the hose support bolts. f. Install the passenger's compartment nut. g. Connect the vacuum hose and the retainer. h. Engage the windshield washer hose retainer. i. If equipped with a 3.0L or 4.0L engine, install the support bracket. j. lf equipped, install the speed control servo bolt and connect the connector.

k. If equipped, install the air conditioning vacuum reservoir tank and the bracket screws. |. Using new O-rings, install the refrigerant lines to the evaporator core. 15. Install the instrument panel by performing the following procedure:

a. Using an assistant, install the instrument panel. b. Connect the harness and tighten the instrument panel-to-body harness bolt. c. Push the instrument panel toward the dash. d. Install both the right and left instrument panel-to-cowl bolts. e. Under the steering column, install the instrument panel brace bolt. f. Install the upper instrument panel bolts. g. Install the instrument panel defroster grille. h. Install the glove compartment. i. Connect the radio's antenna connector. j. Connect the climate control vacuum harness connector. k. Connect the blend door actuator's electrical connector. |. Install the passenger's side air bag module, connect the electrical connector and torque the air bag module-to-instrument panel screws to 67—92 inch Ibs. (7.6-10.4 Nm). m. Connect the bulkhead electrical connector handle wiring harness. n. In the engine compartment, connect the electrical connectors and tighten the bulkhead wiring harness bolts. 0. Connect the power distribution box to its bracket. p. Install the instrument panel fuse door. q. Install both sides windshield garnish moldings. r. At the right side cowl panel, connect the electrical connectors and ground wires.

16. Install the steering column by performing the following procedure: 17. Install the steering column by performing the following procedure: a. Install the lower steering column and the steering column-to-instrument panel nuts; then, torque the nuts to 10-13 ft. Ibs. (13-17 Nm). b. Using a new bolt, install the upper intermediate steering shaft-to-column shaft bolt and torque to 19-25 ft. Ibs. (26-34 Nm). c. Install the air bag sliding contact. d. Connect the brake shift interlock solenoid electrical connector. e. If equipped with an automatic transmission, connect the shift cable from the steering column shift tube lever and the steering column bracket. f. If equipped with an automatic transmission, install the transmission range indicator cable and bolt. g. At the base of the steering column, connect the electrical connectors. h. Connect the ignition switch electrical connector and install the ignition Switch bolt. i. Install the instrument panel steering column opening reinforcement and the reinforcement bolts. j. Install the instrument panel-tosteering column cover and the 2 cover SCreWS. k. Install the hood release and the hood release screws. |. Install the parking brake release handle and the release handle screws. m. Install the steering wheel to the steering column. n. Install the steering wheel-to-steering column nut and torque the nut to

20-34 ft. Ibs. (34-46 Nm). ‘ 0. At the both sides of the steering wheel, install the air bag module, connect the air bag electrical connector,

install the steering wheel-to-air bag module screws and the cover plugs.

18. Refill the cooling system.

19. Connect the negative battery cable. _ 20. Evacuate and charge the air conditioning system. 21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

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1998-01 Mercury Villager

«REMOVAL & INSTALLATION Front System 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Disconnect and plug the heater hoses at the bulkhead. 4. Remove the storage bin, then remove both side covers by the bin and the footlamp, if equipped.

5. Remove the contro! console bezel (1 screw in the center), then remove the ashtray assembly. 6. Remove the climate contro! console screws, pull the console rearward and detach the electrical connectors. Remove the 4 radio assembly screws and take the radio out of the vehicle. 7. Remove the floor duct and the right and left knee reinforcement plates. Remove the ABS control module. 8. The speed control module, keyless entry module (if equipped) and the passive restraint (air bag) module are all located behind the center console and can be © removed after detaching the respective con-

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nectors and removing the retaining nuts or SCFeWS.

The control modules are very sensitive to static electricity and can be damaged if exposed to static or stray electrical impulses. 9, Remove the center air duct. 10. Remove the 2 ground wire bolts. Remove the U-bracket and the 2 console brackets. 11. Remove the glove box and lamp. 12. Remove the accelerator pedal and pedal stop.

i Side defroster

grille

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Center register Side ventilator duct

93113GC1

Exploded view the front heater/air conditioning assembly—1998 Mercury Villager

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

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HEATER CORES FORD MOTOR CO.

13. Remove the floor air duct. 14. Remove the temperature blend sir door actuator and mode door actuator by removing the attaching bracket bolts and detaching the electrical connections. 15. Remove the center distribution duct. 16. Remove the 4 evaporator/blower assembly screws, then the 4 heater assembly screws and remove the heater assembly. 17. Remove the heater pipe plate from the assembly. 18. Remove the heater core retainer, disengage the shut-off valve control rod and remove the heater core from the assembly.

To install: 19. Reassemble the heater core to the case, install the retainer and pipe plate. 20. Position the heater assembly in the vehicle and attach the 4 retaining screws. 21. Install the center distribution duct, the blend air and mode door actuators. Install the floor air duct. 22. Install the accelerator stop and pedal. 23. Install the glove box and lamp, then the center console and U-brackets. 24. Install the center air duct, the passive restraint, the keyless entry, the speed control and the ABS modules, as removed.

25. Reassemble the rest of the center console components. 26. Connect the heater hoses to the heater core. 27. Refill the cooling system. 28. Connect the negative battery cable. 29. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks. Rear Auxiliary System >The rear heater/air conditioning assembly must be removed as a complete unit in order to remove the heater core and/or evaporator core.

1. Disconnect the negative battery cable.

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Center ventilator duct

Exploded view the front heater/air conditioning assembly—1999-01 Mercury Villager

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View the front heater core and heater housing assembly—Mercury Villager

LOW PRESSURE SWITCH

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Location of the coolant control solenoid

and coolant control actuator for the rear

auxiliary heater/air conditioning system— 1998 Mercury Villager

HIGH PRESSURE SWITCH

93113660 View the air conditioning service valve locations—1998 Mercury Villager

For complete service labor times, order the Chilton Labor Guide

; 9-A4 HEATER CORES FORD MOTOR CO.

SPECIAL TOOL

CAGE OPENING

PUSH TOOL INTO

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LUBRICATE FITTINGS PUSH AND TWIST

OVER FLARED END

FEMALE FITTING

PLASTIC INDICATOR RING REMOVE TOOL WHEN DISCONNECTED

Spring lock coupling disconnect/connect procedures—1998 Mercury Villager

93113G61

HEATER CORES

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FORD MOTOR CO.

HEATER CORE AND SEAL ASSEMBLY

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REAR A/C SYSTEM INNER HOUSING

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REAR A/C SYSTEM UPPER HOUSING 93113G62

Exploded view the rear auxiliary heater/air conditioning system components—1998 Mercury Villager

2. Drain the cooling system into a clean container for reuse. 3. Discharge and recover the air conditioning system refrigerant. 4. Disconnect and plug the heater hoses at the bulkhead. 5. Remove the center seats. Remove the 2 left half seat belt lower anchor bolts. Remove the left rear cargo net retainers, if equipped. 6. Remove the lift gate scuff plate and the 3 screws from the left rear quarter trim panel. Gently pry the rear seat remote control (if equipped) from the trim panel. Disconnect the remote contro! wiring connector and remove the rear radio control panel. Pull the top of the trim panel away from the body. 7. Disconnect the rear climate control panel wiring, if equipped. 8. Release the left front lap belt guide from the left quarter trim panel and pass the belt through the trim panel. Remove the trim panel from the vehicle. 9. Remove the upper duct from the assembly (6 screws). 10. Disconnect the blower motor and resistor wiring. Detach the temperature blend and vent door actuator connectors. 11. Raise and safely support the vehicle. Use the spring lock coupling tool to discon-

nect and plug the refrigerant line connections from beneath the vehicle. 12. Lower the vehicle. 13. Remove the 4 heater/air conditioning assembly bolts and remove the assembly from the vehicle. Remove the heater core and/or evaporator core from the assembly. To install: 14. Install the heater core and/or evaporator core into the assembly. Install the 4 retaining bolts. 15. Raise and safely support the vehicle. 16. Using new O-rings, reconnect the refrigerant lines to the evaporator. 17. Lower the vehicle. Connect all wiring connectors. Install the upper air duct with the 6 screws. 18. Reposition the trim panel and pass the lap seat belt through the panel slot. 19. Connect the rear climate control panel. Install the rear radio and rear remote control. 20. Reinstall the rest of the trim panel and components. 21. Refill the cooling system. 22. Connect the negative battery cable. 23. Evacuate and charge the air conditioning system. 24. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

1998-01 Ford Windstar

REMOVAL & INSTALLATION Front System 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Remove the cowl top vent panel for clearance. 4. Disconnect the heater hoses from the heater core inlet and outlet tubes in the engine compartment. 5. Remove the cassette box/center instrument support trim. 6. Pull out and remove the ashtray cup holder by depressing the service lever. 7. Remove the floor/rear seat lower air duct. 8. Disconnect the keyless entry wiring harness, if equipped. 9. Remove the center instrument panel support brackets. 10. Disconnect the climate control vacuum harness connector. 11. Remove the heater floor/rear seat upper air duct. 12. Remove the heater core cover retaining screws and remove the heater core cover.

Please visit our web site at www.chiltonsonline.com

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Heater Housing Core Plate A/C Electronic Door Actuator Motor

Vacuum Control Motor

Shaft — Heater Air Damper Door Windshield Defroster Door Shaft

Windshield Defroster Duct Connector 89696G06

Front heater housing assembly—Ford Windstar

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The center instrument panel is attached using special plastic screws—Ford Windstar

89696P11

The rear seat airflow duct carries air to the rear of the passenger compartment—Ford Windstar

89696P12

The instrument panel support bracket must be removed to lower the heater core—Ford Windstar

89696P13

The heater outlet floor duct is attached to the bottom of the housing core—Ford Windstar

89696P14

The heater core is located in a box at the bottom of the housing core—Ford Windstar

Timing belt service is covered in Section 3 of this manual

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Rear Auxiliary System — 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Discharge and recover the rear auxiliary air conditioning refrigerant. 4. Raise and support the vehicle safely. 5. Place a drain pan under the heater water hose connections for the rear heater assembly. _ 6. Drain and recycle the engine coolant from the auxiliary heater core and hoses. 7. Disconnect the 2 air conditioning spring lock couplings using a quick disconnect coupling tool. 8. Lower the vehicle. 9. Remove all rear passenger's seating. 10. Remove the 3 push pin retainers from the lower edge of the auxiliary heater and air conditioning service cover. 11. Lift the service cover outward and

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A foam liner is used to cushion the heater core—Ford Windstar

13. Remove the heater core. 14. Remove the seal from the heater core tubes and discard. To install: 15. Install the seal to the heater core tubes and discard. 16. Install the heater core. 17. Install the heater core cover and the heater core cover retaining screws. 18. Install the heater floor/rear seat upper air duct. 19. Connect the climate control vacuum harness connector. 20. Install the center instrument panel support brackets. 21. Connect the keyless entry wiring harness, if equipped. 22. Install the floor/rear seat lower air duct. 23. Install the ashtray cup holder by depressing the service lever. 24. Install the cassette box/center instrument support trim. 29. Connect the heater hoses to the heater core inlet and outlet tubes in the engine compartment. 26. Install the cowl top vent panel for clearance. 27. Refill the cooling system. 28. Connect the negative battery cable. 29. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks,

upward to remove. 12. Label and disconnect the electrical harnesses.

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Heater and A/C Assembly

Body Main Wiring Screw and Washer Assembly 89696604

Rear heater and air conditioning assembly—Ford Windstar

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Rear heater housing assembly—Ford Windstar

13, lines. 14. 15. tioning

Label and disconnect the vacuum Remove the body side trim panels. Disconnect and plug all air condirefrigerant lines.

eit is extremely important that the air conditioning lines be plugged to prevent the entry of dirt or moisture.

16. Remove the lower air conditioning recirculation air duct and heater extension air duct. 17. Remove the auxiliary heater and air conditioning assembly. 18. Remove the housing cover screws and the cover. 19. Remove the heater core and the heater core case seal.

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To install: 20. Install the heater core and the heater core case seal. 21. Install the housing cover and SCFeWS. 22. Position the auxiliary heater and air conditioning assembly in the vehicle. Guide the heater water hoses through the floor grommet. Tighten the retaining screws to 16-23 inch Ibs. (2-3 Nm). 23. Connect all air conditioning refrigerant lines. 24. Install the lower air conditioning recirculation air duct and heater extension air duct. Tighten the retaining screws to 16-23 inch Ibs, (2-3 Nm). : 25. Install the body side trim panels. 26. Connect the vacuum lines. 27. Connect the electrical harnesses. 28. Install the auxiliary heater and air conditioning service cover and secure with 3 push pin retainers. 29. Install all rear passenger's seating. 30. Raise and support the vehicle safely. 31. Connect the heater water hoses to the heater core tubes. 32. Lower the vehicle. 33. Refill the cooling system. 34. Connect the negative battery cable. 35. Evacuate and charge the rear auxiliary air conditioning refrigerant. 36. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

1998-01 CHEVY/GEO

REMOVAL & INSTALLATION 1. Disconnect the negative battery cable. 2. Disable the SIR by performing the following procedure: a. From the fuse box, located near the base of the steering column, remove the AIR BAG fuse. b. Remove the steering wheel side cap, disconnect the Connector Positive Assurance (CPA) and the yellow 2-way driver's inflator module connectors. c. Pull the instrument panel compartment out by pushing the right-side and

left-side stoppers (located on both sides) inward. d. Disconnect the CPA and the yellow 4-way passenger's inflator module connectors.

->With the AIR BAG fuse removed and the ignition switch turned ON, the AIR BAG warning light will be ON; this is normal operation and does not indicate a SIR system malfunction.

3. Drain the cooling system into a clean container for reuse. 4. Remove the instrument panel as follows: a. Remove the center console. b. Remove the lower steering column cover by loosening the mounting Screws.

c. Remove the glove box. d. Detach the wiring harness connectors from the heater unit and the blower motor assembly. e. Detach the wiring harness connectors from the ignition switch, contact coil and combination switch. f. Open the hood. g. Remove the steering column shaft joint bolt, then separate the steering column shaft from the lower steering shaft. h. Loosen all of the steering columnto-firewall and instrument panel brace bolts. i. lf equipped, remove the shift (key) interlock cable screw. Disconnect the cable from the ignition switch. j. Remove the steering column from the vehicle.

Brake service is covered in Section 4 of this manual

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1 YELLOW 2—WAY SIR CONNECTOR (DRIVER)

hoses are disconnected form the instrument panel. 5. Remove the 2 bolts and the rightside instrument panel center support. 6. If equipped with air conditioning, remove the evaporator. 7. Remove the 2 screws securing the SIR harness clip on the Sensing and Diagnostic Module (SDM) bracket. 8. Disconnect the SDM electrical connector. 9. Remove the 4 screws and the SDM bracket from the vehicle. 10. Remove the speedometer cable and antenna cable (if equipped) from the heater case. 11. Remove the floor duct from the heater case. 12. If equipped with air conditioning, disconnect the electrical jumper harness for the air conditioning amplifier. 13. Remove the relay bracket screws and the relay bracket. 14. From the engine compartment, remove the 2 heater assembly-to-chassis _

2

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1 RELEASE LOCK LEVER 2 DISCONNECT CONNECTOR

4

CONNECTOR

POSITION

ASSURANCE

(CPA)

3 AIR BAG FUSE

4 YELLOW 4-WAY SIR CONNECTOR (PASSENGER) 5 GLOVE BOX

15. Remove the heater case from the

vehicle.

93113690

16. Remove the dampers and linkages from the heater case.

Disabling the air bag system—tTracker

Do not rest the steering column assembly on the steering wheel with the air bag module facing downward and the column vertical—personal injury may be the result. k. Disconnect the speedometer cable from the speedometer, then remove the instrument cluster. |. Remove the hood latch handle. m. Remove the radio, the heater control panel and the heater control cables from the instrument panel. n. Disconnect and label all wiring harness connectors from the instrument panel. 0. Remove the instrument panel mounting screws and bolts. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly. Then, remove the upper cover plates and loosen the remaining mounting fasteners p. Have an assistant help you carefully lift the instrument panel up and out of the vehicle. When separating the instrument panel from the firewall, ensure that all of the cables, wires and

CONNECT CONNECTOR LOCK CONNECTOR WITH LOCK LEVER

YELLOW 2-WAY SIR CONNECTOR (DRIVER) CONNECTOR POSITION ASSURANCE (CPA) AIR BAG-IG FUSE YELLOW 4—WAY SIR CONNECTOR (PASSENGER) OrWNH GLOVE BOX 93113G91

Enabling the air bag system—Tracker

nu

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ea

HEATER CORES

CHEVY/GEO

Fe

= 2

51

33. Install the instrument panel as follows: a. Have an assistant help you position the instrument panel in the vehicle. When installing the instrument panel on the firewall, ensure that all of the cables, wires and hoses are routed properly. b. Install and tighten the instrument panel mounting screws and bolts. c. Reattach all wiring harness connectors to the instrument panel. d. Install the radio, the heater control panel and the heater contro! cables. Be sure to adjust the heater control cables. e. Install the hood latch handle. f. Install the instrument cluster, then connect the cable to the speedometer. g. Install the steering column in the vehicle. h. If equipped, connect the cable from the ignition switch, then install the shift (key) interlock cable screw. i. Install and tighten all of the steering column-to-firewall and instrument panel brace bolts to 221 inch Ibs. (25 Nm). j. Install and tighten the steering column shaft joint bolt to 221 inch Ibs. (25 Nm). k. Reattach the wiring harness connectors to the ignition switch, contact coil and combination switch. |. Reattach the wiring harness connectors to the heater unit and the blower motor assembly. m. Install the glove box.

117

n. Install the lower steering column 93113689

Exploded view of the heater case assembly and related components—Tracker

17. Remove the heater core bracket screw and the bracket. 18. Remove the heater core from the heater case. To install: 19. Install the heater core to the heater case. 20. Install the heater core bracket and the bracket screw.

21. Install the dampers and linkages to the heater case. 22. Install the heater case to the vehicle. 23. In the engine compartment, install

the 2 heater assembly-to-chassis nuts and the 2 bolts. Torque the nuts/bolts to 89 inch lbs. (10 Nm). 24. Install the relay bracket and the relay bracket screws. 25. If equipped with air conditioning,

connect the electrical jumper harness for the aif conditioning amplifier. 26. Install the floor duct to the heater case. 27. Install the speedometer cable and antenna cable (if equipped) to the heater case. 28. Install the SDM bracket and the 4 screws to the vehicle. Torque the screws to 49 inch Ibs. (5.5 Nm). 29. Connect the SDM electrical connector. 30. Install the 2 screws securing the SIR harness clip on the Sensing and Diagnostic Module (SDM) bracket. Torque the screws to 49 inch Ibs. (5.5 Nm) 31. If equipped with air conditioning, install the evaporator. 32. Install the 2 bolts and the right-side instrument panel center support.

cover. 0. Install the center console. 34, Refill the cooling system.

35. Enable the SIR by performing the following procedure: a. Turn the ignition switch to LOCK and remove the key. b. Connect the Connector Positive Assurance (CPA) and the yellow 4-way passenger's inflator module connectors. c. Close the instrument panel compartment.

d. Connect the Connector Positive Assurance (CPA) and the yellow 2-way driver Inflator module connectors and install the steering wheel side cap. e. At the fuse box, located near the base of the steering column, install the AIR BAG fuse. 36. Connect the negative battery cable. 37. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

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

a.

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2-02 rr

HEATER CORES GENERAL MOTORS

eS

1998-01 GENERAL MOTORS

\

f. ( :

Chevy Astro and GMC Safari

~ REMOVAL & INSTALLATION

i)

4

f

Front System 1. Disconnect the negative battery cable. 2. Drain the engine cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core. 4. Remove the heater core cover-toheater assembly screws and the cover. 5. Remove the heater core-to-heater assembly strap screws and the straps. 6. Remove the heater core. To install: 7. Install the heater core. 8. Install the heater core straps and the straps-to-heater assembly screws, then tighten the screws to 18 inch Ibs. (2 Nm). 9. Install the heater core cover and the cover-to-heater assembly screws, then tighten the screws to 18 inch Ibs. (2 Nm). 10. Connect the heater hoses to the heater core. 11. Refill the cooling system. 12. Connect the negative battery cable. 13. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Rear Auxiliary System 1. Disconnect the negative battery cable.

2. Drain the engine cooling system into a clean container for reuse. 3. Remove the body side front lower interior trim panel. 4. Remove the clamps from the rear auxiliary heater hoses. 5. Disconnect the heater hoses from the rear auxiliary heater case. 6. From the right side of the heater core, remove the screws and band clamp.

18. Connect the negative battery cable. 19. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Chevrolet Venture, Oldsmobile Silhouette, Pontiac Montana and

Trans Sport REMOVAL & INSTALLATION

7. From the left side of the heater core, remove the screw and band clamp. «Place a cloth on the floor to catch

any coolant that may spill from the heater core.

8. Remove the heater core from the rear auxiliary Case assembly. 9. Remove the seals from the heater core. To install: 10. Install new seals to the heater core. 11. Install the heater core to the rear auxiliary case assembly. 12. To the left side of the heater core, install the screw and band clamp, then tighten to 18 inch Ibs. (2 Nm). 13. To the right side of the heater core, install the screws and band clamp, then tighten to 18 inch Ibs. (2 Nm). 14. Connect the heater hoses to the rear auxiliary heater case. 15. Install the clamps to the rear auxiliary heater hoses. 16. Install the body side front lower interior trim panel. 17. Refill the engine cooling system.

Front System 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Remove the air cleaner and duct assembly.

4, Remove the wiper linkage. 5. Remove heater core. 6. Remove 7. Remove lators. 8. Remove Screws. 9. Remove 10. Remove

the heater hoses from the the lower center console. both instrument panel insuthe heater outlet module the heater cover.

the heater core mounting clip and line clamp screws. 11. Remove the heater core. To install: 12. Install the heater core.

13. Install the heater core mounting clip and line clamp screws. 14. Install the heater cover. 15. Install the heater outlet module SCreWS.

View of the front heater assembly—Chevrolet Venture, Oldsmobi le Silhouette, Pontiac Montana and Trans Sport

93113GK9

wis Cn

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ae

.

HEATER CORES GENERAL MOTORS

Heater A/C Module Center Outlet Duct Side Window Duct Side Window Nozzle Main Duct

Side Window Outlet Duct Floor Duct Module Bracket OMmMAINMNDRWNHNe Lower Floor Duct 93113GKO

Exploded view of the front heater ventilation system—Chevrolet Venture, Oldsmobile Silhouette, Pontiac Montana and Trans Sport

16. Install both instrument panel insulators. 17. Install the lower center console. 18. Install the heater hoses from the

heater core. 19. Install the wiper linkage. 20. Install the air cleaner and duct assembly. 21. Refill the cooling system. 22. Connect the negative battery cable. 23. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

REAR AUXILIARY SYSTEM 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Remove the left rear side quarter

] 2 3

Rear Heater A/C Module Lower Duct Upper Duct

trim.

93113GL1

4, Remove the rear heater hoses from the rear heater core.

View of the rear auxiliary heater assembly ventilation system—Chevrolet Venture, Oldsmobile Silhouette, Pontiac Montana and Trans Sport

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

e e: att a, i a eal HEATER CORES 9-54 H GENERAL MOTORS

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93113GL2

View of the rear auxiliary heater assembly—Chevrolet Venture, Oldsmobile Silhouette, Pontiac Montana and Trans Sport

5. Remove the bracket bolt securing the hoses to the heater core. 6. Release the rear heater core-to-rear heater housing tabs. 7. Remove the heater core. To install: 8. Install the heater core. 9, Connect the rear heater core-to-rear heater housing tabs. 10. Install the bracket bolt securing the hoses to the heater core.

11. Install the rear heater hoses from the

rear heater core. 12. Install the left rear side quarter trim. 13. Refill the cooling system. 14. Connect the negative battery cable.

4. Discharge and recover the air conditioning system refrigerant. 5. Remove the surge tank (diesel) or the coolant recovery reservoir (except diesel).

6. Remove the positive battery cable, the battery hold-down and the battery. 7. Disconnect the refrigeration lines from the air conditioning accumulator and discard the gaskets.

Sth

HHH

Zak Ne {

G-Series Van, Express and Savana REMOVAL & INSTALLATION Front Heater

1. Disconnect the negative battery cable. 2. Drain the engine cooling system into a Clean container for reuse.

3. Disconnect the heater hoses from the heater core.

Underhood view of the heater assembly—Chevy/GMC Express and Savana

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HEATER CORES

GENERAL MOTORS:

93113684

View of the heater case screws—Chevy/GMC Express and Savana

8. Remove the:air conditioning accumulator. 9. From the right side, remove the lower right kick panel and the knee bolster.

10. Remove the lower outer floor air outlet duct. 11. Remove the heater case screws.

12. Carefully open the heater core access door. 13. Remove the heater core-to-heater case retainers and the heater core.

To install: 14. Install the heater core and the heater

core-to-heater case retainers.

wt

Pe

2-55

15. Carefully, close the heater core access door. 16. Install the heater case screws. 17. Install the lower outer floor air outlet duct. 18. To the right side, install the knee bolster and the lower right kick panel. 19. Install the air conditioning accumulator. 20. Using new gaskets, connect the refrigeration lines to the air conditioning accumulator. 21. Install the battery, the battery holddown and the positive battery cable. 22. Install the surge tank (diesel) or the coolant recovery reservoir (except diesel). 23. Evacuate and charge the air conditioning system. 24. Connect the heater hoses to the heater core. 25. Refill the engine cooling system. 26. Connect the negative battery cable. 27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks. Rear Auxiliary Heater

1. Disconnect the negative battery © cable. . .

2. Drain the engine cooling system into

a Clean container for reuse. 3. Disconnect the heater hoses from the

rear auxiliary heater core.

93113G85

View of the heater core and retainers—Chevy/GMC Express and Savana

4. From the left rear side, remove the rear interior quarter trim panel. 5. Remove the blower motor from the rear auxiliary heater case. 6. Remove the rear auxiliary heater case retainers and the case. 7. Remove the lower auxiliary heater case retainers and the lower case. 8. Remove the rear heater core from the case. To install: 9. Install the rear auxiliary heater core to the case. 10. Install the lower case and the lower auxiliary heater case retainers. 11. Install the rear auxiliary heater case retainers and the case. 12. Install the blower motor from the rear auxiliary heater case. 13. To the left rear side, install the rear interior quarter trim panel. 14. Connect the heater hoses to the rear auxiliary heater core.

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

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93113G80

View of the front heater assembly—Chevy/GMC C/K-Series, Blazer, Jimmy, Sierra, Suburban, Tahoe, Yukon

93113G86

View of the rear auxiliary heater core, case and retainers—Chevy/GMC Express and Savana

15. Refill the engine cooling system. 16. Connect the negative battery cable.

C/K-Pick-Up, Blazer, Jimmy, Sierra, Suburban, Tahoe, Yukon

REMOVAL & INSTALLATION Front Heater

1. Disconnect the negative battery cable. 2. Drain the engine cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core. 4. Remove the instrument panel storage compartment. 5. Disconnect the electrical connectors,

as necessary, that may be in the way. 6. Remove tion duct. 7. Remove panels. 8. Remove screws and the 9. Remove and the blower 10. Remove

the center floor air distribu-

the hinge pillar trim kick the blower motor cover cover. the blower motor screws motor. the steering wheel and the

Steering column (standard & tilt).

93113681

Location of the front heater assembly-to-chassis fasteners—Chevy/GMC C/K-Series, Blazer, Jimmy, Sierra, Suburban, Tahoe, Yukon

11. Remove the instrument panel fasteners and pull the instrument panel back far enough to gain access to the heater assembl 12. While holding the heater assembly against the firewall, remove the screw located on the interior side near the evaporator pipe, if equipped. 13. In the engine compartment, remove the 4 heater assembly-to-chassis screws and the 2 heater assembly-to-chassis nuts. e>Removal of the heater assembly may require the help of an assistant.

14. Remove the 7 heater cover-to-heater assembly screws and the cover. 15. Remove the heater core from thé heater assembly. To install: 16. Install the heater core to the heater assembly. 17. Install the heater cover and the 7 heater cover-to-heater assembly screws.

e>Installation of the heater assembly may require the help of an assistant.

18. In the engine compartment, install the 4 heater assembly-to-chassis screws

at

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HEATER CORES

GENERAL MOTORS and the 2 heater assembly-to-chassis nuts. Torque the screws to 17 inch Ibs. (1.9 Nm) and the nuts to 25 inch Ibs. (2.8 Nm). * 19. While holding the heater assembly against the firewall, install the screw located on the interior side near the evaporator pipe, if equipped. Torque the screw to 97 inch Ibs. (11 Nm). 20. Install the instrument panel and the instrument panel fasteners. 21. Install the steering column (standard & tilt) and the steering wheel. 22. Install the blower motor and the blower motor screws. 23. Install the blower motor the cover and the cover screws. . 24. Install the hinge pillar trim kick panels. 29. Install the center floor air distribution duct. 26. Connect the electrical connectors. that were disconnected. 27. Install the instrument panel storage

2

compartment. 28. Disconnect the heater hoses to the

heater core.

i

29. Refill the engine cooling system. 30. Connect the negative battery cable. 31. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Rear Auxiliary Heater 1. Disconnect the negative battery cable. 2. Drain the engine cooling system into a clean container for reuse. 3. Remove the rear quarter trim panel, as necessary. 4. Remove the right rear quarter trim panel. 5. Remove the right rear wheelhouse. 6. Disconnect the heater hoses from the rear auxiliary heater core. 7. Disconnect the electrical connectors, as necessary. 8. Remove the drain valve. 9. Remove the rear auxiliary heater assembly-to-chassis nuts and bolts. 10. Remove the rear auxiliary heater assembly. 11. If necessary, remove the blower motor from the heater assembly. 12. Remove the rear auxiliary heater assembly cover. 13. Remove the heater core from the rear auxiliary assembly.

93113G82

View of the rear auxiliary heater assembly—Chevy/GMC Suburban

To install: 14. Install the heater core to the rear auxiliary assembly. 15. Install the rear auxiliary heater assembly cover. 16. If removed, install the blower motor to the heater assembly. 17. Install the rear auxiliary heater assembly. 18. Install the rear auxiliary heater assembly-to-chassis nuts and bolts. Torque the bolts to 13 inch Ibs. (1.5 Nm) and the nuts to 89 inch Ibs. (10 Nm). 19. Install the drain valve. 20. Connect the electrical connectors, as necessary. 21. Connect the heater hoses from the rear auxiliary heater core. 22. Install the right rear wheelhouse. 23. Install the right rear quarter trim panel. 24. Install the rear quarter trim panel, as necessary. 25. Refill the engine cooling system. 26. Connect the negative battery cable. 27. Run the engine to normal operating

temperatures; then, check the climate control operation and check for leaks.

Chevy/GMC Silverado REMOVAL & INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core. 4. Disconnect the temperature control cable from the heater case assembly. 5. Disconnect the mode control cable from the heater case assembly. 6. Remove the instrument panel carrier to provide access to the heater case assem7. Disconnect any electrical connectors that may interfere with the heater case assembly removal. 8. Remove the heater case assemblyto-chassis screws/nuts and the assembly. 9. Place the heater case assembly on a

For Wheel Alignment specifications, see Section 7 of this manual

Se ts

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20. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Chevy/GMC S-Series Pick-Up,

Blazer, Bravada, Envoy, Jimmy, Sonoma, Syclone, and Typhoon

REMOVAL & INSTALLATION EEE

93113G87

View of the heater case assembly —Chevy/GMC Silverado

93113G88

View of the heater core—Chevy/GMC Silverado

bench and remove the heater core cover SCreWS. 10. Remove the heater core from the heater case. To install:

11. Install the heater core to the heater case. 12. Install the heater core cover screws and tighten to 14 inch Ibs. (1.6 Nm). 13. Install the heater case assembly and the assembly-to-chassis screws, then,

tighten the screws to 35 inch Ibs. (4 Nm) and the nuts to 80 inch Ibs. (9 Nm). 14. Connect any electrical connectors that may have been disconnected. 15. Install the instrument panel carrier. 16. Connect the mode control cable to the heater case assembly. 17. Connect the temperature control cable to the heater case assembly, 18. Connect the heater hoses to the heater core. 19. Connect the negative battery cable.

EEE

1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Remove the heater hoses from the heater core. 4. Remove the instrument panel as follows: a. Disable the air bag system. b. Set the parking brake and block the wheels. c. Disconnect the parking brake release cable from the parking brake lever. d. Unfasten the screws that retain the DLC instrument panel left side sound insulator. Feed the DLC through the hole in the sound insulator. e. Unfasten the right side sound insulator panel screws and remove the panel. f. Unfasten the screws that attach the instrument panel left side sound insulator to the knee bolster and cowl panel. g. Unfasten the nut that attaches the left side sound insulator to the accelerator pedal bracket. h. Unplug the remote control door lock receiver module electrical connector. i. Remove the door lock receiver module from the left side sound insulator. Remove the left side sound insulator. j. Unfasten the screws that attach the instrument panel center sound insulator to the knee bolster, instrument panel, heater assembly and floor duct. k. Remove the center sound insulator. |. Unfasten the screws that attach the courtesy lamp to the knee bolster. m. Unfasten the screws that attach the knee bolster to the instrument panel. n. Disconnect the lap cooler duct from the knee bolster. o. Unplug the lighter electrical connection and remove the knee bolster. p. Unfasten the steering column-toinstrument panel nuts and lower the column. q. Unfasten the screws that attach the instrument panel accessory trim plate to the instrument panel.

Veta

93113G77

View of the heater case assembly—Chevy/GMC S-Series Pick-up, Bravada, Sonoma and Envoy

93113678

View of the heater case cover—Chevy/GMC S-Series Pick-up, Bravada, Sonoma and Envoy

r. Remove the trim plate and unplug all necessary electrical connection. s. Remove the heater and/or air conditioning control assembly. t. Remove the radio and the storage compartment assembly (if equipped). u. If necessary, remove the instrument cluster. v. Unfasten the left and right instru-

ment panel pivot bolts and the panel lower support bolt. w. Unfasten the speaker grilles retaining screws and remove the speaker grilles. x. Remove the windshield defroster grille using a flat-bladed prytool. Start at one end of the grille and work your way down the grille.

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y. Unfasten the 4 instrument panel upper support screws. z. Tag and unplug all necessary electrical connections. aa. Remove the instrument panel from the vehicle. 5. Remove the air inlet assembly, if equipped. 6. Remove the vacuum hoses. 7. From inside the engine compartment, remove the heater assembly studs. 8. Remove the blower motor resistor. 9. From inside the heater case assembly, remove the stud; the stud is located behind the blower motor resistor. 10. Remove the heater assembly-tochassis screws. 11. Remove the heater assembly from the vehicle. 12. Remove the access cover screws and cover from the heater assembly. 13. Remove the heater core from the heater case assembly. To install: 14. Install the heater core to the heater case assembly. 15. Install the access cover to the heater assembly and the cover screws. 16. Install the heater assembly to the vehicle. 17. Install the heater assembly-to-chasSis screws and torque them to 40 inch lbs. (4.5 Nm). 18. Working inside the heater case assembly, install the stud; the stud is located behind the blower motor resistor. 19. Install the blower motor resistor. 20. Working inside the engine compartment, install the heater assembly studs and torque them to 17 inch Ibs. (1.9 Nm), 21. Install the vacuum hoses. 22. Install the air inlet assembly, if equipped. 23. Install the instrument panel as follows: a. Rest the instrument panel on the lower pivot studs. b. Attach the electrical connections. c. Install but do not tighten the 4 upper instrument panel support screws. d. Install the left and right panel pivot bolts. Tighten the bolts to 102 inch Ibs. (11.5 Nm). e. Install the panel lower support bolt. Tighten the bolt to 102 inch Ibs. (11.5 Nm). f. Tighten the upper support screws to 17 inch Ibs. (1.9 Nm). g. Install the windshield defroster grille and the speaker grilles.

For Maintenance Interval recommendations, see Section 1 of this manual

260 _HERR COR

Ye:

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sound insulator in position. Install the screws that attach the center sound insulator to the knee bolster, instrument panel and the floor duct. Tighten the screws to 17 inch Ibs. (1.9 Nm). r. Install the screw that attaches the center sound insulator to the heater

93113679

View of the heater core—Chevy/GMC S-Series Pick-up, Bravada, Sonoma and Envoy

h. Install the radio and storage compartment assembly (if equipped). i. If removed, install the instrument cluster. j. Install the heater and/or air conditioning control assembly. k, attach the electrical connections to the instrument panel accessory trim plate. |. Place the trim plate in position and install its retaining screws. Tighten the screws to 17 inch Ibs. (1.9 Nm). m. Place the steering column into

position and install its retaining nuts. Tighten the nuts to 22 ft. Ibs. (30 Nm). n. Attach the lighter electrical connection and the lap cooler duct to the knee bolster. o. Place the knee bolster into position and install its retaining screws. Tighten the Torxe head screws to 80 inch Ibs. (9 Nm) and the hex head screws to 17 inch lbs. (1.9 Nm). p. Place the courtesy lamp in position and install its screws. Tighten the screws to 17 inch Ibs. (1.9 Nm). q. Place the instrument panel center

assembly, Tighten the screw to 13 inch lbs. (1.5 Nm). s, Install the remote contro! door lock receiver module to the instrument panel _ left side sound insulator. t. Attach the door lock receiver electrical connection. u. Install the nut that attaches the left side sound insulator to the accelerator pedal bracket. Tighten the nut to 35 inch lbs. (4 Nm). v. Install the screw that attaches the left side sound insulator to cow! panel. Tighten the screw to 13 inch Ibs. (1.5 Nm). w. Install the screws that attach the left side sound insulator to knee bolster. Tighten the screw to 17 inch Ibs. (1.9 Nm). x. Feed the DLC through the hole in the sound insulator, place the DLC in position and install its retaining screws. Tighten the screws to 21 inch Ibs. (2.4 Nm). y. Install the right side sound insulator and tighten the screws z. Connect the parking brake release cable to the lever. aa. Enable the air bag system. 24. Install the heater hoses to the heater core. 25. Refill the cooling system. 26. Connect the negative battery cable. 27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

1998-01 HONDA

REMOVAL & INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. In the engine compartment, open the heater valve cable clamp and disconnect the cable from the heater valve arm. Then, turn the heater valve to the fully opened position. 4. Disconnect the heater hoses from the heater core. 9. Remove the heater housing-to-chassis nut.

e>When removing the heater housing nut, be careful not to damage or bend the fuel lines, the brake lines, etc.

6. Remove the instrument panel by performing the following procedure: a. Remove the driver's side lower instrument panel cover screws, disengage the clips and remove the lower cover. b. Remove the knee bolster bolts and the knee bolster. c. Remove the glove box stops from each side of the glove box. d. Remove the glove box-to-instrument panel bolts and the glove box. e. Remove the lower console cover by disengaging the 4 clips and removing the cover.

f. Remove the 6 center pocket-toinstrument panel screws; then, insert a flat tipped screwdriver at the upper right side corner of the center pocket, push down on the top of the hook and remove the center pocket/beverage holder

assembly.

:

g. Remove the center instrument panel lower cover screws and disengage the clips on the upper left side; then, disconnect the electrical connectors and remove the cover. h. Gently, push the power window switch from the instrument panel's lower cover opening by hand. Disconnect the electrical connectors and remove the power window switch. i. Close the driver's side air vent;

”

|

4° UE.

then, gently, push out the clips and pull ; ; out the vent. Disconnect the electrical connectors and remove the vent.

j. Gently, push out the driver's side

defogger trim; then, disconnect the electrical connector and remove the side defogger trim. k. At the base of the steering wheel, remove the access panel and disconnect the air bag electrical connector. |. Remove the steering column covers screws and the covers. m. Remove the steering column-to-

instrument panel nuts/bolts and lower the steering column. n. Remove the instrument panel side

covers. 0. Disconnect the wiring harness connector and remove the nuts.

p. Move the under-dash fuse/relay Dox. qg. Disconnect the antenna connector and the harness clips.

gs1136i2 Exploded view of the steering column and related components—Honda CR-V P: Bok locations

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PROTECTIVE TAPE

DASHBOARD

GUIDE PINS

FRONT PASSENGER'S AIRBAG CONNECTOR PROTECTIVE TAPE GUIDE PIN

Loosen.

CONNECTORS UNDER-DASH FUSE/RELAY BOX

CONNECTOR

HARNESS CLIPS HARNESS

CLIPS 93113G13

Exploded view of the instrument panel and related components—Honda CR-V

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

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1 2 3

Heater Core Case (Temperature Control) Heater Unit

4 5 6

Mode Door Duct Case (Mode Control) 93113GB0

Exploded view of the heater housing assembly—Isuzu Rodeo

e Passenger's inflator module con-

nector e Radio antenna cable plug e Ground cable bolt on the left dash side panel e The 8 instrument panel-to-chassis bolts and the 3 nuts. k. Remove the instrument panel assembly. 7. Remove the instrument panel bracket by performing the following procedure:

a. Remove the 2 passenger's inflator

ster reinforcement screws and the rein-

module bolts and 4 nuts.

forcement.

b. Remove the 4 meter assembly screws. Then, disconnect the meter wiring harness connectors and remove the meter assembly. c. Remove the 5 vent duct assembly screws and the assembly. d. Remove the 3 lower passenger bracket screws and the bracket. e. Remove the 9 passenger knee bol-

f. Remove the 6 instrument panel center reinforcement screws and the reinforcement. g. Remove the instrument panel wiring harness assembly clips and the wiring harness. h. Remove the 2 instrument panel bracket nuts and 2 bolts for each bracket; then, remove the bracket(s).

For complete service labor times, order the Chilton Labor Guide

2-84

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HEATER CORES ISUZU

8. Remove the 5 cross beam assembly nuts, 2 bolts and the 6 lower bolts; then, remove the crossbeam. 9. Disconnect the resistor wiring connector.

10. Remove the duct from the heater assembly. 11. If equipped with air conditioning, remove the evaporator assembly. 12. Remove the driver's lap vent. 13. Remove the lower ventilation duct. 14. Remove the footrest, the carpet, the 3 clips and the rear heater duct. 15. Remove the heater assembly. 16. Remove the mode control case-totemperature control case screws and remove the mode contro! case; do not remove the link unit. 17. Remove the temperature control case Screws and separate the cases. 18. Remove the heater core from the case. To install: 19. Install the heater core to the case. 20. Assemble the temperature control cases and install the case screws. 21. Install the mode control case and the mode control case-to-temperature control case SCrews. 22. Install the heater assembly. 23. Install the rear heater duct, the footrest, the carpet, and the 3 clips. 24. Install the lower ventilation duct. 25. Install the driver's lap vent. 26. If equipped with air conditioning, install the evaporator assembly. 2/7. Install the duct to the heater assembly. 28. Connect the resistor wiring connector. 29. Install the crossbeam, the 5 crossbeam assembly nuts, 2 bolts and the 6 lower bolts. 30. Install the instrument panel bracket by performing the following procedure: a. Install the instrument panel bracket and the 2 nuts and 2 bolts for each bracket. b. Install the instrument panel wiring pe assembly and the wiring harness Clips. c. Install the instrument panel center reinforcement and the 6 reinforcement SCreWS. d. Install the passenger knee bolster reinforcement and the 9 reinforcement SCrews., é. Install the lower passenger bracket and the 3 bracket screws. f. Install the vent duct assembly and the 5 vent duct assembly screws.

g. Install the meter assembly and the

4 meter assembly screws. Then, connect the meter wiring harness connectors. h. Install the 2 passenger's inflator module bolts and 4 nuts. 31. Install the instrument panel by performing the following procedure: a. Install the instrument panel assembly. b. Connect or install the following instrument panel harness connectors or items: The 6 driver's side connectors The 3 passenger's side connectors The 2 center connectors Passenger's inflator module connector Radio antenna cable plug Ground cable bolt on the left dash side panel The 8 instrument panel-to-chassis bolts and the 3 nuts. (a_ Install the radio/audio sub box assembly and the 4 radio/audio sub box assembly Screws. d. Connect the 3 control cables (unit side) and the 3 harness connectors. Install the 4 control lever assembly bolts. e. Install the knee bolster assembly and the 6 driver's knee bolster assembly bolts and screws. f. Install the instrument cluster assembly. Connect the 8 switch connectors. Install 5 instrument cluster screws and the 2 clips. g. Install the 2 hood release screws, the 6 instrument panel driver's lower cover assembly screws and the cover assembly. h. Install the glove box and the 2 glove box screws. i. Install the dash side trim panel sill plates and the panels. j. Install both the rear and front console. k. Connect the cigarette lighter connector and install the lower center cover

-SCIeW. 32. Connect the cooling system hoses. 33. Refill the cooling system. 34. Install the evaporator lines at the firewall. 35. If equipped, evacuate and charge the air conditioning system. 36. Connect the negative battery cable. 37. If equipped with an air bag, perform the following procedure:

a. Turn the ignition to the LOCK position and remove the key. b. Connect the 2-pin yellow connector located behind the glove box. C. Install the glove box assembly. d. Connect the 2-pin yellow connec-

tor located at the base of the steering column.

e. At the lower left dash side fuse block, install the SRS-1 fuse. f. Turn the ignition switch to ON and verify that the AIR BAG warning light flashes 7 times and turns OFF. 38. Run the engine to normal operating temperatures; then, check the climate con-_ trol operation and check for leaks.

REMOVAL & INSTALLATION

The vehicle is equipped with a driver’s side and a passenger’s side air bag. Before starting service procedures on components, especially under the instrument panel and/or near the steering column, disable the air bag systems. There is sufficient voltage in the system to cause a deployment for up to 15 seconds after the battery has been disconnected, the ignition turned OFF or fuse C-21 is removed from the fuse panel. 1. If equipped with an air bag, perform the following procedures: a. Disconnect the negative battery cable, then disconnect the positive battery cable. b. Disconnect the yellow 2-pin connector located at the base of the steering column. c. Remove the glove box and disconnect the yellow 2-pin connector located behind the glove box.

2. Disconnect the negative battery — cable. 3. Drain the cooling system. 4. lf equipped with air conditioning, discharge and recover the refrigerant. 5. Remove the instrument panel assembly by performing the following procedure: a. At the front console assembly, disconnect the switch connectors; then, remove the console-to-chassis screws and the console. b. At the lower cluster assembly, remove the cluster-to-instrument panel screws, disconnect the cigarette lighter and light connectors and remove the lower cluster. c. Remove the glove box and the instrument panel lower cover and the passenger knee bolster reinforcement.

HEATER CORES ISUZU

(1) Instrument Panel Assembly

(7) Heater Unit Assembly

(2) Instrument Panel Center Bracket (3) Resistor

(8) Center Ventilation Lower Duct (9) Driver Lap Vent Nozzle

(4) Duct (5) Evaporator Assembly (A/C only) (6) Rear Heater Duct

(10) (11) (12)

Water Hose Electro Thermo Connector (With A/C) Resistor Connector 93113G01

Exploded view of the heater unit and related components—Isuzu Trooper

d. At the left side, remove the instru-

g. Disconnect the air conditioning

ter assembly screws, disconnect the

ment panel lower cover and the knee bolster assembly. e. At the top of the instrument panel, pry the 8 claws on the front side toward you, raise the defroster grille and remove

control cables from the unit. h. Remove the instrument panel harness connectors (5 on the driver's side and 3 on the passenger's side), the pasSenger air bag module connector, the

switch connectors and the instrument panel assembly. 6. Disconnect the heater hoses from the heater unit. 7. Disconnect the heater resistor con-

it.

radio antenna plug and the center bracket ground cable bolt. i. Remove the passenger's air bag module nuts, disconnect the connectors and remove the module. j. Remove the instrument panel clus-

nector and the electro thermo connector (if equipped with air conditioning). 8. Remove the heater duct. 9. If equipped with air conditioning, remove the evaporator assembly by performing the following procedure:

f. At the cross beam bag module, and remove assembly.

SRS adjust bracket and under the passenger air remove the 2 fixing bolts the instrument panel

Please visit our web site at www.chiltonsonline.com

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(1) Case (Temperature Control) (2) Mode Door (3) Duct

2

(5) Case (Mode Control) (6) Heater Core 93113G02

Exploded view of the heater unit—Isuzu Trooper

a. Disconnect the drain hose. b. Using a backup wrench, disconnect the refrigerant lines from the evaporator.

c. Plug or cap the refrigerant lines. d. Remove the evaporator assembly. 10. Remove the instrument panel center bracket (crossbeam assembly) by performing the following procedure: a. Remove the side support bracket bolts and brackets from both sides of the vehicle. b. Remove the crossbeam center bracket nuts, disconnect the electrical connectors and the center bracket.

11. Remove the rear heater duct and

heater assembly. 12. Disassemble the heater unit assembly by performing the following procedure: a. Remove the lower air duct; do not remove the link unit. b. Remove the temperature control case screws and lift the case from the heater unit. c. Remove the heater core. To install: 13. Assemble the heater unit assembly by performing the following procedure: a. Install the heater core into the heater unit.

b. Install the temperature control case onto the unit and secure with screws. c. Install the lower air duct. a 14. Install the heater unit assembly into the vehicle. 15. Install the rear heater duct. 16. Install the instrument panel cross beam assembly by reversing the removal procedures. 17. lf equipped with air conditioning, install the evaporator assembly by performing the following procedures: a. If installing a new evaporator assembly, add 1.7 fl. oz. (50mL) of refrigerant oil to the evaporator.

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(1) Vent Duct Assembly

(9) Glove Box

(2) Instrument Harness Assembly (3) Instrument Panel Assembly (4) Side Defroster Grille

(10) (11) (12)

Lower Cluster Assembly Front Console Assembly Radio Assembly

(5) Passenger Inflator Module

(13)

Instrument Panel Driver Lower Cover

(6) Control Lever Assembly

Assembly

(7) Passenger Knee Bolster Reinforcement

(14) Driver Knee Bolster Assembly (15)

Instrument Panel Cluster Assembly

(8)

Instrument Panel Passenger Lower Cover

(16)

Meter Assembly

Assembly

(17) Front Defroster Grille

Assembly

93113G03

Exploded view of the instrument panel and accessories—Isuzu Trooper

Timing belt service is covered in Section 3 of this manual

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b. Using new O-rings and a backup wrench, install the refrigerant lines and torque the outlet line to 18 ft. Ibs. (25 Nm) and the inlet line to 11 ft. Ibs. (15 Nm). 18. Install the heater duct. 19. Connect the heater resistor connector and the electro-thermo connector (if equipped with air conditioning). 20. Connect the heater hoses to the heater unit. 21. Install the instrument panel assembly by reversing the removal procedures. 22. \f equipped with air conditioning,

_ evacuate and charge and leak-test the system. 23. Refill the cooling system. 24. Connect the negative battery cable.

*k¢ CAUTION Never use an air bag assembly from another vehicle and/or different model year. Starting in 1999, the air bag assemblies are equipped with identification colors on the bar code label as follows: YELLOW for the driver’s air bag assembly, WHITE for the passenger’s air bag assembly. 25. Enable the air bags by performing the following procedure: a. Connect the passenger's side air bag yellow 2-pin connector. b. Install the glove box.

c. At the base of the steering column, connect the yellow 2-pin connector. d. Install the air bag fuse C-21 (if removed) or connect the negative battery cable. e. Turn the ignition switch ON and verify that the AIR BAG warning light flashes 7 times and then turns OFF. 26. Run the engine to normal operating temperatures and check for leaks. Check the systems for correct operation.

REMOVAL & INSTALLATION

¢ CAUTION The vehicle is equipped with a driver’s side and a passenger’s side air bag. Before starting service procedures on components, especially under the instrument panel and/or near the steering column, disable the air bag systems. There is sufficient voltage in the system to cause a deployment of the air bags for up to 15 seconds after the battery has been disconnected. 1. If equipped with an air bag, perform the following procedures: a. Disconnect the negative battery

cable, then disconnect the positive battery cable. -b. Disconnect the yellow 3-pin connector located at the base of the steering column. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. If equipped with air conditioning, discharge and recover the refrigerant. 5. Remove the instrument panel assembly by performing the following procedure: a. Remove the front lower console cover Screws and cover. b. Remove the glove box door and box. c. At the passenger's side, remove the instrument panel lower cover screws and panel. d. At the driver's side, disconnect the

accelerator cable from the pedal and remove the instrument panel lower cover screws and panel. e. Remove the lower cluster. f. At the meter cluster assembly, disconnect the switch connectors, then remove the screws, clips and the meter assembly. g. At the driver's side, disconnect the data link connector, then remove the bolts and the knee bolster. h. At the lower cluster cover, remove the cover-to-instrument panel screws,

1 Instrument Panel Assembly

2 Center & Lower Vent Duct 3 Instrument Panel Center Bracket 4 Evaporator Assembly

5 Heater Unit Assembly

6 Heater Hose 7 Blower

Unit

93113G04

Exploded view of the heater unit and related compon ents—Isuzu VehiCROSS

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(1) Case (Temperature Control) (2) Mode Door (3) Duct

HEATER CORES ISUZU

9-89

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(5) Case (Mode Control) (6) Heater Core 93113G02

Exploded view of the heater unit—lsuzu VehiCROSS

disconnect the cigarette lighter and remove the lower cover. i. Disconnect the air conditioning control cables from the unit. j. Remove the instrument panel clus-

ter assembly screws, disconnect the switch connectors and the instrument panel assembly. k. Remove the instrument harness connectors, the radio antenna plug. |. Remove the side defroster grille. Remove the instrument panel nuts,

bolts and screws and the instrument panel. 6. Remove the passenger's air bag reinforcement screws and the reinforcement.

10. Remove the instrument panel center bracket bolts, nuts and bracket. 11. Remove the heater resistor connectors and the electro thermo connector (if equipped with air conditioning).

7. At the meter assembly, disconnect

12. Remove the blower motor assembly.

the electrical connector, then remove the screws and the meter assembly. 8. Remove the radio and the vent duct assembly. 9. Remove the passenger's knee bolster screws and bolster.

13. If equipped with air conditioning, remove the evaporator assembly by performing the following procedure: a. Disconnect the drain hose. b. Using a backup wrench, disconnect the refrigerant lines from the evaporator.

Brake service is covered in Section 4 of this manual

;

HEATER CORES ISUZU

1

Vent Duct Assembly

12 Lower Cluster

2 Passenger Air Bag Reinforcement

13° Instrument Pane! Lower Center Cover

3

Instrument Panel Assembly

14 Instrument Panel Driver Lower Cover

4

Passenger Air Bag Assembly

45

Driver Knee Bolster

5

Glove Box Cover

16

Meter Cluster Assembly

6

Passenger Knee Bolster

17

Meter Assembly

7 Glove Box Assembly

18 Instrument Harness Assembly

8

Radio Assembly

19

Brake Pedal & Bracket Assembly

9

Air Conditioner Control Lever Assembly

20

Instrument Panel Center Bracket

10

Instrument Panel Passenger Lower Cover

21

Cross

11

Front Lower Console Cover

Beam

Assembly

93113G05

Exploded view of the instrument panel and accessories—Isuzu VehiCROSS

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HEATER CORES

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c. Plug or cap the refrigerant lines. d. Remove the evaporator assembly. 14. Remove the driver's side lap vent duct. 15. Remove the center and lower vent ducts. 16. Remove the heater assembly. 17. Disassemble the heater unit assembly by performing the following procedure: a. Remove the lower air duct; do not remove the link unit. b. Remove the temperature control case screws and lift the case from the heater unit. c. Remove the heater core. To install: 18. Assemble the heater unit assembly by performing the following procedure: a. Install the heater core into the heater unit. b. Install the temperature control case onto the unit and secure with SCrews. c. Install the lower air duct.

|

19. Install the heater unit assembly into the vehicle. 20. Install the center and lower vent ducts. 21. Install the driver's side lap vent duct. 22. Install the instrument panel cross beam assembly by reversing the removal procedures, 23. If equipped with air conditioning, install the evaporator assembly by performing the following procedures: a. If installing a new evaporator assembly, add 1.7 fl. oz. (50mL) of refrigerant oil to the evaporator. b. Using new O-rings and a backup wrench, install the refrigerant lines and torque the outlet line to 18 ft. Ibs. (25 Nm) and the inlet line to 11 ft. Ibs. (15 Nm). 24. Install the blower motor. 25. Cognect the heater resistor connectors and the electro-thermo connector (if equipped with air conditioning). 26. Connect the heater hoses to the heater unit.

harness connector at the left side of ~

REMOVAL & INSTALLATION 1. Disconnect and remove the negative battery.

sto CAUTION After disconnecting the negative battery cable, wait 2 minutes for the driver’s/passenger’s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument. IT SP

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2/. Install the instrument panel \ assembly by reversing the removal proce: dures... 28. If equipped with air conditioning, ? evacuate and recharge the system. 29. Refill the cooling system. 30. Connect the negative battery cable.

4k CAUTION Never use an air bag assembly from another vehicle and/or different model year.

31. Enable the air bag by performing the following procedure: a. At the base of the steering column, connect the yellow 3-pin connector. b. Connect the negative battery cable. c. Turn the ignition switch ON and verify that the AIR BAG warning light flashes 7 times and then turns OFF. 32. Run the engine to normal operating temperatures and check for leaks. Check the systems for correct operation.

1998-02 JEEP e Instrument panel wiring harness connector from the 100-way wiring

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2. Drain the cooling system into a clean container for reuse. 3. Remove the instrument panel by performing the following procedure: a. Turn the steering wheel in the straight-ahead position. b. Remove the knee blocker from the instrument panel. c. Remove the steering column; do not remove the air bag module, the steering wheel or switches from the steering column. d. From under the driver's side of the instrument panel, disconnect the following items:

the inner panel. e Side window demister hose at the heater/air conditioning housing demister/defroster duct on the driver's side. e. Remove the glove box. f. Reaching through the glove box opening, disconnect the following items: Two halves of the heater/air conditioning system vacuum harness connector. Instrument panel wiring harness

connector from the heater/air conditioning system wiring harness connector. Instrument panel wiring harness connector from the passenger's side air bag module wiring harness connector.

Side window demister hose at the heater/air conditioning housing demister/defroster duct (passenger's side). Two halves of the radio antenna coaxial cable connector. Two instrument panel wiring harness connectors from the passen-

ger air bag ON/OFF switch wiring harness connector. Passenger's side air bag ON/OFF Switch wiring harness from the retainer clip on the plenum bracket that supports the heater/air conditioning housing just inboard of the fuse block module. Two lower passenger's side air bag module bracket-to-dash panel nuts. g. Remove the upper cover from the instrument panel. h. Remove the 3 instrument panel-todoor hinge pillar screws. i. Remove the 4 upper instrument panel-to-dash nuts. j. Using an assistant, remove the instrument panel from the vehicle. 4. If equipped with air conditioning, discharge and recover the air conditioning system refrigerant. 5. Disconnect the refrigerant lines from the evaporator. Plug the refrigerant openings to prevent evaporation. 6. Disconnect the heater hoses from the heater core tubes.

7. Disconnect the heater/air conditioning system vacuum supply line connector from the T-fitting near the heater core tubes. 8. In the engine compartment, remove the 5 heater/air conditioning housing-to-

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

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HEATER CORES —

JEEP

1 — STUDS 2 — NUT 3 -— SCREW 93113GA6

View of the instrument panel and fasteners—Jeep Cherokee

chassis nuts. If necessary, loosen the battery hold-downs and reposition the battery for access. j 9. Remove the cowl plenum drain tube from the heater/air conditioning housing stud; it's located behind the cylinder head on the cowl. 10. From the bottom of the heater/air conditioning housing, remove the floor duct. 11. On the passenger side, remove the heater/air conditioning housing-to-plenum bracket screw. 12. Pull the heater/air conditioning housing down far enough to clear the defrost/demist and fresh air ducts, then, rearward far enough to clear the mounting studs and the evaporator drain tube to clear the dash panel holes. 13. Remove the heater/air conditioning housing assembly from the vehicle. 14. Remove the heater/air conditioning housing upper case. 15. Lift the heater core from the lower half of the heater/air conditioning housing. To install: 16. Assemble the heater core into the lower half of the heater/air conditioning housing. 17. Install the heater/air conditioning housing upper case. 18. Install the heater/air conditioning housing assembly to the vehicle. 19. On the passenger's side, install the heater/air conditioning housing-to-plenum

bracket screw. 20. At the bottom of the heater/air conditioning housing, install the floor duct. 21. Install the cow! plenum drain tube to the heater/air conditioning housing stud; it’s located behind the cylinder head on the cowl. 22. In the engine compartment, install the 5 heater/air conditioning housing-tochassis nuts. 23. Connect the heater/air conditioning system vacuum supply line connector to the T-fitting near the heater core tubes. 1 2 3 4 5 6 7 8

— — — — — —

24. Connect the heater hoses to the ‘ heater core tubes. 29. Connect the refrigerant lines to the

DEFROST/DEMIST DUCT COLLAR FRESH AIR DUCT HEATER-A/C HOUSING SCREWS FLOOR DUCT NUT NUT

evaporator. 26. If equipped with air conditioning, evacuate and charge the air conditioning

93113GA7

Exploded view of the heater core assembly—Jeep Cherokee

system refrigerant. 27. Install the instrument panel by performing the following procedure: a. Using an assistant, install the instrument panel to the vehicle. b. Install the 4 upper instrument panel-to-dash nuts.

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HEATER CORES

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temperatures; then, check the climate control operation and check for leaks.

REMOVAL & INSTALLATION 1. Disconnect and remove the negative battery.

2+ CAUTION After disconnecting the negative battery cable, wait 2 minutes for the driver’s/passenger’s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument.

1 — HEATER CORE 2 — LOWER HEATER-A/C HOUSING 93113GA8

View of the heater core—Jeep Cherokee

c. Install the 3 instrument panel-todoor hinge pillar screws. d. Install the upper cover to the instrument panel. e. Reaching through the glove box opening, connect the following items. e Two lower passenger's side air bag module bracket-to-dash panel nuts. Passenger’s side air bag ON/OFF switch wiring harness to the retainer clip on the plenum bracket that supports the heater/air conditioning housing just inboard of the fuse block module. Two instrument panel wiring harness connectors to the passenger air bag ON/OFF switch wiring harness connector. Two halves of the radio antenna

coaxial cable connector. Side window demister hose at the heater/air conditioning housing demister/defroster duct (passenger's side). Instrument panel wiring harness connector to the passenger's side

air bag module wiring harness connector. Instrument panel wiring harness connector to the heater/air conditioning system wiring harness connector. Two halves of the heater/air conditioning system vacuum harness connector. f. Install the glove box. g. Under the driver's side of the instrument panel, connect the following items: e Side window demister hose at the heater/air conditioning housing demister/defroster duct on the driver's side. e |nstrument panel wiring harness connector to the 100-way wiring harness connector at the left side of the inner panel. h. Install the steering column. i. Install the knee blocker to the instrument panel. 28. Connect and remove the negative battery. 29. Refill the cooling system. 30. Run the engine to normal operating

2. Drain the cooling system into a clean container for reuse. 3. Remove the instrument panel by performing the following procedure: a. Turn the steering wheel in the straight-ahead position. b. Remove the knee blocker from the instrument panel. c. Remove the steering column; do not remove the air bag module, the steering wheel or switches from the steering column. d. From under the driver's side of the instrument panel, disconnect the following items: e Instrument panel wiring harness connector from the 100-way wiring harness connector at the left side of the inner panel. e Side window demister hose at the heater/air conditioning housing demister/defroster duct on the driver's side. e. Remove the glove box. f. Reaching through the glove box Opening, disconnect the following items: e Two halves of the heater/air conditioning system vacuum harness connector. Instrument panel wiring harness connector from the heater/air conditioning system wiring harness connector. Instrument panel wiring harness connector from the passenger's Side air bag module wiring harness connector. Side window demister hose at the heater/air conditioning housing

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

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demister/defroster duct (passenger's side). e Two halves of the radio antenna coaxial cable connector. e Two instrument panel wiring harness connectors from the passenger air bag ON/OFF switch wiring harness connector. e Passenger's side air bag ON/OFF switch wiring harness from the retainer clip on the plenum bracket that supports the heater/air conditioning housing just inboard of the fuse block module. e Two lower passenger's side air bag module bracket-to-dash panel nuts. g. Remove the upper cover from the instrument panel. h. Remove the 3 instrument panel-todoor hinge pillar screws. i. Remove the 4 upper instrument panel-to-dash nuts. _j. Using an assistant, remove the

1 — STUDS

instrument panel from the vehicle.

2 — NUT

3 -— SCREW

.

93113GA6

View of the instrument panel and fasteners—Jeep Wrangler

1 — DEFROST/DEMIST DUCT 2 — COLLAR 3 — FRESH AIR DUCT

4 5 6 7

— — —

rearward far enough to clear the mounting

HEATER-A/C HOUSING SCREWS FLOOR DUCT NUT

8 — NUT Exploded view of the heater core assembly—Jeep Wrangler

4. If equipped with air conditioning, discharge and recover the air conditioning system refrigerant. 5. Disconnect the refrigerant lines from the evaporator. Plug the refrigerant openings to prevent evaporation. 6. Disconnect the heater hoses from the heater core tubes. 7. Disconnect the heater/air conditioning system vacuum supply line connector from the T-fitting near the heater core tubes. 8. In the engine compartment, remove the 5 heater/air conditioning housing-tochassis nuts. If necessary, loosen the battery hold-downs and reposition the battery for access. 9. Remove the cowl plenum drain tube from the heater/air conditioning housing Stud; it's located behind the cylinder head on the cowl. 10. From the bottom of the heater/air conditioning housing, remove the floor duct. 11. On the passenger side, remove the heater/air conditioning housing-to-plenum bracket screw. \ 12. Pull the heater/air conditioning housing down far enough to clear the defrost/demist and fresh air ducts, then,

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Studs and the evaporator drain tube to clear the dash panel holes. 13. Remove the heater/air conditioning housing assembly from the vehicle. 14. Remove the heater/air conditioning housing upper case. 19. Lift the heater core from the lower

half of the heater/air conditioning housing.

Note the position of the irregular shaped gasket so that it may be reinstalled in its correct position. 17. Remove the heater core retainers and SCreWS. 18. If necessary, remove the mode door actuator for clearance to remove the core. 19. Remove the heater core from the heater/air conditioning housing assembly. To install: 20. Install the heater core tom the heater/air conditioning housing assembly.

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21. If removed, install the mode door actuator.

.

22. Install the heater core retainers and SCrewS. 23. Install the foam gasket around the heater core tubes. 24. Install the heater/air conditioning housing assembly to the vehicle. 25. In the passenger compartment, install the heater/air conditioning housingto-chassis nuts. 26. Connect the heater/air conditioning housing wire harness connectors. 27. At the center of the dashboard, install the rear floor ducts to the floor heat duct outlets. 28. In the engine compartment, install the heater/air conditioning housing-tochassis nuts. 29. At the passenger's side in the engine compartment dash panel, install the PCM. 30. At the passenger's side inner fender shield, install the coolant reservoir/overflow bottle. 31. If equipped with a manual temperature control system, plug the heater/air conditioning system vacuum supply line connector to the T-fitting located near the heater core tubes. 32. Connect the heater hoses to the heater core. 33. Connect the air conditioning system lines to the evaporator. 34. Evacuate and charge the air conditioning system refrigerant. 35. Remove the instrument panel by per-. forming the following procedure: a. Turn the steering wheel in the straight-ahead position. b. Install the A-pillar trim to both

Sides of the vehicle. c. Install the top cover to the instrument panel.

d. Near the windshield line, install the 4 instrument panel-to-chassis nuts. e. Install the scuff plates to both front door sills. f. Install the trim panels to both sides of the inner cowl. g. Install the floor console. : h. Install the fuse cover to the junction box. i. Install the instrument panel cluster bezel. j. Install the steering column opening cover to the instrument panel. k. Install the steering column bracket to the instrument panel column support bracket.

1

- TUBE-TO-CORE CLAMPS 2 — GROUND STRAP 3 ! HVAC HOUSING 4 TUBE RETAINERS AND SCREWS 5 HEATER CORE 93113GA5

View of the heater core screws, gasket and retainers—Jeep Grand Cherokee

|. Install the lower steering column

shroud cover-to-multifunction switch screw; then, snap both halves of the

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_ HEATER CORES

JEEP

shroud cover to the steering column. m. Connect the instrument panel wiring harness connectors to the following steering column components: Sentry Key Immobilizer Module (SKIM) receptacle, if equipped Shifter interlock solenoid receptacle Both ignition switch receptacles oe multifunction switch receptaCle Left multifunction switch receptacle Both lower clockspring connector receptacles — . Turn the ignition switch to ON position; then, release and install the shifter interlock cable connector to the ignition lock housing receptacle. 0. Install the 4 steering column-toinstrument panel steering column bracket nuts. p. Install the steering column to the instrument panel. g. Connect both side body wiring harness bulkhead connectors, the Ignition Off Draw (IOD) wiring harness connector and the fused wiring harness connector to the junction block connector receptacles. . r. Disconnect the instrument panel wiring harness-to-floor console component connectors: e Transmission shifter connector receptacle e Parking brake switch terminal e Air bag control module connector receptacle s. Install the 2 instrument panel wiring harness-to-floor console ground terminals located behind the air bag control module. t. Connect the instrument panel wiring harness-to-floor console retainers. u. Install the instrument panel-tofloor console bracket and the screws. v. Install the driver's side floor duct and the duct-to-heater/air conditioning housing assembly screw. w. If equipped with a manual heatingair conditioning system, connect the vacuum harness connector behind the driver's side floor duct. x. Install the instrument panel steering column support bracket-to-driver's side of the heater/air conditioning housing assembly screw. y. Install the instrument panel steering column support bracket-to-intermediate bracket screw. z. Install the instrument panel steer-

ing column support bracket-to-driver’s side cowl plenum panel nut. aa. Install the 2 instrument panel-todriver's side cowl side inner panel Screws. bb. Install the instrument panel end cap. cc. Install the lower right center bezel to the instrument panel. dd. At the passenger's side cowl side inner panel, connect the instrument panel wiring harness bulkhead connector to the lower cavity of the inline connector. ee. Near the right cowl side inner panel located under the end of the instrument panel, connect both halves of the radio antenna coaxial cable connector. ff. Connect the 2 instrument panel-toheater/air conditioning assembly wiring harness connectors. gg. Atthe passenger's side, install the 2 instrument panel structural duct-toheater/air conditioning housing assembly Screws. hh. At the passenger's side cowl side inner panel, install the 2 instrument panel-to-passenger’s side cowl side inner panel screws. ii. With the help of an assistant, lift the instrument panel into the vehicle. 36. Refill the cooling system. 37. Connect the negative battery. 38. Run the engine to normal operating temperatures. Check the climate contro! operation and check for leaks. Liberty 1. Disconnect and remove the negative battery.

>< CAUTION After disconnecting the negative battery cable, wait 2 minutes for the driver’s/passenger’s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument. 2. Drain the cooling system into a clean container for reuse. 3. Remove the instrument panel by performing the following procedure: a. Turn the steering wheel in the straight-ahead position. b. Remove the A-pillar trim from both sides of the vehicle. c. Remove the top cover from the instrument panel. d. Remove the speakers.

e. Remove the floor console. f. Remove the radio. g. Remove the center support bracket. h. Remove the trim panels from both sides of the inner cowl. i. Remove the fuse cover from the junction box. j. Remove the instrument panel cluster bezel. k. Remove the steering column opening cover from the instrument panel. |. Remove the steering column bracket from the instrument panel column support bracket. m. Remove the lower steering column shroud cover-to-multifunction switch screw; then, unsnap both halves of the shroud cover from the steering column. n. Disconnect the instrument panel wiring harness connectors from the following steering column components: e Both lower clockspring connector receptacles Left multifunction switch receptacle Right multifunction switch receptacle Both ignition switch receptacles Shifter interlock solenoid receptacle Sentry Key Immobilizer Module (SKIM) receptacle, if equipped 0. Turn the ignition switch to ON position: then, release and remove the shifter interlock cable connector from the ignition lock housing receptacle. p. Turn the ignition switch to OFF position; this will prevent the steering wheel from turning and the loss of the clockspring centering following steering column removal. q. Remove the 4 steering column-toinstrument panel steering column bracket nuts. r. Remove the steering column from the instrument panel.

4. Remove the driver's side cowl trim cover. 5. Disconnect the green and light blue wire harness bulk connectors at the junction block. 6. Disconnect the electrical connector at the inner side of the pedal support bracket. 7. Remove the 2 bolts from the front and the 2 from the side of the pedal support bracket. 8. Remove the glove box. 9. Remove the 2 HVAC mounting bolts behind the center trim. 10. Remove the passenger trim bezel.

For Maintenance Interval recommendations, see Section 1 of this manual

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BLOWER MOTOR AND CAGE RECIRCULATION DOOR ACTUATOR LINKAGE RECIRCULATION DOOR VACUUM ACTUATOR CASE RETAINER SCREW BLEND DOOR ACTUATOR MOUNTING SCREWS ELECTRIC BLEND DOOR ACTUATOR ELECTRICAL CONNECTOR FOR BLEND DOOR ACTUATOR HEATER CORE RETAINER TABS (4) AND SCREWS (2)

9 - HEATER CORE 10 - HVAC CASE RETAINER CLIP 11 - HEATER CORE INPUT AND OUTPUT CONNECTIONS 12 - EVAPORATOR CONNECTION FLANGE 13 - HVAC CASE RETAINER SCREWS 14 - HVAC HOUSING

9355PG99

HVAC case components—Liberty

11. Remove the HVAC mount bolt above the glove box. 12. Remove the HVAC bolt at the lower outside glove box opening. 13. Remove the passenger trim cover, disconnect the blower resistor, remove the rolldown brackets ta the right cowl side panel. 14. Disconnect the vacuum check valve and the vacuum reservoir. 15. Disconnect the blower connectors. 16. Remove the 4 top bolts connecting the instrument panel to the cowl. 17. Roll the instrument panel rearward and disconnect the wiring. 18. Remove the panel. 19. Discharge and recover the air conditioning system refrigerant.

20. Disconnect the air conditioning system lines at the evaporator. Plug the openings to prevent contamination. 21. Disconnect the heater hoses from the heater core. Plug the openings to prevent coolant loss. 22. If equipped with a manual temperature control system, unplug the heater/air conditioning system vacuum supply line connector from the T-fitting located near the heater core tubes. 23. Remove all remaining fasteners and connections and remove the HVAC unit. 24. Disconnect all remaining hoses and wires. 29. Remove the blower motor.

26. Pop out the grommet on the vacuum supply line and slide hole. 27. Remove the foam gasket from around the heater core tubes. 28. Pry off the 4 snap clips that hold the halves of the unit together and separate the unit halves. 29. Installation is the reverse of removal. 30. Refill the cooling system. 31. Connect the negative battery. 32. Evacuate, charge and leak test the system. 33. Run the engine to normal operating temperatures. Check the climate control operation and check for leaks.

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1998-00 KIA d. Remove the steering wheel-tosteering column nut.

mS Sportage REMOVAL & INSTALLATION

e>if may be necessary to mark the steering wheel to steering column alignment.

1. Disconnect the negative battery cable.

+2 CAUTION After disconnecting the negative battery cable, wait for at least 10 minutes for the air bag module to deplete its stored energy. 2. Remove the driver's side air bag and steering wheel by performing the following procedure: a. Position the front wheels in the straight-ahead position. b. Remove the 4 steering wheel-to-air bag module bolts. c. Carefully, lift the air bag module and disconnect the electrical connector.

24k CAUTION Place the air bag module in a safe location with the front facing upward.

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e. Using a steering wheel puller, press the steering wheel from the steering column. 3. Drain the cooling system into a clean container for reuse. 4, Discharge and recover the air conditioning system refrigerant. 5. Remove the instrument panel by performing the following procedure: a. Remove both the rear and front consoles. b. Remove the knee bolster assembly. c. Remove the “T” bar section. d. Remove the relay bracket. e. Remove the turn signal assembly and the upper/lower steering column covers. f. Remove the hood release handle lockscrew, the hood release handle and the cable assembly nut. g. Remove the left side front pillar

trim and the lower left side cover. h. Remove the 2 left side of the “T” bar-to-chassis bolts. i. At the left side of the instrument panel, remove the 3 instrument panel-tochassis bolts. j. Remove the ashtray. k. Remove the center panel trim. |. Remove the ventilation control panel. m. At the center of the windshield next to the windshield, remove the cap and the mounting bolt. n. Remove the right side front pillar trim and the lower right side cover. 0. Remove the 2 right side of the “T” bar-to-chassis bolts. p. At the right side of the instrument panel, remove the 3 instrument panel-tochassis bolts. g. Remove the steering column-toinstrument panel bolts and lower the steering column. r. Disconnect the instrument panel electrical connectors. s. Remove the instrument panel.

Oblong Hole

Clockspring Assembly

Combination Switch

Steering Wheel Air Bag Module

Steering Wheel Housing

93113G14

Exploded view of the steering wheel and air bag module assembly—Kia Sportage

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

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9-102 HEATER CORES h. Remove the blower/evaporator housing. 7. Disconnect the heater hoses from the heater core. 8. Remove the temperature control cable from the heater housing. 9. Remove the 2 lower heater housing nuts and the upper heater housing-to-bulkhead nut.

10. Remove the heater housing.

11. Disassemble the heater housing by performing the following procedure:

a. Remove the seal from the heater

93113GI5

View of the blower/evaporator housing assembly—Kia Sportage

6. Remove the blower/evaporator housing by performing the following procedure: a. Disconnect the air conditioning refrigerant lines from the evaporator core and discard the gaskets. Plug the openings to prevent contamination. b. Disconnect the fresh air control cable from the blower/evaporator housing inlet duct. c. Disconnect the 5 connectors from

h. Remove the 8 remaining heater

the bottom of the blower/evaporator housing. d. Move the carpeting from the bulkhead to gain access to the hole cover plate. e. Remove the 4 hole cover plate nuts and the plate. f. Remove the 2 upper blower/evaporator housing bolts. g. Remove the 2 lower blower/evaporator housing-to-bulkhead nuts.

93113GI6

Exploded view of the heater core and heater housing assembly—Kia Sportage

core tube connections. b. Remove the vent seal. c. Remove the 2 wiring harness-toheater servo Screws. ~ d. Remove the 8 heater housing clips located on the servo side (left side). e. Remove the left side of the heater housing. f. Remove the 6 heater housing assembly clips. g. Remove the 4 heater core tube mounting bracket screws and the bracket. housing clips and disassemble the housings. i. Remove the heater core from the housing. To install: 12. Assemble the heater housing by performing the following procedure: a. Install the heater core to the housing. b. Assemble the housings and install the 8 remaining heater housing clips. c. Install the heater core tube mounting bracket and the 4 bracket screws. d. Install the 6 heater housing assembly clips. e. Install the left side of the heater housing. 4, f. Install the 8 heater housing clips located on the servo side (left side). g. Install the 2 wiring harness-toheater Servo Screws. h. Install the vent seal. i, Install the seal to the heater core tube connections. 13. Install the heater housing. 14. Install the 2 lower heater housing nuts and the upper heater housing-to-bulkhead nut. 15. Install the temperature control cable to the heater housing. 16. Connect the heater hoses to the heater core. 17. Install the blower/evaporator housing by performing the following procedure: _ a. Install the blower/evaporator housing.

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HEATER CORES 9.43 _D. Install the 2 lower blower/evaporator housing-to-bulkhead nuts. c. Install the 2 upper blower/evaporator housing bolts. d. Install the hole cover plate and the 4 plate nuts. e. Move the carpeting over the bulkhead. f. Connect the 5 connectors to the bottom of the blower/evaporator housing. g. Connect the fresh air control cable to the blower/evaporator housing inlet duct. h. Using new gaskets, connect the air conditioning refrigerant lines to the evaporator core. 18. Install the instrument panel by performing the following procedure: a. Install the instrument panel. b. Connect the instrument panel electrical connectors. c. Install the steering column and lower the steering column-to-instrument panel bolts. Torque the bolts to 15 ft. Ibs. (20 Nm). _ d. At the right side of the instrument

|

1. Turn the steering wheel 90° from horizontal.

2. Turn the ignition switch OFF. 3. Disconnect the negative (() battery cable and then the positive (+) battery cable. e>Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

4. Drain the cooling system into a clean container for reuse. 5. Discharge and recover the air conditioning system refrigerant. 6. Remove the dash panel assembly by performing the following procedure: a. Move the seats rearward. b. Working under the dash panel assembly, disconnect the air bag multiplug electrical connectors. c. Remove the glove box. d. Remove the center console assem-

bly. e. Remove the driver's SRS module, by disconnecting or removing following

.

the steering wheel, release

the lower dash panel cover turnbuckles and remove the lower dash panel.

k. At the left side of the instrument panel, install the 3 instrument panel-tochassis bolts. |. Install the 2 left side of the “T” barto-chassis bolts. m. Install the lower left side cover and

the left side front pillar trim. n. Ingtall the cable assembly nut, the hood release handle and the hood release handle lockscrew. 0. Install the turn signal assembly and the upper/lower steering column COVerS.

p. Install the relay bracket. q. Install the “T” bar section. r._ Install the knee bolster assembly. s. Install both the rear and front consoles. 19. Evacuate and charge the air conditioning system refrigerant. 20. Refill the cooling system. 21. Install the driver's side air bag and steering wheel by performing the following procedure: a. Install the steering wheel to the steering column. b. Install the steering wheel-to-steering column nut and torque the nut to 33 ft. Ibs. (45 Nm). c. Carefully, install the air bag module and connect the electrical connector. d. Install the 4 steering wheel-to-air bag module bolts and torque to 72-106 inch Ibs. (8-12 Nm). 22. Connect the negative battery cable. 23. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

1998-00 LAND ROVER

Discovery

items: e Under

panel, install the 3 instrument panel-tochassis bolts. é. Install the 2 right side of the “T” bar-to-chassis bolts. f. Install the right side front pillar trim and the lower right side cover. g. At the center of the windshield next to the windshield, install the cap and the mounting bolt. h. Install the ventilation control panel. i. Install the center panel trim. j. Install the ashtray.

Disconnect the air bag harness connector from the yellow air bag column harness. Using a special socket, remove the 2 tamper-proof resistor air bag module-to-steering wheel screws. Remove the air bag module from the steering wheel.

kk CAUTION Do not allow the air bag module to hang by electrical harness.

e Disconnect the air bag harness connector. e Remove the air bag module. f. Remove the passenger's SRS module, by disconnecting or removing following items: e Open the glove box door and disconnect the air bag module electrical connector. Using a special socket and a long

extension, remove both front air bag module-to-dash panel screws. Using a Torx® socket, remove both

rear air bag module-to-dash panel

SCTEWS. e Remove the air bag module from the dash panel.

kk CAUTION Do not allow the air bag module to hang by electrical harness. e Disconnect the air bag harness connector.

g. Release the clamp and lower the steering column. h. Remove the steering wheel and the steering column switch. i. Remove the instrument housing. j. Disconnect the electrical connectors and remove the radio.

k. Remove the exterior mirrors switch panel and the coin tray. |. Remove the switch panel and the clock. m. Remove the passenger's side relay assembly mounting bracket screw and move the assembly aside. n. Turn the heater controls fully clockwise. Noting the position of the levers, disconnect the heater control cables from the levers and outer cable from the retaining clips. 0. Remove the 4 dash panel-to-center lower mounting bracket bolts.

p. Remove the 4 dash panel-to-side lower mounting bracket bolts. q. Working below the steering col-

For complete service labor times, order the Chilton Labor Guide

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UU cee umn, remove the 4 driver's knee bolster pads screws and both knee bolster pads. r. Remove the 4 instrument bracketto-dash panel nuts. s, Using an assistant, partially maneuver the dash panel rearward. t. At the driver's side, disconnect the 6 dash harness-to-main harness multiplugs connectors. u. Disconnect the 3 dash harness-tofusebox multi-plug connectors. v. Using an assistant, remove the dash panel assembly from the vehicle. 7. Inthe engine compartment, disconnect the heater hoses from the heater tubes. 8. Release the P-clip securing both the high and low air conditioning pressure tubes. 9. Remove both the high and low pressure tubes-to-evaporator bolts; then, separate the tubes from the evaporator and discard the O-rings. 10. At the lower right side of the heater/air conditioning housing, disconnect the heater-to-blower motor multi-plug connector. 11. Remove the 3 blower motor housing screws and remove the blower motor hous-

93113GC8

View of the steering wheel, SRS module and special tool—Land Rover Discovery

ing. 12. Remove the 5 heater/air conditioning housing-to-chassis screws. 13. Remove the 2 center console front mounting bracket-to-chassis bolts and remove the center console front mounting bracket. 14. Disconnect both drain tubes. 15. Carefully, remove the heater/air conditioning housing from the vehicle. 16. Remove both right side footwell outlet-to-heater/air conditioning housing screws and the outlet. 17. Remove the heater hoses-to-heater assembly clip. 18. Slide the heater core from the heater/air conditioning housing. To install: 19. If installing a new heater core, transfer the heater hoses to the new heater core. 20. Slide the heater core into the heater/air conditioning housing. 21. Install the heater hoses-to-heater assembly clip. 22. Install the right side footwell outlet and both outlet-to-heater/air conditioning housing screws. 23. Carefully, install the heater/air conditioning housing to the vehicle. 24. Connect both drain tubes. 20. Install the center console front mounting bracket and the 2 center console front mounting bracket-to-chassis bolts.

93113GC9

View of the passenger’s side SRS module and special screws—Land Rover Discovery

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26. Install the 5 heater/air conditioning housing-to-chassis screws. 27. Install the blower motor housing and the 3 blower motor housing screws. 28. At the lower right side of the heater/air conditioning housing, connect the heater-toblower motor multi-plug connector. 29. Using new O-rings, assemble the tubes to the evaporator and install both the high and low pressure tubes-to-evaporator bolts. 30. Install the P-clip securing both the high and low air conditioning pressure tubes. 31. In the engine compartment, connect the heater hoses to the heater tubes. 32. Install the dash panel assembly by performing the following procedure: a. Using an assistant, install the dash panel assembly to the vehicle. b. Connect the 3 dash harness-tofuse box multi-plug connectors. c. At the driver's side, connect the 6

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dash harness-to-main harness multi-

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plugs connectors. d. Using an assistant, partially maneuver the dash panel forward. e. Install the 4 instrument bracket-todash panel nuts. f. Working below the steering column, install both knee bolster pads and the 4 driver's knee bolster pads screws. g. Install the 4 dash panel-to-side lower mounting bracket bolts. h. Install the 4 dash panel-to-center lower mounting bracket bolts. i. Noting the position of the levers, connect the heater control cables to the levers and outer cable to the retaining clips. j. Install the passenger's side relay assembly mounting bracket and the assembly screw. k. Install the switch panel and the clock. |. Install the exterior mirrors switch panel and the coin tray. m. Connect the electrical connectors and install the radio. n. Install the instrument housing. o. Install the steering column switch and the steering wheel. p. Raise the steering column and install the clamp. q. Install the passenger's SRS module, by connecting or installing following items: e Connect the air bag harness con-

View of the heater core and related components—Land Rover Discovery

Please visit our web site at www.chiltonsonline.com

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e Install the air bag module to the dash panel. Using a Torx® socket, install both rear air bag module-to-dash panel SCrews. : Using a special socket and a long extension, install both front air bag module-to-dash panel screws. Open the glove box door and connect the air bag module electrical connector. r._ Install the driver's SRS module, by connecting or installing following items: e Install the air bag module. e Connect the air bag harness con-

nector. Install the air bag module to the steering wheel. Using a special socket, install the 2 tamper-proof resistor air bag module-to-steering wheel screws.

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lower dash panel cover turnbuckles. s. Install the center console assembly.

t. Install the glove box. u. Working under the dash panel assembly, connect the air bag multi-plug

electrical connectors.

ae View of the center switch assembly—Range Rover

c. Disconnect the pipes and discard

v. Move the seats forward. 33. Refill the cooling system.

the O-rings. d. Plug the openings to prevent con-

34. Connect the positive (+) battery

tamination.

cable and then the negative (() battery cable. 35. Evacuate and charge the air condi-

tioning system. 36. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

a. Remove the center console.

b. Remove the wiper motor and linkage. c. Remove the steering column.

6. Remove the dash panel assembly by

performing the following procedures:

d. At the passenger's side, remove the

clip and disconnect the heated front screen multi-plug connector.

1. Disconnect the negative (() battery cable; then the positive (+) battery cable. e»Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

2. lf equipped with SRS, remove the battery. 3. Drain the cooling system into a clean container for reuse. 4. Loosen the hose clips and disconnect the heater hoses from the heater tubes. 9. If equipped with air conditioning, perform the following procedure: a. Discharge and recover the air conditioning refrigerant. b. Remove the refrigerant pipes mount-to-evaporator bolt

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93113GD3

View of the heater/air conditioning housing assembly and related components—Range Rover

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HEATER CORES 9-1 07° LAND ROVER

harness-to-underside wheel arches: then, move the harness through the bulkhead and into the dash. ee. At the top of the dash panel, remove the 4 dash panel-to-scuttle panel

tube bolts.

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93113GD4

View of the heater/air conditioning housing—Range Rover

e. Remove the 6 scuttle side panel-

to-chassis bolts and the side panel. f. Remove the heater intake pollen filters. g. Remove the 8 pollen filter housing screws from each housing and remove both housings. h. Remove the radio. i. Near the A-post lower trim panels, remove the door aperture seal. j.. If equipped with a footrest on the driver's side, remove the 3 foot rest-to-Apost lower trim bolts and remove the foot

rest. k. At each A-post's lower trim panel, remove the screw and release the spring clip and remove both trim panels. |. At the driver's seat base trim, remove the fuse cover. m. Remove the screw, the 2 trim studs and the seat base trim. n. At the driver's side, release the 4 spring clips and remove the carpet retainer. 0. Remove the 2 lower closing panelto-passenger side scrivet fasteners and the panel. p. Release the closing panel, disconnect the footwell lamp and the diagnostic multi-plug connector; then, remove the closing panel. q. Remove the 4 dash center bracket bolts and the bracket. r. Disconnect the 4 multi-plug connectors from the Body Control Module

(BCM).

s. At the base of the A-post on the driver's side, remove the ground wires from the stud. t. Disconnect the multi-plug electrical connectors at the base of each Apost. u. Disconnect the BCM electrical harness from the sill and move it into the dash panel so it will not hamper removal of the dash panel. v. At the brake and clutch switches, disconnect the multi-plug electrical connectors and vacuum hose. w. If equipped with SRS, disconnect the following items: e The SRS harness connector from the main wiring harness e The SRS harness connector from the control module x. Remove both front wheel arch liners. y. At the left wheel arch, remove the 2 air Cleaner baffle scrivet fasteners and the baffle. z. lf equipped with SRS, disconnect both SRS crash sensor electrical connectors. aa. Remove the 4 battery tray bolts and the 2 air cleaner-to-valance bolts. bb. Raise the air cleaner and battery tray to access the crash sensor harness Clips. cc. Disconnect the crash sensor harness-to-valance clips; then, move the harnesses into the wheel arches. dd. Disconnect the 3 crash sensor

ff. Remove the dash panel-to-chassis bolts. Pull the panel rearward and support it on 50mm deep wooden blocks. 7. With the dash panel supported on 50mm deep wooden blocks, remove the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash. 8. Remove the face level vent ducts inserts from the heater unit. 9. Remove the passenger's side blower duct. 10. Remove the 4 heater contro! panelto-dash panel screws and remove the panel. 11. Disconnect the 4 multi-plug connectors from the heater control panel and remove the control panel. 12. Remove the 5 center switch assembly-to-dash screws and remove the center switch assembly. 13. Disconnect the multi-plug connectors from the solar sensor and the alarm LED; then push the leads into the dash ducting. 14. Disconnect the harness-to-dash ducting clip; then, position the solar sensor/LED harness aside. 15. Disconnect the water temperature sensor-to-heater core inlet pipe clip and position the sensor aside. 16. Disconnect the multi-plug connector from the evaporator sensor. 17. Disconnect the 2 harness-to-heater base clips. 18. Remove the 4 heater housing-todash frame bolts. 19. Using an assistant, hold the harness away and remove the heater housing. 20. Remove the right side duct-toheater/air conditioning housing screws and the duct. 21. Remove the heater pipe bracket SCIeW. 22. Remove the 2 right side servo-toheater/air conditioning housing screws and the servo. 23. Remove the heater core/pipe assembly-to-heater/air conditioning housing clips and the heater core/pipe assembly. 24. If installing a new heater core, remove the 2 heater core-to-heater pipe assembly screws and separate the heater pipe assembly. Discard the O-rings.

Timing belt service is covered in Section 3 of this manual

: 4

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2-108 tinoroven 36. Connect the multi-plug connectors to the solar sensor and the alarm LED. 37. Install the center switch assembly and the 5 center switch assembly-to-dash SCeWS. 38. Install the control panel and connect the 4 multi-plug connectors to the heater control panel. 39. Install the heater control panel and the 4 panel-to-dash panel screws. 40. Install the passenger's side blower duct. 41. Install the face level vent ducts inserts to the heater unit. 42. With the dash panel supported on 50mm deep wooden blocks, install the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash. 43. Install the dash panel assembly by performing the following procedures:

93113GD5

View of the heater core, heater tubes and

seals—Range Rover

To install: 25. If installing a new heater core, install new O-rings, the heater pipe assembly and the 2 heater core-to-heater pipe assembly SCeWS. 26. Install the heater core/pipe assembly and the heater core/pipe assembly-toheater/air conditioning housing clips. 27. Install the right side servo and the 2 servo-to-heater/air conditioning housing SCreWS. 28. Install the heater pipe bracket screw. 29. Install the right side duct and the duct-to-heater/air conditioning housing SCIeWS. 30. Using an assistant, install the heater housing. 31. Install the 4 heater housing-to-dash frame bolts. 32. Connect the 2 harness-to-heater base clips. 33. Connect the multi-plug connector to the evaporator sensor. 34. Connect the water temperature sensor-to-heater core inlet pipe clip. ne Connect the harness-to-dash ducting Clip.

a. Push the panel forward and support it on 50mm deep wooden blocks. Install the dash panel-to-chassis bolts. b. At the top of the dash panel, install the 4 dash panel-to-scuttle panel tube bolts. c. Connect the 3 crash sensor harness-to-underside wheel arches. d. Connect the crash sensor harnessto-valance clips. e. Install the 4 battery tray bolts and the 2 air cleaner-to-valance bolts. f. If equipped with SRS, connect both SRS crashi sensor electrical connectors. g. At the left wheel arch, install the air cleaner baffle and the 2 baffle scrivet fasteners. h. Install both front wheel arch liners.

i. If equipped with SRS, connect the following items: e The SRS harness connector to the main wiring harness e The SRS harness connector to the contro! module j. At the brake and clutch switches, connect the multi-plug electrical connectors and vacuum hose. k. Connect the BCM electrical harness to the sill. |. Connect the multi-plug electrical connectors at the base of each A-post. m. At the base of the A-post on the driver's side, install the ground wires to the stud. n. Connect the 4 multi-plug connectors to the Body Control Module (BCM).

o. Install the dash center bracket and the 4 bracket bolts. p. Install the closing panel; then, connect the footwell lamp and the diagnostic multi-plug connector. q. Install the lower closing panel and the 2 panel-to-passenger side scrivet fasteners. : r. At the driver's side, install the carpet retainer and the 4 spring clips. s. Install the seat base trim, the 2 trim ~ studs and the screw. t. At the driver's seat base trim, install the fuse cover. u. At each A-post's lower trim panel, install both trim panels, the screw and the spring clip. v. If equipped with a foot rest on the driver's side, install the foot rest and the 3 foot rest-to-A-post lower trim bolts. w. Near the A-post lower trim panels, install the door aperture seal. x. Install the radio. y. Install the both pollen filter housings and the 8 housing screws to each housing. z. Install the heater intake pollen filters.

aa. Install the scuttle side panel and the 6 side panel-to-chassis bolts. bb. At the passenger's side, connect the heated front screen multi-plug connector and install the clip. cc. Install the steering column. dd. Install the wiper motor and link-

age. ee. Install the center console. 44. \f equipped with air conditioning, perform the following procedure: a. Lubricate and install new O-rings and connect the pipes. b. Install the refrigerant pipes mountto-evaporator bolt. 45. Connect the heater hoses to the heater tubes and install the hose clips. 46. Refill the cooling system. 47. \f the battery was removed, install

it. 48. Connect the positive (+) battery cable; then, the negative (() battery cabte. 49. Evacuate and charge the air conditioning system.

90. Run the engine to normal operating temperatures; then, check the oe control operation and check for eaks.

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HEATER CORES 2.109 Bea ms

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LX 470 REMOVAL & INSTALLATION Front Heater

1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core. 4. Remove the steering wheel by performing the following procedure: a. Position the front wheels facing straight-ahead. b. Remove the steering wheel side Covers. c. Using a Torx® wrench, loosen the 2 screws located at each side of the steering wheel until the screw’s circumference groove catches on the screw case. d. Pull the air bag module from the steering wheel and disconnect the electrical connector’

1998-01 LEXUS h. Remove the lower left side panel. i. Remove the 3 steering column cover screws and the covers. j. At the steering column, disconnect the electrical connectors; then, remove the clamp, the 3 screws and the combination switch. k. Remove the No. 2 heater-to-register duct screw and the duct. |. Remove the steering column-toinstrument panel bolts and the steering column. m. At the combination meter, disconnect the electrical connectors; then, remove the 4 screws and the combination meter. n. Remove the glove compartment door stoppers, the 2 screws and the glove box door. o. At the passenger's side air bag module, remove the No. 1 undercover, pull the air bag connector up from the undercover and disconnect it; then, remove the air bag.

kk CAUTION Place the air bag module in a safe place with the front side facing upward.

Place the air bag module in a safe place with the front side facing upward. e. Remove the steering wheel nut. f. Place alignment marks on the steering wheel and the main shaft. g. Using a steering wheel puller, press the steering wheel from the steering column. 5. Remove the instrument panel and reinforcement by performing the following procedure: a. Remove the front door scuff plates, the cowl side trim and the front door opening trim. b. At the driver's side, remove the 2 assist grip plugs, the 2 screws and assist grip and the front pillar garnish. c. At the passenger's side, remove the 4 assist grip plugs, the 4 screws, the 2 assist grips and the front pillar garnish. d. Remove the instrument cluster finish panel. e. Remove the 2 screws and the hood lock control cable. f. Remove the 2 screws and the fuel lid control cable lever. g. Remove the lower No. 1 panel screw and the panel.

p. Remove the 3 lower No. 2 panel screws and the panel. q. Remove the center cluster; then, pry the center cluster from the dash by prying the 8 clips in the following order:

e Left side e Right side e Top left side e Top right side r. Remove the 4 radio screws, pull the radio outward, disconnect the electrical connectors and remove the radio. s. At the rear console panel, remove the transfer shift lever knob; then, pry the panel upward disengaging the 4 clips (2 on each side) and remove the panel. t. At the rear of the console, remove the 2 rear end panel-to-console screws; then, pry the end panel rearward disengaging the 2 clips and remove the panel. u. If not equipped with a rear air conditioning system, disconnect the connector and control cable; then, remove the 3 rear heater control panel screws and the panel. v. Remove the 4 rear console box-tochassis screws/bolts and the console box. w. Remove the center lower cluster finish panel by prying panel rearward disengaging the 5 clips; then, disconnect the electrical connector. x. Remove the 2 front console-tochassis bolts/screws, disengage the 2 clips and remove the console. y. At the instrument panel, disconnect the junction connectors (the connectors can be disconnected by loosening the bolts), the instrument panel-to-chassis 8

93113GG4

View the steering wheel’s Torx® bolts—LX 470

Brake service is covered in Section 4 of this manual

R ¥

[34 (350,25) ] | Steering Wheel Pad ——

Steering Wheel Lower Bae

BB

hie Steering Wheel Lower No. 3 Cover

Torx Screw

8.8(90,78in.-Ibf) |_

\

Steering Column Assembly

Steering Wheel Combination Switch (w/ Spiral Cable)

ae

y

yest \ >

©

‘

No. 2 Hole Cover

pany

\ L \

Sliding Yoke

Hose Clamp

Hole Cover

Thrust Stopper

No. 2 Intermediate Shaft

Cluster Finish Panel

Assembly 34 (350, 25)

Hood Lock Release Lever Fuel Lid Release Lever

No. 2 Heater to Register Duct

Scuff Plate

N-m (kgf-cm, ft:lbf) |:Specified torque

Cowl Trim 93113GG5

Exploded view the steering column—Lexus LX 470 (Part 1 of 2)

:

Transponder Key ap

Amplifier

x

Key Cylinder Lamp

| Turn Signal Bracket Transponder Key u

Assembly

Coil

Column Upper Tube .

ss ey Unlock

y’

Warning Switch

Key C ine

72.

ae

Solenoid

Column Upper

Bracket

f

\

J

D“Tilt

a

eas

au

Sa

Tension rid

AS

Tilt Lever

@ Energy Absorbing Clip

Tilt Lever Rejainer

NS

Ignition Switch

Spring

Energy Absorbing

a

ae

oA

®-

Sd Energy Absorbing

fy)

ete

Spring

Upper Clamp

@ Tapered—head Bolt

b)

. Bearing Thrust Collar

© Bearing

@ Energy Absorbing

Clip

Column Tube

%

Tension Spring 5

Column Tube

Support

Compression

Tilt Lever Link @ Tilt Steering No. 2 Shaft

Gulp

Steering Bolt

ee

a

e.ee

Pa

¥

Tilt Steering as

Tilt Steering Pawl

D

@ Snap Ring

(

"Spring Nut ai

[20 (210,18)

Key Interlock

?

Main Shaft Assembly

.4 Bushing

(150, 45 11)|

8

Energy Absorbing

y

Plate

@ Energy Absorbing

Thrust ust St stopper

Guide

Tube Attachment

No. 2 Lower Cover

Intermediate Shaft Assembly

24.5 (240, 17) No. 2 Lower Cover

N-m (kgf-cm, ft-Ibf) |: Specified torque @ Non-—reusable part ya Molybdenum disulfide lithium base grease 93113GG6

Exploded view the steering column—Lexus LX 470 (Part 2 of 2)

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

—

eeeee Ce 1,

212 HHEATER CORES

N NN py

ms

EXUS

Reinforcement

Y ©

©

®

Vin, Floor Brace

®

® ® Sa

No.3 Brace

ai plata

Center Cluster

No.3 Heater to Register Duct

Radio Assembly

O

No.4 Heater to Register Duct

Center Lower Cluster Finish Panel

Front Ash

©

im) it 8 & Front Ash

cea

ESS

ws."

Instrument Panel

H naakiout

© Panel

a , Panel

;

Dy

Lower No.2

Box@ Rear Console ae

a

Glove Compartment Door Console Cup

Holder Box

ee

ee

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Box ie LQ Sp

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ter Finish

ow, a

[GR

Switch

©

ibe

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[34 (350, 25)|

@ ay

Panel

o sep? Lower No.1 Panel

2°

Rear Heater Control Panel

>

Column Cover

&

496:

raed rf % H Lower

Combination

Rear Console Box

.

Console Rear End Panel Front Pillar Garnish

_7 Steering Wheel Pad

a

Steering Wheel

a

vm y\

=

|

Wa Front Pillar Garnish

ae Assist Grip

COFFERS

Ra

Deg

‘©g* Front Assist Grip Ye

Cow! Side Trim

Cowl Side Trim Front Door Scuff Plate

N-m (kgf-cm, ft-lbf)

|: Specified torque 93113GG7

Exploded view the instrument panel and related components—LX 470

f

.

a

ithe:

hh

a

oie

;

SS

ATER

eee

SS

bolts and 2 nuts. Using an assistant, remove the instrument panel. z. Disconnect the electrical connector and remove the ECM. aa. Remove the No. 3 and No. 4 heater-to-register ducts. bb. Remove the floor brace, the No. 1 brace and'the reinforcement. 6. Remove the evaporator housing by performing the following procedure:

PMO

CORE

texus

yy

VY 3

Center Bracket

©

PF

)

ww:

:

)

cr 5 na

2 f

©

is

6.0(61, 53in.-Ibf) No.2 Side Defroster

feNozzle Duct

io,

No.1 Side Defroster

|

©

Nozzle Duct

®

© No.1 Heater to

One

7]

®

No.4 Register

®

Register Duct No.1 Register N-m (kgf-cm, ft-lbf)

271

qq

IO)

f. Remove the evaporator housing-tochassis 4 screws/2 nuts and the housing. 7. Remove the heater housing by performing the following procedure: a. Remove the defroster nozzle. b. Disconnect the electrical connector. c. Remove the 4 nuts and the heater housing. 8. Remove the heater core-to-heater housing packing, the screw, the bracket, the clamp and the heater core.

Instrument Panel Wire

Defroster Nozzle

‘

(

a. Discharge and recover the air conditioning system refrigerant. b. Remove the air conditioning liquid line clamp. c. Remove the air conditioning suction line clamp. d. Disconnect both air conditioning lines and plug the openings to prevent contamination. Discard the 4 O-rings. e. Remove the antenna relay electrical connector, the 2 screws and the relay.

Front Passenger Airbag Assembly

Leh od

No.5 Heater to

Register Duct

|: Specified torque 93113GG8

Exploded view the front ventilation ducts and related components—LX 470

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

To install: 9. Install the heater core, the clamp, the bracket, the screw and the heater core-toheater housing packing. 10. Install the heater housing by performing the following procedure: a. Install the heater housing and the 4 nuts. b. Connect the electrical connector. c. Install the defroster nozzle. 11. Install the evaporator housing by shee Dg,

te

performing the following procedure: a. Install the evaporator housing and the housing-to-chassis 4 screws and 2 nuts. b. Install the antenna relay, the 2 screws and the electrical connector. c. Using new O-rings, connect both air conditioning lines. d. Install the air conditioning liquid line and suction line clamp. 12. Install the instrument panel and reinforcement by performing the following procedure: a. Install the reinforcement, the No. 1 brace and the floor brace. b. Install the No. 3 and No. 4 heaterto-register ducts. c. Install the ECM and connect the electrical connector. d. Using an assistant, install the instrument panel, connect the junction connectors, the instrument panel-tochassis 8 bolts and 2 nuts. e. Install the front the console, engage the 2 clips and install the 2 console-to-chassis bolts/screws. f. Connect the electrical connector; then, install the center lower

cluster finish panel by engaging the 5 clips. g. Install the console box and the 4 rear console box-to-chassis

screws/bolts. h. If not equipped with a rear air conditioning system, install rear heater control panel, the 3 panel screws; then, connect the connector and control cable. i. Install the rear of the console and engage the 2 clips; then, install the 2 rear end panel-to-console screws. j. Install the rear console panel and engage the 4 clips (2 on each side); then, install the transfer shift lever knob. k. Install the radio, connect the electrical connectors and the 4 radio screws. |. Install the center cluster and engage the 8 center cluster clips. m. Install the lower No. 2 panel and the 3 panel screws. n. Install the passenger's side air bag module, connect it and install the No. 1 undercover. 0. Install the glove box door, the 2 -screws and the glove compartment door stoppers. p. Install the combination meter and the 4 screws: then, connect the electrical connectors. g. Install the steering column and the steering column-to-instrument panel bolts. r. Install the No. 2 heater-to-register duct and the duct screw. S. At the steering column, install the combination switch, the 3 screws and the clamp; then, connect the electrical connectors.

t. Install the steering column covers and the 3 covers screws. u. Install the lower left side 20) v. Install the lower No. 1 panel and the panel screw. w. Install the fuel lid control cable lever and the 2 screws. x. Install the hood lock control cable and the 2 screws. y. Install the instrument cluster finish panel. z. At the passenger's side, install the front pillar garnish, the 2 assist grips, the 4 screws and the 4 assist grip plugs. aa. At the driver's side, install the front pillar garnish, assist grip, the 2 screws and the 2 assist grip plugs. bb. Install the front door scuff plates, the cowl side trim and the front door opening trim. 13. Install the steering wheel by performing the following procedure: a. Install the steering wheel to the steering column. b. Align the steering wheel-to--main shaft marks. c. Install the steering wheel nut and torque to 25 ft. Ibs. (34 Nm). d. Install the air bag module to the steering wheel and connect the electrical connector. e. Using a Torx® wrench, tighten the 2 screws located at each side of the steering wheel to 78 inch Ibs. (8.8 Nm). f. Install the steering wheel side covers. 14. Connect the heater hoses to the 4‘

heater core. 15. Refill the cooling system. 16. Connect the negative battery cable. a. Evacuate and charge the air conditioning system refrigerant. 17. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Rear Auxiliary Heater 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the rear heater core. 4. Remove the front seats. 5. Remove the rear heater control assembly. 6. Remove the rear console box. 7. Remove the front console box cover. 8. Remove the lower center cluster finish panel. 93113GG9

View the air conditioning line clamp removal tool—LX 470

9. Remove the front door scuff plates. 10. Remove the cowl side trim.

Water Hose

Heater Unit

3 St AP) s ee

Heater to Register No. 4 Duct

ri tombe

eae Heater to Register No. 3 Duct

o Packing

oo ani e al ee

Heater Radiator Air Duct (Vent)

“ny

4

&

Mix Servomotor

&

Air Duct (Foot)

Heater Case

4

@ Non-reusable part 93113GG0

Exploded view the front heater core, heater housing, evaporator housing and related components—LX 470

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

fA PY

2-110 3

.

Pi:

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~ 11. Remove the rear door scuff plates. 12. Remove the center pillar garnishes. 13. Slide the carpet rearward. 14, Remove the cooler bracket bolts and the bracket. 15. Remove the rear heater duct bolt/screw and the duct. 16. Disconnect the rear heater housing electrical connector. 17. Remove the 3 rear heater housing’

ae

7

&

—“

22. Install the heater housing and the 3

to-chassis bolts and the heater housing. 18. Remove the heater core-to-heater housing 3 screws and 2 clamps. 19. Remove the heater core from the heater housing. To install: 20. Install the heater core to the heater housing. 21. Install the heater core-to-heater housing 3 screws and 2 clamps.

rear heater housing-to-chassis bolts. 23. Connect the rear heater housing electrical connector. 24. Install the rear heater duct and the duct bolt/screw. 25. Install the cooler bracket and the bracket bolts. 26. Slide the carpet rearward. 27. Install the center pillar garnishes. _ 28. Install the rear door scuff plates.

Cowl Side Trim

aa

Center Pillar Garnish

x

Oo)

Front Door Scuff Plate

an

re }

we

ot S

Rear Door Scuff Plate

Console Upper Panel Lower Center Cluster

Finish Panel

Audio Amplifier Front Console Box

¥ Rear Heater

Rear Console Box Unit

Rear Heater Control!

Assembly

Rear Console End Panel

Rear Heater Duct

Cooler Bracket Exploded view of the rear heater housing and related components—LX 470

93113GH1

:

Seed

|

.

HEATER CORES

LEXUS

Blower Resistor

bn

Rear Heater Hi Relay

Heater Case

Heater Radiator Pipe

@ Non-—reusable part

Blower Motor 93113GH2

Exploded view of the rear heater core, heater housing and related components—LX 470

29. 30. 31. panel. 32. 33. 34. bly. 35.

Install the cowl side trim. Install the front door scuff plates. Install the lower center cluster finish Install the front console box cover. Install the rear console box. Install the rear heater control assem-

Install the front seats.

36. Connect the heater hoses to the rear

heater core. 37. Refill the cooling system. 38. Connect the negative battery cable.

RX 200) cae

sce

ce

REMOVAL & INSTALLATION Front Heater

oath Disconnect the negative battery rage ; ;

a

ae Pe

system into a clean

3. Disconnect the heater hoses from the

ae core

4, Remove the steering wheel by per0) | forming the following procedure: a. Position the front wheels facing straight-ahead. b. Remove the steering wheel side covers. c. Using a Torx® wrench, loosen the 2 screws located at each side of the steering wheel until the screws circumference

urbe cath a on se ,

. Pull the air bag module from the ‘i steering wheel and disconnect the elec trical connector.

For Whee! Alignment specifications, see Section 7 of this manual

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a!

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Intermediate Shaft Assembly

__ @— Lower No.2 Cover a)

}

a

if

it

Steering Wheel _ Pad

Torx Screw

ay

q Nie

—

25 (260, 19)

Column Lower Cover

ayy

‘3 :

LH Lower Instrument Panel

tat Lower LH Finish Panel

(i

fe~ Hood Lock Release &&

= Lever

oH Front Door Inside

Scuff Plate

‘

Cowl Side Trim

N-m (kgf-cm, ft:lbf) | : Specified torque 93113GH3

Exploded view of the steering wheel, steering column and related components—Lexus RX 300

’ “al

a

a |7

aR

lo

ee

I

OE' aHEATER I Te

tte 2-119

Instrument Panel Reinforcement

Front Pillar Garnish

Front Door Opening Trim Cover

Cowl Side Board

Front Door Scuff Plate

Cluster Finish

Lower Center

Panel

Front Door

Opening Cover

©

O Steering Wheel Cover

Cluster Finish

Center Cluster Finish Panel

Panel

Steering Wheel

Front Ash Receptacle Retainer

eo

Front Ash Receptacle Box

rage X3 :

RF &

KES

2

EZ

See

|ce

oy, |

625 Audio Amplifer

©

Steering Wheel Pad No.1 Safety Pad Insert

No.2 Finish Panel Cowl Side Board

N-m (kgf-cm, ft-lbf)

Lower Finish Panel

|: Specified torque

Front Door Scuff Plate 93113GH4

Exploded view of the instrument panel and related components—Lexus RX 300

For Maintenance Interval recommendations, see Section 7 of this manual

me Weide 7) Wee kU ha

Ce

,

9.420 HEATER CORES LEXUS

;

lest

re bE Place the air bag module in a safe place with the front side facing upward. e eT ee eT

e. Remove the steering wheel nut. f. Place alignment marks on the steering wheel and the main shaft.

a

hae

icy

d. Remove the front pillar garnish by

g. Using a steering wheel puller,

disengaging the 5clips. If equipped with

press the steering wheel from the steer-

a tweeter speaker, disconnect the electrical connector. e. Remove the steering column covers-to-steering column screws and the

ing column. 5. Remove the instrument panel and reinforcement by performing the following Es

covers. f. Remove the combination switchto-steering column screws, disconnect

a. Remove the front door scuff plates. b. Remove the cowl side boards. c. Remove the front door trim covers.

No.2 Side Defroster Nozzle Duct

No.1 Side Defroster Nozzle Duct

No.2 Heater to Register Duct

Cea)—

No.3 Register

No.1 Heater to

Register Duct

_ Center Bracket

88 instrument Panel

Airbag Door

® Saag Xo

OSE Instrument Panel Wire

nae

Pin 8 Steering Column Release Lever Pin

40

Steering Column Retaining Nuts

41

Wiring Harness Retainer

9

Steering Column Release Lever

42

Steering Actuator Housing

10

‘Tilt Wheel Handle and Shank

43

Steering Column Lock Lever Pin

11.

Column Shift Selector Lever Plunger

44 — Ignition Switch

12

Gearshift Lever

45

Steering Column Position Spring

13

Steering Column Shaft

46

Steering Column Lock Lever

14

Transmission Control Selector Lever

47

Steering Column Position Lock Spring

Pruniger Goring

48

Steering Column Locking Lever

15

Gearshift Lever Pin

49

Lower Steering Column Lock Actuator

17.

Steering Column Spacer (Fixed Column)

51

Steering Column Lock Pawi

SEIT Comin Rivet Screw

19

Hie Secret Control Selector Lever Spring

52

Upper Steering Column Lock Lever Actuator

20

Gearshift Tube Bushing Clamp

54

Steering Column Tilt Flange Bumper

21

Spacer (Fixed Column)

55

Wiring Harness Retainer

22

Steering Shaft (Fixed Column)

hn

bh get nehanid

23

Lever Assembly (Manual Transmission)

57

Steering Column Shroud

24

Pin (Manual Transmission)

58

Steering Column Lock Gear

25 —_Brake Shift Interlock Solenoid

59

Steering Column Lock Housing Bearing

26

Gearshift Lever Socket Bushing

60

Bearing Retainer

27

‘Transmission Shift Selector Position Insert

61 _ Ignition Switch Lock Cylinder

28

Transmission Selector Lever Arm and

62 — Steering Column Tolerance Ring

Support

63

Steering Column Upper Bearing Spring

64

Snap Ring

65

Turn Signal Cancel Cam

16

29

Transmission Column Shift Selector Tube

= Shift Cable and Bracket

30

Gearshift Lever

31

Steering Column Lock Pawi

32

Gearshift Lever Pin

33.

Steering Column Instrument Panel Bracket

50

53

Steering Column Lock Spring

Steering Column Lock Cam

93113GF8

Exploded view of the steering column assembly—Mazda Pick-Ups

7 ta 1

m ‘HEATER CORES

AZDA

Defroster opening grille

Instrument panel steering column cover

Passenger-side airbag module

Instrument panel steering column opening cover reinforcement

Screws (6)

Nut (2)

Screws (2) Instrument panel Glove compartment Pushpin (2) Rivets (2)

Instrument WOH DONS COON =

panel sound insulation

10

Screws (2)

11

Instrument panel sound insulation

Instrument panel steering column opening cover brace

Screw (4) PRNDL indicator Instrument cluster Instrument panel fuse panel opening door

Instrument cluster finish panel

12

Screws (12)

Tighten to 25.5 — 34.5 Nem {2.6 — 3.5 kgfem, 19 — 25 ftelbf}

13.

-Nut (1)

Tighten to 7.2 — 10.8 Nem {73 — 110

14

Instrument panel brace

kgfecm, 64 —

15

Screws (2)

Tighten to

16

+ Ash tray

17

Screws (10)

18

Center trim finish panel

19

Instrument panel radio opening panel

—

96 inelbf}

1— 2 Nem {10 — 20 kgfecm, 9

18 inelbf}

Tighten to

2— 3 Nem {20— 31 kgfecm, 18

— 26 inelbf}

20 _— Instrument panel cover access cover 93113GF9

Exploded view of the instrument panel assembly—Mazda Pick-Ups

For Accessory Drive Belt illustrations, see Section 7 of this manual

2-133

UAB

yt

TR

ager ee Any en

HEATER CORES © MITSUBISHI

a

ALA

a

ve

nee ae Se, ee ES

93113GFO

View of the heater housing and heater core—Mazda Pick-Ups

i. Install the hood release lever. j. Install the parking brake release handle. 17. At the passenger's side, install the

SAS module by performing the following procedure: a. Carefully, install the SAS module and connect the electrical connector.

b. Install the SAS module-to-dash bolts. c. Install the glove compartment and the glove compartment cover. 18. At the driver's side, install the SAS module and the steering wheel by performing the following procedure: a. Install the steering wheel-to-column nut. b. Carefully, install the SAS module to the steering wheel and connect the electrical connector. c. Install the steering wheel-to-SAS module bolts. d. At both sides of the steering wheel, install the cover clips. 19. Connect the heater hoses to the heater core. 20. Refill the cooling system. 21. Connect the negative battery cable. 22. Evacuate and charge the air conditioning system. 23. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

1998-01 MITSUBISHI >: CAUTION REMOVAL & INSTALLATION 1. Place the wheels in the straightahead position. 2. Disconnect the negative battery.

tet CAUTION Wait at least 60 seconds after disconnecting the battery cable before performing any work on the air bag or instrument panel. 3. Drain the cooling system into a clean container for reuse. 4. Discharge and recover the air conditioning system refrigerant. 5. Remove the floor console assembly. 6. Remove the air bag module, column covers and the steering wheel by performing the following procedure: a. Remove the steering column-toinstrument panel cover screws and the cover. b. Carefully, remove the air bag module from the steering wheel. c. Disconnect the electrical connectors from the air bag module.

Store the air bag module facing up. d. Remove the steering wheel nut. e. Using a steering wheel puller, press the steering wheel from the steering column. 7. Remove the passenger's air bag module by performing the following procedure: a. Remove the foot shower duct. b. Remove the glove box stoppers and the glove box. c. Remove the passenger's air bag module nut and remove the air bag module. d. Disconnect the electrical connector from the air bag module. 8. Remove the instrument panel by performing the following procedures: a. Remove the hood lock release handle. b. Remove the filler door lock release handle. c. Remove the knee protector assembly and bracket. d. Remove the meter bezel assembly. e. Remove the under cover, the corner cover and the stopper. f. Remove the glove box assembly.

g. Remove the center under cover assembly. h. Remove the radio and tape player. i. Disconnect and remove the heater/air conditioning control assemj. Remove the combination meter and the speaker. k. Remove the glove box striker and the upper glove box frame. |. Remove the multi-meter panel and the multi-meter assembly. m. Remove the side defroster grille. n. Using an assistant, carefully, remove the instrument panel assembly. 9. Remove the blower motor assembly. 10. Remove both foot ducts. 11. Remove the joint duct from the air conditioning evaporator housing assembly. 12. Remove the foot distribution duct. 13. Remove the center reinforcement. 14. Remove the center ventilation duct. 15. Remove the drain hose from the air conditioning evaporator housing assembly. 16. Disconnect the heater hoses from the heater housing assembly. 17. Disconnect the refrigerant lines from

om ed 2G,

i Meda) os >) i) ee ie ie -.~

—

the air conditioning evaporator housing assembly and discard the O-rings. . a Remove the heater housing assembly. 19. Remove the center duct assembly.

20. Remove the heater core from the heater housing. To install: 21. Install the heater core to the heater housing. 22. Install the center duct assembly. 23. Install the heater housing assembly. 24. Using new O-rings, connect the refrigerant lines to the air conditioning evaporator housing assembly. 25. Connect the heater hoses to the

heater housing assembly. 26. Install the drain hose to the air conditioning evaporator housing assembly. 27. Install the center ventilation duct. 28. Install the center reinforcement. 29. Install the foot distribution duct.

30. Install the joint duct to the air conditioning evaporator housing assembl 31. Install both foot shower ducts. 32. Install the blower motor assembly. 33. Install the instrument panel by performing the following procedures: a. Using an assistant, carefully, install the instrument panel assembly. b. Install the side defroster grille. c. Install the multi-meter assembly and the multi-meter panel. d. Install the upper glove box frame and the glove box striker. e. Install the speaker and the combination meter. f. Connect and install the heater/air conditioning contro! assembly. g. Install the radio and tape player. h. Install the center under cover assembly. i. Install the glove box assembly.

. Switch panel . Suspension control switch or hole cover

uhoO wo Side

console

harness

n. Install the hood lock release handle. 34. Install the passenger's air bag module by performing the following procedure: a. Connect the electrical connector to the air bag module. b. Install the passenger's air bag module and the air bag module nut. c. Install the glove box and the glove box stoppers. d. Install the foot shower duct. 35. Install the steering wheel, the column covers and the air bag module by performing the following procedure:

6. Rear console assembly 7. Transfer shift lever knob 8. Floor console

harness

connector

9. Front console assembly

. Cup holder assembly Rear

j. Install the under cover, the corner cover and the stopper. k. Install the meter bezel assembly. |. Install the knee protector assembly and bracket. m. Install the filler door lock release handle.

connector

panel A 93113GE2

Exploded view of the floor console and related components—Mitsubishi Montero

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

M

(hy e en i CCS tisCa a ee OO ER.CORES 9-136 HEAT MITSUBISHI

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UA Tal ii ib ill UA cal |

7. 8. 9. 10.

ae ae

Foot shower duct (R.H.) Stopper Glove box Air bag module (Passenger’s side)

93113GE3

Exploded view of the passenger’s side air bag module—Mitsubishi Montero

2. 3. 4. 5.

Air bag module (Driver's side) Steering wheel Column cover lower Clock spring and body wiring harness

connection 6. Clock spring @ Pre-installation inspection 93113GE4

Exploded view of the steering wheel and air bag module—Mitsubishi Montero

meas

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Hood lock release handle Fuel filler door lock release handle Knee protector :

13. Radio and tape player 14. Meter bezel assembly 15. Combination meter

Stay Foot shower duct (R.H.) Glove box stopper Glove box assembly Corner cover Stay Passenger-side air bag module assembly

16. 17. 18. 19. 20. 21. 22. 23.

11. Center panel 12. Heater control assembly

See

Column cover Clock Side defroster garnish Door mirror control switch Rheostat Ventilation control wire Harness connector Steering column installation bolts

24. Instrument panel assembly 93113GE5

Exploded view of the instrument panel and related components—Mitsubishi Montero

For Wheel Alignment specifications, see Section 1 of this manual

9.

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Compressor

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. Drain hose . Liquid pipe and suction hose connection

. Foot shower duct (R.H.) . Glove box . Corner cover . Lower frame

11. 12. 13. 14. 15.

Duct joint Blower assembly Resistor Blower motor assembly Blower case assembly

. Engine control relay assembly . Bracket . Air selection control wire connection —_oO . Evaporator OONONNAW 93113GE6

Exploded view of the air conditioning evaporator housing, blower motor assembly and related components—Mitsubishi Montero

—o

|

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HEATER CORES

hee

MITSUBISHI

. Water

hoses connection

. Foot shower duct (RH) . Foot shower duct (LH)

. Evaporator mounting bolt and nut

. Joint duct

. Center duct assembly . Center reinforcement . Heater unit . Foot distribution duct AW OOONDU . Heater core

es

93113GE7

Exploded view of the heater housing, air conditioning evaporator housing and related components—Mitsubishi Montero

e2 ri

a. Install the steering wheel to the steering column. b. Install the steering wheel nut and

torque the nut to 29 ft. Ibs. (39 Nm). c. Connect the electrical connectors

Montero Sport

CE

as

4. Discharge and recover the air conditioning system refrigerant. 5. Remove the floor console assembly.

Ae

to the air bag module.

Front Heater System

d. Carefully, install the air bag module to the steering wheel. e. Install the steering column-to-instrument panel cover and the cover screws.

1. Place the wheels in the straightahead position. 2. Disconnect the negative battery.

36. Install the floor console assembly. 37. Refill the cooling system.

38. Connect the negative battery.

39. Evacuate and charge the air conditioning system refrigerant. 40. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Wait at least 60 seconds after discon-

necting the battery cable before performing any work on the air bag or instrument panel.

3. Drain the cooling system into a clean container for reuse.

6. Remove the air bag module, column covers and the steering wheel by performing

the following procedure:

a. Remove the steering column-toinstrument panel cover screws and the cover. b. Carefully, remove the air bag module from the steering wheel. c. Disconnect the electrical connec-

tors from the air bag module.

Sst: CAUTION ae Store the air bag module facing up. d. Remove the steering wheel nut.

For Maintenance Interval recommendations, see Section 7 of this manual

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. REAR FLOOR CONSOLE ASSEMBLY . CONSOLE LID ASSEMBLY KNOB . REAR HEATER CONTROL PANEL ASSEMBLY . FOOT GRILL . SHIFT LEVER KNOB . FRONT FLOOR CONSOLE ASSEMBLY . CONSOLE PANEL A AWK Nom ON . CONSOLE PANEL B —_—

. CONSOLE PANEL C . CONSOLE PANEL D . SHIFT LEVER BOOT REINFORCEMENT . TRANSFER LEVER BOOT REINFORCEMENT . SHIFT LEVER BOOT . TRANSFER LEVER BOOT

‘

. CONSOLE . BOX

PANEL

93113GD6

Exploded view of the floor console and related components—Mitsubishi Montero Sport

eng ee 2

1. 2. 3. @

NEGATIVE (-) BATTERY CABLE CONNECTION STOPPER AIR BAG MODULE PRE-INSTALLATION INSPECTION 93113GD7

Exploded view of the passenger’s side air bag module—Mitsubishi Montero Sport

2. 3. 4. 5.

é. Using a steering wheel puller, press the steering wheel from the steering column. 7. Remove the passenger's air bag module by performing the following procedure: a. Remove the glove box stoppers and lower the glove box. b. Remove the passenger's air bag module bolts and remove the air bag module. c. Disconnect the electrical connector from the air bag module. 8. Remove the instrument panel by performing the following procedures: a. Remove the hood lock release handle. b. Remove the knee protector assembly and bracket. c. Remove the meter bezel assembly. d. Remove the under cover, the corner cover and the stopper. e. Remove the glove box assembly and the ashtray.

f. Remove the center under cover

assembly and the cup holder assembly. g. Remove the radio and tape player. h. Disconnect and remove the heater/air conditioning contro! assembly.

AIR BAG MODULE STEERING WHEEL COLUMN COVER LOWER CLOCK SPRING 93113GD8

Exploded view of the steering wheel and air bag module—Mitsubishi Montero Sport

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

: |

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a aE al

242 eee

NOTE CAUTION Place the air bag module in safe place with the front facing upward.

f. Remove the steering wheel nut. g. Using a steering wheel puller, press the steering wheel from the steering column. 5. Remove the passenger's side air bag by performing the following procedure: a. Remove the glove box clips and disconnect the passenger's side air bag module connector. b. Remove the lower panel screws; then, disconnect the harness connector and remove the air bag module bracket. c. Using the Tamper Resistant Torx® tool T50, remove the passenger's side air bag module bolts. d. Carefully, remove the air bag module.

“+ CAUTION Place the air bag module in safe place with the front facing upward. 6. Remove the instrument panel by performing the following procedure: a. Remove the steering column cover and the combination switch. b. Remove the instrument panel side lower finisher.

c. At the driver's side, remove the lower panel screws, disconnect the electrical harness connectors and remove the panel. d. Remove the cluster lid “A” screws and the cluster lid “A”. e. Remove the combination meter screws, disconnect the electrical harness connectors and remove the combination meter. f. Remove the cluster lid “C” screws, disconnect the electrical harness connectors and remove the cluster lid “C”.

g. Remove the audio assembly screws and the audio assembly. h. Remove the air conditioning control unit screws, disconnect the electrical harness connectors and the air conditioning control unit. i. Remove the ashtray. j. Remove the shifter (automatic

transmission) or shift lever boot (manual transmission); then, remove the screw and disconnect the harness connector. k. Remove the console box; then,

remove the screw and disconnect the harness connector. |. Remove the lower instrument center panel screws and the lower instrument center panel. m. Remove the defroster grille. n. At both sides, remove the pillar garnishes. 0. Remove the instrument panel and pads nuts and bolts.

HEATER CORES 9.4. (0)29 - 39 (3.0 - 4.0, 22 - 29) Air bag module

Air bag module connector

Special bolt '% CAUTION Place the air bag module in a safe place with the front side facing upward.

p. Remove the 3 lower No. 2 panel screws and the panel. q. Remove the center cluster; then, pry the center cluster from the dash by prying the 8 clips in the following order: e Left side e Right side e Top left side

en

tor and control cable; then, remove the 3 rear heater control panel screws and the panel. v. Remove the 4 rear console box-tochassis screws/bolts and the console box. w. Remove the center lower cluster finish panel by prying panel rearward disengaging the 5 clips; then, disconnect the electrical connector. x. Remove the 2 front console-to* chassis bolts/screws, disengage the 2 clips and remove the console. y. At the instrument panel, disconnect

e Top right side r. Remove the 4 radio screws, pull the radio outward, disconnect the electrical connectors and remove the radio. s. At the rear console panel, remove the transfer shift lever knob. Pry the panel upward disengaging the 4 clips (2 on each side) and remove the panel. t. At the rear of the console, remove the 2 rear end panel-to-console screws; then, pry the end panel rearward disengaging the 2 clips and remove the panel. u. If not equipped with a rear air conditioning system, disconnect the connec-

Instrument Panel Wire

IN 9 oS

Center Bracket

Front Passenger Airbag Assembly Defroster Nozzle

:

©

é

© No.2 Side Defroster oeNozzle Duct

©

No.1 Side Defroster Nozzle Duct

® No.4 Register ®

y=

No.1 Heater to

Register Duct

No.1 Register N-m (kgf-cm, ft-lbf)

No.5 Heater to Register Duct

|: Specified torque

Exploded view the front ventilation ducts and related components—Toyota Land Cruiser

93113668

HEATER CORES 9.4 75 FS g. Install the console box and the 4 rear console box-to-chassis screws/bolts. a

93113GG9

View the air conditioning line clamp removal tool—Toyota Land Cruiser ry

the junction connectors (the connectors can be disconnected by loosening the bolts), the instrument panel-to-chassis 8 bolts and 2 nuts.,Using an assistant, remove the instrument panel. z. Disconnect the electrical connector and remove the ECM. aa. Remove the No. 3 and No. 4 heater-to-register ducts. bb. Remove the floor brace, the No. 1 brace and the reinforcement. 6. Remove the evaporator housing by performing the following procedure: a. Discharge and recover the air conditioning system refrigerant. b. Remove the air conditioning liquid line clamp. c. Remove the air conditioning suction line clamp. d. Disconnect both air conditioning lines and plug the openings to prevent contamination. Discard the 4 O-rings. e. Remove the antenna relay electrical connector, the 2 screws and the relay. f. Remove the evaporator housingto-chassis 4 screws/2 nuts and the housing. 7. Remove the heater housing by performing the following procedure: a. Remove the defroster nozzle. b. Disconnect the electrical connector.

c. Remove the 4 nuts and the heater housing. 8. Remove the heater core-to-heater housing packing, the screw, the bracket, the clamp and the heater core. To install: 9. Install the heater core, the clamp, the

bracket, the screw and the heater core-toheater housing packing. 10. Install the heater housing by performing the following procedure: a. Install the heater housing and the 4 nuts. b. Connect the electrical connector. c. Install the defroster nozzle. 11. Install the evaporator housing by performing the following procedure: a. Install the evaporator housing and the housing-to-chassis 4 screws and 2 nuts. b. Install the antenna relay, the 2 screws and the electrical connector. c. Using new O-rings, connect both air conditioning lines. d. Install the air conditioning liquid line and suction line clamp. 12. Install the instrument panel and reinforcement by performing the following procedure: a. Install the reinforcement, the No. 1 brace and the floor brace. b. Install the No. 3 and No. 4 heater-

to-register ducts. ‘c. Install the ECM and connect the electrical connector. d. Using an assistant, install the instrument panel, connect the junction connectors, the instrument panel-tochassis 8 bolts and 2 nuts. e. Install the front the console, engage the 2 clips and install the 2 console-to-chassis bolts/screws. f. Connect the electrical connector; then, install the center lower cluster fin-

ish panel by engaging the 5 clips.

h. If not equipped with a rear air conditioning system, install rear heater control panel, the 3 panel screws: then, connect the connector and control cable. i. Install the rear of the console and engage the 2 clips; then, install the 2 rear end panel-to-console screws. j. Install the rear console panel and engage the 4 clips (2 on each side); then, install the transfer shift lever knob. k. Install the radio, connect the electrical connectors and the 4 radio screws. |, Install the center cluster and engage the 8 center cluster clips. m. Install the lower No. 2 panel and the 3 panel screws. n. Install the passenger's side air bag module, connect it and install the No. 1 undercover. -0. Install the glove box door, the 2 screws and the glove compartment door stoppers. p. Install the combination meter and the 4 screws; then, connect the electrical connectors. g. Install the steering column and the steering column-to-instrument panel bolts. r._ Install the No. 2 heater-to-register duct and the duct screw. s. At the steering column, install the combination switch, the 3 screws and the clamp; then, connect the electrical connectors. t. Install the steering column covers and the 3 covers screws. u. Install the lower left side panel. v. Install the lower No. 1 panel and the panel screw. w. Install the fuel lid contro! cable lever and the 2 screws. x, Install the hood lock control cable and the 2 screws. y. Install the instrument cluster finish panel. z. At the passenger's side, install the front pillar garnish, the 2 assist grips, the 4 screws and the 4 assist grip plugs. aa. At the driver's side, install the front pillar garnish, assist grip, the 2 screws and the 2 assist grip plugs. bb. Install the front door scuff plates, the cowl side trim and the front door opening trim. 13. Install the steering wheel by performing the following procedure: a. Install the steering wheel to the steering column.

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

Water Hose

Heater Unit

-

“i

No. 2 Brace

i

ion

NESS 0,

oe ‘

Lower Defroster Nozzle

Heater to Register No. 4 Duct

Heater to Register No. 3 Duct

@ Packing

Heater Radiator Air Duct (Vent)

Air Mix Sérvdmetor

4 Nis

&

&

Air Duct (Foot)

Heater Case

4

@ Non-reusable part 93113GG0

Exploded view of the front heater core, heater housing, evaporator housing and related components—Toyota Land Cruiser

1

ae,

~

Leap,

ih

HEATER CORES 9.4477

hy

b. Align the steering wheel-to-main shaft marks. c. Install the steering wheel nut and

torque to 25 ft. Ibs. (34 Nm). d. Install the air bag module to the steering wheel and connect the electrical connector.

e. Using a Torx® wrench, tighten the 2 screws located at each side of the steering wheel to 78 inch Ibs. (8.8 Nm).

f. Install the steering wheel side covers. Connect the heater hoses to the core. Refill the cooling system. Connect the negative battery cable. a. Evacuate and charge the air conditioning system refrigerant. 17. Run the engine to normal operating temperatures. Check the climate control operation and check for leaks.

14. heater 15. 16.

Rear Auxiliary Heater 1. Disconnect the negative battery cable. . 2. Drain the cooling system into a clean container for reuse. 3. Disconnect the heater hoses fromthe

rear heater core. 4. Remove the front seats. 5. Remove the rear heater contro! assembly.

Cowl Side Trim

Center Pillar Garnish

fa NFront Door Scuff Plate G Rea

r

Console Upper Panel

Doo

r

Scuf

f

Plat

e

Lower Center Cluster Finish Panel

Audio Amplifier Front Console Box

¥

Rear Console Box Rear Heater Unit

Rear Heater Control

Assembly

Rear Console End Panel

Rear Heater Duct

Cooler Bracket 93113GH1

a Land Cruiser Exploded view of the rear heater housing and related components—Toyot

For Wheel Alignment specifications, see Section 1 of this manual

4 ae ‘

9-4 79 HEATER CORES TOYOTA 6. Remove 7. Remove cover. 8. Remove ish panel. 9. Remove 10. Remove 11. Remove

the rear console box. the front console box the lower center cluster fin-

the front door scuff plates. the cowl side trim. the rear door scuff plates.

12. Remove the center pillar garnishes. 13. Slide the carpet rearward. 14. Remove the cooler bracket bolts and the bracket. 15. Remove the rear heater duct bolt/screw and the duct.

16. Disconnect the rear heater housing electrical connector.

17. Remove the 3 rear heater housingto-chassis bolts and the heater housing. 18. Remove the heater core-to-heater housing 3 screws and 2 clamps. 19. Remove the heater core from the heater housing. To install: 20. Install the heater core to the heater housing. 21. Install the heater core-to-heater housing 3 screws and 2 clamps. 22. Install the heater housing and the 3 rear heater housing-to-chassis bolts. 23. Connect the rear heater housing electrical connector.

24, Install the rear heater duct and the duct bolt/screw. 25. Install the cooler bracket and the bracket bolts.

26. . . . . _

Slide the carpet rearward. Install the center pillar garnishes. Install the rear door scuff plates. Install the cow! side trim. Install the front door scuff plates. Install the lower center cluster finish

. Install the front console box cover. . Install the rear console box. . Install the rear heater contro! assem. Install the front seats.

Blower Resistor

bos

Rear Heater Hi Relay

Fan

Heater Radiator

Heater Case

Heater Radiator Pipe

@ Non—reusable part Blower Motor Exploded view of the rear heater core, heater housing and related components—Toyota Land Cruiser

93113GH2

HEATER CORES 2-1 79 36. heater 37. 38.

Connect the heater hoses to the rear core. Refill the cooling system. Connect the negative battery cable.

RAV4

“2 CAUTION After the negative battery cable has been disconnected, wait at least 112 minutes for the air bag module to deplete its energy.

_ 2. Drain the cooling system into a clean

REMOVAL & INSTALLATION

container for reuse. 3. Disconnect the heater hoses from the heater core.

1. Disconnect the negative battery cable.

4. Remove the steering wheel by performing the following procedure: a. Position the front wheels in the straight-ahead position. b. At both sides of the steering wheel, remove the side covers. c. Using a Torx® wrench, loosen the steering wheel Torx® screws until the screw’s circumference ring catches on the screw case. d. Carefully, lift the air bag module,

Steering Wheel Pad

34 (350, 25) Steering Wheel Torx Screw

Torx Screw

8.8 (90, 78 in.-Ibf)

8.8(90, 78in.-Ibf)

Steering Column Assembly Column Upper Cover

\

& Combination Switch

(w/ Spiral Cable)

Column Hole Cover

cL ~ het 4 os

Lower LH Instrument Finish Panel

No.2 Intermediate

P

Shaft Assembly

.

&

i Ca

Lock Control Cable

4,

No.2 Heater to Register Duct

N-m (kgf-cm, ft-lbf) |:Specified torque

c 93113GK4

Toyota RAV4 Exploded view of the steering wheel, air bag module, steering column and related components—

For Maintenance Interval recommendations, see Section 1 of this manual

a 2180 se " ' :

Reinforcement

Reinforcement

Canada:

No.2 Brace

No.2 Heater to

Combination

Meter

b

~~

w

|

YY

Combination Switch,

O

r

Heater Control and Accessary Assembly

Register: Duct

a Panel Finish ‘~ Cluster

:

Lida Confel Neem pee

(0)

Cluster Instrument

Panel

A

\

Steering Column Cover

o

©

U.S.A. Only:

igi

|35(360, 25)|

Center Cluster/ a Finish Panel

Lower Panel Insert

Lower Center Cluster

Finish Plate

Lower Finish Panel

_-Side Trim Cover.

i

Cowl Side Trim Board

&

Cluster Instrument Panel oe

i

overs

a Qe Pr

Front Door Scuff Plate

|N-m N-m (kgf-cm, ft:lbf) ft:lbf) lof) | | : Specified torque

Shifting

Hole Bezel

Console Box 93113GK5

Exploded view of the instrument panel and related components—Toyota RAV4

HEATER CVn 2-181

rt

Defroster Duct Bracket

Defroster Nozzle Assembly

No.3 Heater to Register Duct Front Passenger Airbag Door

© EN we

:

Front Passenger

Airbag Assembly

in

ed

No.1 Lower Mounting Bracket

No.1 Register

No.1 Heater to Register Duct

N-m (kgf-cm, ft-lbf) | : Specified torque 93113GK6

Exploded view of the instrument panel air bag module, ventilation components and wiring harness—Toyota RAV4

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

viens

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Se oe”

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Instrument Panel

No. 2 Instrument panel Brace

Heater to Register Center Duct

Rear Heater Duct

Defroster Nozzle

Heater Unit Case

@ Non-reusable part 93113GK7

Exploded view of the heater core, heater housing, evaporator housing and related components—Toyota RAV4

HEATER CORES 9-183 —

ee

disconnect the electrical connector and

remove the air bag. :¢ CAUTION

Place the air bag module in a safe location with the front facing upward. SS

a

ee

e. Remove the steering wheel nut. f. Using a steering wheel puller, press the steering wheel from the steering column. 5. Remove the instrument panel and reinforcement by performing the following procedure: a. Disconnect the seat belt pre-tensioner connector. b. Remove both front door scuff plates. c. At both sides, remove the 2 cowl side trim board clips and the trim boards. d. Remove the combination switchto-steering column screws, disconnect the electrical connectors and remove the combination switch.

e. Remove the 4 steering column cover screws and the cover. f. Remove the cluster finish panel screw and the panel. g. Remove the 4 combination meter screws, disconnect the electrical connectors and the. meter. h. Remove the hood lock release lever. i. Remove the 2 lower finish panel screws and the panel. j. For USA models, remove the lower panel insert. k. Remove the No. 2 heater-to-register duct. |, Remove the steering column-toinstrument panel nuts/bolts and the lower steering column bolt; then carefully, remove the steering column. m. Remove the 2 center cluster finish panel screws and the panel. n. Pull off the heater contro! knobs. >For Canada models, remove the 2 screws.

o. Pry off the heater control name plate and the cluster instrument panel. p. Remove the 3 heater control assembly screws and the assembly. q. Disconnect the connectors and remove the cluster instrument panel. r. Remove the heater control and accessory assembly. s. Remove the radio.

t. Remove the side trim cover and the console box. u. Remove the lower center cluster finish panel and disconnect the connectors. v. Remove the stereo opening cover. w. Remove the glove compartment door. x. Remove the instrument panel-tochassis fasteners. y. Remove the instrument panel and disconnect the electrical connectors. z. Remove the No. 1 and No. 2 brace nuts/bolts and the braces. aa. Remove the instrument panel reinforcement-to-chassis nuts/bolts and the reinforcement. 6. Remove the evaporator housing by performing the following procedure: a. Discharge and recover the air conditioning system refrigerant. b. Disconnect the refrigerant lines from the evaporator core. Discard the Orings and plug the openings to prevent contamination. c. Disconnect the electrical connectors. d. Remove the 3 evaporator housingto-chassis nuts/bolts and the housing. 7. Remove the rear heater duct from the heater housing. 8. Remove the heater housing-to-chassis nuts and the housing. 9. Remove the 2 defroster nozzle-toheater housing screws and the nozzle. 10. Remove the 2 heater core-to-heater housing screws, clamps and the heater

core. To install: 11. Install the heater core and the 2 heater core-to-heater housing screws and clamps. 12. Install the defroster nozzle and the 2 nozzle-to-heater housing screws. 13. Install the heater housing and the housing-to-chassis nuts. 14, Install the rear heater duct to the heater housing. 15. Install the evaporator housing by performing the following procedure: a. Install the evaporator housing and

the 3 housing-to-chassis nuts/bolts. b. Connect the electrical connectors. c. Using new O-rings, connect the refrigerant lines to the evaporator core. 16. Install the instrument panel and reinforcement by performing the following procedure: a. Install the instrument panel rein-

forcement and the reinforcement-tochassis nuts/bolts. b. Install the No. 1 and No. 2 brace and the braces nuts/bolts. c. Install the instrument panel and connect the electrical connectors. d. Install the instrument panel-tochassis fasteners. é. Install the glove compartment door. f. Install the stereo opening cover. g. Install the lower center cluster finish panel and connect the connectors. h. Install the side trim cover and the console box. i. Install the radio. j. Install the heater control and accessory assembly. k. Connect the connectors and install the cluster instrument panel. |. Install the heater control assembly and the 3 assembly screws. m. Install the cluster instrument panel and the heater control name plate. >For Canada models, install the 2 screws.

n. Push on the heater control knobs. 0. Install the center cluster finish panel and the 2 panel screws. p. Carefully, install the steering column. Then, install the steering columnto-instrument panel nuts/bolts and torque the nuts/bolts 19 ft. Ibs. (25 Nm) and the lower steering column bolt to 26 ft. Ibs. (6 Nm). q. Install the No. 2 heater-to-register duct. r. For USA models, install the lower panel insert. s. Install the lower finish panel and the 2 panel screws. t. Install the hood lock release lever. u. Install the combination meter, connect the electrical connectors and the 4 meter screws. v. Install the cluster finish panel and

the panel screw. w. Install the steering column cover and the 4 cover screws. x. Install the combination switch, connect the electrical connectors and install the combination switch-to-steering column screws. y. At both sides, install the cowl side trim board and the 2 trim boards clips. z. Install both front door scuff plates. aa. Connect the seat belt pre-tensioner connector.

For complete service labor times, order the Chilton Labor Guide

‘

weiv 4

9-4 Gd HEATER CORES.

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17. Install the steering wheel by performing the following procedure: a. Install the steering wheel to the steering column. b. Install the steering wheel nut and eae et ee Sa torque the nut to 25 ft. Ibs. (34 Nm). c. Connect the electrical connector and carefully, install the air bag module. d. Using a Torx® wrench, tighten the steering wheel screws to 78 inch Ibs. (8.8 Nm). e. At both sides of the steering wheel, install the side covers. 18. Connect the heater hoses to the heater core. 19. Refill the cooling system. 20. Connect the negative battery cable. 21. Evacuate and charge the air conditioning system. 22. Run the engine to normal operating temperatures. Check the climate control operation and check for leaks. va

REMOVAL & INSTALLATION Front Heater

1. Disconnect the negative battery Cable. 2. Drain the cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core. 4, Remove the steering wheel by performing the following procedure: a. Position the front wheels facing straight-ahead. b. Remove the steering wheel side covers. c. Using a Torx® wrench, loosen the 2 screws located at each side of the steering wheel until the screw's circumference groove catches on the screw case. d. Pull the air bag module from the steering wheel and disconnect the electrical connector.

CAUTION Place the air bag module in a safe place with the front side facing upward. e. Remove the steering wheel nut. f. Place alignment marks on the steering wheel and the main shaft. g. Using a steering wheel puller, press the steering wheel from the steering column. 5. Remove the instrument panel and

reinforcement by performing the following procedure: a. Remove the front door scuff plates. b. Remove the cowl side boards. c. Remove the front door trim covers. d. Remove the front pillar garnish by disengaging the 5 clips. If equipped with a tweeter speaker, disconnect the electrical connector. e. Remove the steering column covers-to-steering column screws and the covers. f. Remove the combination switchto-steering column screws, disconnect the electrical connector(s) and remove the combination switch. g. Remove the 2 hood open lever screws and the hood open lever. h. Remove the 2 lower finish panel bolts and disengage the panel from the 3 clips. i. Remove the 2 No. 1 safety pad insert bolts and the insert. j. Remove the 2 No. 2 finish panel bolts and disengage the panel from the 4 clips. k. In the left side of the glove compartment, pry. out the glove box door finish plate and disconnect the air bag module connector. |. Remove the glove box 3 nuts and 2 screws and the glove box. m. Remove the center cluster finish panel by disengaging the claw (bottom center) and 4 clips (one at each corner). n. Remove the ashtray, the 2 ashtray receptacle box screws. 0. Remove the 4 lower center cluster finish panel screws and disconnect the connector. p. Remove the clock, the No. 1 and No. 2 registers from the panel. qg. Remove the 3 cluster finish panel screws, disengage the 8 clips and remove the panel. r. Remove the combination meter. s. Remove the radio assembly. t. Remove the heater control assembly. u. Remove 2 passenger's side air bag module bolts; then, disconnect and remove the air bag module.

“-¢ CAUTION Place the air bag module in a safe place with the front side facing upward. v. Remove the instrument panel-tochassis 5 bolts and nut. w. Remove the audio amplifier.

x. Remove the No. 1 and No. 2 braces.

y. Remove the No. 2 cowl brace.

z. Remove the instrument panel reinforcement. . 6. Remove the evaporator housing by performing the following procedure: a. Discharge and recover the air conditioning system refrigerant. b. In the engine compartment, remove the refrigerant lines-to-cow! connector bolts; then, disconnect the lines and dis~ card the O-rings. c. Disconnect the electrical connector at the evaporator housing. d. Disconnect the wiring harness clamp. e. Remove the evaporator housing-tochassis 2 rivets, 3 bolts and nut. f. Remove the evaporator housing. 7. Remove the 4 defroster nozzle nuts and the nozzle. 8. Disconnect and remove the theft deterrent and the wireless door lock ECUs. 9. Release the 2 air duct claws and the air duct. 10. Remove the 2 heater housing-tochassis rivets and the heater housing. ->When installing the heater housing, use new screws in place of the rivets. 11. Remove the heater core-to-heater housing cover. 12. Remove both heater core screws and clamps; then, remove the heater core. To install: 13. Install the heater core and both heater core screws and clamps. 14. Install the heater core-to-heater housing cover.

e>When installing the heater housing, use new screws in place of the rivets.

15. Install the heater housing-to-chassis and the 2 heater housing screws. 16. Release the air duct and the air duct claws. 17. Connect and install the theft deterrent and the wireless door lock ECUs. 18. Install the defroster nozzle and the 4 nozzle nuts. ‘ 19. Install the evaporator housing by performing the following procedure: a. Install the evaporator housing. b. Install the evaporator housing-tochassis 2 rivets, 3 bolts and nut. c. Connect the wiring harness clamp. d. Connect the electrical connector at the evaporator housing. é. In the engine compartment, use new O-rings and install the refrigerant dei eee connector and install the olts.

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20. Install the instrument panel and reinforcement by performing the following procedure: * a. Install the instrument panel reinforcement.

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b. Install the No. 2 cowl brace. c. Install the No. 1 and No. 2 braces. d. Install the audio amplifier. e. Install the instrument panel-tochassis 5 bolts and nut.

_ HEATER CORES 94 85 f. Connect and install the air bag module and the 2 passenger's side air bag module bolts. g. Install the heater control assembly. h. Install the radio assembly.

Steering Wheel Pad

Torx Screw

Combination Switch (w/ Spiral Cable)

Steering Column Assembly

t Transmission Control

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Scuff Plate Cowl Side Trim

N-m (kgf-cm, ft-lbf) | : Specified torque 93113GH3

and related components—Toyota Sienna Exploded view of the steering wheel, steering column

Please visit our web site at www.chiltonsonline.com

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Exploded view of the front heater core, heater housing, evaporator housing and related components—Toyota Tacoma

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

2-196

HEATER CORES TOYOTA

ah.

i. Install the lower No. 2 finish panel and the 3 panel screws. j. Connect the passenger's side air bag module electrical connector and the No. 1 undercover. k. Install the No. 4 heater-to-register duct. |. Install the glove compartment reinforcement and the 3 reinforcement Screws. m. Install the glove compartment door and the2 door screws. n. Install the steering column and torque the steering column-to-instrument panel nuts/bolts to 19 ft. Ibs. (26 Nm) and the lower steering column joint bolt to 26 ft. Ibs. (35 Nm). o. If equipped with a column shifter, connect the transmission control cable to the steering column. p. Install the No. 1 heater-to-register duct and the duct screw. g. Install the No. 1 register and the 2 register Screws. r._ Install the combination meter and connect the electrical connectors. __§. Install the radio and stereo opening cover. t. Install the cluster finish panel and the 3 panel screws. u. Pry out the starter switch bezel. v. Install the front ashtray and the center cluster finish panel retainer. w. Install the cigar lighter hole bezel. x. Install the center cluster finish panel, engage the 5 clips, connect the electrical connectors and install the 2 panel screws. y. Install the heater control panel. z. Install the heater control knobs. aa. Install the No. 2 heater-to-register duct and the duct screw. bb. Install the lower center cover and engage the 2 clips. cc. Install the upper console box mounting bracket and the 2 bracket SCIeWS. dd. Install the front console box. ee. If equipped, install the rear console box and the 2 rear console box bolts/screws. ff. Install the lower left side finish panel, the 4 bolts and the screw. gg. Install the fuse box opening COVEr. hh. Install the hood lock release lever and the 2 hood lock release lever screws. li. Install the combination switch-tosteering column and the combination Switch screws. jj. Install the steering column cover and the covers screws.

17. Install the steering wheel by performing the following procedure: a. Install the steering wheel from the steering column. b. Install the steering wheel nut and torque to 26 ft. Ibs. (35 Nm). c. Carefully, install the air bag module and connect the electrical connector. d. Using a Torx® wrench, tighten the steering wheel screws to 78 inch Ibs. (8.8 Nm). e. At both sides of the steering wheel, install the side covers. 18. Connect the heater hoses to the heater core. 19. Refill the cooling system. 20. Connect the negative battery cable. 21. Evacuate and charge the air conditioning system refrigerant. 22. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

T-100 REMOVAL & INSTALLATION ->l|f equipped with a theft-deterrent system, be sure to acquire code. Also, write down the frequencies of the preset radio push buttons so the audio system may be reprogrammed.

1. Disconnect the negative battery cable.

Torx Screw

4k CAUTION After disconnecting the negative battery cable, be sure to wait at least 1% minutes so that the air bag module can deplete its energy.

2. Drain the cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core. 4. Discharge and recover the air conditioning system refrigerant. 5. Remove the front pillar garnish, the front door scuff plate and the cowl side trim. 6. Remove the steering wheel by performing the following procedure: a. Position the front wheels in the straight-ahead position. b. At both sides of the steering wheel, - remove the side covers. c. Using a Torx® wrench, loosen the steering wheel Torx® screws until the screw’s circumference ring catches on the screw case. d. Carefully, lift the air bag module, disconnect the electrical connector and remove the air bag.

*k- CAUTION Place the air bag module in a safe location with the front facing upward.

Screw Case

93113GJ4

View of the driver’s side air bag module Torx® screws—Toyota T-100

wean cones 2-197 k. Remove the 2 center cluster finish lower panel screws and the panel: then, disconnect the connector. |. Remove the stereo opening cover. m. Remove the 5 cluster finish pane screws and the combination meter. n. Remove the No.1 register. 0. Remove the heater ducts from the No.1 and No. 2 registers. p. Remove the glove compartment door reinforcement. q. Remove the No. 1 and No. 2 brace. r. Remove the instrument panel electrical connectors. s. Remove the 2 instrument panel bolts and the instrument panel. t. Remove the instrument panel reinforcement. 8. Remove the evaporator housing by performing the following procedure: a. Disconnect the refrigerant lines from the evaporator housing; then, discard the O-rings and plug the openings to prevent contamination. b. Remove the evaporator-to-chassis grommets. c. Remove the drain pipe grommet. d. Disconnect the connectors to the evaporator housing. e. Remove the 5 evaporator housingto-chassis screws, the nut and the evaporator housing. 9. Disconnect the contro! cables from the heater housing.

Airbag Connector

Correct

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Exploded view of the steering wheel and air bag module assembly—Toyota T-100

e. Remove the steering wheel nut. f. Using a steering wheel puller, press the steering wheel from the steering column. 7. Remove the instrument panel by performing the following procedure: a. Remove the steering column cover screws and the cover. b. Remove the hood lock release lever. c. Remove the No. 1 lower finish panel.

d. Remove the combination switch. e. Remove the glove compartment door. f. Remove the No. 2 lower finish panel. g. Remove the lower center cover. h. Remove the rear console box. i. Remove the heater contro! knobs; then, pry out the center cluster finish panel. j. Remove the radio and the heater control assembly.

10. Remove the heater housing-to-No.4 register duct screw and the duct. 11. Remove the heater housing-to-center register duct screw and the duct. 12. Remove the heater housing-to-foot air duct screw and the duct. 13. Remove the 2 heater housing-tochassis bolts/nut and the heater housing. 14. Remove the 3 heater core-to-heater housing screws, plates and clamp. 15. Remove the heater core from the heater housing. To install: 16. Install the heater core to the heater housing. 17. Install the 3 heater core-to-heater housing screws, plates and clamp. 18. Install the heater housing and the 2 heater housing-to-chassis bolts/nut. 19. Install the heater housing-to-foot air duct and the ductscrew. 20. Install the heater housing-to-center register duct and the duct screw. 21. Install the heater housing-to-No.4 register duct and the duct screw.

For Wheel Alignment specifications, see Section 1 of this manual

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Yo) When the timing marks are aligned, the No. 2 piston is at Top Dead Center (TDC) of the compression.

* WARNING ~» Align the camshaft and crankshaft sprockets with their alignment marks before removing the timing belt. Failure to align the belt and sprocket marks may result in valve damage.

11. Use tool No. J-8614-01 ora suitable pulley holding tool to remove the crankshaft pulley center bolt. Remove the crankshaft pulley.

the lower timing cover. 13. Remove the lower timing belt cover. 14. Remove the pusher assembly (tensioner) from below the belt tensioner pulley. The pusher rod must always face upward to prevent oil leakage. Depress the pusher rod, and insert a wire pin into the hole to keep the pusher rod retracted. 15. Remove the timing belt. 16. Inspect the water pump and replace it if there is any doubt about its condition. 17. Repair any oil or coolant leaks before installing a new timing belt. If the timing belt has been contaminated with oil or coolant, or is damaged, it must be replaced. To install: 18. Verify that the sprocket timing marks are still aligned and that the groove and the keyway on the crankshaft timing sprocket align with the mark on the oil pump. The white pointers on the camshaft timing sprockets should align with the dots on the front plate. 19. Install the timing belt. Use clips to secure the belt onto each sprocket until the installation is complete. Align the dotted marks on the timing belt with the timing mark opposite the groove on the crankshaft sprocket.

e>The arrows on the timing belt must follow the belt’s direction of rotation. The manufacturer’s trademark on the belt’s spine should be readable left-toright when the belt is installed.

REMOVAL & INSTALLATION Acura SLX

3.2L AND 3.5L ENGINES 1. Disconnect the negative battery cable.

2. Drain the engine coolant into.a sealable container. 3. Remove the air cleaner assembly and intake air duct. 4. Disconnect the upper radiator hose from the coolant inlet. 5. Remove the upper fan shroud from the radiator. 6. Remove the 4 nuts retaining the cooling fan assembly. Remove the cooling fan from the fan pulley. 7. Loosen and remove the drive belts. 8. Remove the upper timing belt covers.

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LV 79245608

Using a double clip to hold the belt in place—Acura 3.2L and 3.5L engines

For complete service labor times, order the Chilton Labor Guide

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Honda CR-V

2.0L (B20B4) ENGINE

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1. Disconnect the negative battery cable. ; 2. Position crankshaft so that No. 1

piston is at Top Dead Center (TDC).

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3. Remove the splash guard.

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11. Remove the timing belt. 79245647

Rotate the crankshaft clockwise until the camshaft and crankshaft timing marks are aligned—

GEO/Chevrolet Tracker 1.6L 16-valve engine

19. Rotate the crankshaft clockwise 2 full revolutions, then tighten the tensioner stud to 97 inch Ibs. (11 Nm). Then, tighten the tensioner bolt to 18 ft. Ibs. (24 Nm). 20. Ensure that all 4 timing marks are still aligned as before; if they are not, remove the timing belt, and install and tension it again. 21. Install the timing belt cover and all related components.

7. Remove upper engine bracket. 8. Remove the valve cover.

the adjusting bolt.

belt pulley

e>in this position, the No. 4 cylinder is at Top Dead Center (TDC) on the compression stroke.

oil pan and the jack, support the engine

witha jack.

; 10. eat the adjusting bolt 180 egrees. Release the tension from the belt by pushing on the tensioner, then retighten

_ crankshaft timing

16. Rotate the camshaft sprocket clockwise until the timing mark on the sprocket and the V mark on the timing belt inside cover are aligned. 17. Using a wrench, or socket and breaker bar, on the crankshaft sprocket center bolt, turn the crankshaft clockwise until the punch mark on the sprocket is aligned with the arrow mark on the oil pump. 18. With the camshaft and crankshaft marks properly aligned, push the tensioner up with your finger and install the timing belt on the 2 sprockets, ensuring that the drive side of the belt is free of all slack. Release your finger from the tensioner. Be sure to install the timing belt so that the directional arrow is pointing in the appropriate direction.

trol balsa . Place a piece of wood between the

To install: 12. Be sure the timing marks are properly aligned. 13. Install the timing belt on the pulleys following this sequence:

POINTER

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TIMING BELT DRIVE PULLEY

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79245644

Crankshaft timing mark will be easier to verify when clean—Honda CR-V 2.0L (B20B4) engine

Timing belt service is covered in Section 3 of this manual

3.9

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Install the accessory drive belts. Install the splash guard. i Connect the negative battery cable. Check the engine operation and road

Honda Passport

3.2L (6VD1) ENGINES 1. Disconnect the negative battery

cable.

;

2. Remove the air cleaner assembly and intake air duct. 3. Remove the upper fan shroud from the radiator.

4. Remove the 4 nuts retaining the cooling fan assembly. Remove the cooling fan from the fan pulley. 5. Loosen and remove the drive belts. 6. Remove the upper timing belt covers. 7. Remove the fan pulley assembly. 8. Rotate the crankshaft to align the

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TDC MARKS

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Intake and exhaust camshaft timing marks properly aligned at TDC—Honda CR-V 2.0L (B20B4)

engine

a. Crankshaft pulley. b. Adjusting pulley. c. Water pump pulley. d. Exhaust camshaft pulley. e. Intake camshaft pulley. 14. Loosen and retighten the adjusting bolt to allow tension to be applied to the belt. 15. Install the lower and middle timing COVETS. 16. Install the crankshaft pulley and tighten the bolt to 130 ft. Ibs. (177 Nm).

22. Retighten the crankshaft pulley bolt to 130 ft. Ibs. (177 Nm) 23. Install the valve cover. 24. Install the engine mounting bracket, then remove the jack.

camshaft timing marks with the pointer dots on the back covers. Verify that the pointer on the crankshaft aligns with the mark on the lower timing cover.

e>When the timing marks are aligned, the No. 2 piston is at Top Dead Center (TDC) of the compression. Sag WARNING ee oes Shs : he ein Whe Gawsial Beaten

sprockets with their alignment

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

17. Rotate the crankshaft about 5-6 times counterclockwise to seat the timing belt. 18. Position the No. 1 piston to TDC. 19. Loosen the adjusting bolt % turn. 20. Rotate the crankshaft counterclockwise 3 teeth on the camshaft pulley.

21. Tighten the adjusting bolt to 40 ft.

Ibs. (54Nm).

Using a double clip to hold the belt in place—Honda Passport 3.2L engine

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For maximum timing belt life, install the belt as shown—Honda Passport 3.2L engine

marks before removing the timing belt. Failure to align the belt and sprocket marks may result in valve damage.

Belt tensioner

Pusher

93025610

View of timing belt tensioner and pusher—Honda Passport 3.2L engine

Alignment mark on

timing belt

Crankshaft gear

alignment mark

Alignment mark on oil pump

Groove on timing pulley 79245606

Proper crankshaft alignment marks for timing belt installation—Honda Passport 3.2L SOHC (VIN V) engine

9. Use tool No. J-8614-01 or a suitable pulley holding tool to remove the crankshaft pulley center bolt. Remove the crankshaft pulley. 10. If present, disconnect the 2 oil cooler hose bracket bolts on the timing cover. Move the oil cooler hoses and bracket off of the lower timing cover. 11. Remove the lower timing belt cover. 12. Remove the pusher assembly (tensioner) from below the belt tensioner pulley. The pusher rod must always face upward to prevent oil leakage. Depress the pusher rod and insert a wire pin into the hole to keep the pusher rod retracted. 13. Remove the timing belt. 14. Inspect the water pump and replace it if there is any doubt about its condition. 15. Repair any oil or coolant leaks before installing a new timing belt. If the timing belt has been contaminated with oil or coolant, or is damaged, it must be replaced. To install: 16. Verify that the sprocket timing marks are still aligned and that the groove and the | keyway on the crankshaft timing sprocket align with the mark on the oil pump. The white pointers on the camshaft timing sprockets should align with the dots on the front plate. 17. Install the timing belt. Use clips to secure the belt onto each sprocket until the installation is complete. Align the dotted marks on the timing belt with the timing mark opposite the groove on the crankshaft sprocket.

Heater Core replacement is covered in Section 2 of this manual

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TIMING BELT ->The arrows on the timing belt must follow the belt’s direction of rotation. The manufacturer’s trademark on the belt’s spine should be readable left-to-

right when the belt is installed.

18. Align the white line on the timing belt with the alignment mark on the right bank camshaft timing pulley. Secure the belt with a clip.

+k WARNING If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

:

‘

1) Crankshaft timing pulley 2) RH bank timing pulley 3) Water pump pulley 4) Idler pulley 5) LH bank timing pulley 6) Tension pulley

93025609

Timing mark alignment and timing belt routing—Honda Passport 3.2L SOHC (VIN V) engine

19. Rotate the crankshaft counterclockwise to remove the slack between the crankshaft sprocket and the right camshaft timing belt sprocket. 20. Install the belt around the water pump pulley. 21. Install the belt on the idler pulley. 22. Align the white alignment mark on the timing belt with the alignment mark on the left bank camshaft timing belt sprocket. 23. Install the crankshaft pulley and tighten the center bolt by hand. Rotate the crankshaft pulley clockwise to give slack between the crankshaft timing belt pulley and the right bank camshaft timing belt pulley. 24. Insert a 1.4mm piece of wire through the hole in the pusher to hold the rod in. Install the pusher assembly while pushing the tension pulley toward the belt. 25. Pull the pin out from the pusher to release the rod. 26. Remove the clamps from the sprockets. Rotate the crankshaft pulley clockwise2 turns. Measure the rod protrusion to ensure it is between 0.16—0.24 in. (4-6mm). 2/. If the tensioner pulley bracket pivot bolt was removed, tighten it to 31 ft. Ibs. (42 Nm). 28. Tighten the pusher bolts to 14 ft. Ibs. (19 Nm).

29. Remove the crankshaft pulley. Install

the lower and upper timing belt covers and tighten their bolts to 12 ft. Ibs. (17 Nm). 30. Fit the oil cooler hose onto the timing cover and tighten its mounting bracket bolts to 16 ft. Ibs. (22 Nm). 31. Install the crankshaft pulley and he the pulley bolt to 123 ft. Ibs. (167 m). 32. Install fan pulley assembly and

930256 Timing mark alignment and timing belt routing—Honda Passport 3.2L DOHC (VIN W) engine

tighten the bolts to 16 ft. Ibs. (22 Nm). 33. Install and adjust the accessory drive belts.

—

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TIMING BELTS

3-11.

Approx. 100 kg Direction for installation

79245611

View of timing belt tensioner pusher—Honda Passport 3.2L engine

34. Install the cooling fan assembly and tighten the bolts to 72 inch Ibs. (8 Nm). 35. Install the upper fan shroud. 36. Install the air cleaner assembly and intake air duct. 37. Connect the negative battery cable.

2.2L (X22SE/D) ENGINE 1. Disconnect the negative battery cable.

2. Using a box-end wrench on the drive belt adjuster, turn the adjuster clockwise and remove the drive belt. 3. From the left rear of the engine compartment, disconnect the 3 electrical connectors from the chassis harness. 4. Remove the crankshaft pulley-tocrankshaft bolts and remove the pulley. 5. From the front of the engine, remove the nut and the engine harness cover. J-43037

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93025612

Aligning the timing marks and installing the timing belt—Honda Passport 2.2L (X22SE/D) engine

6. Remove the timing belt cover. 7. Rotate the crankshaft to position the timing marks at Top Dead Center (TDC) of the No. 1 cylinders compression stroke. e» Mark the rotational direction of the timing belt for reinstallation purposes.

8. Remove the timing belt tensioner adjusting bolt and the tensioner from the engine. 9. Remove the timing belt. To install: 10. Install the timing belt tensioner and finger-tighten the tensioner bolt. 11. Inspect the timing marks to be sure that the engine is positioned at TDC of the No. 1 cylinder’s compression stroke. 12. Using tool J-43037, or equivalent, place it between the intake and exhaust sprockets to prevent the camshaft gear from moving during the timing belt installation. 13. Install the timing belt. 14. Position the timing belt to ensure that the tension side of the belt is taut and move the timing belt tension adjusting lever clockwise until the tensioner pointer is flowing. 15. If installing a used timing belt (used over 60 min. from new), the pointer should be positioned approximately 0.16 in. (4mm) to the left of the “V” notch when viewed from the front of the engine. 16. If installing a new timing belt, the pointer should be positioned at the center of the “V” notch when viewed from the front of the engine. 17. Torque the timing belt tensioner adjusting bolt to 18 ft. Ibs. (25 Nm). 18. Install the timing belt front cover and torque the bolts to 53 inch Ibs. (6 Nm). 19. Install the engine harness connectors.

Brake service is covered in Section 4 of this manual

3.4 9 TIMING BELTS at)

20. Install the crankshaft pulley and

toque the pulley-to-crankshaft bolts to 14 ft. lbs. (20 Nm). 21. Move the drive belt tensioner to the loose side and install the drive belt to its normal position. 22. Connect the negative battery cable.

Hyundai Santa Fe

2.4L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Align the timing marks to set the No. 1 piston to Top Dead Center (TDC) by rotating the crankshaft clockwise. The timing

93025613 - Tensioning the timing belt for a used timing belt—Honda Passport 2.2L (X22SE/D) engine Timing belt upper cover

(80-100, 6-7)

(200-270, 14-20) Drive belt (A/C, P/S)

Damper pulley

10-12 (100-120, os Counter shaft

Camshaft sprocket

ve

sprocket

(

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43-49 (430-490, 31-35)

80-1 00 (800-1000, m 56-72)

~-@— Plug rubber 30-42 (300-420, 22-30)

Tensioner arm

Crankshaft sprocket "B"

Tensioner pulley

Timing belt "B"

43-55 (430-550, 31-40)

Tensioner "B"

20-27 (200-270, aN ¢

wp

Idler pulley

2

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Oil pump sprocket

50-60 (500-600, 36-43) Crankshaft sprocket

Auto te nsioner

Special washer

110-130 (1100-1300, 89-94) TORQUE

: Nm (kg-cm, Ib-ft) 9355LG73

Exploded view of the timing belt assembly and related components—2.4L engine

TIMING BELTS 3-4 3 4 Exhaust camshaft sprocket

Intake camshaft ;

sprocket

Timing marks

Oil pump sprocket s Crankshaft sprocket 9355LG74

Correct sprocket alignment when the belt is installed—2.4L engine

marks of the camshaft sprocket and the cylinder head cover should be aligned and the dowel pin of the camshaft sprocket should be at the upper side. 3. Remove the crankshaft pulley, water pump pulley and drive Belt. 4. Remove the timing belt cover. 5. Remove the auto tensioner. 6. Mark the timing belt is being reused, mark an arrow on the belt noting the direction of rotation or the front of the engine to make sure the belt is reinstalled in its original position. 7. Remove the timing belt. 8. Hold the camshaft with a wrench and loosen the camshaft sprocket bolts. 9. Remove the sprockets. 10. When removing the oi! pump socket nut, first remove the plug at the side of the block and insert a 0.3 inch (8mm) diameter screwdriver to keep the left counterbalance shaft in position. Insert the screwdriver at least 2.36 inch (60 mm). 11. Remove the oil pump sprocket nut and the sprocket. 12. Loosen the right counterbalance shaft sprocket bolt until you can loosen it by hand. 13. Remove the tensioner B and timing belt B. Refer to the accompanying illustration for tensioner and belt identification.

“kk CAUTION Do not attempt to loosen bolts while holding the sprocket with pliers or any tool after removing timing belt B. 14. Remove the crankshaft sprocket B from the crankshaft. To install: 15. Install the crankshaft sprocket B to the crankshaft. 9355LG75

Hold the camshaft with a wrench and loosen the camshaft sprocket bolts—2.4L engine

@& Front

Counter balance shaft

~ Cylinder block 9355LG76

Insert a 0.3 inch (8mm) diameter screwdriver to keep the left counterbalance shaft in position—2.4L engine

> CAUTION Pay attention to the direction of the flange. If it is installed in the wrong direction, the belt will break.

16. Apply engine oil to the outer surface of the spacer lightly and install the spacer to the right counterbalance shaft. Be sure to install spacer correctly. 17. Install the counterbalance shaft sprocket onto the right counterbalance shaft and then tighten the flange bolt by hand until it is tight. 18. Align the timing mark on each sprocket with its corresponding timing mark on the front case.

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

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ET

I

19. Install timing belt B and make sure there is no slack. 20. Install tensioner B so that the center of the pulley is located on the left side of the mounting bolt and the pulley flange faces the front of the engine. 21. Align the timing mark on the right counterbalance shaft sprocket with the timing mark on the front case. 22. Lift the tensioner B to tighten tensioner B so that its tension side is pulled tight. Tighten the bolt on tensioner B. As the bolt is being tightened, make sure the shaft does not turn. If the shaft turns, the belt will be overtightened. 23. Make sure the timing marks are aligned. 24. Check the belt tension by depressing the center of the belt span with an index finger. The deflection should be 0.20—0.28 inch (5-7mm).

ATOE eat

Installing the flange incorrectly will cause the belt to break. 26. Install the crankshaft washer and bolt. Tighten the bolt to 80-94 ft. Ibs. (110-130 Nm). 27. Insert a 0.3 inch (8mm) diameter screwdriver through the plug hole on the left side of the block to keep the left counterbalance shaft in position. Insert the screwdriver at least 2.36 inch (60 mm). 28. Install the oil pump sprocket and tighten the nut to 36-43 ft. Ibs. (50-60 Nm) 29. Install the camshaft sprockets and the bolts. 30. Hold the camshaft with a wrench and tighten the camshaft sprocket bolts to 56-72 ft. Ibs. (80-100 Nm). 31. Reset the auto tensioner as follows: a. Place the tensioner in a soft jawed vice in a level position. If there is a plug at the bottom of the tensioner use a plain washer.

25. Install the flange and crankshaft sprocket making sure it is installed properly.

b. Compress the rod slowly using the vice until the set hole in the rod is aligned with the set hole on the cylinder. c. Insert a set pin through the body and rod and leave the pin installed. 32. Install the tensioner and tighten the bolts to 14-20 ft. Ibs. (20-27 Nm). Leave the set pin in place. 33. Install the tensioner pulley and tighten the bolt to 31-40 ft. Ibs. (43-55 Nm). ~ 34. Rotate the camshaft sprockets so that the dowel pin is at the upper side. Set the timing mark of the sprocket correctly. ->Before installing the belt, the timing mark of the camshaft sprocket doers not coincide with that of the rocker cover, do not rotate the cam sprocket more than 2 teeth of the sprocket in any direction. Rotating the sprocket more that 2 teeth may make the valve and piston contact each other. If it is necessary to rotate the sprocket more

Cushion metal

Timing belt B C—

Cushion metal

Crankshaft sprocket “B" Tensioner "B" 9355LG77

Remove tensioner B and timing belt B—2.4L engine

9355LG78

Place the tensioner in a soft jawed vice in a level position. If there is a plug at the bottom of the tensioner use a plain washer—2.4L engine

Apply thin

Crankshaft sprocket "B"

coat of oil

o> Crankshaft

Right counter

balance shaft

ES

Spacer Chamfer 9355LG80

9355LG79

Pay attention to the direction of the flange, if it is installed in the wrong direction, the belt will break—2.4L engine

Apply engine oil to the outer surface of the spacer lightly and install the spacer to the right counterbalance shaft. Be sure to install Spacer correctly—2.4L engine

Timing belt "B"

Timing mark (on sprocket)

ie |

is Sie gd: So.

=F

(on front case) Timing mark (notch in

Barnlng park

DASE

=.=

Te)

Timing mark

Tension side

CGC

“ES

&

mA

AOC

fl

Ras

oe .

ry|

=

ee

Zz

Ss

(0) :

9) :

sprocket)

(slot in front case)

W\-Cénter of boft

9355LG81

Align the timing mark on each sprocket with its corresponding timing mark on the front case—2.4L engine

9355LG82

Align the timing mark on the right counterbalance shaft sprocket with the timing mark on the front case—2.4L engine

we ©

acy

= “7mmze 2-0.Rien)

O

a oe

©)

ing ane)

9355LG83 9355LG84

Lift the tensioner B to tighten tensioner B so that its tension side is pulled tight—2.4L engine

Make sure the timing belt Bmarks are aligned and the belt tensioner is correct—2.4L engine

Crankshaft sprocket "B"

Pin hole

Crankshaft

sprocket

Crankshaft

Fiange

9355LG86 9355LG85

Install the flange and crankshaft sprocket making sure it is installed properly —2.4L engine

Install the tensioner pulley—2.4L engine

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

'

3-1 6

TIMING BELTS

s

Dowel pin

Camshaft sprocket

.

Intake

2

86°+55'

‘

p

Timing mark i ‘

93551687

}

9355LG88

Rotate the camshaft sprockets so that the dowel pin is at the upper side, set the timing mark of the sprocket correctly—2.4L engine

Camshaft sprocket alignment—2.4L engine

s

yyy

=) Ig Timing marks KO)

NG

Timing marks

9355LG89

9355LG90

Measure the auto tensioner protrusion A—2.4L engine

Align the oil pump sprocket timing marks—2.4L engine

that 2 teeth, rotate the crankshaft sprocket counterclockwise first based on the timing mark. After the camshaft sprocket is properly timed, return the crankshaft to TDC.

A:8-10 N.m (80-100 kg.cm, 6-7 Ib.ft) B:10-12 N.m (100-120 ka.cm., 7-9 Ib.ft) 9355LG91

Timing cover bolt location and torque specificationsA—2.4L engine

35. Align the crankshaft sprocket timing marks. 36. Align the pump sprocket timing marks. 37. Install the timing belt counterclockwise around the tensioner pulley and crankshaft sprocket. Hold the belt onto the tensioner pulley using your hand. 38. Pull the belt around the oil pump sprocket using your other hand. 39. Install the belt around the right-hand idler pulley, then the intake camshaft sprocket. 40. Turn the exhaust camshaft sprocket one tooth clockwise to align its timing mark with the cylinder top surface, then pull the belt around the exhaust camshaft sprocket. 41. Raise the tensioner pulley gently so

TIMING BELTS3Q. 1 : that the belt does not sag and temporarily tighten the pulley center bolt. 42. Recheck that all timing marks are

bolts as shown in the accompanying illustration to specification as shown in the accompanying illustration.

Correct. 43. Remove the set pin from the auto tensioner. 44, Rotate the crankshaft two turns clockwise and let itsit for around 15 minutes. After 15 minutes, measure the auto tensioner protrusion A (the distance between the tensioner arm and tensioner) as shown in the accompanying illustration. The specification should be 0.24—0.35 inch

2.7L ENGINE

(6—9mm). 45. Install the timing covers. Tighten the

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the engine cover. 3. Using a 16mm wrench, rotate the tensioner arm clockwise about 14 degrees and remove the drive belt. 4. Remove the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley.

5. Remove the upper and lower timing covers. 6. Remove the timing belt tensioner. 7. Rotate the crankshaft clockwise and align the timing mark to set the No. 1 cylinder to Top Dead Center (TDC). Make sure ~ the timing marks of the camshaft sprocket and cylinder head cover should align with each other.

if reusing the belt, mark the direction of rotation on the belt to ensure proper belt installation. 8. Unbolt the tensioner and remove the belt.

Timing belt upper cover

Under cover panel

10-12 (100-120, 7-9) Crank shaft puller

. Timing belt lower cover

TORQUE : Nm (kg.cm, Ib.ft) Exploded view of the timing belt assembly—2.7L engine

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

9355LG92

OT

a

Re!

hadi

:

ol

‘ al

We

.

Engine coolant pump pulley

Timing mark

16. Install the tensioner and tighten the

Timing mark

ee

carne)

Camshaft sprocket

;

ning belt tensioner

;‘ ,

rset tak

Ba

Timing belt

18. Remove the tensioner set pin. : ‘v Adjust the timing belt tension as fol-

a. Rotate the crankshaft 2 turns clockwise and measure the projected length of the auto tensioner at TDC after being

Crankshaft sprocket

I

BS a

.

installed for 5 minutes.

__b. The projected length should be 6—8mm.

Correct timing marks alignment with the timing belt installed—2.7L engine

Make sure the timing marks are in

}

their specified positions or remove and

a

9. Hold the flange of the camshaft with

j ‘ h

a wrench, unfasten the sprocket bolts and remove the sprockets. To install: 10. Install the idler pulley on the water pump boss. 11. Install the idler pulley to the roll pin that is pressed in the water pump boss.

:

Camshaft sprocket on the right.

e Tensioner pulley

eae

if BW

-e

hand side

ab \4 es

bolt to 14-20 ft. Ibs. (20-27 Nm). 17. Align the sprocket timing marks and install the belt in the following order: Crankshaft sprocket e Idler pulley e Camshaft sprocket on the left hand side 4 e Water pump pulley

srrans side)

ay

cs

install a set pin to keep the plunger in

position.

12. Install the tensioner arm and plain

washer to the block. 13. Install the tensioner pulley to the tensioner arm. 14. Install the camshaft sprockets and align the timing marks. Tighten the bolts to 65-80 ft. Ibs. (90-110 Nm). 15. Compress the tensioner and

reinstall the belt.

20. Install the upper and lower timing belt covers. 21. Install the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley. 22. Install the drive belt. 23. Install the engine cover.

Projected length 6-8mm(0.24-0.31)

9355LG95

9355LG94

Remove the set pin from the auto tensioner—2.7L engine

The projected length of the auto tensioner at Top Dead Center (TDC) should be 6-8mm —2.7L engine

TIMING BELTS Infiniti OX4 3.3L (VG33E) ENGINE

11. Remove the crankshaft pulley bolt, then pull off the pulley with a suitable puller. 12. Remove the bolts, then remove the front upper and lower timing belt covers. 13. Set the No. 1 piston at Top Dead Center (TDC) of its compression stroke. Align the punchmark on the left camshaft sprocket with the punchmark on the timing belt upper rear cover. Align the punchmark on the crankshaft sprocket with the notch on the oil pump housing. Temporarily install the-crank pulley bolt so the crankshaft can be rotated if necessary. 14. Loosen the timing belt tensioner and

1. Remove the engine undercover, 2. Remove the radiator shroud, the fan and the pulleys.

, 3. Drain the coolant from the radiator and remove the water pump hose.

4k CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and

are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity.

return spring, then remove the timing belt. To install:

Always drain the coolant into a seal-

+ CAUTION

able container. Coolant should be reused unless it is contaminated or

Before installing the timing belt, con-

several years old.

firm that thé No. 1 cylinder is set at the TDC of the compression stroke.

4. Remove the radiator. 5. Remove the power steering, air conditioning compressor and alternator drive

belts.

15. Remove both cylinder head covers and loosen all rocker arm shaft retaining bolts.

:

>The rocker arm shaft bolts MUST be loosened so that the correct belt tension can be obtained.

6. Remove the spark plugs. 7. Remove the distributor protector (dust shield). 8. Remove the air conditioning compressor drive belt idler pulley and bracket. 9. Remove the fresh air intake tube at the cylinder head cover. 10. Disconnect the radiator hose at the thermostat housing.

16. Install the tensioner and the return spring. Using a hexagon wrench, turn the tensioner clockwise and temporarily tighten the locknut. 17. Be sure that the timing belt is clean and free from oil or water.

Aligning

=

marks

Aligning o\ Marks

OON

Oke

A

Ne of

(RAN

a

NN VOD,

AAS OOS E\XOOOW

/camshatt

owe

sprocket

: ly oS

Camshaft Sprocket

=“

(LH)

Ups. belt

(RH)

Crankshaft timing sprocket

No. 1 cylinder at TDC in compression stroke Aligning marks 79245635

9.4 Bie .

18. When installing the timing belt, align the white lines on the belt with the punchmarks on the camshaft and crankshaft sprockets. Have the arrow on the timing belt pointing toward the front belt covers. e>A good way (although rather tedious!) to check for proper timing. belt installation is to count the number of belt teeth between the timing marks. There are 133 teeth on the belt; there should be 40 teeth between the timing marks on the left and right side camshaft sprockets, and 43 teeth between the timing marks on the left side camshaft sprocket and the crankshaft sprocket.

19. While keeping the tensioner steady, loosen the locknut with a hex wrench. 20. Turn the tensioner approximately 70-80 degrees clockwise with the wrench, then tighten the locknut.

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

21. Turn the crankshaft in a clockwise direction several times, then slowly set the No. 1 piston to TDC of the compression stroke. 22. Apply 22 |bs. (10 kg) of pressure (push it in!) to the center span of the timing belt between the right side camshaft sprocket and the tensioner pulley, then loosen the tensioner locknut. 23. Using a 0.0138 in. (0.35mm) thick feeler gauge (the actual width of the blade must be % in. or 13mm!), turn the crankshaft clockwise (slowly!). The timing belt should move approximately 2’ teeth. Tighten the tensioner locknut, turn the crankshaft slightly and remove the feeler gauge. 24. Slowly rotate the crankshaft clockwise several more times, then set the No. 1 piston to TDC of the compression stroke. 25. Position the 2 timing covers on the block, then tighten the mounting bolts to 24 ft. Ibs. (35 Nm). 26. Press the crankshaft pulley onto the shaft, then tighten the bolt to 90-98 ft. Ibs. (123-132 Nm). 27. Connect the radiator hose to the thermostat housing.

Timing belt alignment mark locations—Infiniti QX4 3.3L engine

For Wheel Alignment specifications, see Section 1 of this manual

i

¥r ‘hb 4 “ : ]

i 3.90 TIMING BELTS 28. Reconnect the fresh air intake tube at the cylinder head cover. 29. Install the air conditioning compressor drive belt idler pulley and bracket. 30. Install the distributor protector (dust shield). 31. Install the spark plugs. 32. Install the power steering, air conditioning compressor and alternator drive

J-43037

ss “

33. Install the radiator.

34. Reconnect the water pump hose and

:

fill the engine with coolant. Install the fan

fe

shroud and pulleys.

4

35. Install the engine undercover.

36. Start the engine and check for any leaks.

Isuzu Amigo, Rodeo and Trooper

2.2L (X22SE/D) ENGINE

3

1. Disconnect the negative battery cable. ' 2. Using a box-end wrench on the drive belt adjuster, turn the adjuster clockwise and remove the drive belt. 3. From the left rear of the engine com-

partment, disconnect the 3 electrical con-

nectors from the chassis harness. 4. Remove the crankshaft pulley-tocrankshaft bolts and remove the pulley. 5. From the front of the engine, remove

93025612 Aligning the timing marks and installing the timing belt—Isuzu Amigo and Rodeo 2.2L (X22SE/D) engine

the nut and the engine harness cover. 6. Remove the timing belt cover. 7. Rotate the crankshaft to position the

timing marks at Top Dead Center (TDC) of the No. 1 cylinder’s compression stroke. e>Mark the rotational direction of the timing belt for reinstallation purposes.

8. Remove the timing belt tensioner adjusting bolt and the tensioner from the engine. 9. Remove the timing belt. To install: 10. Install the timing belt tensioner and finger-tighten the tensioner bolt. 11. Inspect the timing marks to be sure that the engine is positioned at TDC of the No. 1 cylinder’s compression stroke. 12. Using tool J-43037, or equivalent, place it between the intake and exhaust sprockets to prevent the camshaft gear from moving during the timing belt installation. 13. Install the timing belt. 14. Position the timing belt to ensure that the tension side of the belt is taut and move the timing belt tension adjusting lever clockwise until the tensioner pointer is flowing.

15. If installing a used timing belt (used over 60 min. from new), the pointer should

93025613

Tensioning the timing belt for a used timing belt—lsuzu Amigo and Rodeo 2.2L (X22SE/D) engine

TIMING BELTS — 3-91 be positioned approximately 0.16 in. (4mm) to the left of the “V” notch when viewed from the front of the engine. * 16. If installing a new timing belt, the pointer should be positioned at the center of the “V” notch when viewed from the front of the engine. 17. Torque the timing belt tensioner adjusting bolt to 18 ft. Ibs. (25 Nm). 18. Install the timing belt front cover and torque the bolts to 53 inch Ibs. (6 Nm). 19. Install the engine harness connectors. 20. Install the crankshaft pulley and toque the pulley-to-crankshaft bolts to 14 ft. lbs. (20 Nm). 21. Move the drive belt tensioner to the loose side and install the drive belt to its normal position. 22. Connect the negative battery cable.

3.2L AND 3.5L (6VE1) ENGINES 1. Disconnect the negative battery cable. 2. Remove the air cleaner assembly and intake air duct. 3. Remove the upper fan shroud from the radiator. 4, Remove the 4 nuts retaining the cooling fan assembly. Remove the cooling fan from the fan pulley. 5. Loosen and remove the drive belts. 6. Remove the upper timing belt covers. 7. Remove the fan pulley assembly. 8. Rotate the crankshaft to align the camshaft timing marks with the pointer dots on the back covers. Verify that the pointer on the crankshaft aligns with the mark on the lower timing cover. When the timing marks are aligned, the No. 2 piston is at Top Dead Center (TDC) compression.

79245608

&

Using a double clip to hold the belt in place—tsuzu 3.2L and 3.5L engines

Engine rotation direction

'Cylind ylinder head side

ye 2s BANDO “t's s- BANDO

>r

“S52

tsbeneseery.

BANDO

STS STS

STS

5G1000 861000

Timing belt 79245G07

For maximum timing belt life, install the belt as shown—Isuzu 3.2L and 3.5L engines

Belt tensioner

Align the camshaft and crankshaft sprockets with their alignment marks before removing the timing belt. Failure to align the belt and sprocket marks may result in valve damage.

9. Use tool No. J-8614-01, or a suitable pulley holding tool to remove the crankshaft pulley center bolt. Remove the crankshaft pulley. 10. If present, disconnect the 2 oil cooler hose bracket bolts on the timing cover.

pump

861000 =>

Pusher

93025610

View of timing belt tensioner and pusher—Isuzu 3.2L and 3.5L engines

For Maintenance Interval recommendations, see Section 1 of this manual

2.99 _TIMING BELTS Move the oil cooler hoses and bracket off of Alignment mark on

timing belt

Crankshaft gear

alignment mark

Alignment mark on oil pump

Groove on timing pulley 79245606

Proper crankshaft alignment marks for timing belt installation—Isuzu 3.2L SOHC (VIN V) engine

the lower timing cover. 11. Remove the lower timing belt cover. 12. Remove the pusher assembly (tensioner) from below the belt tensioner pulley. The pusher rod must always face upward to prevent oil leakage. Depress the pusher rod, and insert a wire pin into the hole to keep the pusher rod retracted. 13. Remove the timing belt. 14. Inspect the water pump and replace ‘it if there is any doubt about its condition. 15. Repair any oi! or coolant leaks before installing a new timing belt. If the timing belt has been contaminated with oil or coolant, or is damaged, it must be replaced. To install: 16. Verify that the sprocket timing marks are still aligned and that the groove and the keyway on the crankshaft timing sprocket align with the mark on the oil pump. The white pointers on the camshaft timing sprockets should align with the dots on the front plate. 17. Install the timing belt. Use clips to secure the belt onto each sprocket until the installation is complete. Align the dotted marks on the timing belt with the timing mark opposite the groove on the crankshaft sprocket. >The arrows on the timing belt must follow the belt’s direction of rotation. The manufacturer’s trademark on the belt’s spine should be readable left-toright when the belt is installed.

18. Align the white line on the timing belt with the alignment mark on the right bank camshaft timing pulley. Secure the belt with a clip.

+: WARNING If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves. a

1) 2) 3) 4) 5) 6)

Crankshaft timing pulley RH bank timing pulley Water pump pulley Idler pulley LH bank timing pulley Tension pulley 93025609

Timing mark alignment and timing belt routing—Isuzu 3.2L SOHC (VIN V) engine

19. Rotate the crankshaft counterclackwise to remove the slack between the crankshaft sprocket and the right camshaft timing belt sprocket. 20. Install the belt around the water pump pulley. 21. Install the belt on the idler pulley. 22. Align the white alignment mark on the timing belt with the alignment mark on the left bank camshaft timing belt sprocket. 23. Install the crankshaft pulley and tighten the center bolt by hand. Rotate the crankshaft pulley clockwise to give slack

TIMING BELTS

— 3-2 > eke

28. Tighten the pusher bolts to 14 ft. Ibs. 9 Nm)

29. Remove the crankshaft pulley. Install

the lower and upper timing belt coversand tighten their bolts to 12 ft. Ibs. (17 Nm). 30. Fit the oil cooler hose onto the tim- ing cover and tighten its mounting bracket bolts to 16 ft. Ibs. (22 Nm). 31. Install the crankshaft pulley and rai the pulley bolt to 123 ft. Ibs. (167 Nm

32. Install fan pulley assembly and tighten the bolts to 16 ft. Ibs. (22 Nm). 33. Install and adjust the accessory drive belts. 34. Install the cooling fan assembly and tighten the bolts to 72 inch Ibs. (8 Nm). 35. Install the upper fan shroud. 36. Install the air cleaner assembly and intake air duct. 37. Connect the negative battery cable. KIA Sportage

2.0L (DOHC) ENGINE 93025611

Timing mark alignment and timing belt routing—Isuzu 3.2L (VIN W) and 3.5L DOHC engines

Approx.

100 kg Direction for installation

7924511

View of timing belt tensioner pusher—tsuzu 3.2L and 3.5L engines

between the crankshaft timing belt pulley and the right bank camshaft timing belt pulley. 24. Insert a 1.4mm piece of wire through the hole in the pusher to hold the rod in. Install the pusher assembly while pushing the tension pulley toward the belt. 25. Pull the pin out from the pusher to release the rod.

26. Remove the clamps from the sprockets. Rotate the crankshaft pulley clockwise 2 turns. Measure the rod protrusion to ensure it is between 0.16—0.24 in. (46mm). 27. lf the tensioner pulley bracket pivot bolt was removed, tighten it to 31 ft. Ibs. (42 Nm).

1. Disconnect the negative battery cable. 2. Properly relieve the fuel system pressure. 3. Remove the alternator drive belt. 4. Remove the fresh air duct from the top of the radiator. 5. Remove the upper radiator hose. 6. Remove the 4 attaching nuts to the clutch fan. 7. Remove the 5 fan shroud bolts. Remove the fan and shroud as an assembly, 8. Remove the 4 splash guard mounting bolts and the splash guard. 9. Loosen the lockbolts and loosen the air conditioning drive belt. 10. Loosen the power steering lock and mounting bolt. Remove the power steering belt. 11. Remove the 5 upper timing belt cover bolts and remove the cover. 12. Remove the 2 lower timing belt cover bolts and remove the cover. 13. Align the timing marks. e>When aligning the cam pulleys with the seal plate marks, align the left cam pulley | mark and the right cam pulley on the E mark.

When aligning the timing marks, do not turn the timing gear counterclockwise. Damage to the engine will occur.

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

=

vw & tT 14. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten the tensioner bolt to relieve the pressure against the timing belt. 15. Remove the timing belt. 16. Remove the camshaft pulley attaching bolts. Use a driver placed through one of the holes in the pulley to prevent it from moving when the attaching bolt is removed. Remove and mark the pulleys. 17. Remove the lower timing belt pulley and locking bolt. To install: 18. Install the camshaft pulleys. Tighten the bolts to 35—-48 ft. Ibs. (47-65 Nm). 19. Install the lower timing belt pulley and locking bolt. Tighten the bolt to 120 ft. lbs. (162 Nm). 20. If necessary, align the timing marks.

| ry MATCHING MARK

When aligning the cam pulleys with _ the seal plate marks, align the left cam pulley “1” mark and the right cam pulley on the “E” mark.

When aligning the timing marks, do not turn the timing gear counterclockwise. Damage to the engine will occur.

79245625

Align the crankshaft marks before removing the timing belt—KIA Sportage 2.0L (DOHC) engine

21. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten tensioner bolt to relieve the pressure against the timing belt. 22. Install the timing belt.

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

23. Loosen the tensioner bolt and allow the tensioner to tighten the timing belt. Tighten the tensioner bolt 27-38 ft. Ibs. (37-52 Nm). 24. Check the timing belt deflection. If there is more than 0.30—0.33 in. (7.5-8.5mm) replace the tensioner spring. 20. Install the 2 lower timing belt cover bolts to the cover. 26. Install the 5 upper timing belt cover bolts to the cover. 27. Install and adjust the air conditioning and power steering drive belts. 28. Install the splash guard. 29. Install and tighten the alternator belt. 30. Install the upper radiator hose.

YO 1 Proper alignment of the intake and exhaust camshaft pulley timing marks—KIA Sportage 2.0L (DOHC) engine

31. Install the fan and shroud as an assembly. 32. Install the 4 attaching nuts to the clutch fan. , 33. Install the 5 fan shroud bolts. 34. Install the fresh air duct to the top of the radiator. . 35. Properly fill the cooling system. 36. Connect the negative battery cable. 37. Start the engine and check for leaks. 38. Road test the vehicle.

Silent shaft sprocket

Mitsubishi Montero and Montero Sport

2.4L (VIN G) ENGINE 1. Be sure that the engine’s No. 1 piston is at Top Dead Center (TDC) in the compression stroke.

79245630

Silent shaft alignment marks. Notice the tension side of the inner (silent shaft) belt—Mitsubishi Montero Sport 2.4L engine

*¢ CAUTION Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

s

Timing mark (punch on sprocket)

2. Disconnect the negative battery

cable.

Timing mark (on cylinder head)

J

3. Remove the spark plug wires from

f

the tree on the upper cover.

4. Drain the cooling system. 5. Remove the shroud, fan and accessory drive belts. 6. Remove the radiator as required. 7. Remove the power steering pump, alternator, air conditioning compressor, tension pulley and accompanying brackets, as required. 8. Remove the upper front timing belt cover. 9. Remove the water pump pulley and the crankshaft pulley(s). 10. Remove the lower timing belt cover mounting screws and remove the cover. 11. If the belt(s) are to be reused, mark the direction of rotation on the belt. 12. Remove the timing (outer) belt tensioner and remove the belt. Unbolt the tensioner from the block and remove. 13. Remove the outer crankshaft sprocket and flange. 14. Remove the silent shaft (inner) belt tensioner and remove the inner belt. Unbolt the tensioner from the block and remove it. 15. To remove the camshaft sprockets, use SST MB990767-01 and MIT308239 or their equivalents.

Nie Timing mark (on front case)

‘Timing mark

(notch in atk

Timing mark (notch in sprocket) 79245631

Timing belt pulley alignment marks—Mitsubishi Montero Sport 2.4L engine

To install:

16. Install the camshaft sprockets and tighten the center bolt to 65 ft. Ibs. (90 Nm). 17. Align the timing mark of the silent shaft belt sprockets on the crankshaft and

silent shaft with the marks on the front case.

Wrap the silent shaft belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are aligned. 18. Install the tensioner initially so the

For complete service labor times, order the Chilton Labor Guide

3.96 TIMING BELTS ~ actual center of the pulley is above and to the left of the installation bolt. 19. Move the pulley up by hand so the center span of the long side of the belt deflects about Y% in. (6mm). 20. Hold the pulley tightly so it does not rotate when the bolt is tightened. Tighten the bolt to 15 ft. Ibs. (20 Nm). If the pulley has moved, the belt will be too tight. 21. Install the timing belt tensioner fully toward the water pump and temporarily tighten the bolts. Place the upper end of the spring against the water pump body. Align the timing marks of the cam, crankshaft and oil pump sprockets with the corresponding marks on the front case or head. e>if the following steps are not followed exactly, there is a chance that

the silent shaft alignment will be 180 degrees off. This will cause a noticeable vibration in the engine and the

entire procedure will have to be repeated.

22. Before installing the timing belt, ensure that the left side silent shaft is in the correct position. >It is possible to align the timing marks on the camshaft sprocket, crankshaft sprocket and the oil pump sprocket with the left balance shaft out of alignment.

23. With the timing mark on the oil pump pulley aligned with the mark on the front case, check the alignment of the left balance shaft to assure correct shaft timing. a. Remove the plug located on the left side of the block in the area of the starter. b. Insert a tool having a shaft diameter of 0.3 in. (8mm) into the hole. c. With the timing marks still aligned, the tool must be able to go in at least 23

in. If it can only go in about 1 inch, turn the oil pump sprocket one complete revolution. d. Recheck the position of the balance shaft with the timing marks realigned. Leave the tool in place to hold the silent shaft while continuing. 24. Install the belt to the crankshaft sprocket, oil pump sprocket and the camshaft sprocket, in that order. While doing so, be sure there is no slack between the sprockets except where the tensioner will take it up when released. 29. Recheck the timing marks’ alignment. 26. If all are aligned, loosen the tensioner mounting bolt and allow the tensioner to apply tension to the belt.

27. Remove the tool that is holding the silent shaft in place and turn the crankshaft clockwise a distance equal to 2 teeth of the camshaft sprocket. This will allow the tensioner to automatically tension the belt the proper amount.

2k WARNING Do not manually apply pressure to the tensioner. This will over tighten the belt and will cause a howling noise. 28. First tighten the lower mounting bolt and then tighten the upper spacer bolt.

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves. 29. To verify that belt tension is correct, check that the deflection of the longest span (between the camshaft and oil pump sprockets) is ¥% in. (13mm). 30. Install the lower timing belt cover. Be sure the packing is properly positioned in the inner grooves of the covers when installing. 31. Install the water pump pulley and the crankshaft pulley(s). 32. Install the upper front timing belt cover. : 33. Install the power steering pump, alternator, air conditioning compressor, tension pulley and accompanying brackets, as required. 34. Install the radiator, shroud, fan and accessory drive belts. 35. Install the spark plug wires to the tree on the upper cover. 36. Refill the cooling system. 37. Connect the negative battery cable. Start the engine and check for leaks.

1998 3.0L (VIN P) ENGINES 1. Position the engine with No. 1 cylinder at Top Dead Center (TDC) of the compression stroke. 2. Disconnect the negative battery cable. 3. Drain the cooling system. Remove the drive belts.

ek CAUTION-. Never open, service or drain ator or cooling system when serious burns can occur from steam and hot coolant. Also,

the radihot; the when

draining engine coolant, keep in mind that cats and dogs are attracted — to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old. 4. Remove the upper radiator shroud. 5. Remove the fan and fan pulley. 6. Without disconnecting the lines, remove the power steering pump from its bracket and position it aside. Remove the pump brackets. 7. Remove the belt tensioner pulley bracket. 8. Without releasing the refrigerant, remove the air conditioning compressor from its bracket and position it aside. Remove the bracket. 9. Remove the cooling fan bracket. 10. On some vehicles, it may be necessary to remove the pulley from the crankshaft to access the lower cover bolts. 11. Remove the timing belt cover bolts, and the upper and lower covers from the engine. 12. If the same timing belt will be reused, mark the direction of the timing belt's rotation, for installation in the same direction. Be sure engine is positioned so that the No. 1 cylinder is at TDC of its compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators. 13. Loosen the timing belt tensioner bolt and remove the belt. If not removing the tensioner, position it as far away from the center of the engine as possible and tighten

the bolt. x 14. If tensioner is being removed, mark outside of the spring to ensure that it is not installed backwards. Unbolt the tensioner and remove it along with the spring. 15. Using SST MB990767-01 and MIT308239 or their equivalents, remove the camshaft sprockets. To install: 16. Hold the hexagonal portion of the camshaft with a wrench when tightening the

camshaft sprocket bolt and tighten to 64 ft. lbs. (88 Nm). 17. If removed, install the tensioner and hook the upper end of the spring to the water pump pin. Install the lower end of the spring to the tensioner in exactly the same position as originally installed. _ 18. Position both camshafts so the timing marks align with those on the alternator

Pe

TIMING BELTS

Camshaft sprocket (RH)

ees

3.97 “a

Camshaft sprocket (LH) Timing marks

Crankshaft sprocket 79245633

Be sure to align the timing marks before removing or installing the timing belt—Mitsubishi 1999-01 3.0L (VIN H) and 3.5L (VIN M and R) engines

bracket (rear bank) and inner timing cover (front bank). Rotate the crankshaft so the timing mark aligns with the mark on the oil pump. 19. Install the timing belt on the crankshaft sprocket, and while keeping the belt tight on the tension side (right side), install the belt on the front camshaft sprocket. 20. Install the belt on the water pump pulley, then the rear camshaft sprocket and the tensioner.

21. Rotate the front camshaft counterclockwise to tension the belt between the front camshaft and the crankshaft. If the tim-

ing marks came out of line, repeat the procedure.

22. Install the crankshaft sprocket flange. 23. Loosen the tensioner bolt and allow

the spring to tension the belt.

If any binding is felt when adjusting the timing belt tension by turning the

crankshaft, STOP turning the engine, because the pistons may be hitting the valves. 24. Slowly turn the crankshaft 2 full turns in the clockwise direction until the timing marks align. Now that the belt is properly tensioner, tighten the tensioner lockbolt to 35 ft. Ibs. (48 Nm). 25. Install the upper and lower covers to the engine and secure with the retaining screws. Be sure the packing is positioned in

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TIMING BELT S Able

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the inner grooves of the covers properly when installing.

— 26. Install the crankshaft pulley if it was removed. Tighten the bolt to 110 ft. Ibs. (150 Nm).

27.

Install the air conditioning bracket

and compressor on the engine. Install the belt tensioner. 28. Install the power steering pump into position. Install the fan pulley and fan. 29. Install the fan shroud to the radiator. 30. Refill the cooling system. 31. Connect the negative battery cable.

MD998715

MB990767 93025614

i)Start the engine and check for fluid leaks. eke

1999-01 3.0L (VIN H) AND 3.5L (VIN

ie Rem,

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Removing or installing Pan besanaetnesataes

the crankshaft pulley bolt—Mitsubishi 1999-01 3.0L (VIN H) and 3.5L

M AND R) ENGINES

1. Disconnect the negative battery ADICK pt _ _ 2, Drain the engine coolant and store it for reinstallation. Remove the upper radiator

3. Remove the cooling fan shroud assembly, 4. Remove the cooling fan-to-clutch bolts and the fan.

hose.

5. Remove the cooling fan clutch-

CAMSHAFT

to-water pump nuts and the clutch assembly. 6. Remove the drive belts for the alternator, power steering pump and air conditioning compressor.

cap

SPROCKET SPROCKET (RIGHT SIDE)

(LEFT SIDE)

TIMING

TIMING

TENSION PULLEY

TIMING MARK

CRANKSHAFT SPROCKET 93025615

View of the timing belt alignment marks—Mitsubishi 1999-01 3.0L (VIN H) and 3.5L (VIN M and R) engines

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SAS,

TIMING BELTS. 3-29 A

7. Disconnect the electrical connectors from the alternator.

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8. Remove the alternator-to-engine

bolts and the alternator bracket-to-engine bolts; then, remove the alternator and bracket from the engine. 9. Remove the power steering pump cover. Remove the power steering pump-toengine bolts and move the pump aside with the hoses and electrical connector attached. 10. Remove the air conditioning compressor-to-bracket bolts and move the compressor aside with the lines and electrical connector attached. 11. Remove the air conditioning compressor bracket-to-engine bolts and the bracket. 12. Remove the timing indicator bracket (near crankshaft pulley) bolts and the bracket. 13. Remove the accessory mount assembly-to-engine bolts and the mount assembly. 14. Remove the upper timing belt cover assembly. 15. Using the End Yoke Holder tool

AMOUNT PUSHED IN ©

PUSHROD AUTO-TENSIONER 93025616

Inspecting the auto-tensioner movement—Mitsubishi 1999-01 3.0L (VIN H) and 3.5L (VIN M

& SAY FH

MD990767 and 2 Crankshaft Pulley Holder Pin tools MD998745, or equivalent to hold the crankshaft pulley, and a socket wrench, remove the crankshaft pulley bolt and the pulley. 16. Remove the lower timing belt cover. 17. Rotate the crankshaft clockwise to align the timing marks to position the No. 1 cylinder at the Top Dead Center (TDC) of its compression stroke. 18. Use chalk to mark the rotating (clockwise) direction of the timing belt for reinstallation purposes. 19. Loosen the auto-tensioner pulley center bolt and remove the timing bolt. 20. Remove the auto-tensioner pulley and the auto-tensioner arm assembly. To install: 21. Press the end of the auto-tensioner inward with 72-145 ft. Ibs. (98-196 Nm) of force and measure the distance that the pushrod is pushed in. If the standard distance is not 0.04 in. (1mm), replace the auto-tensioner. 22. Position the auto-tensioner in a softjawed vise and SLOWLY compress the pushrod until the pushrod and housing holes align; then, install a setting pin to secure the auto-tensioner in the retracted position. 23. Align the camshaft and crankshaft TDC timing marks. 24. Install the timing belt (noting its

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Ls 93025617

Adjusting the timing belt tensioner pulley—Mitsubishi 1999-01 3.0L (VIN H) and 3.5L (VIN M and R) engines

VA

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po \

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TIMIN MARK

\ 93025618

Using crankshaft spacer tool to rotate the crankshaft—Mitsubishi 1999-01 3.0L (VIN H) and 3.5L (VIN M and R) engines

Timing belt service is covered in Section 3 of this manual

3.30 “TIMING BELTS ~ q

Sa al

a

rotational direction)so that there is no

deflection between the sprockets and pulleys in the following manner: e Crankshaft sprocket e Idler pulley e Left camshaft sprocket e Water pump pulley e Right camshaft sprocket e Tension pulley

29. Turn the camshaft sprocket counter-

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clockwise until the tension side of the timing belt is firmly stretched, then, recheck the timing marks. 26. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, push the tensioner pulley into the timing belt and secure the center bolt. 27. Using the Crankshaft Pulley Spacer tool MD998769, or equivalent, rotate the crankshaft V4 turn counterclockwise, then, turn it again clockwise to align the timing marks, 28. Loosen the timing belt tensioner center bolt. Using the Tension Pulley Socket Wrench tool MD998767, or equivalent, and a torque wrench, apply 39 inch Ibs. (4.4 Nm) pressure on the timing belt. Torque the tensioner pulley center bolt to 35 ft. Ibs. (48 Nm). 29. Remove the setting pin from the auto-tensioner. 30. Rotate the crankshaft 2 complete revolutions and realign the timing marks. Then, wait for 5 minutes until the auto-tensioner pushrod extends to its standard value. If the standard value is not 0.15—0.20 in. (3.8-5.0mm), repeat the adjustment procedure. If the standard value is still not achieved, replace the auto-tensioner. 31. Install the lower timing belt cover and crankshaft pulley. 32. Using the End Yoke Holder tool MD990767 and 2 Crankshaft Pulley Holder Pin tools MD998715, or equivalent to hold the crankshaft pulley, and a socket torque wrench, torque the crankshaft pulley bolt to 134 ft. Ibs. (181 Nm). 33. Install the upper timing belt cover assembly. 34. Install the remaining items by reversing the removal procedures. 35. Refill the cooling system. 36. Connect the negative battery cable.

“ ee

3. Drain the coolant from the radiator

and remove the water pump hose. —

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

4. Remove the radiator. 5. Remove the power steering, air conditioning compressor and alternator drive belts. 6. Remove the spark plugs. 7. Remove the distributor protector (dust shield). 8. Remove the air conditioning compressor drive belt idler pulley and bracket. 9. Remove the fresh air intake tube at the cylinder head cover. 10. Disconnect the radiator hose at the thermostat housing. 11. Remove the crankshaft pulley bolt, then pull off the pulley with a suitable puller. 12. Remove the bolts, then remove the front upper and lower timing belt covers. 13. Set the No. 1 piston at Top Dead Center (TDC) of its compression stroke. Align the punchmark on the left camshaft

« CAUTION Before installing the timing belt, confirm that the No. 1 cylinder is set at the TDC of the compression stroke. 15. Remove both cylinder head covers and loosen all rocker arm shaft retaining bolts. >The rocker arm shaft bolts MUST be loosened so that the correct belt tension can be obtained.

16. Install the tensioner and the return spring. Using a hexagon wrench, turn the tensioner clockwise and temporarily tighten the locknut. 17. Be sure that the timing belt is clean and free from oil or water. 18. When installing the timing belt, align the white lines on the belt with the punchmarks on the camshaft and crankshaft sprockets. Have the arrow on the timing belt pointing toward the front belt covers. eA good way (although rather tedious!) to check for proper timing belt installation is to count the number of belt teeth between the timing marks.

Aligning marks

ORE

o\

Aligning Marks

Camshaft sprocket. Camshaft Sprocket

SS

(RH)

Nissan Pathfinder

Crankshaft timing Sprocket

3.0L (VG30E) AND 3.3L (VG33E) ENGINES 1. Remove the engine undercover. 2. Remove the radiator shroud, the fan and the pulleys.

sprocket with the punchmark on the timing belt upper rear cover. Align the punchmark on the crankshaft sprocket with the notch on the oil pump housing. Temporarily install the crank pulley bolt so the crankshaft can be rotated if necessary. 14. Loosen the timing belt tensioner and return spring, then remove the timing belt. To install:

(LH) No. 1 cylinder at TDC in compression stroke Aligning marks 79245635

Timing belt alignment mark locations—Nissan Pathfinder 3.0L (VG30E) and 3.3L (VG33E)

engines

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There are 133 teeth on the belt; there should be 40 teeth between the timing

marks on the left and right side camshaft sprockets, and 43 teeth

between the timing marks on the left side camshaft sprocket and the crankshaft sprocket.

19. While keeping the tensioner steady, loosen the locknut with a hex wrench. 20. Turn the tensioner approximately 70-80 degrees clockwise with the wrench, then tighten the locknut.

i WARNING If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves. 21. Turn the crankshaft in a clockwise direction several times, then slowly set the No. 1 piston to TDC of the compression stroke. 22. Apply 22 Ibs. (10 kg) of pressure (push it in!) to the center span of the timing belt between the right side camshaft sprocket and the tensioner pulley, then loosen the tensioner locknut. 23. Using a 0.0138 in. (0.35mm) thick feeler gauge (the actual width of the blade must be % in. or 13mm!), turn the crankshaft clockwise (Slowly!). The timing belt should move approximately 21% teeth. Tighten the tensioner locknut, turn the crankshaft slightly and remove the feeler gauge. 24. Slowly rotate the crankshaft clockwise several more times, then set the No. 1 piston to TDC of the compression stroke. 25. Position the 2 timing covers on the block, then tighten the mounting bolts to 24 ft. Ibs. (35 Nm). 26. Press the crankshaft pulley onto the shaft, then tighten the bolt to 90-98 ft. Ibs. (123-132 Nm). 27. Connect the radiator hose to the thermostat housing. 28. Reconnect the fresh air intake tube at the cylinder head cover. 29. Install the air conditioning compressor drive belt idler pulley and bracket. 30. Install the distributor protector (dust shield). 31. Install the spark plugs. 32. Install the power steering, air conditioning compressor and alternator drive belts. 33. Install the radiator.

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34. Reconnect the water pump hose and fill the engine with coolant. Install the fan shroud and pulleys. 35. Install the engine undercover. 36. Start the engine and check for any leaks. Subaru Forester

2.5L DOHC ENGINE When servicing the timing belt, note the following: e The intake and exhaust camshafts can be rotated independently when the timing belt is removed. If the intake and exhaust valves are lifted off of their seats simultaneously, their heads will contact each other, possi bly causing damage.

7

TIMING BELTS 3.94

Sere

-, ere

e When the timing belt is removed, the camshafts are positioned so that none of the

valves are lifted off of their seats, resulting ina “zero-lift’ position.

¢ The left-hand cylinder head camshafts must be rotated from the “zero-lift” position as little as possible when orienting it for timing belt installation, otherwise possible valve head interference may occur. e Never allow the camshafts to rotate in the direction shown in the accompanying illustration, which would cause both the intake and exhaust valves to lift simultaneously, causing interference. 1. Remove all necessary components to gain access to the timing belt. 2. If equipped with manual transmissions, loosen the 2 timing belt guide

XQ

Rotate direction Rotate

direction

EE

7924562

only a if the camshafts must be rotated, do not turn them in toward each other (upper diagram); engine DOHC 2.5L Forester aru diagram)—Sub (lower other each rotate them away from

Heater Core replacement is covered in Section 2 of this manual

Timing belt guide (MT vehicles only)

(2) (3)

Belt idler Timing belt

(4)

Alignment marks 79245648

Timing belt routing and timing belt guide (manual transmission equipped vehicles only) location—Subaru Forester 2.5L DOHC engine

Alignment mark

Notch

Belt cover

Belt cover

Notch yp

Ngee Crank

(single line)

Alignment mark (single line)

sprocket

Alignment mark

Intake camshaft

Intake camshaft

sprocket

sprocket

Alignment mark

Alignment mark

(double line)

(double line) N

: we)

Wf

4

Notch

(

Belt cover

Belt cover Exhaust camshaft Alignment mark (single line)

sprocket

Alignment mark (single tine}

Exhaust

camshaft

sprocket 79245649

Before removing the timing belt, turn the crankshaft sprocket until all of the alignment marks are aligned as indicated—Subaru Forester 2.5L DOHC engine

or

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tit Maar) a so

TIMING BELTS

3-33 a

mounting bolts, then separate the guide from the engine block. 3. Ifthe directional arrow and alignment marks on the timing belt are faded, and the belt is to be reused, remark the belt with white paint or a grease pencil as follows:

a. Using a Subaru tool No. ST499987500 Crankshaft Socket, or equivalent, installed on the crankshaft sprocket, rotate the crankshaft until the crankshaft sprocket, left-hand exhaust camshaft sprocket, left-hand intake

camshaft sprocket, right-hand intake 79245650

camshaft sprocket and right-hand exhaust camshaft sprocket timing mark Fi . .

On models equipped with a manual transmission, loosen the 2 timing belt guide bolts and sep-

Mess tehail

arate the guide from the engine block—Subaru Forester 2.5L DOHC engine

block

ee

b. Make alignment and/or arrow marks on the timing belt in relation to the sprockets as indicated in the accompanying illustration. e 71: 54.5 tooth length e 72:51 tooth length e 73: 28 tooth length 4. Loosen the center bolt from the timing belt idler pulley, then remove the idler pulley from the engine block.

rene If the original marks on the timing belt are worn or faded, make new alignment marks in the positions indicated—Subaru Forester 2.5L DOHC engine

(1)

Belt idler

(2)

Belt idler No. 2

After removing the timing belt, DO NOT rotate the camshafts. Damage to the valves may occur.

(3) Automatic belt tension adjuster ASSY

79245652

Forester 2.5L DOHC engine It is necessary to remove the automatic adjuster assembly and reset the pushrod for timing belt installation—Subaru

Brake service is covered in Section 4 of this manual

BELTS

79245G53

79245654

Never bend the timing belt into a radius tighter than 2.36 in./60mm (bh), otherwise it will be damaged beyond use—Subaru Forester 2.5L DOHC engine

Use a vertical press to push the adjuster rod into its housing until it is flush with the assembly’s outer surface . . . —Subaru Forester

2.5L DOHC engine

moke

Alignment mark

xm

Stopper pin

79245655

. . . then insert a 0.08 in. (2mm) diameter pin or Allen wrench into the housing and rod holes to hold it in position—Subaru Forester

2.5L DOHC engine

5. Carefully remove the timing belt from all of the sprockets. 6. Remove the automatic belt tension adjuster assembly as follows: a. Remove the 2 timing belt idler pulleys, as indicated in the accompanying illustration. b. Loosen the automatic tension adjuster assembly mounting bolts, then separate the adjuster assembly from the engine block. To install:

Do not allow oil, grease, or coolant to come in contact with the timing belt. If this occurs, quickly and thoroughly remove all traces of the compound. Also, never bend the timing

If the camshaft sprockets are no longer aligned, rotate the crankshaft sprocket until the marks are aligned . . .—Subaru Forester 2.5L DOHC engine

belt sharply; the minimum bending radius is 2.36 in. (60mm). 7. Inspect the camshaft and crankshaft sprocket teeth for abnormal or excessive wear or scratches. Ensure there is no freeplay between the sprocket and the key. Inspect the crankshaft sprocket sensor notch for damage or contamination with debris or dirt. e>When preparing the automatic tension adjuster assembly for installation, adhere to the following points:

e Always use a vertical press, rather than a horizontal press or vise, to depress the adjuster assembly rod e Depress the adjuster rod in a vertical position ONLY

e Depress the adjuster rod slowly (taking more than 3 minutes) with a force of 66 Ibs. (30 kg) Do not allow the press force to

exceed 2205 Ibs. (1000 kg) Press the adjuster rod in as faras the end surface of the cylinder—do not press the rod into the cylinder, which may cause damage to the assembly Do not release the press force from the rod until the stopper pin is completely inserted in the cylinder 8. Prepare the automatic timing belt tension adjuster assembly for installation as follows: a. Position the adjuster assembly in a vertical press. b. Slowly depress the adjuster rod

TIMING BELTS

i

3-35 a

Alignment mark (single line) Alignment mark (single line)

it

Alignment mark — Exhaust camshaft sprocket RH 79245657

79245G58

Spin the right-hand intake camshaft sprocket so that the single line mark is aligned with the notch in the belt cover—at this point, the double line marks on both right-hand camshaft sprockets must be aligned—Subaru Forester 2.5L DOHC engine

. . . then turn the right-hand exhaust camshaft until the single line mark is aligned with the notch in the belt cover—Subaru Forester

2.5L DOHC engine

Notch * }

AGA)

Alignment

mark (single line)

oN | Intake camshaft Ni serce LH

|

Alignment mark (single line)

iy, Alignment mark

apa | |(double line) 79245G60

79245659

Rotate the left-hand exhaust camshaft until the single line mark is aligned with the notch in the belt cover. . .—Subaru Forester 2.5L DOHC engine

(GS

. . . then align the single line mark on the left-hand intake sprocket with the belt cover notch—Subaru Forester 2.5L DOHC engine

@O

Be CO

G) 79245G61

2.5L DOHC engine After orienting all 5 sprockets, the alignment marks should be positioned as shown—Subaru Forester

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

+ 3-36

7

TIMING

BELTS

with a force of 66 Ibs. (30 kg) until the hole in the rod is aligned with the hole in the adjuster cylinder housing. c. Insert a 0.08 in. (2mm) diameter stopper pin or Allen wrench through the hole in the cylinder housing and rod, then slowly release the press force from the adjuster rod. 9. Install the adjuster assembly onto

~ the engine block.

10. Install timing belt idler pulley No. 2 on the engine block. 11. Install the timing belt idler pulley No. 1 on the engine block. 12. If the camshaft and crankshaft timing marks are no longer aligned, perform the following: a. Position the crankshaft sprocket so that its mark is aligned with the mark on the oil pump cover on the engine block. b. Align the single line mark on the right-hand exhaust camshaft sprocket with the notch on the belt cover. c. Rotate the right-hand intake camshaft so that the single line mark is aligned with the notch on the belt cover. e>At this point, the double line marks on both right-hand camshaft sprockets should be aligned.

d. Turn the left-hand exhaust (lower) camshaft counterclockwise (as viewed from the front of the engine) until the single line mark is aligned with the notch on the belt cover. é. Position the single line mark on

the left-hand intake camshaft sprocket so that it is aligned with the notch on the belt cover. When rotating the camshaft, do so only in a clockwise direction (as viewed from the front of the engine). e>At this point, the double line marks on both left-hand camshaft sprockets should be aligned. f. Ensure the timing marks are aligned as shown in the accompanying illustration. If they are not, repeat SubSteps 12a through 12e until they are properly aligned. 13. Install the timing belt around the camshaft, crankshaft and idler pulleys so that the positioning marks on the timing belt are aligned with the marks on the sprockets as follows: a. Position the timing belt on the crankshaft sprocket so that the marks are aligned. b. Route the belt down and under the left-hand, upper idler pulley, then up and around the left-hand intake camshaft sprocket, ensuring the camshaft sprocket mark is aligned with the mark on the belt. c. Route the belt down and around the left-hand exhaust camshaft sprocket, making sure the marks are properly aligned, then up and over the first lower idler pulley and down and around the second lower idler pulley. d. While holding the timing belt on the inner, left-hand, lower idler pulley, route the other side of the timing belt

Arrow

28 tooth length

mark

(from the crankshaft sprocket) down and under the right-hand upper idler pulley. e. Route the timing belt up and around the right-hand intake camshaft sprocket so that the belt and sprocket marks are aligned.

f, Position the belt down and around the right-hand exhaust camshaft sprocket, ensuring the positioning marks ~ are aligned. 14. Install the right-hand lower idler pulley so that the timing belt is routed over the top side of it. Once the belt is completely installed on all of the pulleys and sprockets, ensure that the positioning marks are still all aligned. . 15. After ensuring all of the marks are still aligned, use a pair of pliers to withdraw the stopper pin or Allen wrench from the adjuster assembly housing. 16. On models with manual transmissions, perform the following: a. Install the timing belt guide by temporarily tightening the mounting bolts. b. Position the timing belt guide so that there is 0.019-0.059 in. (0.5—1.5mm) clearance between the timing belt and the belt guide. c. Tighten the guide mounting bolts securely, then double check the guide clearance. 17. Install the timing belt covers and all remaining engine components.

Timing belt

28 tooth length

51 tooth length

(A)

7

Install

it in the end.

(oye

alee 79245663

When installing the timing belt, be sure to route it in the proper order (a through e), and ensure that all of the matchmarks are properly aligned— Subaru Forester 2.5L DOHC engine

TIMING BELTS

3-37

5. Remove the timing belt tensioner, tensioner plate and spring from the engine.

6. Install Suzuki tool 09917-68220, or equivalent, onto the camshaft sprocket to hold the camshaft from rotating. Loosen the camshaft sprocket retaining bolt, then pull the camshaft sprocket off of the end of the camshaft. 7. Remove the crankshaft timing belt sprocket by loosening the center bolt, while preventing the crankshaft from rotating. To hold the crankshaft from turning, use Suzuki tool 09927-56010, or equivalent, or a large prybar inserted in the transmission housing Slot and the flywheel teeth. Pull the sprocket off of the end of the crankshaft. Be sure to retain the crankshaft sprocket key and belt 79245664

On models equipped with manual transmissions, ensure the timihg belt-to-guide clearance (arrows) is correct before tightening the mounting bolts—Subaru Forester 2.5L DOHC engine

Suzuki Sidekick, Vitara and X-90

->During these procedures, identify all components removed from the engine so that they may be reinstalled in their original positions. If discarding the old components so that new components can be installed, identifying the old items is not necessary.

7.6L 16-VALVE ENGINE The 1.6L 16-valve engine is known as an interference motor, because it is fabricated with such close tolerances between the pistons and valves that, if the timing belt is incorrectly positioned, jumps teeth on one of the sprockets or breaks, the valve and pistons will come into contact. This can cause severe internal engine damage.

Do not rotate the crankshaft or camshaft once the timing belt is removed, because the valves and pistons can come into contact, which may cause internal engine damage. 4, Disconnect one end of the tensioner spring. Loosen the timing belt tensioner bolt and stud, then, using your finger, press the tensioner plate up and remove the timing belt from the crankshaft and camshaft sprockets.

guide for assembly. 8. If necessary, remove the timing belt inside cover from the cylinder head. To install: 9. If necessary, install the timing belt inside cover.

10. Slide the timing belt guide on the crankshaft so that the concave side faces the oil pump, then install the sprocket key in the groove in the crankshaft. 11. Slide the pulley onto the crankshaft, and install the center retaining bolt. Tighten the center bolt to 80 ft. Ibs. (110 Nm). To hold the crankshaft from turning, use Suzuki tool 09927-56010, or equivalent, or a large prybar inserted in the transmission housing slot and the flywheel teeth. 12. Install the timing belt camshaft sprocket, ensuring that the slot in the sprocket engages the camshaft (pulley)

Do not rotate the crankshaft counterclockwise or attempt to rotate the crankshaft by turning the camshaft sprocket. 1. Remove the timing belt cover. 2. If the timing belt is not already marked with a directional arrow, use white paint, a grease pencil or correction fluid to do so. 3. Rotate the crankshaft clockwise until the timing mark on the camshaft sprocket and the “V” mark on the timing belt inside cover are aligned, and the punch mark on the crankshaft sprocket is aligned with the mark on the engine.

5

\

1. 2.

"V" mark Timing mark by

"Ee"

79245622

Camshaft timing marks—Suzuki Sidekick, Vitara and X-90 1.6L 16-valve engine

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

mv. wie) | D Rak

Be oP ARN

3-38

TIMING BELTS Tighten the mounting bolt and stud only finger-tight at this time. Ensure that when the tensioner is moved in a counterclockwise direction, the tensioner moves in the same direction. If the tensioner does not move, remove it and the tensioner plate to

reassemble them properly. 15. Loosen all rocker arm valve lash

locknuts and adjusting screws. This will permit movement of the camshaft without

1. 2.

Arrow mark Punch mark 79245623

Align the punch mark with the arrow for proper timing belt installation—Suzuki Sidekick, Vitara and X-90 1.6L 16-valve engine

1.

“V" mark on cylinder head cover

2. Timing mark by "E” on camshaft timing belt pulley Arrow mark on oil pump case Punch mark on

3. 4.

crankshaft timing belt pulley

any rocker arm associated drag, which is essential for proper timing belt tensioning. If the camshaft does not rotate freely (free of rocker arm drag), the belt will not be properly tensioned. 16. Rotate the camshaft sprocket clockwise until the timing mark on the sprocket and the “V” mark on the timing belt inside cover are aligned. 17. Using a wrench, or socket and breaker bar, on the crankshaft sprocket center bolt, turn the crankshaft clockwise until the punch mark on the sprocket is aligned with the arrow mark on the oil pump. 18. With the camshaft and crankshaft marks properly aligned, push the tensioner up with your finger and install the timing belt on the 2 sprockets, ensuring that the drive side of the belt is free of all slack. Release your finger from the tensioner. Be sure to install the timing belt so that the directional arrow is pointing in the appropriate direction. e>in this position, the No. 4 cylinder is at Top Dead Center (TDC) on the compression stroke.

19. Rotate the crankshaft clockwise 2 full revolutions, then tighten the tensioner stud to 97 inch Ibs. (11 Nm). Then, tighten the tensioner bolt to 18 ft. Ibs. (24 Nm). 20. Ensure that all 4 timing marks are still aligned as before; if they are not, remove the timing belt, and install and tension it again. 21. Install the timing belt cover and all related components.

79245647

Rotate the crankshaft clockwise until the camshaft and crankshaft timing marks are aligned— Suzuki Sidekick, Vitara and X-90 1.6L 16-valve engine

pin; this ensures that the sprocket is prop-

erly positioned on the end of the

camshaft. Secure the camshaft with the holding tool used during removal, then tighten the sprocket bolt to 44 ft. Ibs. (60

Nm).

c

13. Assemble the timing belt tensioner plate and the tensioner, making sure that the lug of the tensioner plate engages the tensioner.

stk WARNING

'

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine,

because the pistons may be hitting

the valves.

SS 2

14. Install the timing belt tensioner, tensioner plate and spring on the engine.

Toyota 4Runner

4

3.4L (5VZ-FE) ENGINE 1. Disconnect the negative battery cable.

+ CAUTION Wait 90 seconds from the time the key is turned to LOCK and the negative battery cable is disconnected to begin work. This allows the SRS capacitor to discharge and prevent deployment of the air bag(s).

TIMING BELTS

3-39

a

a

Ye

2. Raise and safely support the vehicle. 3. Remove the engine undercover. 4. Drain the engine coolant.

Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old. 5. Disconnect the upper radiator hose from the engine. 6. Remove the power steering drive belt. 7. Remove the.air conditioning drive belt by loosening the idler pulley nut and the adjusting bolt.8. If equipped with air conditioning, disconnect the compressor from the engine and set aside. Do not disconnect the lines from the compressor. 9. If equipped with air conditioning, disconnect the air conditioning bracket. 10. Remove the fan with the fluid coupling and fan pulleys. 11. Loosen the lockbolt, pivot bolt, and the adjusting bolt and the alternator drive Delt. 12. Remove the No. 2 fan shroud by removing the 2 clips. 13. Disconnect the power steering pump from the engine and set aside. Do not disconnect the lines from the pump. 14. Remove the oil dipstick and the guide. 15. Remove the No. 2 timing belt cover as follows: a. Detach the camshaft position sensor connector from the No. 2 timing belt cover. b. Disconnect the 4 spark plug wire clamps from the No. 2 timing belt cover. c. Remove the 6 bolts and remove the timing belt cover. 16. Remove the fan bracket as follows: a. Remove the power steering adjusting strut by removing the nut. b. Remove the fan bracket by removing the bolt and nut:

17. Using SST 09213-54015, or equivalent, remove the crankshaft pulley. 18. Remove the starter wire bracket and the No. 1 timing belt cover. 19. Remove the timing belt guide. 20. Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke, as follows: a. Temporarily install the crankshaft pulley bolt to the crankshaft. b. Turn the crankshaft and align the timing marks of the crankshaft timing pulley and the oil pump body. c. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley one revolution (360 degrees). aif reusing the timing belt, be sure that you can still read the installation marks. If not, place new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys.

21. Remove the timing belt tensioner by alternately loosening the 2 bolts. 22. Remove the right and left camshaft pulleys. 23. Remove the No. 2 idler pulley. 24. Using a 10mm hex wrench, remove the pivot bolt, No. 1 idler pulley and the plate washer. 25. Remove the timing belt guide and remove the timing belt.

26. Remove the crankshaft timing pulley. To install: 27. Install the crankshaft timing belt pulley, as follows: a. Align the timing belt pulley set key with the key groove of the timing pulley and slide on the timing pulley. . b. Slide on the timing belt pulley with the flange side facing inward. 28. Install the plate washer and the No. 1 — idler pulley with the pivot bolt and tighten it to 26 ft. Ibs. (35 Nm). Check that the pulley bracket moves smoothly. 29. Install the No. 2 timing belt idler with the bolt. Tighten the bolt to 30 ft. Ibs. (40 Nm). Check that the pulley bracket moves smoothly. 30. Install the left and right camshaft timing pulleys. 31. Set the No. 1 cylinder to TDC of the compression stroke, as follows: a. Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and the oil pump body. b. Using SST 09960-10010, or equivalent, to turn the camshaft pulley to align the marks of the camshaft timing belt pulley and the No. 3 timing belt cover. 32. Install the timing belt, as follows: e>The engine should be cold. a. Face the front mark on the timing belt forward. b. Align the installation mark on the

EAS Wy

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J

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x Ky) 79245638

Crankshaft and camshaft timing mark locations—Toyota 4Runner 3.4L (5VZ-FE) engine

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

DCT

ee sh *? Gg”

E acan TIMING BELTS timing belt with the timing mark of the crankshaft timing pulley. c. Align the installation marks on the timing belt with the timing marks of the camshaft pulleys. 33. Install the timing belt in the following order: e Left camshaft pulley e No. 2 idler pulley e Right camshaft pulley e Water pump pulley e Crankshaft pulley e No. 1 idler pulley

WARNING If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves. 34. Set the timing belt tensioner as follows: a. Using a press, slowly press in the pushrod using 220-2205 Ibs. (981-9807 N) of force. b. Align the holes of the pushrod and housing, pass a 1.27mm wrench through the holes to keep the setting position of the pushrod. c. Release the press and install the dust boot to the tensioner. 35. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. Ibs. (27 Nm). Using pliers, remove the 1.27mm wrench from the belt tensioner. 36. Check the valve timing, as follows: a. Slowly turn the crankshaft and align the timing marks of the crankshaft timing pulley and the oil pump body. Always turn the crankshaft pulley clockwise. b. Check that the timing marks of the right and left timing pulleys align with the timing marks of the No. 3 timing belt cover. If the marks do not align, remove the timing belt and reinstall it. 37. Install the timing belt guide with the Cup side facing outward. 38. Install the No. 1 timing belt cover and starter wire bracket. Tighten the timing belt cover fasteners to 80 inch Ibs. (9 Nm). 39. Install the crankshaft pulley, as follows: a. Align the pulley set key with the key groove of the pulley and slide the pulley. b. Using SST 09213-54014, or equivalent, tighten the bolt to 184 ft. Ibs. (250 Nm). 40. Install the fan bracket with the bolt and nut.

41. Install the No. 2 timing belt cover, and tighten the bolts to 80 inch Ibs. (9 Nm). Install the remaining components. 42. Fill the cooling system with coolant. 43. Connect the negative battery cable. 44. Start the engine and check for leaks. 45. Check the ignition timing.

7. Remove the power steering drive belt. 8. Slightly raise the engine using a block of wood and floor jack under the oil pan to prevent damage. 9. Remove the 4 bolts, 2 nuts, and right-hand mounting bracket. 10. Remove the spark plugs.

Toyota RAV4

11. Using SST 09213-54015, or equivalent, loosen the crankshaft pulley bolt and remove it by pulling it straight off the crankshaft. 12. Using SST 09249-63010, or equivalent, loosen the retaining bolts and remove the right engine mounting bracket. 13. Remove the upper (No. 2) timing belt

2.0L (3S-FE) ENGINE The timing belt is not adjustable. 1. Disconnect the negative battery cable.

“kk CAUTION To avoid air bag deployment, if equipped, work must be started after approximately 90 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected from the battery. 2. Disconnect the power steering reservoir tank and remove the reservoir bracket. 3. Detach the wiring harness bracket for the Data Link Connector 1 (DLC1). 4. Remove the alternator and alternator bracket. 5. If equipped with ABS brakes, remove the ABS actuator. 6. Remove the right front wheel and the fender apron seal.

cover. 14. Install the crankshaft pulley to the

crankshaft and temporarily install the retaining bolt. 15. Turn the crankshaft pulley and align its groove with the timing mark O of the No. 1 timing belt cover. Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap. If not, turn the crankshaft 360 degrees and align the marks. e>|f the timing belt is to be reused, matchmark the timing belt to the timing pulleys and timing belt covers so the belt can be reinstalled in its original position. Also, be sure to mark an arrow on the belt to indicate which direction it was turning.

79245639

It is necessary to align the timing reference indicators prior to removing the timing belt—Toy-

ota RAV4 2.0L (3S-FE) engine

et i

16. Remove the timing belt from the camshaft timing pulley. * 17. Hold the camshaft sprocket with a spanner wrench and remove the mounting bolt. Remove the camshaft pulley. 18. Remove the crankshaft pulley bolt and remove the crankshaft pulley. 19. Remove the No. 1 timing belt cover. 20. Remove the timing belt guide and the timing belt. 21. Remove the No. 1 idler pulley and tension spring. 22. Remove the No. 2 idler pulley. 23. Remove the crankshaft timing pulley. 24. Support the oil pump sprocket with a Spanner wrench, then remove the mounting bolt and remove the sprocket. To install: 29. Install the oil pump pulley. Tighten the nut to 18 ft. Ibs. (24 Nm). 26. Install the crankshaft timing pulley. Align the pulley set key with the key groove -Of the pulley. Slide on the pulley facing the flange side inward. 27. Install the No. 2 idler pulley and tighten the mounting bolt to 31 ft. Ibs. (42 Nm). Be sure that the pulley moves smoothly. ‘ 28. Install the No. 1 idler pulley with the bolt and the tension spring. Pry the pulley toward the left as far as it will go and tighten the bolt. Make sure that the pulley moves smoothly. 29. Temporarily install the timing belt. Using the crankshaft pulley bolt, turn the crankshaft and position the key groove of the crankshaft timing pulley upward. If reusing the timing belt, align the points marked during removal. 30. Install the timing belt on the crankshaft timing pulley, oil pump pulley, No. 1 idler pulley, water pump pulley and the No. 2 idler pulley. 31. Install the timing belt guide. e>if the old timing belt is being reinstalled, be sure the directional arrow is facing in the original direction and that the belt and sprocket/cover matchmarks are properly aligned.

32. Install the lower (No. 1) timing belt cover and new gasket with the 4 bolts. 33. Align the crankshaft pulley set key with the pulley key groove. Temporarily install the crankshaft pulley and bolt. 34. Align the camshaft knock pin with the groove of the pulley, and slide the timing pulley onto the camshaft with the plate washer and set bolt.

35. Tighten the pulley set bolt to 40 ft. lbs. (54 Nm).

b. Tighten the 3 bolts to hold the mounting insulator to the body. Tighten the bolts to 47 ft. Ibs. (64 Nm). c. Tighten the 2 nuts and bolt to hold

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

the mounting insulator to the mounting

36. Turn the crankshaft pulley and align the’O mark on the lower (No. 1) timing belt cover. 37. Finish installing the timing belt and check the valve timing, as follows: a. If reusing the old timing belt, align

the matchmarks made previously and install the timing belt onto the camshaft pulley. b. Aliga the marks on the timing belt with the marks on the camshaft pulley. c. Loosen the No. 1 idler pulley set bolt % turn. d. Turn the crankshaft pulley 2 complete revolutions TDC to TDC. ALWAYS turn the crankshaft CLOCKWISE. Check that the pulleys are still in alignment with the timing marks. e. Ifthe No. 1 idler pulley uses a green tension spring, slowly turn the crankshaft pulley 17% revolutions, and align its groove with the mark at 45 degrees BIDC (for the No. 1 cylinder) of the No. 1 timing belt cover. f. Tighten the No. 1 idler pulley set bolt to 31 ft. Ibs. (42 Nm). g. Be sure there is belt tension between the crankshaft and camshaft timing pulleys. 38. Place the right-hand engine mounting bracket in position but do not install the bolts. 39. Install the upper (No. 2) timing cover with a new gasket(s). 40. Remove the engine crankshaft pulley bolt and pulley. 41. Using SST 09249-63010, or equivalent, install the mounting bolts for the righthand mounting bracket. Tighten the mounting bolts to 38 ft. Ibs. (62 Nm). 42. Align the crankshaft pulley set key with the pulley key groove. Install the pulley. Tighten the pulley bolt to 80 ft. Ibs. (108 Nm). 43. Install the spark plugs. 44. |nstall the right-hand mounting insulator, as follows: a. Attach the mounting insulator to the body and mounting bracket with the 4 bolts and 2 nuts.

bracket. Tighten the bolt to 27 ft. Ibs. (37 Nm) and the nut to 38 ft. Ibs. (52 Nm). 45. Install and adjust the power steering pump drive belt. 46. Install the right-hand engine undercover. 47. Install the right front wheel. 48. Lower the engine. 49. If equipped, install the ABS actuator. 50. Install the alternator and alternator bracket. 51. Install the wiring harness bracket for the DLC1. 52. Install the power steering reservoir bracket and reservoir. 53. Connect the negative battery cable. 54. Start the engine and check the timing. Toyota Land Cruiser

4.7L (2UZ-FE) ENGINE 1. Disconnect the negative battery cable. 2. Raise and safely support the vehicle. 3. Remove the oil pan protector and the engine under cover. 4. Drain the cooling system and store the coolant for refilling purposes. 5. Lower the vehicle and remove the battery clamp cover. 6. From the top of the engine, remove the fuel return hose, the engine cover nuts/bolts and the cover. 7. Remove the air cleaner and the intake air connector assembly. 8. Remove the cooling fan pulley by performing the following procedures: a. Loosen the 4 fan clutch-to-fan pulley nuts. b. Using a box-end wrench on the serpentine drive belt tensioner bolt, rotate the tensioner counterclockwise and remove the drive belt. ->The serpentine drive belt tensioner bolt is a left-hand thread.

c. Remove the fan clutch-to-fan pulley nuts, the fan, the clutch assembly and the fan pulley. 9. Remove the radiator by performing the following procedures: a. Disconnect the upper, lower and reservoir hoses from the radiator. b. Disconnect and plug the automatic

For Wheel Alignment specifications, see Section 1 of this manual

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TIMING BELTS

P/S Air Hose

Radiator Reservoir Tank

Fuel Return

Fan Shroud @

Hose

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Fan Pulley :

Fan with Fluid Coupling

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A/T Oil Cooler Hose

65a A/C Compressor Connector

Se

A/C Compressor Generator Drive Belt

Engine Under Cover No.1 93025624

Exploded view of vehicle components for timing belt replacement—Toyota Land Cruiser 4.7L (2UZ-FE) engine

cr ee

eT

en ae ga

oore™

No.2 Timing Belt Cover

Camshaft Position Sensor Connector

Z Oil Cooler Pipe oF ee

LH No.3 Timing Belt Cover

Engine Wire

|N-m (kgf-cm, ft-Ibf) |:Specified torque :

93025625

Exploded view of upper timing belt covers—Toyota Land Cruiser 4.7L (2UZ-FE) engine

RH Camshaft Timing Pulley LH Camshaft Timing Belt Pulley

Timing Belt

r\

N

=

16 (160, 12)

Dust Boot

32 (330, 24)

N-m (kgf-cm, ft-Ibf) |: Specified torque

Fan Bracket

8

Timing belt Tensioner

26 (270, 19) 93025626

Exploded view of upper timing sprockets and components—Toyota Land Cruiser 4.7L (2UZ-FE) engine

For Maintenance Interval recommendations, see Section 1 of this manual

Generator

Timing Belt Guide

No.2 Idler Pulley

(yaad

(Crankshaft Angle Sensor Plate)

Gasket

Timing Belt Cover Spacer N-m (kgf-cm, ft-lbf)

|: Specified torque

* Precoated part 93025627

Exploded view of lower timing belt cover, sprockets and components—Toyota Land Cruiser 4.7L (2UZ-FE) engine

pe

®

hk eat

at ir ol

aac

transmission oil cooler at the radiator. Disconnect the automatic transmission oil cooler hoses from the fan shroud clamp. c. Remove the radiator reservoir tank. d. Remove the fan shroud-to-radiator bolts and the shroud. e. Remove the 2 upper radiator-tochassis nuts. f. Remove the middle radiator-to-

chassis nut/bolts and brackets.

g. Carefully, lift the radiator from the vehicle. 10. Remove the serpentine drive belt idler pulley bolt, cover plate and pulley. 11. Remove the right side (No. 3) timing belt cover. 12. Remove the left side (No. 3) timing belt cover by performing the following procedures: a. Disconnect the engine wire from both wire clamps. b. Disconnect the camshaft position sensor wire from the wire clamp on the left-side (No.3) timing belt cover. c. Disconnectthe sensor connector from the connector bracket. d. Disconnect the sensor connector. e. Remove the wire grommet from the left-side (No. 3) timing belt cover. f. Remove the oil cooler tube bolts and tube. 13. Remove the middle (No. 2) timing belt cover bolts and cover. 14. Remove the cooling fan bracket nuts/bolts and bracket.

Pea" Rloe

tS

eee

~ TIMING BELTS. 3- 45 approximately 50 degrees (CLOCKWISE) and align the crankshaft pulley timing mark between the centers of the crankshaft pulley bolt and the idler pulley bolt.

2 WARNING If the timing belt is disengaged, having the crankshaft pulley in the wrong angle can cause the valve to come into contact with the piston when removing the camshaft pulley.

17. Remove the crankshaft pulley bolt. elif reusing the timing belt and the installation marks have disappeared, place new installation marks on the timing belt to match the camshaft timing sprocket marks. e>To avoid meshing the timing sprocket and the timing belt, secure one with a string; then, place matchmarks on the timing belt and the right-side camshaft timing sprocket.

18. Remove the timing belt tensioner bolts and the tensioner. 19. Using the Camshaft Holding tool 09960-10010, or equivalent, slightly turn the left-side camshaft sprocket clockwise to loosen the tension spring. Then, disconnect the timing belt from the camshaft sprockets.

20. Remove the alternator by performing the following procedures: a. Disconnect the electrical connector from the alternator. b. Remove the rubber cap/nut and disconnect the battery wire from the alternator. c. Disconnect the wire clamp from the alternator cord clip. d. Remove the alternator-to-engine

nuts/bolts and the alternator. 21. Remove the serpentine drive belt tensioner nuts/bolts and the tensioner. 22. Using the Crankshaft Puller Assembly tool 09950-50012, or equivalent, press the crankshaft pulley from the crankshaft.

DO NOT rotate the crankshaft pulley. 23. Remove the lower (No. 1) timing belt cover bolts and the cover. 24. Remove the timing belt guide, spacer and the timing belt. To install: e>With the timing belt removed, this is a perfect opportunity to inspect and/or replace the water pump.

25. Inspect the timing belt tensioner by performing the following procedures:

e>|f reusing the timing belt, make sure that there are 3 installation marks on

the belt; if there are none, install them. 15. Using the Crankshaft Pulley Holding tool 09213-70010, Bolt tool 90105-08076 and Companion Flange Holding tool 09330-00021, or equivalent, loosen the

crankshaft pulley bolt. 16. Position the No. 1 cylinder to approximately 50 degrees After Top Dead Center (ATDC) of the compression stroke by performing the following procedures: a. Rotate the crankshaft pulley (CLOCKWISE) to align its groove with the timing mark “O” on the lower (No. 1) timing belt cover. b. Check that the camshaft sprocket timing marks are aligned with the rear timing belt plate marks; if not, rotate the crankshaft 1 revolution (360 degrees). c. Rotate the crankshaft pulley

93025628

Alignment of timing belt with the timing sprockets—Toyota Land Cruiser 4.7L (2UZ-FE) engine

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

beansie ce

. 3-46

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TIMING BELTS

(wz Approx. 50°

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No.2 Idler

To install the serpentine drive belt

Securing the timing belt with string and matchmarking the camshaft with the timing belt—Toyota Land Cruiser 4.7L (2UZ-FE) engine

a. Inspect the seal for leakage; if leakage Is suspected, replace the tensioner. b. Using both hands to hold the tensioner facing upward, strongly press the pushrod against a solid surface. If the pushrod moves, replace the tensioner.

Never hold the tensioner with the pushrod facing downward. ——— SS c. Measure the pushrod protrusion

pact use a holt 4.18 in. (1 06mm) dae Jo

32. Check that the crankshaft pulley’s timing mark is aligned with the centers of the idler pulley and crankshaft pulley bolts. 33. Install the alternator and torque the alternator-to-engine nuts/bolts to 29 ft. Ibs. (Soi CONC ieraleniaesac ea connectors and clip.

TIMING BELTS—3-47

93025631

Installing the timing ‘belt on the crankshaft sprocket—Toyota Land Cruiser 4.7L (2UZ-FE) engine

34. Install the timing belt to the left-side camshaft by performing the following procedures: a. Rotate the left-side camshaft pulley to align the timing belt installation mark with the camshaft sprocket’s timing mark and slide the belt onto the camshaft timing sprocket. b. Using the Camshaft Holding tool 09960-10010, or equivalent, slightly turn the left-side camshaft sprocket counterclockwise to place tension on the timing belt between the crankshaft sprocket and the camshaft sprocket. 35. Rotate the right-side camshaft pulley to align the timing belt installation mark with the camshaft sprocket’s timing mark and slide the belt onto the camshaft timing sprocket. 36. Using a vertical press, slowly press the pushrod into the housing using 200-2205 Ibs. (981-9807 N) until the holes align, then, install a 1.27mm Allen® wrench to secure the pushrod and release the press. Install the dust boot on the tensioner housing. 37. Install the timing belt tensioner and torque the bolts to 19 ft. Ibs. (26 Nm). 38. Using a pair of pliers, remove the Allen® wrench from the tensioner housing. 39. Check the valve timing by performing the following procedure: a. Temporarily install the crankshaft pulley bolt. b. Slowly, rotate the crankshaft pulley 2 revolutions (CLOCKWISE) and realign the TDC marks. elf the pulley/sprocket timing marks do not realign, remove the timing belt and reinstall it.

40. Using the Crankshaft Pulley Holding too! 09213-70010, Bolt tool 90105-08076

1.27

pa

and Companion Flange Holding tool 09330-00021, or equivalent, torque the crankshaft pulley bolt to 181 ft. Ibs. (245 Nm). 41. Install the cooling fan bracket and torque the 12mm (head size) bolt to 12 ft. lbs. (16 Nm) and the 14mm (head size) bolt

mm

Hexagon

Wrench

93025632

to 24 ft. Ibs. (32 Nm). 42. Install the air conditioning compresSor. 43. Install the middle (No. 2) timing belt cover and torque the bolts to 12 ft. Ibs. (16 Nm). 44. Install the upper right-side (No. 3) timing belt cover and torque the bolts to 66 inch Ibs. (7.5 Nm).

Securing the timing belt tensioner pushrod—Toyota Land Cruiser 4.7L (2UZ-FE) engine

For complete service labor times, order the Chilton Labor Guide

|

45. Install the upper left-side (No. 3) timing belt cover by performing the following procedures: a. Install the oil cooler tube and bolt. b. Feed the Camshaft Position Sensor (CPS) through the left-side (No. 3) timing belt cover hole. c. Install the left-side (No. 3) timing belt cover and torque the bolts to 66 inch lbs. (7.5 Nm). ‘ d. Install the wire grommet to the leftside (No. 3) timing belt cover. e. Install the sensor connector to the connector bracket and connect the sensor connector.

f. Install the sensor wire and the engine wire to the clamps on the left-side (No. 3) timing belt cover. 46. Install the drive belt idler pulley and cover plate; then, torque the pulley bolt to 93025633 hi :

Checking the TDC alignment marks after rotating the crankshaft 2 revolutions—Toyota Land

%

Cruiser 4.7L (2UZ-FE) engine

27 ft. Ibs. (37 Nm).

47. To complete the installation, reverse the removal procedures.

48. Refill the cooling system and connect the negative battery cable.

1998-01 ACURA..............00. 4-2 BrakEIC@NDer bk LE Bvt Mb coc. csceesess 4-2

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4-28 4-28 4-29 4-29 4-29

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Brake, Calipehs cnarine. Uhaataancne 4-45

4-6

Removal & Installation.............. 4-29

Removal & Installation............... 4-6

1998-01 HYUNDAI............. 4-30

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Removal & Installation... 4-46 1998-01 MITSUBISHI ......... 4-48

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Removal & Installation... 4-45

Removal & Installation........0.0.... 4-6

Removal & installation.............. 4-30

Brake Cabiper ..:cecsscssssc-....chteneee 4-48

Brake Shoes.......... hoa tO leiy ha 4-7 Removal & Installation... 4-7 1998-01 FORD................... 4-8

Tae rorOGS.. va: 5 casement teMeceneete? 4-30 Removal & installation............. 4-30 1998-00 INFINITI .............. 4-31

Removal & Installation... 4-48 DiS Brake Pads 208!) 226 Bie aes ae 4-50 Removal & Installation.............. 4-50

Drake-Caliners. caste.

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1998-01 NISSAN............... 4-50

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Removal & Installation.............. 4-31 8 cee ae -32 MSG Brake Pads, oc Removal & Installation.............. 4-32 Brae CUINS is. cacass cccaon areas -33 Removal & Installation... 4-33 Brake Shoes.) sue! adh toannnagill. -34 Removal & Installation... 4-34 1998-01 ISUZU ................ 4-34 Brake Caliognn Gan SMe oor... 4-34 Removal & Installation.............. 4-34 isc aecsete. 4-36 Dise Brake Paiste... Removal & Installation.............. 4-36 Brake :DturnSiies 21 site ccrcestcxnoett 4-37 Removal & Installation............ 4-37 Rear Brake [email protected] 4-37 Removal & Installation.............. 4-37 1998-01 JEEP.................. 4-38 Brake Caliper. adv Mtineterssca.actess 4-38 Removal & Installation............. 4-38 otis. 4-40 ise: Brake-Pads, cs. Removal & Installation... 4-40) Bi AKG LTO cecdeu ca hccest buteoocuis4-4? Removal & Installation............. 4-42 auc BOR.4-42 BRAKE ORS cn ec recta Removal & Installation............ 4-4? 1998-00 KIA.................08. 4-43 yacnseas4-43 TEMES GIDOL cts Wieeieeee Removal & Installation.............. 4-43

Brake Galioel tate tas ke cteoteae 4-50 Removal & Installation.............. 4-50 Disc. Brake PadSicn ont. Hintary. cua: 4-5] Removal & Installation... 4-51 Brake Drums ie baste naar 4-54 Removal & Installation... 4-51 BrakeShoes. £98.42) ei 4-51 Removal & Installation... 4-51 1998-01 SUZUKI............... 4-52 Brake Gallpeia cen, cc secs te4-52 Removal & Installation.............. 4-52 DisCiBrake. Padsstne..ccas. curse 4-52 Removal & Installation... 4-52 Brakes «aeXoucs.t/ ccResaeaeaes 4-54 Removal & Installation............. 4-54 BAKE ONOGS hd antes cremecnbe ieee, 4-55 Removal & Installation... 4-55 1998-01 TOYOTA.............. 4-57 Ai thaasaact 4-57 Su. 7ceBrake’ Galiper..s2 Removal & Installation... 4-57 mre. 4-60 Oise’ Brake-Pads:...aetmbak-fo:. Removal & Installation... 4-60 eer came:4-62 Brak@cDPUMS owe cere Removal & Installation............. 4-62 te e 4-64 Brake: SHOGS Koi wos Removal & Installation.............. 4-64

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BRAKES ACURA

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Brake Caliper :

REMOVAL & INSTALLATION

SLX FRONT 1. Raise and safely support the vehicle. 2. Remove some brake fluid from the reservoir. 3. Remove the front wheels. 4. Disconnect the brake fluid line from the caliper. Plug the line to prevent fluid loss. ~. 5, Loosen the brake caliper mounting bolt and guide bolt. Remove the caliper from the mount. 6. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear and replace them if necessary. To install: 7. Fill the brake caliper with clean brake fluid and connect the fluid line to the caliper using new washers. Tighten the brake line banjo fitting to 26 ft. Ibs. (35 Nm). Install the brake pads and clips onto the caliper. 8. Install the caliper onto the mounting bracket. Lubricate the caliper bolts and their boots. Then, install the caliper mounting bolts and tighten them to 54 ft. Ibs. (74 Nm). 9. Refill and bleed the brake system. 10. Install the front wheels and lower the vehicle.

(3) Lock Bolt (4) Pad Assembly

(1) Caliper Assembly

(2) Clip

93026601

Rear caliper assembly—SLX

REAR 1. Raise and safely support the vehicle. 2. Remove some brake fluid from the reServoir. 3. Remove the rear wheels. 4. Disconnect the brake fluid line from the caliper. Plug the line to prevent fluid loss.

5. Loosen the brake caliper mounting bolt and guide bolt. Remove the caliper from the mount bracket. 6. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear; replace them if necessary. 7. If necessary for servicing, unbolt the caliper mounting bracket from the backing plate. To install: 8. If removed, install the caliper mounting bracket and tighten its bolts to 76 ft. Ibs.

(103 Nm). 9. Fill the brake caliper with clean brake fluid and connect the fluid line to the caliper using new washers. Tighten the brake line banjo fitting to 26 ft. Ibs. (35 Nm). Install the brake pads and clips onto the caliper. 10. Install the caliper on the mounting bracket. Lubricate the caliper bolts and their boots. Then, install the caliper mounting bolts. Tighten them to 32 ft. Ibs. (44 Nm). 11. Refill and bleed the brake system. 12. Install the rear wheels and lower the vehicle. (1) Guide Bolt (2)

Brake Flexible Hose

(3) Lock Bolt

(4) (5) (6) (7)

Caliper Assembly Clip Support Bracket with Pad Assembly Pad Assembly 93026602

Front caliper assembly—SLX

MDX FRONT 1. Remove some fluid from the reservoir with a suction pump. 2. Raise and safely support the vehicle.

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PR Oo

:

_ BRAKES

Bs

2

ACURA

_ 3, Remove the front wheels.

.

To Install:

4, Remove the banjo bolt and disconnect the brake hose from the caliper. Plug the hose to prevent fluid loss and contamination. 5. Remove the mounting bolts and remove the caliper from its mounting bracket.

9. Fill the reservoir with fluid and bleed

6. Fit the caliper over the pads and onto _ the brakes. its mounting bracket. . 10. Install the front wheels and lower the— 7. Torque both caliper bolts to 27 ft. vehicle. lbs. (36 Nm). 8. Reconnect the brake hose to the REAR caliper using new sealing washers. Carefully 1. Remove some fluid from the resertorque the banjo bolt to 25 ft. Ibs. (34 Nm). voir with a suction pump.

Front Brake Caliper Overhaul

ACAUTION Frequent inhalation of brake pad dust, regardless of Beene composition, could be hazardous to your health. + Avoid breathing dust particles. | + Never use an air hose or brush to clean brake assemblies. Use an OSHA- pea

|

dais vacuum cleaner.

Remove, disassemble, inspect, reaceerneie and install the anges aand note these items:

e

Do not spill brake fluid on the vehicle; it may ware: the paint; if brake fluid gets on the paint, wash it off immediately with water. To prevent dripping brake fluid, cover ationhecisd hose joints with rags or shop towels. Clean all parts in brake fluid and air dry; blow out all passages with compressed air. Before reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones as specified in the illustration. Make sure no dirt or other foreign matter gets in the brake fluid. Make sure ‘no grease or oil gets on the brake discs or pads. When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Use only clean Genuine Honda DOT 3 Brake Fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system.

Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Replace all rubber parts with new ones. After installing the caliper, check the brake hose and line for leaks, interference, and twisting. WEAR INDICATOR setae inner pad with of its wear indicator upward.

ee

PIN BOOT Replace.

PADS Be OUTER PAD SHIM C

Fs

U7 OUTER PAD SHIM D

ah

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ee PAD SHIM B

MAIN PIN

CALIPER

BRACKET

A

INNER PAD SHIM A

BANJO BOLT

AKE HOSE

J

34N-m ee (3.5 kgf-m, 25 Ibf-ft)

en

x 1.0mm 6Nim

Bk |é @.

SEALING WASHERS Replace.

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Ss

7 kgf-m, 27 Ibf-ft) Z&

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©. 12x 1.25mm

|

108 N-m (11.0 kat, 80.0 Ibf-ft)

BLEED SCREW

pales

10x 1.0mm Pht

9.8 N-m (1.0

7.2 Ibf-ft)

kgf-m,

CALIPER BODY

PISTON SEAL

Replace.

PISTON BOOT pe nlsce:

PAD RETAINERS

CALIPER BRACKET 93552GZ2Z

Exploded view of the front caliper components—MDX

For complete service labor times, order the Chilton Labor Guide

4-4

BRAKES ACURA |

Rear Brake Caliper Overhaul

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.

%* Avoid breathing dust particles. + Never use an air hose or brush to clean brake assemblies. vie an So) sap Pigy eevacuum cleaner.

Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: Do not spill brake fluid on the vehicle; It may damage the paint; If brake fluid gets on the paint, wash it off

immediately with water. To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels. Clean all parts in brake fluid and air dry; blow out all passages with compressed air. Before reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones as specified in the illustration.

°

Make sure no dirt or other foreign matter gets into the brake fluid. Make sure no grease or oil gets on the brake discs or pads. By When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Use only clean Genuine Honda DOT 3 Brake Flujd. Non-Honda brake fluid can cause corrosion and shorten the life of the system.

Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Replace all rubber parts with new ones. After installing the caliper, check the brake hose and line for leaks, interference, and twisting. SESH.

8x 1.0 mm

BRAKE HOSE

Silicone grease

az?

eee aaiy.Rubber grease

Sry BOLT

CALIPER BRACKET

PIN

4 “m (3.5 kgf-m, 25 Ibf-ft)

37 N-m (3.8 kgf-m, 27 Ibf-ft) CALIPER BODY

@

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seating’ °

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SCREW

9.0.ON-m (0.9 kgf-m, 7 Ibf-ft) PISTON

WASHERS Replace.

PIN BOOTS Replace.

INNER ca PADpec G SHIM A aoe PAD

SHIM B

Cea

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PIN BOOTS Replace.

tare PAD SHIM

CALIPER BRACKET \ PADS WEAR INDICATOR Install inner pad with its wear indicator downward 10 x 1.25 mm 55 N-m (5.6 kgf-m, 41 Ibf-ft)

PAD RETAINERS 4

93552GZB

Exploded view of the rear caliper components—MDX

2. Raise and safely support the vehicle. 3. Remove the rear wheels. 4. Remove the banjo bolt and disconnect the brake hose from the caliper. Plug the hose to prevent fluid loss and contamination. 5. Remove the 2 caliper mounting bolts. Remove the caliper from its mounting bracket. To Install: 6. Fit the caliper over the pads and onto its mounting bracket.

7. Tighten the caliper bolts to 27 ft. Ibs. (37 Nm). 8. Reconnect the brake hose with new sealing washers. Tighten the banjo bolt to 20 ft. Ibs. (34 Nm). 9. Fill the reservoir with fluid and bleed the brake system. Adjust the parking brake if necessary, 10. Install the rear wheels and lower the vehicle.

Disc Brake Pads

REMOVAL & INSTALLATION ————————

SLX FRONT 1. Remove about ¥% of the brake fluid

from the master cylinder reservoir to prevent

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10. Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid level in the master cylinder reservoir and add as necessary.

REAR 1. Use a vacuum pump to remove some brake fluid from the master cylinder reservoir to prevent overflow when. the caliper piston is compressed. 2. Raise and safely support the vehicle. 3. Remove the rear wheels. 4. Remove the brake caliper from the caliper bracket without disconnecting the brake line. Support the caliper with a length of wire. Do not let the caliper hang from the brake hose. 5. Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining.

ee

To install: 6. Use a large C-clamp or brake piston tool to push the caliper piston into its bore. 7. Apply a thin coat of brake grease to both sides of both inner shims. Assemble the pads and shims, then install them into the caliper. The wear indicator on the inner pad must face down. 8. Install the calipers. Clean and lubricate the caliper mounting bolts and lubricate the mounting bolt boots. Install the mounting bolts and tighten them to 32 ft. lbs. (44 Nm). 9. Install the rear wheels and lower the

vehicle.

:

10. Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid level in the master cylinder

reservoir and dd as necessary.

BRAKES 4 eet

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easily accomplished with a pad spreader or large C-clamp. 11. Pivot the caliper down into position and tighten the mounting bolt to 27 ft. Ibs. (37 Nm). 12. Connect the brake hose to the knuckle, if removed. 13. Install the wheel and lower the vehicle to the ground. 14. Add brake fluid to the master cylinder reservoir and install the cap. 15. Depress the brake pedal several times and make sure that the movement feels normal. The first brake pedal application may result in a very long pedal action due to the pistons being retracted. Always make several brake applications before starting the vehicle. Bleed the system if nec-

essary.

REAR

MDX FRONT 1. Raise and support the vehicle Safely. 2. Remove the front wheels. 3. Remove a small amount of brake fluid from the reservoir using a suction ump. 4, Unbolt the brake hose clamp from the knuckle by removing the retaining bolts. 5. Remove the lower caliper retaining bolt and pivot the caliper upward, off of the pads. 6. Remove the pad shim and pad retainers. Remove the disc brake pads from the caliper. To install: 7. Clean the caliper thoroughly; remove any rust from the lip of the disc or rotor. Check the brake rotor for grooves or cracks. If any heavy scoring is present, the rotor must be replaced. 8. Install the pad retainers. Apply molybdenum brake grease to both surfaces of the shims and the back of the disc brake pads. 9. Install the pads and shims. The pad with the wear indicator goes in the inboard

position.

4

ACURA

eee

overflow when the caliper piston is compressed. « 2. Raise and safely support the vehicle. 3. Remove the front wheels. 4. Remove the brake caliper from the caliper bracket without disconnecting the brake line. Support the caliper with a length of wire. Do not let the caliper hang from the brake hose. 5. Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining. To install: 6. Use a large C-clamp or brake piston tool to push the caliper piston into its bore. 7. Apply a thin coat of brake grease to both sides of both inner shims. Assemble the pads and shims, then install them into the caliper. The wear indicator on the inner pad must face down. 8. Install the calipers. Clean and lubricate the caliper mounting bolts and lubricate the mounting bolt boots. Install the mounting bolts and tighten them to 54 ft. lbs. (74 Nm). : 9. Install the front wheels and lower the vehicle.

¢

.

10. Push in the caliper piston so the caliper will fit over the pads. This is most

1. Raise and safely support the vehicle. 2. Remove a small amount of brake fluid from the reservoir using a suction pump. 3. Remove the rear wheels. 4, Remove the 2 caliper mounting bolts and remove the caliper from the bracket. 5. Remove the pads, shims, and pad retainers. To install: 6. Clean the caliper thoroughly; remove any dirt or dust. Check the brake rotor for grooves or cracks and machine or replace, as necessary. 7. Install the pad retainers. Apply molybdenum brake grease to both surfaces of the shims and the back of the disc brake ads. 8. Install the pads and shims. The wear retainer on the inboard pad faces down. 9. Use a suitable tool to push caliper piston into its bore and enable the caliper to fit over the pads. Lubricate the piston boot with silicon grease. Avoid twisting the boot. 10. Install the brake caliper. Tighten the mounting bolts to 27 ft. Ibs. (37 Nm). 11. Install the rear wheels. Lower the vehicle. 12. Add brake fluid to the master cylinder reservoir. Depress the brake pedal several times to seat the pads. Bleed the brakes if necessary.

Please visit our web site at www.chiltonsonline.com

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SHOE SPRING

Brake Caliper

Sea

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REMOVAL & INSTALLATION Durango

1. Raise and support the front end on jackstands. 2. Remove the wheels. 3. Disconnect the rubber brake hose from the tubing at the frame mount. If the pistons are to be removed from the caliper, leave the brake hose connected to the caliper. Check the rubber hose for cracks or chafed spots. 4. Plug the brake line to prevent loss of fluid. 5. Remove the caliper slide pins. 6. Remove the caliper and brake pads from the rotor adapter. To install: 7. Position the outboard shoe in the caliper. The shoe should not rattle in the caliper. If it does, or if any movement is obvious, bend the shoe tabs over the caliper to tighten the fit. 8. Slide the caliper into position on the adapter and over the rotor. 9. Align the caliper and start the pins in by hand. 10. Tighten the pins to 22 ft. Ibs. (30 Nm). 11. Connect the brake hose to the caliper. Use new washers to attach the hose fitting if the original washers are scored, worn or damaged. 12. Fill and bleed the brake system. 13. Install the wheels. 14. Lower the vehicle.

Disc Brake Pads

—

REMOVAL & INSTALLATION Durango 1. Raise and support the front end on jackstands. 2. Remove the wheels. 3. Press the caliper piston back into the bore with a suitable prytool. Use a large Cclamp to drive the piston into the bore of additional force is required. 4. Remove the caliper mounting bolts with a % in. hex wrench or socket. 5. Rotate the caliper rearward off the rotor and out from its mount. 6. Set the caliper on a crate or sturdy box, then remove the inboard and outboard

OUTBOARD SHOE 93026608

Prying the disc brake from the 4WD front brake caliper assembly—Durango

brake pads. The inboard pad has a spring clip that holds it in the caliper. Tilt this pad out at the top to unseat the clip. The outboard pad has a retaining spring that secures it in the caliper. Unseat 1 spring end and rotate the pad out of the caliper. 7. Secure the caliper to a chassis or Suspension component with a sturdy wire. Do not let it hang from the hose. To install: 8. Clean the caliper and steering knuckle sliding surfaces with a wire brush. Then, apply a coat of Mopar® multi-mileage grease or equivalent. 9. Clean the caliper slide pins with brake cleaner or brake fluid. Then apply a light coating of silicone grease to the pins. elf there is minor rust or corrosion on the pins, first polish them with a crocus cloth. If they are severely rusted, replace them.

10. Install the inboard pad and its spring Clip. 11. Install the outboard brake pad. 12. Install the caliper over the rotor and seat it in its original position until flush. 13. Final tighten the caliper slide pins to 18-26 ft. Ibs. (25-35 Nm). 14. Install the wheels. 15. Lower the vehicle. 16. Pump the brakes several times to seat the pads.

Brake Drums

REMOVAL & INSTALLATION Durango

CHRYSLER SERVO TYPE WITH SINGLE ANCHOR 1. Raise and safely support the truck. 2. Remove the plug from the brake adjustment access hole. 3. Insert a thin bladed screwdriver through the adjusting hole and hold the adjusting lever away from the starwheel. 4. Release the brake by prying down against the starwheel with a brake spoon. 5. Remove the rear wheel and clips from the wheel studs. Remove the brake drum. ‘ 6. Installation is the reverse of removal. Adjust the brakes.

BENDIX DUO-SERVO TYPE 1. Raise and safely support the vehicle. 2. Remove the rear wheel and tire. 3. Remove the axle shaft nuts, washers and cones. If the cones do not readily release, rap the axle shaft sharply in the center. 4. Remove the axle shaft. 5. Remove the outer hub nut.

4

CHRYSLER Con

93026604

Use a lever releasir(g tool to depress the adjuster lever while turning the starwheel with a prytool—Bendix brakes

6. Straighten the lockwasher tab and remove it along with the inner nut and bearing. 7. Carefully remove the drum. To install: 8. Position the drum on the axle housing. 9. Install the bearing and inner nut. While rotating the wheel and tire, tighten the adjusting nut until a slight drag is felt. 10. Back off the adjusting nut % turn so that the wheel rotates freely without excessive end-play. 11. Install the lockrings and nut. Place a new gasket on the hub and install the axle shaft, cones, lockwashers and nuts. 12. Install the wheel and tire. 13. Road-test the vehicle.

Brake Shoes

REMOVAL & INSTALLATION Durango

SERVO TYPE WITH SINGLE ANCHOR 1. Raise and support the vehicle. 2. Remove the rear wheel, drum retain-

ing clips and the brake drum. 3. Remove the brake shoe return

springs, noting how the secondary spring overlaps the primary spring. 4, Remove the brake shoe retainer, Springs and nails. 5. Disconnect the automatic adjuster cable from the anchor and unhook it from the lever. Remove the cable, cable guide, and anchor plate. 6. Remove the spring and lever from the shoe web. 7. Spread the anchor ends of the primary and secondary shoes and remove the parking brake spring and strut. 8. Disconnect the parking brake cable and remove the brake assembly. 9. Remove the primary and secondary brake shoe assemblies and the star adjuster as an assembly. Block the wheel cylinders to retain the pistons. To install: 10. Measure the drum as described in this section. 11. Apply a thin coat of lubricant to the support platforms. 12. Attach the parking brake lever to the rear of the secondary shoe. 13. Place the primary and secondary shoes in their relative positions on a workbench. 14. Lubricate the adjuster screw threads. Install it between the primary and secondary

AT

shoes with the star wheel next to the secondary shoe. The star wheels are stamped with an L (left) and R (right). 15. Overlap the ends of the primary and. second brake shoes and install the adjusting spring and lever at the anchor end. 16. Hold the shoes in position and install the parking brake cable into the lever. 17. Install the parking brake strut and spring between the parking brake lever and primary shoe. 18. Place the brake shoes on the support and install the retainer nails and Springs. 19. Install the anchor pin plate. 20. Install the eye of the adjusting cable over the anchor pin and install the return spring between the anchor pin and primary shoe. 21. Install the cable guide in the secondary shoe and install the secondary return spring. Be sure that the primary spring overlaps the secondary spring. 22. Position the adjusting cable in the groove of the cable guide and engage the hook of the cable in the adjusting lever. 23. Install the brake drum and retaining clips. Install the wheel and tire. 24. Adjust the brakes and road-test the truck.

BENDIX DUO-SERVO TYPE 1. Unhook and remove the adjusting lever return spring. 2. Remove the lever from the lever pivot in. 3. Unhook the adjuster lever from the adjuster cable. 4, Unhook the upper shoe-to-shoe spring. 5. Unhook and remove the shoe holddown springs. 6. Disconnect the parking brake cable from the parking brake lever. 7. Remove the shoes with the lower shoe-to-shoe spring and star wheel as an assembly. To install: 8. The pivot screw and adjusting nut on the left side have left-hand threads and right-hand threads on the right side. 9. Lubricate and assemble the star wheel assembly. Lubricate the guide pads on the support plates. 10. Assemble the star wheel, lower shoe-to-shoe spring, and the primary and secondary shoes. Position this assembly on the support plate.

Timing belt service is covered in Section 3 of this manual

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RETURN

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SPRING

ADJUSTER ADJUSTER HOLDDOWN LEVER spriNG AND screw RETAINERS ASSEMBLY

SHOE PRIMARY ahictenee RETURN S 93026G09

Exploded view of the rear brake components—B-Series Van, Dakota, Durango and Ram Pick-Up

11. Install and hook the hold-down springs. 12. Install the upper shoe-to-shoe spring.

13. Install the cable and retaining clip. 14. Position the adjuster lever return spring on the pivot (green springs on left brakes and red springs on right brakes).

15. Install the adjuster lever. Route the adjuster cable and connect it to the adjuster. 16. Install the brake drum and adjust the brakes.

1998-01 FORD Brake Caliper REMOVAL & INSTALLATION Explorer and Mountaineer

FRONT 1. Siphon part of the brake fluid out of the master cylinder to avoid overflow when the caliper piston is pressed into the caliper bore. 2. Raise the vehicle and support it Safely. Remove the wheel and tire assembly. 3. Position an 8 in. (20cm) C-clamp on the caliper and tighten the clamp to move the caliper piston into the bore approximately Ye in. (8mm). Avoid clamp contact with the outer shoe spring clip. Remove the clamp. e>Do not pry the piston away from the rotor.

4. Clean excess dirt from the pin tab area. 5. Using a ¥% in. drive socket and a light hammer, tap the upper caliper pin towards the outboard side until the pin tabs pass the spindle face. 6. Compress the inboard pin tab, if equipped, with pliers and, with a hammer, drive the pin out until the tab slips into the spindle groove. 7. Place an end of a “e in. (11mm) diameter punch against the end of the caliper pin and tap the pin out of the caliper slide groove. 8. Repeat Steps 5, 6 and 7 to remove the lower pin. 9. Disconnect and plug the brake hose at the caliper. Remove the caliper from the rotor. To install: 10. Make sure the caliper mounting surfaces are free of dirt. Lubricate the caliper

grooves with disc brake caliper grease and install the caliper. 11. From the caliper outboard side, position the pin between the caliper and spindle grooves. The pin must be positioned so the tabs will be installed against the spindle outer face. 12. Tap the pin on the outboard end with a hammer until the retention tabs on the sides of the pin contact the spindle face. 13. Repeat Steps 11 and 12 for the lower pin. e>During installation, do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens, it will be necessary to tap the other end of the caliper pin until the tabs snap in place. The tabs on each end of the pin must be free to catch on the spindle face.

BRAKES FORD

14. Connect the brake hose to the caliper. Bleed the brake system. *15. Install the wheel and tire assembly and lower the vehicle. Check the brake fluid level and check the brakes for proper operation.

REAR 1. Siphon part of the brake fluid out of the master cylinder to avoid overflow when the caliper piston is pressed into the caliper bore. 2. Raise the vehicle and support it Safely. Remove the wheel and tire assembly. 3. Position an 8 in. (20cm) C-clamp on the caliper and tighten the clamp to move the caliper piston into the bore approximately Ye in. (3mm). Remove the clamp. ->Do not pry the piston away from the rotor.

4. Clean excess dirt from the retainer bolt area. 5. Using a Torx® socket, remove the 2 retainer bolts securing the caliper to the bracket and adapter plate. 6. Disconnect and plug the brake hose at the caliper. Remove the caliper from the rotor. To install: 7. Make sure the caliper mounting surfaces are free of dirt. Lubricate the caliper grooves with disc brake caliper grease and install the caliper. 8. Position the caliper to the bracket and secure in place with the retainer bolts. Tighten the bolts to 20 ft. Ibs. (27 Nm). 9. Install the caliper brake hose using new washers. Tighten the bolt to 29 ft. Ibs. (40 Nm). 10. Fill and bleed the brake system. 11. Install the wheel and tire assembly and lower the vehicle. Check the brake fluid level and check the brakes for proper operation.

the 2 slide pins. Tighten the bolts to 21-26 ft. Ibs. (28-36 Nm). 6. Using new copper washers, attach the front brake hose to the brake caliper, then install and tighten the retaining bolt to 23-29 ft. Ibs. (30-40 Nm). 7. Bleed the brake system. 8. Clean the wheel hub mounting surface. 9. Install the front wheels and snug the nuts to fully seat the wheel against the ub. 10. Lower the vehicle until some of the vehicle's weight rests on the front tires, then tighten the lug nuts to 83-112 ft. Ibs. (113-153 Nm). 11. Lower the vehicle completely. 12. Make sure that the brakes are operating correctly.

REAR

?

The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly.

+k CAUTION Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running

water for 15 minutes. If eye irritation

Expedition and Navigator

FRONT 1. Raise and safely support the vehicle securely on jackstands. 2. Remove the front wheels. 3. Remove the front brake hose bolt, then remove the copper washers and plug the front brake hose. 4, Remove the 2 front disc brake caliper slide pins, then lift the caliper off of the front caliper anchor plate. To install: 5. Install the front disc brake caliper onto the caliper anchor plate, then install

persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. 3. Remove bolt and disconnect the rear wheel brake hose. 4. Remove the copper washers and plug the brake hose.

tk WARNING — Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not

4-9

repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the Caliper slide pins. Other greases can swell the guide pin bocts, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. 5. Remove the brake caliper bolts. 6. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. 7. Inspect the rear disc brake caliper for leaks. To install: e>When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper.

8. Install the rear disc brake caliper. 9. Install the rear wheel brake hose. 10. Connect the brake hose and install and use new copper washers. 11. Tighten the brake hose bolt. 12. Bleed the disc brake caliper. e>|lf equipped with air suspension, reactivate the system by turning on the air suspension switch.

13. Install the wheel and tire assembly. 14. Verify correct brake operation.

Disc Brake Pads

REMOVAL & INSTALLATION Explorer and Mountaineer

FRONT 1. Siphon part of the brake fluid out of the master cylinder to avoid overflow when the caliper piston is pressed into the caliper bore. 2. Raise the vehicle and support it Safely. Remove the wheel and tire assembly. 3. Remove the brake caliper, but do not disconnect the brake hose. Secure the caliper aside with mechanic's wire. 4. Compress the anti-rattle clip and remove the inner brake pad from the caliper. 5. Press each ear of the outer brake pad away from the caliper and slide the torque buttons out of the retention notches. To install: 6. Bottom out the caliper piston in the caliper bore using an 8 in. (20cm) C-clamp

Heater Core replacement is covered in Section 2 of this manual

Front Brake Anti-Lock Sensor

Front Disc Brake Hub and

Nut Retainer

Front Wheel Spindle

Rotor

Hub Grease Cap

Front Disc Brake Rotor Shield

Front Wheel Bearing

Disc Brake Caliper

Rotor Shield Bolt

Front Wheel Outer Bearing Retainer Washer

Front Disc Brake Caliper Anchor Plate

Grease Seal fb NWN WY Front Wheel

Hub Spindle Nut Bearing

Cotter Pin

Caliper Anchor Plate Bolts Disc Brake Caliper Bolt 93026622

Exploded view of the 2WD front disc brake assembly—1998-01 Explorer and Mountaineer

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]_ Front Disc Brake Caliper Anchor Plate Bolt (2 Req'd) Front Brake Hose Bolt

Disc Brake Caliper Pads BP nA LY W

Front Disc Brake Caliper Anchor Plate

ON

Front Disc Brake Rotor

7

Front Axle Wheel Hub Retainer

8 Front Disc Brake Rotor Shield

Bolt (3 Req'd) 9 Front Disc Brake Rotor Shield 10 Front Wheel! Knuckle 93026623

Exploded view of the 4WD front disc brake assembly—1998-01 Explorer and Mountaineer

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

NOPE Tn hy eer

Pane =

or equivalent and a worn out inner brake pad or block of wood to push against the piston. Do not attempt to bottom out the piston with the outer brake pad installed. 7. Place a new anti-rattle clip on the lower end of the inner brake pad. Make sure the tabs on the clip are properly positioned and the clip is fully seated. 8. Position the inner brake pad and _anti-rattle clip in the pad abutment with the ant-rattle clip tab against the pad abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the upper end of the pad in position. 9. Install the outer pad, making sure the torque buttons on the pad are seated solidly in the matching holes in the caliper. 10. Install the caliper on the spindle. 11. Install the wheel and tire assembly and lower the vehicle. Apply the brakes several times before moving the vehicle to seat the pads. 12. Check the brake fluid level. Check the brakes for proper operation.

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1 stainless slippers 2 pads

REAR -1. Siphon part of the brake fluid out of 93026624

Position of the front disc brake components—1998-01 Explorer and Mountaineer

the master cylinder to avoid overflow when the caliper piston is pressed into the caliper bore. 2. Raise the vehicle and support it safely. Remove the wheel and tire assembly. 3. Remove the brake caliper, but do not disconnect the brake hose. Secure the caliper aside with mechanic’s wire. 4. Remove the inner and outer brake pad from the caliper. To install: 5. Bottom out the caliper piston in the caliper bore using an 8 in. (20cm) C-clamp or equivalent and a worn out inner brake pad or block of wood to push against the piston. Do not attempt to bottom out the piston with the outer brake pad installed. 6. Position the inboard brake pad in the caliper and press the retainer spring fully into the caliper piston. 7. Start one end of the outboard brake

93026627 93026625

View of the front disc brake anti-rattle spring—1998-01 Explorer and Mountaineer

Installing the rear disc brake pads— Explorer and Mountaineer

Make sure the cable end is not cocked or binding on the anchor pin when installed. All parts should be flat on the anchor pin.

17. Apply high temperature lithium grease to the threads and the socket end of the adjusting screw. Turn the adjusting screw into the adjusting pivot nut to the end of the threads and then loosen, ¥ turn. 18. Place the adjusting socket on the screw and install the assembly between the shoe ends with the adjusting screw nearest the secondary shoe. ->Be sure to install the adjusting screw on the same side of the vehicle from which it came. To prevent incorrect installation, the socket end of each adjusting screw is stamped with R or L, ®

Brake Caliper REMOVAL & INSTALLATION

:

to indicate installation on the right or left side of the vehicle. The adjusting pivot nuts have lines machined around the body of the nut, 2 lines indicating the right side nut and 1 line indicating the left side nut.

19. Hook the cable hook into the hole in the adjusting lever from the outboard plate side. The adjusting levers are also stamped with an R or L to indicate right or left side installation. 20. Place the hooked end of the adjuster spring in the large hole in the primary shoe web and connect the loop end of the spring to the adjuster lever hole. 21. Pull the adjuster lever, cable and automatic adjuster spring down toward the rear to engage the pivot hook in the large hole in the secondary shoe web. 22. After installation, check the action of the adjuster by pulling the section of the cable between the cable guide and the adjusting lever toward the secondary shoe web far enough to lift the lever past a tooth

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4

on the adjusting screw wheel. The lever should snap into position behind the next tooth and releasing the cable should cause the adjuster spring to return the lever to its original position. This return action will turn the adjusting screw 1 tooth. 23. If pulling the cable does not produce the action described previously, or if lever action is sluggish instead of positive and sharp, check the position of the lever on the . adjusting screw toothed wheel. With the brake in a vertical position, anchor at the top, the lever should contact the adjusting wheel 1 tooth above the centerline of the adjusting screw. If the contact point is below the centerline, the lever will not lock on the adjusting screw wheel teeth and the screw will not turn, since the lever is actuated by the cable. 24. Adjust the brake shoes using either a “brake adjustment gauge or manually with the drums installed. 25. Install the wheels, and lower the vehicle.

1998-01 GENERAL MOTORS REAR 1. Raise and safely support the vehicle. 2. Remove rear wheels. 3. Remove brake hose and cap line.

4. Remove retainers from caliper and remove caliper. To install: 5. Install brake pads if removed.

Blazer, Bravada, Envoy, Jimmy

FRONT 1. Remove % of the brake fluid from the master cylinder reservoir. 2. Raise and support the vehicle safely. Remove the tire and wheel assembly. 3. Disconnect and plug the caliper fluid line. Remove the bolts retaining the caliper to the rotor. Remove the caliper from the rotor. 4. Remove the disc brake pads from the caliper. Remove the disc brake pad retaining clips from inside the caliper. To install: 5. Clean and lubricate the sleeves and bushings with silicon grease. Install the pads in the caliper. 6. Install the caliper in position over the rotor and install the mounting bolts. Tighten the mounting bolts to 38 ft. Ibs. (561 Nm). 7. Connect the fluid lines to the caliper, if disconnected, and tighten to 33 ft. Ibs. (45 Nm). 8. Install the wheel and tire assembly. 9. Lower the vehicle and refill the master cylinder to the correct level. Bleed the brake system if the fluid lines were disconnected from the caliper.

8

A CALIPER BORE 6 VALVE, REAR BRAKE CALIPER SLEEDER 7 CAP, REAR BRAKE CALIPER BLEEDER VALVE 3 BOLT/SCREW, REAR BRAKE CALIPER GUIDE PIN UPPER 14 HOUSING, REAR BRAKE CALIPER 15 PIN, REAR BRAKE CALIPER GUIDE 16 BOOT, REAR BRAKE CALIPER GUIDE PIN 17 BRACKET, REAR BRAKE CALIPER ANCHOR 18 SEAL, REAR BRAKE CALIPER PISTON 19 PISTON, REAR BRAKE CALIPER 20 BOOT, REAR BRAKE CALIPER PISTON 29 PAD, REAR DISC BRAKE INNER 30 PAD, REAR DISC BRAKE OUTER 52 BOLT/SCREW, REAR BRAKE CALIPER GUIDE PIN LOWER 53 INSULATOR, REAR DISC BRAKE OUTER PAD 93026644

Rear Brake Caliper—Bravada

GENERAL yORoKG

a

6. Install caliper over rotor, and onto mounts. . * 7. Install retainers, and tighten to 23 ft. lbs. or (31 Nm).

_

8. Install brake hose, and tighten to 20

ft.Ibs. (27 Nm). 9. Bleed brake system. 10. Install tires. .

~ 11. Lower the vehicle.

12. Lower the vehicle, refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle.

Denali, Escalade, Suburban, Tahoe and Yukon af

e>There are 2 caliper designs and they can be identified by the method used to secure the assembly to the spindle bracket. The Delco caliper is secured by a bolt and sleeve combination. The Bendix caliper assembly is secured by a slider, spring and bolt.

1. Remove the cover on the master cylinder and siphon enough fluid out of the reservoirs to bring the level to ¥% full. This step prevents spilling fluid when the piston

is pushed back.

:

assembly with the mounting bolts or sliders. 9. Reconnect the brake line to the caliper. 10. Bleed the brakes 11. Pump the brake pedal and verify there is minimal brake pedal travel. 12. Check the brake fluid level. Install the tire and wheel assembly. 13. Lower the vehicle. Disc Brake Pads

REMOVAL & INSTALLATION Blazer, Bravada, Envoy, Jimmy

FRONT 1. Remove % of the brake fluid from

the master cylinder.

2. Raise and safely support the vehicle. 3. Place a C-clamp around the outer pad and caliper; tighten the C-clamp until the piston is fully compressed in the caliper. Remove the brake caliper pads.

4-1 if |

4, Remove the inboard pad and retaining spring from the caliper. 5. Remove the outboard pad from the caliper. . 6. Remove the sleeves and bushings. To install: 7. Clean and lubricate the sleeves and bushing with silicone lubricant and install them in the caliper. 8. Clip the retaining spring onto the inboard pad and install the pad in the caliper. 9. Install the outboard pad into the caliper. 10. Install the caliper in position over the rotor and install the mounting bolts. Bend the tabs, on the outboard brake pad, over the caliper. 11. Install the wheel and tire assemblies. 12. Lower the vehicle, refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle.

REAR 1. Remove % of the brake fluid from the master cylinder: 2. Raise and safely support the vehicle. 3. Remove wheels

2. Raise and support the vehicle safely. Remove the front wheels and tires. 3. Position a C-clamp around the outside pad and caliper; tighten the C-clamp until the caliper piston bottoms in its bore. 4. Remove the brake hose from the caliper by removing the inlet fitting. 5. Remove the bolt and sleeve or bolt and slider assemblies that hold the caliper and then lift the caliper off the rotor. 6. Remove the inboard and outboard pad. To install: 7. Install the pads onto the caliper. 8. Position the caliper onto the knuckle/rotor assembly and secure the

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93026645

Compressing the caliper piston—Denali, Escalade, Suburban, Tahoe and Yukon

93026647

Compressing the caliper piston with a C-clamp—Blazer, Bravada, Envoy, Jimmy

For Wheel Alignment specifications, see Section 1 of this manual

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RRC wee ae A Tee ee BRAKES _ GENERAL MOTORS

6. Remove the inboard and outboard shoe. . 7. Remove the pad support spring from the piston, if equipped. To install: 8. Thoroughly inspect, clean and lubricate all caliper slide points, bolts and hardware, 9. Position the retainer spring on the inner pad and insert the assembly into the center cavity of the piston. 10. Push down on the inner pad until it lays flat against the caliper. It is important to push the piston all the way into the caliper if new linings are installed or the caliper will not fit over the rotor. 11. Position the outboard pad with the

ears of the pad over the caliper ears and the tab at the bottom engaged in the caliper

93026648

Exploded view of the disc brake assembly—Blazer, Bravada, Envoy, Jimmy

4. Place a C-clamp around the outer pad and caliper; tighten the C-clamp until the piston is fully compressed in the caliper. Remove top caliper retainer, and rotate caliper away from rotor. 5. Remove the inboard pad and retaining spring from the caliper. 6. Remove the outboard pad from the caliper. To install:

7. Clean and lubricate the sleeves and bushing with silicone lubricant and install them in the caliper. 8. Clip the retaining spring onto the inboard pad and install the pad in the caliper. 9. Install the outboard pad into the caliper. 10. Install the caliper in position over the rotor and install the mounting bolts. 11. Install the wheel and tire assemblies. 12. Lower the vehicle, refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle. Denali, Escalade, Suburban, Tahoe and Yukon

DELCO TYPE 1. Remove the cover on the master cylinder and siphon out % of the fluid. This Step prevents spilling fluid when the piston is pushed back into the caliper bore. 2. Raise and support the vehicle safely.

3. Remove the wheels. 4. Compress the brake piston back into its bore using a C-clamp. 5. Remove the 2 bolts holding the caliper and then lift the caliper off the disc.

cutout. 12. With the 2 pads in position, place the caliper over the brake disc and align the holes in the caliper with those of the mounting bracket. 13. Install the mounting bracket bolts through the sleeves in the inboard caliper ears and through the mounting bracket, making sure the ends of the bolts pass under the retaining ears on the inboard pad. 14. Tighten the mounting bolts to 38 ft. lbs. (61 Nm). After both calipers are mounted pump the brake pedal to seat the pad against the rotor. Use a pair of channel

Bushing Mounting Bolt Seal Outboard Shoe & Lining Wear Sensor

Inboard Shoe & Lining 1w NNO Caliper Housing 93026649

R eplacing the disc brake pads—Delco type

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4-19

lock pliers to bend over the upper ears of the outer pad so it isn't loose. . 15. Install the wheels and lower the vehicle. 16. Add fluid to the master cylinder reservoirs so they are Y% in. (6.35mm) from the top. 17. Test the brake pedal by pumping it to obtain a hard pedal. Check the fluid level again and add fluid as necessary. Do not move the vehicle until a pedal is obtained.

BENDIX TYPE 1. Remove approximately ¥% of the brake fluid from the master cylinder. Discard the used brake fluid. 2. Raise and support the vehicle safely and remove the wheel. 3. Push the piston back into its bore. This can be done by using a C-clamp. 4. Remove the bolt at the caliper slider. Use a brass drift pin to remove the slider and spring. 5. Rotate the caliper up and forward from the bottom and Jift it off the caliper support. 4 6. Tie the caliper out of the way with a piece of wire. Be careful not to damage the

brake line. 7. Remove the inner shoe from the caliper support. Discard the inner shoe clip. 8. Remove the outer shoe from the caliper. To install: 9. Thoroughly clean, inspect and lubricate the caliper, slider and spring with silicone. 10. Install a new inboard shoe clip on the shoe. 11. Install the lower end of the inboard shoe into the groove provided in the support. Slide the upper end of the shoe into position. Be sure the clip remains in position. 12. Position the outboard shoe in the caliper, with the ears at the top of the shoe over the caliper ears and the tab at the bottom of the shoe engaged in the caliper cutout. If assembly is difficult, a C-clamp may be used. Be careful not to damage the lining. 13. Position the caliper over the brake disc, top edge first. Rotate the caliper downward onto the support. 14. Place the spring over the caliper support key, install the assembly between the support and lower caliper groove. Tap into place until the key retaining screw can be installed.

93026650

Replacing the disc brake pads—Bendix type

15. Install the screw and torque to 15 ft. lbs. (20 Nm). The boss must fit fully into the circular cutout in the key. 16. Install the wheel and add brake fluid as necessary. Brake Drums

j

REMOVAL & INSTALLATION Blazer, Bravada, Envoy, Jimmy 1. Raise and safely support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake drum. If the drum will not pull of the axle, use a rubber mallet and tap it around the edge. To install: 4. Install the drum on the axle and install the wheel and tire assembly. 5. Lower the vehicle. 6. Refill the master cylinder and pump pedal to attain full brake pedal before roadtesting the vehicle. Denali, Escalade, Suburban, Tahoe and Yukon

W/SEMI-FLOATING AXLES 1. Raise and support the vehicle safely. 2. Mark the relationship of the wheel to the hub and remove the wheel. 3. Mark the relationship of the drum to the hub and pull the drum from the brake assembly. If the brake drums have been

scored from worn linings, the brake adjuster must be backed off so the brake shoes will retract from the drum. The adjuster can be backed off by inserting a brake adjusting tool through the access hole provided. In some cases the access hole is provided in the brake drum. A metal cover plate is over the hole. This may be removed by using a hammer and chisel. To install: 4. Align the mark on the drum to mark on hub and install drum 5. Align the mark on the wheel to mark on drum and install wheel 6. Adjust brake lining as needed. Pump brakes

W/FULL FLOATING AXLES To remove the drums from full floating rear axles, the axle shaft will have to be removed. Full-floating rear axles can be identified by a bearing housing that protrudes through the center of the wheel. 1. Raise and support the vehicle safely. 2. Remove the wheel. 3. Remove the axle shaft. 4. Remove the retaining ring, key and adjusting nut. 5. Remove the hub and drum. To install: 6. Install the hub and drum to the tube. 7. Install the adjusting nut and torque to specification. 8. Install the key and retaining ring. 9. Install the axle shaft and wheel.

For Maintenance Interval recommendations, see Section 1 of this manual

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BRAKES

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GENERAL MOTORS

Brake Shoes

REMOVAL & INSTALLATION Blazer, Bravada, Envoy, Jimmy

1. Raise and safely support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake drum. 4. Remove the return springs from the brake shoes. Remove the shoe guide. 5. Remove the hold-down springs and pins. Remove the actuator lever and pivot. 6. Remove the lever return spring. Remove the actuator link. 7. Remove the parking brake strut and spring. Remove the parking brake lever.

8. Remove the brake shoes and the adjuster assembly. To install: 9. Lubricate the contact points on the backing plate and the adjuster with lithium grease. 10. Install the parking brake lever, adjusting screw and spring assembly. 11. Install the shoe assembly onto the backing plate. 12. Install the parking brake lever, strut and strut spring. 13. Install the actuator lever and lever pivot. Install the actuator link. 14. Install the lever spring, the holddown pins and springs. 15. Install the shoe guide. Install the

return springs and install the brake drum in position. 16. Adjust the brakes as follows: a. Remove the knockout area in the backing plate, behind the adjuster assembly. b. Ensure the parking brake system is adjusted properly with no tension on the cables or parking brake lever. The tops of the shoes should be firmly seated against the upper spring retaining anchor, if not as specified, loosen the parking brake cables. c. Install the drum and turn the brake adjuster until the wheels can just be turned by hand. d. Then, back the adjuster off 24

1. HOLD DOWN PINS 2. BACKING PLATE 3. PARKING BRAKE LEVER 4. SECONDARY SHOE 5. SHOE GUIDE 6. PARKING BRAKE STRUT 7. ACTUATOR LEVER 8. ACTUATOR LINK 9. RETURN SPRING 10. RETURN SPRING 11, HOLD DOWN SPRING 12. LEVER PIVOT 13. LEVER RETURN SPRING 14. STRUT SPRING 1§. ADJUSTING SCREW ASSEMBLY 16. ADJUSTING SCREW SPRING 17. PRIMARY SHOE 93026651

Exploded view of the drum brake components—Astro, Blazer, Bravada, Envoy, Jimmy, Safari, $10/S15 Pick-Up, Sonoma

el

BRAKES

GENERAL MOTORS notches. No brake drag should be felt after 12 notches. . « @. Install an adjusting hole plug in the backing plate to prevent dirt and moisture from entering. f. Readjust the parking brake cable as necessary. 17. Install the wheel and tire assemblies. 18. Lower the vehicle, refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle. Denali, Escalade, Suburban, Tahoe and Yukon

LEADING/TRAILING BRAKES 1. Raise the vehicle and support it Safely. 2. Remove the tire and wheel assembly. 3. Remove the brake drums. 4. Raise the lever arm of the actuator until the upper end is clear of the slot in the adjuster screw. 5. Slide the actuator off the adjuster pin. Disconnect the actuator spring from the shoe. :

6. Remove the hold-down spring assemblies and pins. 7. Pull the bottom ends of the shoes apart and lift the lower return spring over the anchor plate. Allow the shoe ends to come together and remove the spring. 8. Remove the shoe assembly, along with the upper return spring and the adjusting screw assembly. 9. Remove the upper return spring and the adjusting screw assembly from the shoes. 10. Remove the retaining ring, pin, spring washer, and parking brake lever. To install: 11. Clean adjuster wheel and the backing plates with a suitable cleaner. Lubricate the backing plate contact points, levers and adjuster with a suitable lubricant. 12. Assemble the parking lever, spring washer (concave side facing the brake lever), pin, antl retaining ring onto the rearward shoe. 13. Install the adjuster pin in the forward shoe with the pin projecting 0.276 in. (7mm) from the side of the shoe web where the adjuster actuator is installed.

14. With the brake shoes resting on a flat surface (the shoe with the parking lever to the rear of the vehicle), install the upper return spring. 15. Install the adjuster screw assembly with the spring clip facing the backing plate. 16. Place the shoes in position on the backing plate. Do not place the lower shoe webs under the anchor plate. 17. Install the lower return spring, spread the bottom of the shoes and position the shoe against the backing plate.

18. Install the hold-down pins and spring assemblies. 19. Install the adjuster actuator over the end of the adjuster pin so the top leg engages the notch in the adjuster screw. 20. Install the actuator spring, being careful not to over-stretch it more than 3.27 in. (83mm). 21. Install the parking brake cable to the lever. 22. Adjust the parking brake if the shoes will not totally retract. 23. Install the drum, tire and wheel

1. SPRING, ACTUATOR 2. SPRING, UPPER RETURN 3. ACTUATOR, ADJUSTER 4. SPRING, LOWER RETURN 5. ASSEMBLY, HOLD —- DOWN SPRING 6. PIN, HOLD -DOWN 7. SHOE & LINING ’ 8. SHOE & LINING 19. PISTON 9. SOCKET, ADJUSTER 20. SEAL 10. CLIP, SPRING 21. SPRING ASSEMBLY 11. NUT,ADJUSTER 22. VALVE, BLEEDER 12. SCREW, ADJUSTER 23. BODY, WHEEL CYLINDER 13. RING, RETAINING 24. CUP, BLEEDER VALVE 14. PIN 25. PLUG, ACCESS HOLE 15. WASHER, SPRING 26. COVER, INSPECTION 16. LEVER, PARK BRAKE 27. PLATE, BACKING 17. BOLT 28. PIN, ADJUSTER 18. BOOT 93026652

Savana, Suburban, Tahoe and Yukon with Exploded view of the rear drum brake assembly—C/K Pick-Up, Denali, Escalade, G-Series Van, Leading/Trailing type

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

A-22

BRAKES GENERAL MOTORS

resect . Adjust the rear brakes and lower the vehicle.

DUO-SERVO BRAKES 1. Raise the vehicle and support it Safely. 2. Remove the tire and wheel assembly. 3. Remove the brake drums. 4. Using a brake tool, remove the shoe return springs. 5. Remove the shoe guide. 6. Remove the hold-down springs and _ PINS.

~~ 7. Remove the actuator lever and pivot. »., 8. Remove the lever return spring. isda

9. Remove the actuator link, parking brake strut, spring retaining ring. 10. Remove the parking brake lever and washer. 11. Remove the shoe assemblies. 12. Remove the adjuster screw and spring from the shoe assembly. To install: 13. Use a brake cleaning fluid to remove dirt from the brake drum. Check the drums for scoring, cracks and for out-of-round; service the drums as necessary. 14. Check the wheel cylinders by carefully pulling the lower edges of the wheel + cylinder boots away from the cylinders. If

there is excessive leakage, the inside of the cylinder will drip fluid; repair or replace as necessary. 15. Check the flange plate, which is — located around the axle, for leakage of differential lubricant. 16. Lightly lubricate the parking brake cable, parking brake lever where it enters the shoe and the backing plate-toshoe contact points. Use high tempera~ ture, waterproof, grease or special brake lube. 17. Install the parking brake lever into~ the secondary shoe with the attaching bolt, spring washer, lockwasher, and nut. It is

. HOLD DOWN PINS . BACKING PLATE . PARKING BRAKE LEVER . SECONDARY SHOE . SHOE GUIDE . PARKING BRAKE STRUT . ACTUATOR LEVER . ACTUATOR LINK &l&WNH DONA — . RETURN SPRING 10. RETURN SPRING 11. HOLD DOWN SPRING 12. LEVER PIVOT 13. LEVER RETURN SPRING 14. STRUT SPRING 15. ADJUSTING SCREW ASSEMBLY 16. ADJUSTING SCREW SPRING 17, PRIMARY SHOE 93026G53

Exploded view of the rear drum brake assembly—C/K Pick-Up, Denali, Escalade, G-Series Van, Savana, Suburban, Tahoe and Yukon with DuoServo type

re.

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:

|

important that the lever move freely before the shoe is attached. Move the assembly and check for proper action. 18. Lubricate the adjusting screw and

make sure it works freely. -19. Connect the adjuster screw and spring to the bottom portion of both shoes. Ensure the spring does not interfere with the adjuster rotation when installed. The primary (smaller shoe pad area) to the front and secondary shoe

|

ceUCHEVY

SS

(larger shoe pad area) to the rear of the vehicle. 20. Install the shoe assembly. Ensuring the shoe webs are positioned correctly

against the wheel cylinder. 21. Install the parking brake cable. 22. Secure the primary shoes with the hold-down pin and spring. 23. Install the parking brake strut and the strut spring. 24. Install the actuator lever and pivot,

4-23 be

securing the assembly with the hold-down pin and spring. Install the actuator link and spring. 25. Install the return springs. 26. Check the operation of the selfadjusting mechanism by moving the actuating lever by hand. 2/7. Adjust the brakes and install the drum. 28. Adjust the parking brake. . 29. Install the tire and wheel assembly. 30. Lower the vehicle.

Pe he st fv

1998-01 GEO/CHEVY TRACKER aa

Brake Caliper

To install:

5. Install the caliper on the vehicle.

REMOVAL & INSTALLATION

Ne moumng BOM 1020 7S. (27

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’

1. Raise and Safely support the vehicle.

2. Remove the wheels. 3. Disconnect and plug the brake line. 4. Remove the caliper mounting bolts (guide pins) and remove the caliper from the vehicle.

Disc Brake Pads

|

REMOVAL & INSTALLATION

6. Connect the hydraulic brake line, using 2 new washers. Torque the union bolt

to 17 ft. Ibs. 23 Nm). 7. Replace the front wheels. 8. Lower the vehicle. 9. Fill the brake reservoir and bleed the hydraulic brake system.

;

the master cylinder. 2. Raise and safely support the vehicle. 3. Remove the wheels. — 4. Remove the brake caliper mounting

OUTBOARD BRAKE PAD ANTI-RATTLE SPRING INBOARD ANTI-NOISE SHIM PISTON BOOT PISTON PISTON SEAL CALIPER PIN BOLT BOOT CALIPER PIN BOLT

511

CALIPER

516

“Ghd a re S 23. e

1. Siphon about % of the fluid out of

CALIPER CARRIER OUTBOARD ANTI-NOISE SHIM

510

:

INBOARD BRAKE PAD BLEEDER VALVE

Front disc brake components—Tracker

For complete service labor times, order the Chilton Labor Guide

93026637

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bolts and remove the caliper from the mounting bracket. 5. Support the caliper with a wire. 6. Using a large pair of plies or a Cclamp compress the caliper piston back into the bore. 7. Remove the disc brake pads and any shims from the caliper mounting bracket. a To install: i 8. Install the brake pads and any shims removed from the caliper mounting bracket. me 9. Install the caliper on the mounting i bracket and install the mounting bolts. Tighten the mounting bolts to 20 ft. Ibs. (27 Nm).

rr. }

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10. Install the front wheels and lower the vehicle.

* CAUTION Do not attempt to drive the vehicle until after the following step is per-

formed.

513

.

11. Depress the brake pedal repeatedly

until a firm pedal is obtained. Do not

513.

PARKING BRA

attempt to drive the vehicle unless a firm pedal is obtained. 12. Check the fluid level in the master

514

PARKING

cylinder. Add fresh brake fluid, as necessary.

13. Road-test the vehicle.

REMOVAL & INSTALLATION 1. Raise and safely support the vehicle. 2. Remove the rear wheel(s). 3. Release the parking brake. 4. Remove the parking brake lever cover screws and loosen the brake cable locking nut. 5. Install 2, 8mm bolts into the brake drum holes and uniformly tighten each bolt. Tighten each bolt until the brake drum is removed from the vehicle. Ifthere is difficulty in removing the drum, insert a small tool through the hole in the rear of the backing plate, and hold the automatic adjusting lever away from the adjuster. Using another narrow, flat tool at the same time, reduce the brake shoe adjuster by turning the adjusting wheel. To install: 6. Install the brake drum and pull the parking brake lever all the way up until a clicking sound can no longer be heard. 7. Verify that the rear wheels will not turn. If the rear wheels turn, adjust the parking brake cable as necessary. 8. Release the parking brake and

remove the brake drum. Measure the diame-

ter of the brake shoes. Outer diameter should be as follows:

;

KE CABLE LOCKNUT

BRAKE

LEVER

COVER 93026638

‘

Reducing the adjusterto remove the brake drum—tTracker

e 2 door models: 8.638 (0.0012 inches (219 ( 0.3mm) e 4 door models: 9.980 (0.0079 inches (253.5 (0.2mm) 9. If the brake shoe clearance is not

1

DRUM

2

TWO

correct, adjust the brake shoes until the clearance is correct. 10. Reinstall the brake drum, replace the wheel(s), and safely lower the vehicle.

8mm

BOLTS 9302639

Removing the brake drum with the 2, 8mm bolts—Tracker

Sst

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BRAKES GEO/CHEVY

Cee

—

8. Disengage the parking brake lever from the parking brake cable and remove the rear shoe. 9. Remove the C-washer, the automatic adjuster lever and spring, the C-

WHEEL CYLINDER ADJUSTER SHOE RETURN LOWER SPRING BRAKE SHOES SHOE HOLD DOWN SPRING ADJUSTER SPRING PAWL LEVER SHOE RETURN UPPER SPRING BACKING PLATE asCOMIN AMAGHAWH — SHOE HOLD DOWN PIN 93026640

Exploded view of the rear brake components—Tracker

11. Adjust the parking brake and install the cover with the 2 screws. 12. Road-test the vehicle for proper brake operation.

Brake Shoes

REMOVAL & INSTALLATION 1. Raise and safely support the vehicle. 2. Remove the rear wheel(s). 3. Remove the brake drum.

4. Using a suitable tool, remove the brake shoe return spring. 5. Using a brake spring hold-down tool, disengage the hold-down spring and retainers from the front shoe. Remove the hold-down retainer pinch 6. Disconnect the anchor spring from the front shoe and remove the front shoe. 7. Remove the anchor spring from the rear shoe. Using a brake spring hold-down tool, disengage the hold-down spring and retainers from the rear shoe. Remove the hold-down pinch

washer, and the parking brake lever from the rear shoe. 10. Thoroughly clean the backing plate and brake hardware with brake cleaning solvent. Apply high temperature grease to the backing plate shoe contact points, anchor plate and shoe contact points, adjusting bolt, and adjuster and brake shoe contact points. To install: 11. Reinstall the automatic adjuster lever and the parking brake lever to the rear shoe using new C-washers. 12. Connect the parking brake lever to the parking brake cable. Set the adjuster and spring to the rear shoe. 13. Set the rear brake shoe in place, install the hold-down pin and install the hold-down spring and retainers. Make sure that the shoe is inserted in the wheel cylinder and that the other end is in the anchor plate. 14. Install the anchor spring to the rear shoe. 15. Install the front shoe to the other end of the anchor spring and set the front shoe in place. Make sure that the front shoe engages the wheel cylinder, adjuster mechanism and spring, and the anchor plate. 16. Reinstall the front brake shoe holddown pin and secure with the hold-down spring and retainers using a Suitable tool. 17. Install the return spring. 18. Install the brake drum and pull the parking brake lever all the way up until a clicking Sound can no longer be heard. 19. Verify that the rear wheels will not turn. If the rear wheels turn, adjust the parking brake cable as necessary. 20. Release the parking brake and remove the brake drum. Measure the diameter of the brake shoes. Brake diameter should be as follows: e 2 door models: 8.638 ( 0.0012 inches (219 (0.3mm) e 4 door models: 9.980 (0.0079 inches (253.5 (0.2mm) 21. If the brake shoe clearance is not correct, adjust the brake shoes until the clearance is correct. 22. Reinstall the brake drum, replace the wheel(s), and safely lower the vehicle. 23. Road-test the vehicle for proper brake operation.

Please visit our web site at www.chiltonsonline.com

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4-26 “BRAKES

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CR-V and Passport

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FRONT

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Remove the front wheels.

tighten the bolts to 103-126 ft. Ibs.

4. Remove the brake caliper mounting bolt and guide bolt and remove the caliper from the mount. The brackets can be

(139-171 Nm). 8. Install the caliper on the mounting bracket. Torque the caliper-to-mounting

remove for additional work space.

bracket bolts to:

from the caliper. Inspect the brake pads for

wear; replace them, if necessary. To install:

2. Remove some brake fluid from the master cylinder reservoir.

e

line from the caliper.

5. Remove the brake pads and clips

1. Raise and safely support the vehicle.

-:

7. If the caliper bracket was removed,

3. Disconnect and plug the brake fluid

i

Brake sLallioe Se

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6. Install the brake pads and clips onto the caliper.

INNER PAD SHIMB

WEAR INDICATOR Install inner pad with its wear indicator upward.

OUTER PAD /

e 4-cylinder models: 20-27 ft. Ibs. (27-37 Nm)

~

e 6-cylinder models: 54 ft. Ibs. (74 Nm) 9. Connect the fluid line to the caliper

using new washers. Torque the brake line banjo fitting to 26 ft. Ibs. (35 Nm).

CALIPER PINA

mn

PIN BOOTS Replace.

INNER PAD SHIM A

INNER PAD

?

OUTER PAD SHIM oe

BLEED SCREW 9 N-m (0.9 kgf-m, 6.5 Ibf-ft)

CALIPER PIN B PAD SPRING

CALIPER BRACKET PISTON

CALIPER BODY

PAD RETAINERS

PISTON BOOT Replace.

CALIPER BOLT 49 N-m (5.0 kgf-m,

36 Ibf-ft)

Sa

PISTON SEAL Replace. 93026657

Exploded view of the front caliper components—CR-V

ON

anne 4-27

93026654

Exploded view of the front caliper components—Passport

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=

11. Install the front wheels and lower the vehicle.

Be sure the hook end of the flexible brake line is positioned in the antirotation cavity. «

REAR 1. Raise and safely support the vehicle. Remove the rear wheels.

10. Refill the master cylinder reservoir and bleed the brake system.

3. Disconnect and plug the brake fluid line from the caliper. : i Hai ae nease Peale mounting pin after removal. 4. lf equipped with caliper actuated

2. Remove some fluid from the master

parking brakes; remove the mounting pin

cylinder reservoir.

from the parking brake cable and discon-

4

(1)

Caliper Assembly

(3)

Lock Bolt

(4) Pad Assembly

(2) Clip

93026655

Exploded view of the rear caliper components—Passport

Timing belt service is covered in Section 3 of this manual

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Caliper. 5. Remove the brake caliper mounting bolt and guide bolt and remove the caliper from the mount. 6. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear; replace them, if necessary.

To

FRONT

ing the brake disc, the brake pad should be replaced. . 1. Remove ¥% of the volume of brake fluid from the master cylinder to prevent overflow when the caliper piston is compressed. 2. Raise and safely support the vehicle. 3. Remove the wheel and tire assemblies. ~ 4. Remove the brake caliper without disconnecting the brake line. Support the caliper with a length of wire. Do not let the caliper hang from the brake hose.

Most disc brake pads are equipped with wear indicators. If a squealing noise occurs from the brakes while driving, check the pad wear indicator plate. If there is evidence of the indicator plate contact-

>On some disc brake systems it is not necessary to remove the caliper when installing new brake pads. Remove the lower slide bolt and rotate the caliper upward to remove the pads.

11. Connect the fluid line to the caliper using new washers. Torque the brake line banjo fitting to 26 ft. Ibs. (35 Nm). 12. Refill the master cylinder reservoir and bleed the brake system. 13. Install the rear wheels and lower the vehicle.

~ nect the parking cable from the disc

install:

“ Disc Brake Pads

7. \nstall the brake pads and clips onto the caliper. 8. If the mounting bracket was on . removed, tighten the bolts to 69-84 ft. Ibs. (98-114 Nm). 9. Install the caliper on the mounting bracket. Torque the caliper-to-mounting bracket bolts to 12-17 ft. Ibs. (16-24 Nm), Or 32 ft. Ibs. (43 Nm) on vehicles with shoe-type parking brakes. 10. Connect the parking brake cable to ve the caliper and install a new mounting pin.

|

=

REMOVAL & INSTALLATION CR-V and Passport

INNER SHIM A

CALIPER BOLTS

INNER SHIM B

23 N-m (2.3 kgf-m,

PAD SPRING

17 Ibf-ft)

CALIPER PIN A

BLEED SCREW 9 N-m (0.9 kgf-m,

6.5 Ibf-ft) BRAKE PADS OUTER PAD SHIM

oma)

PIN BOOTS

eplace

CALIPER PIN

CALIPER BRACKET

PAD RETAINERS

CALIPER BRACKET MOUNTING BOLT

GREASE

|

:

ae PISTON SEAL Replace.

38 N-m (3.9 kgf:m,

28 Ibf-ft) PISTON BOOT Replace

Exploded view of the rear caliper components—CR-V

93026658

HONDA 5. Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining. To install: 6. Use a suitable tool to push the caliper piston into its bore. 7. Apply a thin coat of grease to the rear face of the brake pad and install the shim. Install the brake pads. 8. Install the calipers. Lubricate the caliper bolts and boots. If equipped with a 4-cylinder engine, tighten the caliper mounting bolts to 24 ft. Ibs. (33 Nm). If equipped with a 6-cylinder engine, tighten the caliper mounting bolts to 54 ft. Ibs. (74 Nm). 9. Install the wheel and tire assemblies and lower the vehicle. 10. Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid in the master cylinder and add as necessary.

REAR 1. Raise and safely support the vehicle. Remove the rear wheels. 2. Remove the brake caliper mounting bolts and remove the caliper without disconnecting the brake fluid line. Support the caliper so it does not hang on the brake line.

) ) ) )

3. Remove the brake pads and retaining clips from the caliper. 4. If equipped with caliper-activated parking brakes; use tool J-37617 or equivalent, to rotate the piston clockwise until it retracts into the bore. Align the notches of the piston face so the centerline of the notches is perpendicular to the centerline of the mounting bosses. To install: 5. Install the new brake pads and clips in the caliper and install the caliper in the mounting bracket. 6. Tighten the caliper mounting bolts to 12-17 ft. Ibs. (16-24 Nm), or 32 ft. Ibs. (43 Nm) on vehicles with shoe-type parking brakes. 7. Install the rear wheels. Check the brake fluid level. 8. Pump the brake pedal until pressure is felt before moving the vehicle. Brake Drums

REMOVAL & INSTALLATION CR-V and Passport 1. Raise and safely support the vehicle. Release the parking brake. 2. Remove the rear wheels.

Brake Linings Wheel Cylinder Bolts Brake Pipe 93026656

Exploded view of the rear drum brakes—Passport

3. Use chalk to mark the brake drum to one of the wheel studs as an index mark for reinstallation. 4. Remove the retaining screw that holds the brake drum to the axle flange. 5. Pull the brake drum from the axle flange. To install: 6. Align the index mark and install the brake drum to the axle flange. 7. Install the retaining screw to secure the brake drum to the axle flange. 8. Install the rear wheels.

Rear Brake Shoes.

REMOVAL & INSTALLATION CR-V and Passport 1. Raise and safely support the vehicle. 2. Remove the rear wheels. 3. Remove the brake drums. 4, Remove the brake return springs. 5. Remove the leading shoe holding pin and spring, and then the leading shoe. 6. Remove the self-adjuster and the adjuster lever. 7. Remove the trailing shoe holding pin and spring. 8. Disconnect the parking brake cable from the trailing shoe and remove the trailing shoe. Remove the parking brake lever from the trailing shoe. To install: 9. Attach the parking brake lever to the trailing shoe. 10. Connect the parking brake cable to the parking brake lever. 11. Apply a thin coat of high temperature grease to the shoe contact points on the brake backing plate contact surface (B), and self-adjuster (D). 12. Position the trailing shoe on the backing plate and install the hold-down pin, Spring, and retainer. Be careful not to stretch the return spring when fitting the shoes onto the backing plate. 13. Connect the upper return spring and the leading shoe to the trailing shoe and position the leading brake shoe on the backing plate. 14. Install the adjuster assembly and the hold-down pin, spring, and retainer. 15. Use a brake spring tool to install the lower return spring.

Heater Core replacement is covered in Section 2 of this manual

ee

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HONDA 9 N-m (0.9 kgf-m, 6.5 tbf-ft)

BACKING PLATE PARKING BRAKE LEVER

ADJUSTER BOLT UPPER RETURN SPRING CLEVIS B

TENSION PIN U-CLIP 10 mm BOLT 64 N-m (6.5 kgf-m, 47 Ibf-ft)

BRAKE SHOE

WHEEL CYLINDER

SELF-ADJUSTER LEVER

LOWER RETURN SPRING

SELF-ADJUSTER SPRING

RETAINER SPRING 93026659

Exploded view of the rear drum brakes—CR-V

16. Install the self-adjuster lever and adjuster spring. 17. Adjust the shoe-to-drum clearance to 0,0098-0.0157 in. (0.25-0.40mm) and

18. Check the brake drum for scoring or other wear. Machine or replace as necessary. Check the maximum brake drum diameter specification when machin-

install the brake drum.

ing.

19. Install the rear wheels. Lower the vehicle. 20. Road-test the vehicle.

1998-01 HYUNDAI Brake Caliper

_

REMOVAL & INSTALLATION

8. Install the brake hose to the caliper and tighten the fitting too 18-22 ft. Ibs. (25-30 Nm). 9. Install the wheel. 10. Bleed the brake system.

Santa Fe

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Remove the brake hose from the caliper. 4. Remove the caliper mounting bolts. 5. Remove the caliper. To install: 6. Install the caliper. 7. Install the caliper mounting bolts and tighten to 58-73 ft. Ibs. (80-100 Nm).

Disc Brake Pads

REMOVAL & INSTALLATION Santa Fe

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Remove the caliper mounting bolts. 4. Remove the caliper and support aside with wire. Do not let the caliper hang by the

hose. 5. Remove the pads and shims. To install: 6. Install the pads, clips and shims. 7. Bottom the caliper piston using tool 09581-11000 or a C-clamp 8. Install the caliper mounting bolts and tighten to 16-24 ft. Ibs. (22-32 Nm). 9. Install the wheel.

Brake Shoes

REMOVAL & INSTALLATION Santa Fe

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel.

-

weet

BRAKES

HYUNDAI

3. Remove the drum. 4, Remove the brake shoe hold-down

spring. 5. Remove the brake strut.

6. Remove the brake shoe return spring.

7. Remove the brake shoes. To install: 8. Install the brake shoes. 9. Install the brake shoe return spring. 10. Install the brake strut.

11. Install spring. 12. Install 13. Install 14. Adjust

4-31

s x

the brake shoe hold-down the brake drum. the wheel. the brake shoes.

1998-00 INFINITI Brake Caliper

}

REMOVAL & INSTALLATION

Qx4 FRONT 1. Raise the vehicle and support safely. 2. Remove the appropriate tire and wheel assembly. 3. Remove the bolt attaching the brake hose to the caliper. Plug the brake hose to prevent brake fluid loss.

4. Remove the caliper support mounting bolts and lift the caliper assembly from the knuckle. To install 5. Position caliper assembly onto the knuckle and install the bolts. Make sure the rotor fits between the brake pads. Torque the bolts to 53-72 ft. Ibs. (72-97 Nm). 6. Use new copper washers and connect the brake hose to the caliper. Torque the brake hose attaching bolt to 12-14 ft. Ibs. (17-20 Nm). 4 7. Bleed the brake system.

8. Apply the brake pedal and inspect the system. Ensure proper operation and no leakage. 9. Install tire and wheel assembly, Lower the vehicle and road-test.

"Sn be

REAR e>Unlike most rear disc brake designs, this system does not incorporate the parking brake system into the rear brake caliper. The rear brake system is serviced in the same manner as the front system.

ee O s

: Nem (kg-m, in-Ib) {0} : Nem (kg-m, ft-lb)

Orm® to sliding

: PBC (Poly Butyl Cuprysil) grease or silicone-based grease point : Rubber grease point : Brake

fluid point

portion

fo OO OOEA®

[F) 140 - 160 (14.3 - 16.3, 103 - 118)

Main pin Pin boot Torque member fixing bolt Torque member Shim cover Inner shim Inner pad VOO@OO2OHO

Pad retainer

Outer pad Outer shim Connecting bolt Copper washer Main pin bolt QBOSSoOo@

Bleed valve Cylinder body Piston seal Piston Piston boot Pad spring @2OeSeQeQ@®

Exploded view of the dual piston caliper front brake components—QX4

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

93026660

av

BRAKES INFINITI

38 - 52

(3.9 - 5.3, 28 - 38) os,

(0) 31-41

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(3.2 42s south es calla

7209 (0.7 - 0.9, i 78)

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: Nem (kg-m, in-lb)

[BJ ; Nem (kg-m, ft-lb) : PBC (Poly Butyl Cuprysil) grease or silicone-based grease point : Rubber grease point

Hi®

@ @ @ @ © ©

Inner pad Pad retainer

Main pin bolt Pin boot Torque member fixing bolt Torque member Shim cover Inner shim

Outer pad Outer shim Connecting bolt Copper washer Q@OOeCoe9

: Brake fluid point

Bleed valve Cylinder body Piston seal Piston Piston boot Retainer @OSQaaQee@® 93026G61

Exploded view of the rear disc brake components—OX4

1. Raise the vehicle and support Safely. 2. Remove the appropriate tire and wheel assembly. 3. Remove the caliper support mounting bolts and lift the caliper assembly from the baffle plate. 4. Loosen the brake fluid hose with a wrench and turn the caliper to disconnect it from the brake hose. Plug the brake hose to prevent brake fluid loss. To install: 5. Use a new copper washer and connect the brake hose to the caliper. Torque the hose fitting to 11 ft. Ibs. (15 Nm). 6. Position the caliper assembly over the baffle plate and install the bolts. Make Sure the rotor fits between the brake pads. Torque the bolts to 28-38 ft. Ibs. (38-52 Nm). 7. Bleed the brake system. 8. Apply the brake pedal and inspect the system. Ensure proper operation and no leakage. 9. Install tire and wheel assembly. Lower the vehicle and road-test.

Disc Brake Pads

REMOVAL & INSTALLATION

Qx4 ->Both the front and rear disc brake pads can be serviced using the same procedure.

1. Using a syringe, siphon brake fluid from the reservoir, leaving reservoir approximately 2 full. 2. Raise and properly support the vehicle. 3. Remove the wheel assemblies. 4. Remove the lower pin bolt from the brake caliper. 5. Swivel the caliper up and away from the torque member. Tie the caliper to a suspension member so that it is out of the way. 6. Lift the 2 brake pads out of the torque member. 7. Remove the inner and outer shims. Remove the 2 pad retainers if they are not still attached to the pads.

8. Check the pad thickness. and replace the pads if they are less than 0.079 in. (2mm) thick. To install: 9. Install the inner and outer shims into the torque member. 10. Install a pad retainer to the bottom of each pad. 11. Install the pads into the torque member. 12. Use a C-clamp or hammer handle and press the caliper piston(s) back into the housing. 13. Untie the caliper and swivel it back into position over the torque plate so that the dust boot is not pinched. Install the pin bolt and torque it to 16-23 ft. Ibs. (22-31 Nm). 14. Check the condition of the pin boot. Gently pull on it to expel any trapped air. 15. Install the wheel and lower the vehicle. 16. Pump the brakes until the pedal is firm and check the level of brake fluid. Road-test the vehicle.

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a. Strike the face of the drum with a

Qx4 the hub cap and loosen the

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2. Raise the rear of the vehicle and sup-

port it on jackstands.

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plastic or rubber mallet. This will break free any rust which may develop between the drum and the hub.

b. Install 2, 8 x 1.25mm bolts into

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the holes in the drum and gradually tighten them to pull the drum off the hub. To install: 6. Install the brake drum to the hub.

7. Install the tire, wheel and lug nuts.

8. Remove the jackstands and lower the vehicle. 9. Road-test the vehicle to ensure that

the brakes are working properly.

Vid 21 - 27 (2.1 - 2.8, 15 - 20)

Y(

©, [) 11 - 14 (1.1 - 1.4, 8 - a

ie (7)

Front of

vehicle

gy

(0) : Nem (kg-m, ft-lb)

Front of oO A vehicle

: Brake grease point

@ _ Parking brake cable

@

e

BRAES 4-33

ES

3. Remove the lug nuts, tire and wheel. 4. Release the parking brake. 5. Pull the brake drum from the hub. If difficult to remove try the following:

Sa STALL

i

Toggle lever

@®

Anti-rattle spring

Stopper pin

@

Retainer

,

@

Back plate

@

Anchor block

@

Return spring

@ ~ Anti-rattle pin

@ ®

E-ring Lever

@ @

Shoe Adjuster spring

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oes

Adjuster assembly LH Adjuster assembly RH 93026G62

Exploded view of the rear disc brake drum assembly—QX4

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

| -3 f' |

BRAKES INFINITI

Brake Shoes

REMOVAL & INSTALLATION

ax4 1. Release the parking brake. 2. Safely raise and support the vehicle. 3. Remove the rear wheel and drum. 4. Remove the hold-down pin retainers. 5. Remove the leading shoe and then the trailing shoe. 6. Remove the adjuster. 7. Disconnect the parking brake cable from the toggle lever on the rear shoe. To install: 8. Transfer the toggle lever to the new rear shoe.

9. Apply a small amount of brake grease to the tips of the shoes and the 6 pads on the backing plate that contact the brake shoe. 10. Shorten the adjuster by turning it. 11. Connect the parking brake cable to the toggle lever on the rear shoe. 12. Install the lower return spring to both shoes and install the shoes on the backing plate with the hold down pins and retainers. 13. Install the adjuster and the remaining springs. Pay attention to the direction of the adjuster assembly. 14. Inspect the complete assembly and install the brake drum. 15. Adjust the shoe to drum clearance. 16. Install the wheel assembly and lower the vehicle to the floor.

For RH brake

Vehicle front

For LH brake 93026663

Correct direction of brake shoe adjuster—

QXx4

1998-01 ISUZU Brake Caliper REMOVAL & INSTALLATION Trooper

eS Bo ee a a 0

FRONT

1. Raise and safely support the vehicle. 2. Remove some brake fluid from the reservoir. 3. Remove the front wheels. 4. Disconnect the brake fluid line from the caliper. Plug the line to prevent fluid loss. 5. Loosen the brake caliper mounting

(1) Guide Bolt (2) Brake Flexible Hose (3) Lock Bolt

bolt and guide bolt. Remove the caliper from the mount. 6. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear and replace them if necessary, To install: 7. Fill the brake caliper with clean brake fluid and connect the fluid line to the caliper using new washers. Tighten the brake line banjo fitting to 26 ft. Ibs. (35 Nm). Install the brake pads and clips onto the caliper. 8. Install the caliper onto the mounting bracket. Lubricate the caliper bolts and their boots. Then, install the caliper mount-

(4) Caliper Assembly (5) Clip (6) Support Bracket with Pad Assembly (7) Pad Assembly 93026602

Front caliper assembly—tTrooper

ing bolts and tighten them to 54 ft. Ibs. (74 Nm). 9. Refill and bleed the brake system. 10. Install the front wheels and lower the vehicle.

REAR 1. Raise and safely support the vehicle. 2. Remove some brake fluid from the reservoir. 3. Remove the rear wheels. 4. Disconnect the brake fluid line from the caliper. Plug the line to prevent fluid loss. 5. Loosen the brake caliper mounting bolt and guide bolt. Remove the caliper from the mount bracket. 6. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear; replace them if necessary. 7. lf necessary for servicing, unbolt the caliper mounting bracket from the backing plate. To install: 8. If removed, install the caliper mounting bracket and tighten its bolts to 76 ft! Ibs. (103 Nm). 9. Fill the brake caliper with clean brake fluid and connect the fluid line to the caliper using new washers. Tighten the brake line banjo fitting to 26 ft. Ibs. (35 Nm). Install the brake pads and clips onto the caliper. 10. Install the caliper on the mounting bracket. Lubricate the caliper bolts and their boots. Then, install the caliper mountee Tighten them to 32 ft. Ibs. (44 m). 11. Refill and bleed the brake system.

BRAKES

ISUZU

:

4-

35

tighten the bolts to 103-126 ft. Ibs. (139171 Nm). 8. Install the caliper on the mounting bracket. Torque the caliper-to-mounting bracket bolts to: e 4-cylinder models: 20-27 ft. Ibs. (27-37 Nm) ¢ 6-cylinder models: 54 ft. Ibs. (74 Nm) 9. Connect the fluid line to the caliper using new washers. Torque the brake line banjo fitting to 26 ft. Ibs. (35 Nm).

Be sure the hook end of the flexible brake line is positioned in the antirotation cavity. 10. Refill the master cylinder reservoir and bleed the brake system. 11. Install the front wheels and lower the vehicle.

a (1) Caliper Assembly (2) Clip

(3) (4)

Lock Bolt Pad Assembly 93026G01

Rear caliper assembly—Trooper

12. Install the rear wheels and lower the vehicle. Amigo and Rodeo

FRONT 1. Raise and safely support the vehicle. Remove the front wheels. 2. Remove some brake fluid from the master cylinder reservoir. 3. Disconnect and plug the brake fluid line from the caliper.

4. Remove the brake caliper mounting bolt and guide bolt and remove the caliper from the mount. The brackets can be remove for additional work space. 5. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear; replace them, if necessary. To install: 6. Install the brake pads and clips onto the caliper. 7. If the caliper bracket was removed,

REAR 1. Raise and safely support the vehicle. Remove the rear wheels. 2. Remove some fluid from the master cylinder reservoir. 3. Disconnect and plug the brake fluid line from the caliper. Discard the parking brake cable mounting pin after removal.

4. |f equipped with caliper actuated parking brakes; remove the mounting pin from the parking brake cable and disconnect the parking cable from the disc caliper. 5. Remove the brake caliper mounting

8 N-m (69 tb in)

93026654

Exploded view of the front caliper components—Rodeo

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

iS RGR

4- 3

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BRAKES ISUZU

10. Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid in the master cylinder and add as necessary.

REAR 1. Raise and safely support the vehicle. Remove the rear wheels. 2. Remove the brake caliper mounting

bolts and remove the caliper without dis-

(3)

(1) Caliper Assembly (2) Clip

Lock Bolt

(4) Pad Assembly 93026655

Exploded view of the rear caliper components—Rodeo

bolt and guide bolt and remove the caliper from the mount. 6. Remove the brake pads and clips from the caliper. Inspect the brake pads for wear; replace them, if necessary. To install: 7. Install the brake pads and clips onto the caliper. 8. If the mounting bracket was removed, tighten the bolts to 69-84 ft. Ibs. (93-114 Nm). 9. Install the caliper on the mounting bracket. Torque the caliper-to-mounting bracket bolts to 12-17 ft. Ibs. (16-24 Nm), or 32 ft. Ibs. (43 Nm) on vehicles with shoe-type parking brakes. 10. Connect the parking brake cable to the caliper and install a new mounting pin. 11. Connect the fluid line to the caliper using new washers. Torque the brake line banjo fitting to 26 ft. Ibs. (35 Nm). 12. Refill the master cylinder reservoir and bleed the brake system. 13. Install the rear wheels and lower the vehicle.

Disc Brake Pads

REMOVAL & INSTALLATION Amigo and Rodeo

FRONT Most disc brake pads are equipped with wear indicators. If a squealing noise occurs from the brakes while driving, check the pad wear indicator plate. If there is evidence of

the indicator plate contacting the brake disc, the brake pad should be replaced. 1. Remove 1 of the volume of brake fluid from the master cylinder to prevent overflow when the caliper piston is compressed. 2. Raise and safely support the vehicle. 3. Remove the wheel and tire assemblies.

4, Remove the brake caliper without disconnecting the brake line. Support the caliper with a length of wire. Do not let the caliper hang from the brake hose. >On some disc brake systems it is not necessary to remove the caliper when installing new brake pads. Remove the lower slide bolt and rotate the caliper upward to remove the pads.

5. Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining. To install: 6. Use a suitable tool to push the caliper piston into its bore. 7. Apply a thin coat of grease to the rear face of the brake pad and install the shim. Install the brake pads. 8. Install the calipers. Lubricate the caliper bolts and boots. If equipped with a 4-cylinder engine, tighten the caliper mounting bolts to 24 ft. Ibs. (33 Nm). If equipped with a 6-cylinder engine, tighten the Fa mounting bolts to 54 ft. Ibs. (74 Nm). 9. Install the wheel and tire assemblies and lower the vehicle.

connecting the brake fluid line. Support the caliper so it does not hang on the brake line. 3. Remove the brake pads and retaining clips from the caliper. 4. If equipped with caliper-activated parking brakes; use tool J-37617 or equivalent to rotate the piston clockwise until it retracts into the bore. Align the notches of the piston face so the centerline of the notches is perpendicular to the centerline of the mounting bosses. To install: 5. Install the new brake pads and clips in the caliper and install the caliper in the mounting bracket. 6. Tighten the caliper mounting bolts to 12-17 ft. Ibs. (16-24 Nm), or 32 ft. Ibs. (43 Nm) on vehicles with shoe-type parking brakes. 7. Install the rear wheels. Check the brake fluid level. 8. Pump the brake pedal until pressure is felt before moving the vehicle. Trooper

FRONT 1. Remove about % of the brake fluid from the master cylinder reservoir to prevent overflow when the caliper piston is compressed. 2. Raise and safely support the vehicle. 3. Remove the front wheels. 4. Remove the brake caliper from the caliper bracket without disconnecting the brake line. Support the caliper with a length

of wire. Do not let the caliper hang from the brake hose. 5. Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining. To install: 6. Use a large C-clamp or brake piston tool to push the caliper piston into its bore. 7. Apply a thin coat of brake grease to both sides of both inner shims. Assemble the pads and shims, then install them into the caliper. The wear indicator on the inner pad must face down.

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BRAKES

ISUZU

8. Install the calipers. Clean and lubricate the caliper mounting bolts and lubricate the mounting bolt boots. Install the mounting bolts and tighten them to 54 ft. lbs. (74 Nm). 9. Install the front wheels and lower the vehicle. 10. Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid level in the master cylinder reservoir and add as necessary.

REAR 1. Use a vacuum pump to remove some brake fluid from the master cylinder reservoir to prevent overflow when the caliper piston is compressed. 2. Raise and safely support the vehicle. 3. Remove the rear wheels. 4, Remove the brake caliper from the caliper bracket without disconnecting the brake line. Support the caliper with a length of wire. Do not let the caliper hang from the brake hose. 5. Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining.

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To install: 6. Use a large C-clamp or brake piston tool to push the caliper piston into its bore. 7. Apply a thin coat of brake grease to both sides of both inner shims. Assemble the pads and shims, then install them into the caliper. The wear indicator on the inner pad must face down. 8. Install the calipers. Clean and lubricate the caliper mounting bolts and lubricate the mounting bolt boots. Install the mounting bolts and tighten them to 32 ft. lbs. (44 Nm). . 9. Install the rear wheels and lower the vehicle. 10. Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid level in the master cylinder reservoir and add as necessary. Brake Drums

REMOVAL & INSTALLATION Amigo and Rodeo 1. Raise and safely support the vehicle. Release the parking brake. 2. Remove the rear wheels.

3. Use chalk to mark the brake drum to one of the wheel studs as an index mark for reinstallation. 4. Remove the retaining screw that holds the brake drum to the axle flange. 5. Pull the brake drum from the axle flange. To install: 6. Align the index mark and install the brake drum to the axle flange. 7. Install the retaining screw to secure the brake drum to the axle flange. 8. Install the rear wheels.

Lp

Rear Brake Shoes

REMOVAL & INSTALLATION

Amigo and Rodeo

f

1. Raise and safely support the

vehicle. 2. Remove 3. Remove 4. Remove 5. Remove pin and spring, 6. Remove adjuster lever.

the rear wheels. the brake drums. the brake return springs. the leading shoe holding and then the leading shoe. the self-adjuster and the

) Brake Linings ) Wheel Cylinder ) Bolts ) Brake Pipe 93026656

Exploded view of the rear drum brakes—Amigo and Rodeo

For Wheel Alignment specifications, see Section 1 of this manual

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4-38

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BRAKES JEEP

7. Remove the trailing shoe holding pin and spring. 8. Disconnect the parking brake cable from the trailing shoe and remove the trailing shoe. Remove the parking brake lever from the trailing shoe. To install: 9. Attach the parking brake lever to the trailing shoe. 10. Connect the parking brake cable to the parking brake lever. 11. Apply a thin coat of high temperature grease to the shoe contact points on the brake backing plate (locations A and

C in the accompanying illustration), piston contact surface (B), and self-adjuster (D). 12. Position the trailing shoe on the backing plate and install the hold-down pin, spring, and retainer. Don't stretch the return spring when fitting the shoes onto the backing plate. 13. Connect the upper return spring and the leading shoe to the trailing shoe and position the leading brake shoe on the backing plate. 14. Install the adjuster assembly and the hold-down pin, spring, and retainer.

15. Use a brake spring tool to install the lower return spring. ; 16. Install the self-adjuster lever and adjuster spring. 17. Adjust the shoe-to-drum clearance to 0.0098-0.0157 in. (0.25-0.40mm) and install the brake drum. 18. Check the brake drum for scoring or other wear. Machine or replace as necessary. Check the maximum brake drum diameter specification when machining. 19. Install the rear wheels. Lower the vehicle. 20. Road-test the vehicle.

1998-01 JEEP Brake Caliper REMOVAL & INSTALLATION Cherokee, Wrangler and 1998 Grand Cherokee 1. Drain % of the brake fluid from the front reservoir. Use the bleeder screw at the front outlet port to drain the fluid. If. equipped with anti-lock brakes, relieve the system pressure. 2. Raise and safely support the vehicle.

3. Remove the wheels. 4. Place a C-clamp on the caliper so the solid end contacts the back of the caliper and screw end contacts the metal part of the outboard brake pad. 5. Tighten the clamp until the caliper moves far enough to force the piston to the bottom of the piston bore. This will back the brake pads off of the rotor surface to facilitate the removal and installation of the caliper assembly. 6. Remove the C-clamp. 7. Remove both of the mounting bolts

and lift the caliper off the rotor. 8. If the caliper is being removed, it is necessary to disconnect the brake fluid hose. Clean the brake fluid hose-to-caliper connection thoroughly. Remove the hoseto-caliper bolt. Cap or tape the open ends to keep dirt out. Discard the copper gaskets. To install: 9. Connect the brake line to the caliper with new sealing washers and fitting bolt. Hand-tighten the fitting bolt. 10. Position the caliper into place over the rotor. 11. Coat the caliper mounting bolt with silicone grease and torque them to 84-180 inch Ibs. (10-20 Nm). 12. Position the brake line clear of all chassis components, untwisted and free of kinks. Torque the fitting bolt to 23 ft. Ibs. (31 Nm). 13. Install the wheels. 14. Fill the master cylinder with fluid and bleed the brake system. 15. Before driving the vehicle, pump the brakes several times to seat the pads. 1999-01 Grand Cherokee

FRONT 1. Drain % of the brake fluid from the front reservoir. Use the bleeder screw, at the front outlet port to drain the fluid. If equipped with anti-lock brakes, relieve the system pressure.

2. Raise and safely support the vehicle. 3. Remove the wheels. 4. Insert a small prybar through the Caliper opening and pry the caliper (using the outboard brake pad) to bottom the pistons in the caliper bore.

93026G81A

Front caliper mounting—Cherokee, Wrangler and 1998 Grand Cherokee

e>This will back the brake pads off of the rotor surface to facilitate the removal and installation of the caliper assembly.

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NE RON 93026691

View of the support springs on the front caliper—1999-01 Grand Cherokee

5. Remove the brake hose-to-caliper bolt, hose and washers. 6. Pry the caliper support spring out of the caliper. 7. Remove both caliper slide pin bushing caps and slide pins. 8. Lift the caliper from the anchor. To install: 9. Position the caliper into place on the anchor. 10. Coat the caliper slide pins with sili-

For Maintenance Interval recommendations, see Section 7 of this manual

4-40 BBS a Ahoh

cone grease and inate them to 21-30 ft. lbs. (29-41 Nm). Install the slide pin bushing caps. 11. Install the caliper support spring in the top of the caliper under the anchor; then, install the other end into the lower: caliper hole. Hold the spring in the caliper hole with your thumb while prying the spring ~end out and under the anchor.

12. Using new gasket washers, install the brake line and torque the fitting bolt to 23 ft. Ibs. (31 Nm). 13. Fill the master cylinder with fluid and bleed the brake system. 14. Before driving the vehicle, pump the brakes several times to seat the pads. 15. Install the wheels.

Disc Brake Pads

_

REMOVAL & INSTALLATION Cherokee, Wrangler and 1998 Grand Cherokee

CALIPER. ANCHOR 93026693

Bottoming the piston in the rear caliper—1999-01 Grand Cherokee

CALIPER

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View of the support springs on the rear caliper—1999-01 Grand Cherokee

1. Raise and safely support the vehicle. 2. Drain % of the brake fluid from the front reservoir. Use the bleeder screw at the front outlet port to drain the fluid. 3. Raise and support the vehicle safely. 4, Remove the wheels. 5. Remove the brake caliper. Use a suitable tool to compress the caliper piston into the bore. 6. Hold the anti-rattle clip against the caliper anchor plate and remove the outboard brake pad. 7. Remove the inboard pad and its antirattle clip. To install: 8. Clean all the mounting holes fi bushing grooves in the caliper ears. Clean the mounting bolts. Replace the bolts if they are corroded or ifthe threads are damaged. Wipe the inside of the caliper clean, including the exterior of the dust boot. Inspect the dust boot for cuts or cracks and for proper seating in the piston bore. If evidence of fluid leakage is noted, the caliper should be rebuilt.

9. Install the inboard anti-rattle clip on the trailing end of the anchor plate. The split end of the clip must face away from the rotor. 10. Install the inboard pad in the caliper. The pad must lay flat against the piston.

bree 4-41 4. Insert a small prybar through the Caliper opening and pry the caliper (using the outboard brake pad) to bottom the pistons in the caliper bore. >This will back the brake pads off of the rotor surface to facilitate the removal and installation of the caliper assembly.

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93026G82A

Front disc brake padinstallation—Cherokee, Wrangler and 1998 Grand Cherokee

11. Install the outboard pad in the caliper while holding the anti-rattle clip. 12. With the pads installed, position the caliper over the rotor. Line up the mounting holes in the caliper and the support bracket and insert the mounting bolts. Make sure the bolts pass under the retaining ears on the inboard shoes. Push the bolts through until they engage the holes of the outboard pad and caliper ears. Thread the bolts into the support bracket and tighten them to 11 ft. Ibs. (15 Nm). 13. Fill the master cylinder with brake fluid and pump the brake pedal to seat the pads. 14. Install the wheel assembly and lower the vehicle. Check the level of the brake fluid in the master cylinder and fill as necessary. Test the operation of the brakes before taking the vehicle onto the road.

5. Pry the caliper support spring out of the caliper. 6. Remove both caliper slide pin bushing caps and slide pins. 7. Lift the caliper from the anchor. 8. Using a piece of mechanics wire, support the caliper so there is not tension on the brake hose. 9. Remove the brake pads from the caliper. To install: 10. Position the brake pads onto the Caliper. 11. Position the caliper into place on the anchor. 12. Coat the caliper slide pins with silicone grease and torque them to 21-30 ft. lbs. (29-41 Nm). Install the slide pin bushing caps.

CALIPER

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5. Pry the caliper support spring out of the caliper. 6. Remove both caliper slide pin bushing caps and slide pins. 7. Lift the caliper from the anchor. 8. Using a piece of mechanics wire, support the caliper so there is not tension on the brake hose. 9. Remove the brake pads from the caliper. To install: 10. Position the brake pads onto the caliper. 11. Position the caliper into place on the anchor. 12. Coat the caliper slide pins with silicone grease and torque them to 21-30 ft. lbs. (29-41 Nm). Install the slide pin bushing caps. 13. Install the caliper support spring in the top of the caliper under the anchor; then, install the other end into the lower caliper hole. Hold the spring in the caliper hole with your thumb while prying the spring end out and under the anchor.

14. Fill the master cylinder with fluid and bleed the brake system. 15. Before driving the vehicle, pump the brakes several times to seat the pads. 16. Install the wheels.

“7 ~=/

CALIPER

REMOVAL & INSTALLATION Cherokee and Wrangler

1. Raise and safely support the vehicle. 2. Remove the wheel. 3. Remove the spring nuts (if installed) _ from the lug bolts and remove the drum from the vehicle. To install:

4. Ensure the contacting surfaces are —

clean hub. 5. 6. bolts. 7.

and flat. Install the drum on the Adjust the brake shoes, if necessary. Install the spring nuts on the lug Install the wheel.

Brake Shoes

REMOVAL & INSTALLATION Cherokee and Wrangler 1. Raise and safely support the vehicle. 2. Remove the wheel and brake drum. 3. Remove the U-clip and washer securing the adjuster cable to the parking brake lever. 4. Remove the primary and secondary return springs from the anchor pin. 5. Remove the hold-down springs, retainers and pins. 6. Install spring clamps on the wheel cylinders to hold the pistons in place. 7. Remove the adjuster lever, adjuster screw and spring. 8. Remove the adjuster cable and cable guide. 9. Remove the brake shoes and parking brake strut. 10. Disconnect the cable from the parking brake lever and remove the lever. To install: 11. Clean the support plate with brake cleaner. 12. Apply multi-purpose grease to the HON shoe contact surfaces on the backing plate. 13. Lubricate the adjuster screw threads.

INBOARD SHOE 93026695

Installing the inward brake pad on the rear caliper piston—1999-01 Grand Cherokee

14. Attach the parking brake lever to the secondary brake shoe. Use a new washer and U-clip. 15. Remove the wheel cylinder clamps. 16. Attach the parking brake cable to the lever. 17. Install the brake shoes on the sup-

BRAKES

KIA

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CYLINDERTO-SUPPORT SEAL

TRAILING ADJUSTER SHOE LEVER SPRING

HOLDDOWN SPRING AND RETAINERS ADJUSTER CABLE

4-43 4

HOLDDOWN PINS

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ADJUSTER

ACCESS

PLUGS

SUPPORT PLATE

RETURN SPRINGS

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ADJUSTER AND SPRING SCREW ASSEMBLY

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SPRING AND RETAINERS 93026689

Exploded view of the rear drum brake components—Cherokee and Wrangler

port plate. Secure the shoes with new holddown springs, pins and retainers. 18. Install the parking brake strut and spring. 19. Install the guide plate and adjuster cable to the anchor pin.

20. Install the return springs. 21. Install the adjuster cable guide on the secondary shoe. 22. Install the adjuster screw, spring and lever. Connect to the adjuster cable.

23. Adjust the shoes to the drum. Install the drum. 24. Install the wheel/tire assemblies and lower the vehicle. 25. Verify a firm brake pedal before moving the vehicle.

1998-00 KIA 8. Install the front wheels. Tighten the lug nuts 77 ft. Ibs. (99 Nm). 9. Bleed the hydraulic system if the flex hoses were removed. 10. Lower the vehicle.

Brake Caliper REMOVAL & INSTALLATION Sportage 1. Raise and safely support the vehicle. 2. Remove the front wheels. 3. Remove the 2 caliper bolts and lift the caliper from the disc. 4. Disconnect the brake fluid flex line by removing the retaining bolt if the caliper is to be replaced. To install: 5. Seat the caliper piston using a Cclamp. 6. Connect the brake fluid flex line bolt to the caliper. Tighten the bolt to 17 ft. Ibs. (23.5 Nm). 7. Position the caliper over the disc assembly. Install the caliper bolts. Tighten to 72 ft. Ibs. (98 Nm).

Disc Brake Pads

REMOVAL & INSTALLATION

6. Position the disc pads. 7. Position the caliper over the disc assembly. Install the caliper bolts. Tighten to 72 ft. Ibs. (98 Nm). 8. Install the front wheels. Tighten the lug nuts 77 ft. Ibs. (99 Nm). 9. Bleed the hydraulic system if the flex hoses were removed. 10. Lower the vehicle.

Sportage 1. Raise and safely support the vehicle. 2. Remove the front wheels. 3. Remove the 2 caliper bolts and lift the caliper from the disc. 4. Slide the disc pads off the caliper bracket. To install: 5. Clean the caliper bracket contact Surface with a wire brush and lightly coat with assembly lube.

REMOVAL & INSTALLATION Sportage . Raise and safely support the vehicle. . Remove the rear wheels. . Apply the parking brake. . Remove the 4 attaching nuts. . Release the parking brake and remove — Pp w oe the brake drum.

For complete service labor times, order the Chilton Labor Guide

Installation isthe reverse of themova iss

Brake Shoes

_

‘

REMOVAL & INSTALLATION Sportage 1. Raise and safely support the vehicle. 2. Remove the rear wheels. 3. Apply the parking brake. 4. Remove the 4 attaching nuts. 5. Release the parking brake and remove the brake drum. 6. Remove the spring from the secondary shoe to the adjusting lever. 7. Remove the adjusting lever. 8. Remove the return spring above the Star adjusting wheel. 9. Turn the starwheel clockwise to relieve tension on the brake shoes. 10. Remove the starwheel. 11. Remove the hold-down pin clips. 12. Remove the primary shoe. 13. Disconnect the C-clip and pin attaching the parking brake lever to the secondary brake shoe.

Anti-Rattle Soring

Disc Pad 93026687

Exploded view of the front disc brake assembly—Sportage

Parking Brake Cable

Primary Brake Shoe (Leading) Return om

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Parking Brake Operating Lever Secondary Brake Shoe (Trailing)

Brake Drum 93026688

Exploded view of the rear drum brake assembly—Sportage

;

BRAKES LEXUS

To install: 14. Lubricate the backing plate contact points. 15. Connect the parking brake lever to the secondary brake shoe. 16. Attach the primary and secondary brake shoes to the backing plate.

17. Install 18. Install starwheel. 19. Install 20. Install

the starwheel. the return spring above the

the adjusting lever. the spring from the secondary shoe to the adjusting lever. Be sure the lever contacts the starwheel.

4-45

21. Install the brake drum and retaining nuts.

22. Adjust the rear brakes through the slot in the rear of the backing plate. 23. Install the wheels. Tighten the wheel lugs to 77 ft. Ibs. (99 Nm). 24. Lower the vehicle.

1998-01 LEXUS 5. Remove the pad support plates. 6. Installation is the reverse of removal. Torque the caliper bolts to 20 ft. Ibs. (26 Nm). Torque the brake line union bolt to 22 ft. Ibs. (30 Nm).

Brake Caliper REMOVAL & INSTALLATION LX470

RX300

FRONT 1. Disconnect the negative battery cable from the battery. 2. Raise and support the vehicle Safely. 3. Remove the wheels. 4. Disconnect the brake hose from the caliper by removing the union bolt and 2 gaskets. Plug the end of the hose to prevent loss of fluid. 5. Remove the bolts that attach the

caliper to the torque plate. 6. Lift the bottom of the caliper up and remove the caliper assembly. To install: 7. Grease the caliper slides and bolts with lithium grease or equivalent. Install the caliper and secure with the bolts. Torque the bolts to 90 ft. Ibs. (123 Nm). 8. Connect the brake hose to the caliper, using 2 new washers. Make sure the flexible hose lock is securely in the lock hole of the caliper. Torque the union bolt to 22 ft. Ibs. (30 Nm). 9. Fill the brake system to the proper level and bleed the brake system. 10. Install the tire and wheel assembly. 11. Top off the brake fluid level in the master cylinder. Check for leaks and proper brake operation. 12. Connect the negative battery cable to the battery.

FRONT 1. Disconnect the negative battery cable from the battery. 2. Raise and support the vehicle Safely. 3. Remove the wheels. 4. Disconnect the brake hose from the caliper by removing the union bolt and 2 gaskets. Plug the end of the hose to prevent loss of fluid. 5. Remove the caliper mounting bolts. 6. Remove the caliper, pads, shims and support plates.

To install: 7. Grease the caliper slides and bolts with lithium grease or equivalent. Install the support plates, shims, pads and caliper and secure with the bolts. Torque the bolts to 25 ft. Ibs. (84 Nm). 8. Connect the brake hose to the caliper, using 2 new washers. Make sure the flexible hose lock is securely in the lock hole of the caliper. Torque the union bolt to 21 ft. Ibs. (29 Nm). 9. Fill the brake system to the proper level and bleed the brake system. 10. Install the tire and wheel assembly. 11. Top off the brake fluid level in the master cylinder. Check for leaks and proper brake operation. 12. Connect the negative battery cable to the battery.

Pad Wear Indicator Plate

Inner Anti-squeal Shim

Pad Support Plate

REAR 1. Remove the brake line from the caliper. 2. Hold the siding pin and remove the 2 bolts. 3. Remove the caliper from the torque plate. 4. Remove the pads and shims.

efAnti-squeal Shim

N-m (kgf-cm, ft:lbf) |: Specified torque

Disc brake grease

Exploded view of the front disc brake components—RX300

Please visit our web site at www.chiltonsonline.com

93026686

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7

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\Y ig ‘

e014


Disc brake grease

7

@ Lock Washer

@ Outer Bearing

@ >

Cone Washer

x ® Gasket Flange

\

6 1x6

@ Snap Ring - ® Grease Cap

Plate Washer 93026682

Exploded view of the front disc brake components—LX470

Ly ——

7. Press in the pistons with a hammer

safely.

Bleeder Plug

a th

ae

Remove theclip, pins andanti-rattle

-¥

Hi

~~

spring. pay) ; 4. Withdraw the pads and remove the — anti-squeal shims. To install: 5. Before installing the new pads, check the disc thickness and disc runout. 6. Siphon out a small amount of brake fluid from the reservoir.

REMOVAL & INSTALLATION

2. Remove the caliper mounting bolt. _ 3. Remove the caliper, pads, shims and

4.

3.

=

°

. Apply disc brake grease to both sides of the inner anti-squeal shim. Install the anti-squeal shims to the new pads. 9. Install the pads. 10. Install the anti-rattle springs and pins. Install the clip. ~ 11. Install the wheels. 12. Check and adjust the fluid level. Apply the brake pedal several times. 13. Road-test the vehicle for proper

8. Install the anti-squeal shim to the outer pad. Install the pads so the wear indicator plate is facing upward. 9. Install the brake caliper.

10. Install the wheels. an 11. Apply the brake pedal several times. 12. Road-test the vehicle for proper operation.

operation. REAR 1. Raise the vehicle and support it safely. 2. Remove the wheels. 3. Remove the brake caliper and suspend it so the hose is not stretched. 4. Remove the brake pads, anti-squeal shim, pad support plates and wear indicators. . To install: 5. Before installing the new pads, check the disc thickness and disc runout. 6. Install the pad support plates.

Anti-squeal Shim

p

Pad Support Plate

ayo

:

fit) Inner Anti-squeal Shim

&

fy

Puenhae

sh Inner Pad

Inner Anti-squeal Shim

fil

[dy

Peper: N-m (kgf-cm, ft:lbf)} : Specified torque > Disc brake grease

Pad Support Plate

Anti-squea! Shim

7. Install the pad wear indicator plate to each pads.

93026683

Exploded view of the rear disc brake components—LX470

Pad Support Plate Anti—squeal Shim

y

Inner Anti-squeal Shim

iu)\\ &

Pad

Pad

Inner Anti-squeal Shim Pad Support Plate

N-m (kgf-cm, ft-lbf) |: Specified torque Disc brake grease Exploded view of the rear disc brake components—RX300

Timing belt service is covered in Section 3 of this manual

Anti-squeal Shim

93026685

BS a?

ee

doa hk.

ay

X00 FRONT 1. Hold the sliding pin and remove the lower bolt. 2. Lift the caliper up and secure it. 3. Remove the pads, 4 shims and wear indicator plate. Remove the 2 pad support plates. «>The support plates can be reused, provided they have sufficient rebound, are not deformed or cracked, show no signs of wear and are cleaned of all rust and debris. To install:

- hd epee es oN i7’=

_‘a "The support plates can be reused,

provided they have sufficient rebound, are not deformed or cracked, show no signs of wear and are cleaned of all rust and debris. To install: e>Always use new shims and wear indicators, even when re-installing the original pads.

5. Install the support plates. 6. Apply disc brake grease to both sides of the anti-squeal shims. 7. Install the anti-squeal shims. 8. Install the inner pad with the wear indicator plate facing upwards. 9. Install the outer pad. 10. Install the caliper. Torque the bolt to 14 ft. Ibs. (20 Nm). 11. On 2WD, connect the line to the shock absorber. Torque the bolt to 21 ft. Ibs. (29 Nm).

1998-01 MITSUBISHI > as oe Te ee ree fo Gero eee aee Te ee ee ‘el

f

|

> Always use new shims and wear indicators, even when re-installing the original pads.

4. \nstall a wear indicator plate on the inner pad. 5. Apply disc brake grease to both sides of the inner anti-squeal shims and install the shims. 6. Install the inner pad with the wear indicator plate facing upwards. 7. Install the outer pad. 8. Install the caliper. Torque the bolt to 25 ft. Ibs.

Brake Caliper REMOVAL & INSTALLATION Montero and Montero Sport

FRONT 1. Raise and safely support the vehicle.

2. Remove the wheel and tire assembly.

3. Disconnect the brake hose from the

caliper brake line and remove the retaining Clip. 4. Remove the caliper guide pin bolts. 5. Lift the caliper from the caliper support. To install: 6. Make sure the disc brake pad shims and clips are properly positioned. 7. Position the caliper over the rotor so the caliper engages the adapter correctly.

Install the mounting pins and tighten to 54 ft. lbs. (74 Nm) . 8. Connect the brake hose to the caliper brake line and install the retaining clip. 9, Bleed the brake system. 10. Install the wheel and tire assembly.

REAR 1. Raise and safely support the vehicle. 2. Remove the wheel and tire assembly.

74 Nm

54 ftlbs.

. . . .

Lock pin Guide pin Bushing Caliper support (Pad, clip and shim) Pin boot . Boot ring . Piston boot

. Piston OONAM BWM . Piston seal 10. Caliper body

11. Pad and wear indicator assembly 12. Pad assembly 13.

Outer shim

14. Clip 93026699

Exploded view of the front disc brake assembly—Montero and Montero Sport

4-49 a

ursuey 3. Disconnect the brake hose from the caliper brake line and remove the retaining ay ust Remove the caliper guide pin bolts.

To install: _6. Make sure the disc brake pad shims and clips are properly positioned. i

port.

the caliper engages the adapter correctly.

5. Lift the caliper from the caliper sup-

7. Position the caliper over the rotor so

Install the mounting pins and tighten them to 32 ft. Ibs. (44 Nm). 8. Connect the brake hose to the caliper brake line and install the retaining clip.

9. Bleed the brake system.

10. Install the wheel and tire assembly,

44 Nm

ES

14

|

12

C

13

11

32 ft.lbs

G

1.. LockLock pinpi

DS a 70

2. Guide pin

3. Bushing

4. Caliper support (Pad, clip and shim) 5. Pin boot 6. Boot ring 7. Piston boot 8. Piston

6

NS

14

9. Piston seal

10. Caliper body 11. Pad and wear indicator assembly 12. Pad assembly 13. Outer shim

14. Clip

93026600

Exploded view of the rear disc brake assembly—Montero

12

6

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

7

|

ae

CLIP PAD PIN SPRING INNER SHIM PAD AND WEAR INDICATOR ASSEMBLY PAD ASSEMBLY OUTER SHIM RETAINING RING PISTON BOOT PISTON PISTON SEAL SLEEVE BOLT BUSHING SLEEVE PIN BOOT INNER CALIPER TORQUE PLATE BLEEDER SCREW

93026GA1

Exploded view of the rear disc brake assembly—Montero Sport

Heater Core replacement is covered in Section 2 of this manual

4-50 _iissan’ Disc Brake Pads

REMOVAL & INSTALLATION Montero and Montero Sport 1. Remove ¥% of the brake fluid from the master cylinder. 2. Raise and safely support the vehicle. 3. Remove the wheel and tire assembly. 4, Remove the lower caliper guide pin bolt.

5. Lift the caliper from the caliper support. 6. Remove the disc brake pads, shims, and the clips from the caliper support. To install: 7. Clean the exposed portion of the caliper piston, then press the piston back into the caliper bore using the old inner brake pad and a C-clamp. 8. Install the disc brake pads, shims, and the clips. Make sure the shims and Clips are properly positioned. 9. Position the caliper over the rotor

so the caliper engages the adapter correctly. Install the mounting pin(s) and tighten the front caliper to 54 ft. Ibs. (74 Nm) and the rear caliper to 32 ft. Ibs. (44 Nm). 10. Install the wheel and tire assembly and lower the vehicle. 11. Apply the brake pedal several times until a firm pedal is obtained. Check the fluid level in the master cylinder and add ~ fluid, as necessary.

1998-01 NISSAN Brake Caliper REMOVAL & INSTALLATION Pathfinder

FRONT 1. Raise the vehicle and support safely.

the knuckle and install the bolts. Make sure the rotor fits between the brake pads. Torque the bolts to 53-72 ft. Ibs. (72-97 Nm). 6. Using new copper washers, connect the brake hose to the caliper. Torque the brake hose attaching bolt to 12-14 ft. Ibs. (17-20 Nm). 7. Bleed the brake system. 8. Apply the brake pedal and inspect the

2. Remove the appropriate tire and wheel assembly. 3. Remove the bolt attaching the brake hose to the caliper. Plug the brake hose to prevent brake fluid loss. 4, Remove the caliper support mounting bolts and lift the caliper assembly from the knuckle. To install 5. Position the caliper assembly onto

: Nem

(kg-m, in-!b)

: Nem

(kg-m, ft-lb)

: PBC (Poly Butyl Cuprysil) grease silicone-based grease point : Rubber grease point

or

: Brake fluid point

(1)[O) 32 - 42 (3.3 - 4.3, 24 - 31) 7-9

(0.7 - 0.9, 61 - 78)

(

Bib

4

solg

hoe

OH® 9) 140 - 160 (14.3 - 16.3, 103 - 118)

Main pin Pin boot

Torque member fixing bolt Torque member Shim cover Inner shim Inner pad V@Qo@SoeNO

@QQOE®

Pad retainer

Bleed valve

Outer pad Outer shim Connecting bolt

Cylinder body

Copper washer

Main pin bolt ®OOSSeO@

,

Piston seal Piston Piston boot

Pad spring QOOOee@® 93026G60

Exploded view of the dual piston caliper front brake components—Pathfinder

“a

_ BRAKES

NISSAN

4-51

system. Ensure proper operation and no leakage. 9. Install tire and wheel assembly. Lower the vehicle and road-test. Disc Brake Pads

REMOVAL & INSTALLATION Pathfinder e>Both the front and rear disc brake pads can be serviced using the same procedure.

1. Using a syringe, siphon brake fluid from the reservoir, leaving reservoir approximately % full. 2. Raise and properly support the vehicle. 3. Remove the wheel assemblies. 4, Remove the lower pin bolt from the brake caliper. 5. Swivel the caliper up and away from the torque member. Tie the caliper to a Suspension member so that it is out of the way. ’ 6. Lift the 2 brake pads out of the torque member. 7. Remove the inner and outer shims. Remove the 2 pad retainers if they are not attached to the pads. 8. Check the pad thickness and replace the pads if they are less than 0.079 in. (2mm) thick. To install: 9. Install the inner and outer shims into the torque member. 10. Install a pad retainer to the bottom of each pad. 11. Install the pads into the torque member. 12. Use a C-clamp or hammer handle and press the caliper piston(s) back into the housing. 13. Untie the caliper and swivel it back into position over the torque plate so that the dust boot is not pinched. Install the pin bolt and torque it to 16—23 ft. Ibs. (22-31 Nm). 14. Check the condition of the pin boot. Gently pull on it to expel any trapped air. 15. Install the wheel and lower the vehicle. 16. Pump the brakes until the pedal is firm and check the level of brake fluid. Road-test the vehicle.

Bolts (M8 x 1.25) | 93026G66

Install and tighten 2 bolts to remove a stubborn brake drum—Pathfinder

Brake Shoes

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

Pathfinder

Pathfinder

1. Remove the hub cap and loosen the lug nuts. 2. Raise the rear of the vehicle and support it on jackstands. 3. Remove the lug nuts, tire and wheel. 4, Release the parking brake. 5. Pull the brake drum from the hub. If difficult to remove try the following: a. Strike the face of the drum with a plastic or rubber mallet. This will break free any rust that may develop between the drum and the hub. b. Install 2, M8x1.25mm bolts into the holes in the drum and gradually tighten them to pull the drum off the hub. To install: 6. Install the brake drum to the hub. 7. Install the wheel. 8. Remove the jackstands and lower the vehicle. 9. Road-test the vehicle to ensure that the brakes are working properly.

1. Release the parking brake. 2. Safely raise and support the vehicle. 3. Remove the rear wheel and drum. 4. Remove the hold-down pin retainers. 5. Remove the leading shoe and then the trailing shoe. 6. Remove the adjuster. 7. Disconnect the parking brake cable from the toggle lever on the rear shoe. To install: 8. Transfer the toggle lever to the new rear shoe. 9. Apply a small amount of brake grease to the tips of the shoes and the 6 pads on the backing plate that contact the brake shoe. 10. Shorten the adjuster by turning it. 11. Connect the parking brake cable to the toggle lever on the rear shoe. 12. Install the lower return spring to

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

ee e

452 ae both shoes and install the shoes on the plate with the hold down pins and ing : Sa 13. Install the adjuster and the remaining

on springs. Pay attention to the direction of the adjuster assembly. 14. Inspect the complete assembly and install the brake drum.

15. Adjust the shoe to drum clearance. 16. Install the wheel assembly and lower the vehicle to the floor.

hg]6- 11

a aeeS oe

Mh] 7-9 (0.7 - 0.9, 61 - 78)-

ee

: Rubber

grease point

: Brake grease point (0.6 - 1.1, 52- 95)

: Nem

(kg-m, ft-lb)

: Nem

(kg-m, in-Ib)

1. 2... 3.

Shoe hold pin Plug Back plate

10. 11. 12.

Piston Boot Retainer ring

19. 20. 21.

Piston cup Wheel cylinder Adjuster lever

4. 5. 6.

Check plug Spring Shoe (leading side)

13. Toggle lever 14. Wave washer 15. Shoe (trailing side)

22. 23. 24.

Spring seat Shoe hold spring Retainer

7. 8. 9.

Aijr bleeder Spring Piston cup

16. Adjuster 17. Boot 18. Piston

25. 26. 27.

Adjuster spring Return spring (upper) Return spring (lower) 93026G69

Drum brake assembly exploded view—Pathfinder w/LT30C system

1998-01 SUZUKI Brake Caliper REMOVAL & INSTALLATION

Sidekick, Sidekick Sport, Vitara, Grand Vitara and X-90

1, Raise and safely support the vehicle, 2. Remove the wheels. 3. Disconnect and plug the brake line. 4. Remove the caliper mounting bolts ae and remove the caliper from the vehicle.

To install;

.

5. Install the caliper on the vehicle. Tighten the mounting bolts as follows: © Sidekick, X-90: 20 tt. Ibs. (27 Nm).

Disc Brake Pads REMOVAL & INSTALLATION

4

e Sidekick Sport: bottom bolt to 37 ft.

Ibs.; top bolt to 42 ft. Ibs. (58 Nm)

6. Connect the hydraulic brake line,

S40. Tewite elgg Menuien ott 7 Replace thevfront wheels 8 Lowecthe Venicle 9. Fil thelhrake Pe ie 8h hieed the hydraulic brake system

Sidekick, Sidekick Sport, Vitara, Grand Vitara and X-90

1. Siphon about 24 of the fluid out of

the master cylinder. 2. Raise and safely support the vehicle. 3. Remove the wheels. 4. Remove the brake caliper mounting

—ie

wae:

ee or Pete

eee

ee

SUZUKI

502 503 504 505 506 507 508 509 510 514 516 525

CALIPER CARRIER OUTBOARD ANTI-NOISE SHIM OUTBOARD BRAKE PAD ANTI-RATTLE SPRING INBOARD ANTI-NOISE SHIM PISTON BOOT PISTON PISTON SEAL CALIPER PIN BOLT BOOT CALIPER PIN BOLT CALIPER INBOARD BRAKE PAD BLEEDER VALVE 93026637

1. Caliper (slide) pin bolt Boot . Disc brake caliper on

(disc brake cylinder) 4. Piston seal 5. Disc brake piston

6. 7. 8. 9. 10. 11 . 12 . 13 .

Cylinder boot Disc brake inner pad Disc brake outer pad

Brake caliper carrier Pad’spring Bleeder plug

Bleeder plug cap Caliper pin 14 . Anti noise shim alts) . Inner shim

Roy

1

Tightening torque

(a): 8.0 N-m (0.80 kg-m, 6.0 lb-ft) (b): 8.5 N-m (0.85 kg-m, 6.5 Ib-ft) 93026641

Front disc brake components—Vitara

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

ta

i

4-54

FA

KES BRA SUZUKI

ali

1. Caliper (slide) pin bolt . Boot 3. Disc brake caliper (disc brake cylinder) 4. Piston seal 5. Disc brake piston

6. Cylinder boot 7. Disc brake inner pad 8. Disc brake outer pad 9. Brake caliper carrier

10. Pad spring 11. Bleeder plug 12. Bleeder plug cap 13. Caliper pin 14. Anti noise shim 15.

Inner shim

Tightening torque (a): 8.0 N-m (0.80 kg-m, 6.0 Ib-ft) 93026642

Front disc brake components—Grand Vitara

bolts and remove the caliper from the mounting bracket. 5. Support the caliper with a wire. 6. Using a large pair of plies or a Cclamp compress the caliper piston back into the bore. 7. Remove the disc brake pads and any shims from the caliper mounting bracket. To install: 8. Install the brake pads and any shims removed from the caliper mounting bracket. 9. Install the caliper on the mounting bracket and install the mounting bolts. Tighten the mounting bolts to 20 ft. Ibs. (27 Nm). 10. Install the front wheels and lower the vehicle.

REMOVAL & INSTALLATION Sidekick

1. Raise and safely support the vehicle. 2. Remove the rear wheel(s).

3. Release the parking brake. 4. Remove the parking brake lever cover screws and loosen the brake cable locking nut. 5. Install 2, 8mm bolts into the brake drum holes and uniformly tighten each bolt. Tighten each bolt until the brake drum is removed from the vehicle. If there is diffi-

kk CAUTION Do not attempt to drive the vehicle until after the following step is performed. 11. Depress the brake pedal repeatedly until a firm pedal is obtained. Do not attempt to drive the vehicle unless a firm pedal is obtained. 12. Check the fluid level in the master cylinder. Add fresh brake fluid, as necessary. 13. Road-test the vehicle.

513

513

PARKING BRAKE CABLE LOCKNUT

514

PARKING BRAKE LEVER COVER 93026638

Reducing the adjuster to remove the brake drum— Sidekick, Sidekick Sport, Vitara, Grand Vitara and X-90

BRAKES

SUZUKI

4-55 ever a

1

DRUM

2

TWO 8mm

BOLTS 93026639

Removing the brake drum with the 2, 8mm bolts— Sidekick, Sidekick Sport, Vitara, Grand Vitara and X-90

culty in removing the drum, insert a small tool through the hole in the rear of the backing plate, and hold the automatic adjusting lever away from the adjuster. Using another narrow, flat tool at the same time, reduce the brake shoe adjuster by turning the adjusting wheel. To install: 6. Install the brake drum and pull the parking brake lever all the way up until a clicking sound can no longer be heard. 7. Verify that the rear wheels will not turn. If the rear wheels turn, adjust the parking brake cable as necessary. 8. Release the parking brake and remove the brake drum. Measure the diameter of the brake shoes. Outer diameter should be as follows: e For 2 door models: 8.638 (0.0012 inches (219 ( 0.3mm) e For 4 door models: 9.980 (0.0079 inches (253.5 (0.2mm) 9. If the brake shoe clearance is not correct, adjust the brake shoes until the clearance is correct. 10. Reinstall the brake drum, replace the wheel(s), and safely lower the vehicle. 11. Adjust the parking brake and install the cover with the 2 screws. 12. Road-test the vehicle for proper brake operation.

Brake Shoes

REMOVAL & INSTALLATION Sidekick 1. Raise and safely support the vehicle. 2. Remove the rear wheel(s).

1 WHEEL CYLINDER 2 ADJUSTER 3 SHOE RETURN LOWER SPRING 4 BRAKE SHOES

ts) SHOE HOLD DOWN 6 ADJUSTER SPRING 7 PAWL LEVER

8 9

10

SPRING

SHOE RETURN UPPER SPRING BACKING PLATE SHOE HOLD DOWN PIN 93026640

Exploded view of the rear brake components—Sidekick, Sidekick Sport and X-90 models

3. Remove the brake drum. 4. Using a suitable tool, remove the brake shoe return spring. 5. Using a brake spring hold-down tool, disengage the hold-down spring and retainers from the front shoe. Remove the hold-down retainer pinch 6. Disconnect the anchor spring from the front shoe and remove the front shoe. 7. Remove the anchor spring from the rear shoe. Using a brake spring hold-down tool, disengage the hold-down spring and

retainers from the rear shoe. Remove the hold-down pinch 8. Disengage the parking brake lever from the parking brake cable and remove the rear shoe. 9. Remove the C-washer, the automatic adjuster lever and spring, the C-washer, and the parking brake lever from the rear shoe. 10. Thoroughly clean the backing plate and brake hardware with brake cleaning solvent. Apply high temperature grease to the backing plate shoe contact points, anchor

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

~ BRAKES SUZUKI

. . . .

Brake back plate — Brake shoe Shoe return upper spring Adjuster

. Shoe return lower spring . Adjuster lever . Adjuster spring . Shoe hold down spring . Shoe hold down pin . Wheel cylinder . Link WN NRWOCOOANOWMA . Brake strut

—4t ——"

Tightening torque (a): 7.5 N-m (0.75 kg-m, 5.5 Ib-ft) 93026643

Exploded view of the rear brake components—Vitara and Grand Vitara

plate and shoe contact points, adjusting bolt, and adjuster and brake shoe contact points. To install: 11. Reinstall the automatic adjuster lever and the parking brake lever to the rear shoe using new C-washers. 12. Connect the parking brake lever to the parking brake cable. Set the adjuster and spring to the rear shoe. 13. Set the rear brake shoe in place, install the hold-down pin and install the hold-down spring and retainers. Make sure that the shoe is inserted in the wheel cylinder and that the other end is in the anchor plate. 14. Install the anchor spring to the rear shoe.

15. Install the front shoe to the other end of the anchor spring and set the front shoe in place. Make sure that the front shoe engages the wheel cylinder, adjuster mechanism and spring, and the anchor plate. 16. Reinstall the front brake shoe hold-down pin and secure with the holddown spring and retainers using a suitable tool. 17. Install the return spring. 18. Install the brake drum and pull the parking brake lever all the way up until a clicking sound can no longer be heard. 19. Verify that the rear wheels will not turn. If the rear wheels turn, adjust the parking brake cable as necessary.

20. Release the parking brake and remove the brake drum. Measure the diameter of the brake shoes. Brake diameter should be as follows: e For 2 door models: 8.638 (0.0012 inches (219 (0.3mm) e For 4 door models: 9.980 (0.0079 inches (253.5 (0.2mm) 21. If the brake shoe clearance is not correct, adjust the brake shoes until the clearance is correct. ‘ 22. Reinstall the brake drum, replace the wheel(s), and safely lower the vehiCle. 23. Road-test the vehicle for proper brake operation.

4-57

BRAKES

|

ye

alpha aial

TOYOTA

a

1998-01 TOYOTA Brake Caliper

Depending on the brake type, there may be either 1 or 2 sealing washers.

REMOVAL & INSTALLATION

4, Installation is the reverse of removal,

Highlander

.

FRONT

.

Reis crclareac ree ae 2. Remove or disconnect the following: ; : dls Boils aiid walter

ERG

vO!

3. Ifthe caliper is being replaced, disconnect the brake line and plug both open-

per

—_‘'"9S:

Torque the mounting bolts to 25 ft. Ibs. (34Nm). If the brake hose was removed,

e>Depending on the brake type, there may be either 1 or 2 sealing washers.

torque the union bolt to 21 ft. Ibs. (29Nm), REAR

4. Installation is the reverse of removal. Torque the slide pin to 25 ft. Ibs. (34Nm). If the brake hose was removed, torque the union bolt to 21 ft. Ibs. (29Nm).

" St p eal tion.

Ahi aeaan ee Be WB

4Runner

2. Remove or disconnect the following:

e Rear wheel

3. Ifthe caliper is being replaced, disconnect the brake line and plug both openings.

1. Disconnect the negative battery cable

© Slide pin and caliper

1ton:

warn

Piston Seal

from the battery

7

Y Gleeder aa

‘

6

wa

Dust Boot

Sliding Bushing cae @Dust Boot

A:

Set Ring

Brake Caliper

40x

Anti-Squeal Spring

.

|

: Anti-Squeal yar

:

Pad Wear Indicator Plate

Pad Support Plate

ag

0.5 ton:

Gasket

.

Brake Caliper

36(370, 27)

e seen

Bleeder Plug Are ot

gt

Piston Seal

4

Slidinen g

80) | 108 (1,100, |

Torque Plate

Ny

-.)

Ws Gy

Piston

-

] 8) 8)| |11 (110, 8) [11.(110,

eek

©—

TF

eSBoot

Boot

t

A At dg ais

Inner Anti Squeal Shim

iy

YY

: ee. S:Indicator Plate: : ane Pad Wear

Pad Support Ses

: Specified torque g @ Non-reusablie part Apply disc brake grease to both sides of the inner anti-squeal shims.

10. Install the disc pads so the wear indicator plate is facing downward. 11. If removed, install the anti-squeal springs. 12. Carefully install the brake caliper so the boot is not wedged. Torque the caliper mounting bolts, as follows: e 2-Wheel drive w/PD60 type disc: 29 ft. Ibs. (39 Nm) e 2-wheel drive w/FS17 type disc: 65 ft. Ibs. (88 Nm) 13. Install the wheel and tire assembly. 14. Check and adjust the fluid level. Apply the brake pedal several times. 15. Road-test the vehicle for proper operation.

FRONT W/4-WHEEL DRIVE 1. Raise the vehicle and support tt Safely. 2. Remove the wheel and tire assembly. 3. Remove the clip, pins, and the antirattle spring. 4, Remove the pads and the anti-squeal shims. 5. Remove the caliper, but do not disconnect the brake hose. To install: 6. Before installing the new pads, check the disc thickness and disc runout. 7. Siphon out a small amount of brake fluid from the reservoir. 8. Temporarily install the old inner brake pad. Press in the pistons with a Cclamp or equivalent. Remove the old inner brake pad. 9. Apply disc brake grease to both sides of the inner anti-squeal shim. Install the anti-squeal shims to the new pads. 10. Install the pads. 11. Install the anti-rattle springs and pins. Install the clip. 12. Install the caliper and the mounting bolts. Torque the mounting bolts to 90 ft. lbs. (123 Nm). 13. Install the wheel and tire assembly. 14. Check and adjust the fluid level. Apply the brake pedal several times. 15. Road-test the vehicle for proper operation.

REAR 1. Raise the vehicle and support it Safely. 2. Remove the wheel and tire assembly, 3. Remove the brake caliper and suspend it with a wire so the hose is not stretched or stressed.

4

4. Remove the brake pads, anti-squeal shim, pad support plates and wear indicators. To install: . 5. Before installing the new pads, check the disc thickness and disc runout. 6. Temporarily install the old inner brake pad. Press in the piston with a Cclamp or equivalent. Remove the old inner brake pad. 7. Install the pad support plates. 8. Install the pad wear indicator plate to

each pads. 9. Install the anti-squeal shim to the outer pad. Install the pads so the wear indicator plate is facing upward. 10. Install the brake caliper. Torque the main sliding pin and the sub pin to 65 ft. lbs. (88 Nm). 11. Install the wheel and tire assembly. - 12. Apply the brake pedal several times. 13. Road-test the vehicle for proper operation.

RAV4 1. Raise and safely support the vehicle. 2. Remove the wheel(s). 3. Temporarily install 2 wheel stud nuts to hold the brake rotor in place. 4. \f necessary, siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent any brake fluid from overflowing the master cylinder when removing or installing new pads. This may be necessary, as the piston must be forced into the caliper bore to provide sufficient clearance when installing the pads. 5. Grasp the caliper from behind and carefully pull it towards you. This -will start to seat the piston(s) in its bore. Using a C-clamp or other suitable tool, press the piston the remaining way into the caliper. Be careful not to cock the piston in the bore. Also, do not force the piston or the caliper and piston may be, damaged. 6. Hold the sliding pin and loosen the 2 caliper mounting bolts. Remove the bolts and remove the caliper from the torque plate.

7. Secure the caliper assembly out of the way with a wire; so as not to stress the flexible hose. 8. Slide out the old brake pads along with any anti-squeal shims, springs, pad wear indicators and pad support plates. Make sure to note the position of all assorted pad hardware.

ete

Ss

eee

a>

Wek

Par raik

BRAKES TOYOTA To install: e,! Check the brake disc (rotor) for thickness and run-out. Inspect the caliper and piston assembly for breaks, cracks, fluid seepage or other damage. Overhaul or replace as necessary. 10. Install the pad support plates into the torque plate. 11. Install the pad wear indicators onto the pads. Be sure the arrow on the indicator plate is pointing in the direction of rotation. 12. Install the anti-squeal shims on the outside of each pad and then install the pad assemblies into the torque plate. 13. Install the caliper to the torque plate with the 2 mounting bolts. Torque the bolts to 20 ft. Ibs. (26 Nm). 14. Remove the 2 temporary wheel stud nuts and check that the rotor turns freely. 15. Reinstall the wheel(s), safely lower the vehicle, and road-test for proper brake

Land Cruiser

12. Check and adjust the fluid level. Apply the brake pedal several times. 13. Road-test the vehicle for proper operation.

FRONT 1. Raise the vehicle and support it safely. 2. Remove the wheels. 3. Remove the clip, pins and anti-rattle spring. 4. Withdraw the pads and remove the anti-squeal shims. To install: 5. Before installing the new pads, check the disc thickness and disc runout. 6. Siphon out a small amount of brake fluid from the reservoir. 7. Press in the pistons with a hammer handle or equivalent. 8. Apply disc brake grease to both sides of the inner anti-squeal shim. Install

REAR 1. Raise the vehicle and support it Safely. 2. Remove the wheels. 3. Remove the brake caliper and suspend it so the hose is not stretched. 4. Remove the brake pads, anti-squeal shim, pad support plates and wear indicators.

‘To install: 5. Before installing the new pads, check the disc thickness and disc runout. 6. Install the pad support plates. 7. Install the pad wear indicator plates on each pad. 8. Install the anti-squeal shim to the outer pad. Install the pads so the wear indicator plate is facing upward. 9. Install the brake caliper.

the anti-squeat shims to the new pads. 9. Install the pads. 10. Install the anti-rattle springs and pins. Install the clip. 11. Install the wheels.

operation. 16. Be sure to pump the brakes several times prior to moving the vehicle.

4-61

No! Anti-Rattle Spring @ Gasket

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Cm

Bleeder Plug — Sl

a

Brake Caliper Anti-Squeal Shim

Ik

inner Anti-Squeal Shim

Inner Pad Clip +

e

Nt Outer Pad

Qe Qo Piston “Re

@

Non-reusable part

Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor The MDX is equipped with a Distributorless Ignition System (DIS).

Z, heli or disconnect the following: e Negative battery cable Intake manifold and ignition coil covers Accessory drive belt Alternator wiring harness connectors Alternator mounting bolts Wiring harness clamp Alternator

INSTALLATION Alternator

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

1. Install or connect the following: e Alternator ¢ Wiring harness clamp. Tighten the bolt to 105 inch Ibs. (12 Nm). e Alternator mounting bolts. Tighten the 10mm bolt to 33 ft. Ibs. (44

Nm) and the 8mm bolt to 16 ft. Ibs. (22 Nm). ¢ Alternator wiring harness connectors. Tighten the battery terminal nut to 105 inch Ibs. (12 Nm). e Accessory drive belt ‘ e Intake manifold and ignition coil covers ¢ Negative battery cable

Ignition Timing ADJUSTMENT The MDX is equipped with a Distributorless Ignition System (DIS). The ignition timing is controlled by the Powertrain Control module (PCM). No adjustment is necessary.

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ee

ACURA MDX

Engine Assembly

, 5-3 7

B 12x 1.25 mm

74 N-m (7.5 kgf-m, 54 Ibf-ft)

REMOVAL & INSTALLATION >The engine and transaxle are removed from the vehicle as a unit.

1. Before servicing the vehicle, refer to uPprecautions in the beginning of this secion. 2. Drain the cooling system. 3. Drain the power steering system. 4. Drain the transaxle fluid. 5. Drain the engine oil. 6. Relieve fuel system pressure. 7. Remove or disconnect the following: Negative battery cable Battery and tray Intake and ignition coil covers Air intake duct Left engine wire harness connectors Relay bracket

A

Starter cable and harness clamp Accelerator cable Cruise control cable Fuel lines EVAP canister hose 8. Remove the drivers side center console lower panel and pull back the cover to access steering joint cover. Steering joint bolt Powertrain Control Module (PCM) connectors

Heated Oxygen (HO2S) sensor connector and grommet. Pull the PCM harness through the firewall. Brake booster vacuum line Power steering hose(s) clamps and clips Fuse/Relay box battery cable Accessory drive belts Front wheels Splash shield Front sub-frame stiffener Exhaust front pipe Propeller shaft Shift contro! cable Transfer assembly Ball joints Stabilizer bar links Power steering hose and pressure switch connector Transaxle lower front mount Transaxle lower rear mount A/C compressor Heater hoses Radiator hoses Ground cable

14x 1.25 mm

103 N-m (10.5 kgf-m, 75.9 Ibf-ft)

12 x 1.25 mm 117 N-m

B

;

(11.9 kgf-m, 86.1 Ibf-ft) 9302MG69

Sub-frame fastener locations and tightening torque—MDX

e Transaxle oil cooler lines e Radiator 9. Attach a hoist to the engine lifting eyes and support the powertrain weight. 10. Remove or disconnect the following: e Side engine mount bracket e Front mount bracket support nut 11. Matchmark the front subframe to the mounting points. 12. Remove or disconnect the following: e Front subframe e All remaining hoses and electrical connections 13. Lower the powertrain away from the vehicle. To install: 14, Raise the powertrain into position. 15. Installation is the reverse of removal but please note the following torques: e A/C compressor bolts to 16 ft. Ibs. (22 Nm) ¢ Front subframe. Use new bolts and tighten the 14mm bolts to 76 ft.

lbs. (103 Nm). Tighten the front brace bolts to 54 ft. Ibs. (74 Nm) and the rear brace bolts to 86 ft. Ibs. (117 Nm).

Transaxle lower front mount nuts to 28 ft. Ibs. (88 Nm) Transaxle lower rear mount bolts to 28 ft. Ibs. (38 Nm) Front mount bracket support nut to AQ ft. Ibs. (54 Nm) Side engine mount bracket bolts to 33 ft. Ibs. (44 Nm) and the through bolt to 40 ft. Ibs. (54 Nm) 16. Fill the engine crankcase to the correct level. 17. Fill the transaxle to the correct level. 18. Fill the cooling system. 19. Fill the power steering system. 20. Start the engine and check for leaks. 21. Check the wheel alignment and adjust as necessary.

Water Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable

For complete service labor times, order the Chilton Labor Guide

.m (1.2 kaf.m, 8.7 Ibf-ft) 93552G01

e Wiring harness holder and joint connector 5. Support the engine with a jack and a block of wood. Side engine mount bracket Accessory drive belts Power steering pump Alternator Intake Air Temperature (IAT) sensor connector Idle Air Control (IAC) valve connector Throttle Position (TP) sensor connector

Exploded view of the water pump mount-

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tor

Engine Coolant Temperature (ECT) sensor connector

Radiator fan switch connectors ECT gauge sending unit connector Crankshaft Position (CKP) sensor connector

Top Dead Center (TDC) sensor connector

Timing belt tensioner

Cylinder Head REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Ignition coil covers Intake manifold cover Air intake tube Accelerator cable Cruise control cable Evaporative Emission (EVAP) canister, breather, water bypass hoses and the bypass pipe bolt Fuel lines Brake booster vacuum line Intake manifold vacuum line Positive Crankcase Ventilation (PCV) valve and hose Power steering hose clamp Intake Manifold Runner Control

(IMRC) actuator

Crankshaft timing belt sprocket TDC marks. Align sprocket mark (A) with pointer (B)—MDX

Manifold Absolute Pressure (MAP) sensor connector EVAP canister purge valve connec-

e Accessory drive belts e Front cover e Timing belt e Timing belt tensioner e Water pump To install: 4. Install or connect the following: e Water pump. Use a new O-ring seal and tighten the bolts to 105 inch lbs..(12 Nm). Timing belt Front cover Accessory drive belts Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

9302MG74

Exhaust Gas Recirculation (EGR) connector Variable Valve Timing and Valve Lift Electronic Control (VTEC) solenoid valve connector

VTEC oil pressure switch connector Oil pressure switch connector Ignition coils Intake manifold Fuel injector connectors Fuel supply manifold Fuel injection air control valve vacuum lines e Front cover Timing belt. Refer to the Timing Belt unit repair section. Radiator hoses Heater hoses Front and rear exhaust manifolds Coolant cross-over pipe

Cylinder head bolt loosening sequence—

MDX

Camshaft TDC marks. Align sprocket mark (A) with the back cover pointer (B)—MDX

e Valve covers ‘ 6. Loosen the cylinder head bolts in sequence and ¥ turns until all bolts are loose. 7. Remove the cylinder head. To install: 8. Align the crankshaft and camshaft sprocket TDC marks as shown. 9. Install the cylinder heads with new gaskets. 10. Apply clean engine oil to the cylinder head bolt threads and flanges. 11. Tighten the cylinder head bolts in sequence as follows:

mt 5-5 e e e e e

Intake manifold cover Ignition coil covers Accessory drive belts Air intake tube EVAP control canister hose and vacuum hose e Negative battery cable 13. Fill the cooling system. 14. Start the engine and check for leaks.

Rocker Arms/Shafts

REMOVAL & INSTALLATION

9302MG70

Cylinder head bolt tightening sequence—MDX

a. Step 1: 29 ft. Ibs. (89 Nm) b. Step 2: 51 ft. Ibs. (69 Nm) c. Step 3: 72 ft. Ibs. (98 Nm) 12. Install or connect the following: Valve covers Coolant cross-over pipe Front and rear exhaust manifolds Heater hoses Radiator hoses Timing belt

e Side engine mount bracket PCV valve and hose e Intake manifold vacuum line Brake booster vacuum line Fuel lines Cruise control cable Accelerator cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air intake tube e Ignition coil covers e Intake manifold cover e Intake manifold e Valve cover 3. Loosen the valve adjuster locknuts and screws so that all valves are closed. 4° Loosen the rocker arm shaft bolts evenly in Sequence. 5. Remove the rocker arms and shafts from the vehicle as an assembly. Keep all valvetrain components in order for assembly.

6. Remove the rocker arms and springs from the rocker arm shafts.

@ @

Front cover

Fuel injection air control valve vacuum lines Fuel supply manifold Fuel injector connectors Intake manifold Ignition coils Oil pressure switch connector VTEC oil pressure switch connector VTEC solenoid valve connector EGR connector TDC sensor connector CKP sensor connector ECT gauge sending unit connector Radiator fan switch connectors ECT sensor connector MAP sensor connector TP sensor connector IAC valve connector IAT sensor connector Alternator Power steering hose clamp Power steering pump

9308MG17

Rocker arm shaft loosening sequence—MDX

Please visit our web site at www.chiltonsonline.com

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INTAKE ROCKER ARM ASSEMBLY

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EXHAUST ROCKER ARM B

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SPRING EXHAUST ROCKER ARM A

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EXHAUST ROCKER SHAFT

Letter B is stamped on rocker arm.

Letter A is stamped on rocker arm.

9308MG18

Exploded view of the rocker arms and shafts—MDX

9302MG84

Rocker shaft tightening sequence—MDX

To install: 7. Assemble the rocker arms and springs to the rocker arm shafts in their original positions. 8. Install the rocker arm assemblies. Tighten the bolts in sequence and in multiple passes to 17 ft. Ibs. (24 Nm). 9. Adjust the valve clearance. 10. Install or connect the following: e Valve covers e Intake manifold e Intake manifold cover Ignition coil covers Air intake tube

e Negative battery cable

11. Start the engine and check for leaks. ; Intake Manifold

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Evaporative Emissions (EVAP) control canister hose and vacuum hose e Air intake tube

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INTAKE MANIFOLD END PLATE

.7 tbf-ft)

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16 Ibf-ft)

BOOST PLATE

GASKET

Replacal

agen IR TEMPERATURE (IAT)SENSOR 18 N-m (1,8 kgf-m, 13 Ibf-ft) O-RING Replace.

INTAKE MANIFOLD END PLATE

12x 1.5mm

GASKET Replace,

INTAKE MANIFOLD Replace if it is cracked or if the mating surface is damaged.

GASKET Replace.

GASKET

Replace.

SPACER

Replace.

THROTTLE BODY

.

9308MG20

Exploded view of the intake manifold—MDX

e e e e e

Intake manifold cover Accelerator cable Cruise control cable Brake booster vacuum line Intake manifold vacuum line

¢ Positive Crankcase Ventilation

H

(PCV) valve and hose e Intake Air Temperature (IAT) sensor

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6

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connector e Idle Air Control (IAC) valve connector e Throttle Position (TP) sensor connector e Manifold Absolute Pressure (MAP) sensor connector e Intake manifold To install: 3. Install or connect the following: e New intake manifold gasket e Intake manifold. Tighten the fasteners in Sequence and in several passes to 16 ft. Ibs. (22 Nm). e MAP sensor connector e TP sensor connector e IAC valve connector

(8)

* IAT sensor connector

302MG71

e PCV valve and hose e |ntake manifold vacuum line

Intake manifold torque sequence—MDX

Timing belt service is covered in Section 3 of this manual

i

5-8 tae e Side engine mount e Accessory drive belts e Negative battery cable 6. Check the engine oil level and add if necessary. 7. Start the engine and check for leaks.

Brake booster vacuum line Cruise control cable Accelerator cable Intake manifold cover Air intake tube EVAP control canister hose and vacuum hose e Negative battery cable

Camshaft

4. Start the engine and check for proper operation.

~REMOVAL & INSTALLATION

Exhaust Manifold 93552602

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Exhaust manifold heat shield Heated Oxygen (HO2S) sensor connector Exhaust front pipe Exhaust manifold bracket, if equipped Exhaust manifold To install: 3. Install or connect the following: Exhaust manifold. Tighten the fasteners to 23 ft. Ibs. (31 Nm). Exhaust manifold bracket, if equipped. Tighten the bolts to 33 ft. lbs, (44 Nm). Exhaust front pipe. Tighten the nuts to 40 ft. Ibs. (65 Nm). Heated Oxygen (HO2S) sensor connector Exhaust manifold heat shield Negative battery cable

Front crankshaft seal installation

e Crankshaft timing sprocket e Front crankshaft seal To install: 3. Lubricate the crankshaft seal lip with grease prior to installation. 4. Install the front crankshaft seal so that it is flush with the surface of the oil pump housing. _ 5. Install or connect the following: Crankshaft timing sprocket Top Dead Center (TDC) sensor, if equipped Timing belt. Refer to the Timing Belt unit repair section. Balance shaft belt, if equipped Front cover Crankshaft pulley. Tighten the bolt to 181 ft. Ibs. (245 Nm). Valve cover

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air intake tube Accessory drive belts Front cover Timing belt. Refer to the Timing Belt unit repair section.

Camshaft sprockets Timing belt rear covers Ignition coil covers Intake manifold cover Intake manifold Valve cover Rocker arms and shaft assembly Camshaft thrust cover Camshaft To install: >Use new O-rings, seals and gaskets when installing the camshaft.

@ ®

@

Front Crankshaft Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Accessory drive belts Side engine mount Valve cover Crankshaft pulley Front cover Balance shaft belt, if equipped Timing belt. Refer to the Timing Belt unit repair section. Top Dead Center (TDC) sensor, if equipped

9308MG17

Rocker arm shaft loosening sequence—MDX ON,

SS

ML: 6. After adjustment, tighten the locknuts to 14 ft. Ibs. (20 Nm). 7. Install or connect the following: e Valve cover e Intake manifold e Air intake tube e Negative battery cable 8. Start the engine and check for proper operation.

Starter Motor 9302MG84

REMOVAL & INSTALLATION

Rocker shaft tightening sequence—MDX

3. Install or connect the following: Camshaft Camshaft thrust cover. Tighten the bolts to 16 ft. Ibs. (22 Nm). Rocker arms and shaft assembly Valve cover Intake manifold Intake manifold cover Ignition coil covers Timing belt.fear covers Camshaft sprockets. Tighten the

bolts to 67 ft.Ibs. (90 Nm).

Timing belt Front cover Accessory drive belts Air intake tube Negative battery cable 4. Start the engine and check for leaks.

93552604

Inspect the valve clearance, adjust to specification and tighten the retainer to specification

No. 1

Na. 2:

No.3

Valve Lash

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable and wait at least 3 minutes e Transmission fluid cooler line clamp ¢ Starter wiring harness connectors e Starter motor To install: 3. Install or connect the following: e Starter motor. Tighten the 10mm bolt to 33 ft. Ibs. (44 Nm) and the 12mm bolt to 47 ft. Ibs. (64 Nm). e Starter wiring harness connectors. Tighten the battery cable nut to 79 inch Ibs. (9 Nm). e Transmission fluid cooler line clamp e Negative battery cable

ADJUSTMENT Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air intake tube e Intake manifold e Valve cover 3. Rotate the crankshaft so that the valves to be adjusted are closed and the rocker arm is contacting the camshaft lobe base circle. 4. Measure the valve clearance. If adjustment is necessary, loosen the locknut and turn the adjusting screw as necessary to achieve the correct valve clearance.

REMOVAL & INSTALLATION FRONT:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Front splash shield EXHAUST

93552603

Valve adjusting retainer locations

5. The correct valve clearance is: e Intake valves: 0.008-0.009 inches

(0.20-0.24mm) e Exhaust valves: 0.011-0.013 inches (0.28-0.32mm)

e Heated Oxygen (HO2S) sensor connector e Exhaust front pipe Torque converter cover, if equipped with an automatic transaxle e Oil pan To install: 4. Install the oil pan. Apply liquid gasket as shown.

Heater Core replacement is covered in Section 2 of this manual

oP y

CURA

MDX

3. Remove or disconnect the following: Negative battery cable Accessory drive belts Front cover Timing belt. Refer to the Timing Belt unit repair section. Timing belt idler pulley

Crankshaft Position (CKP) sensor Crankshaft timing sprocket Variable Valve Timing and Valve Lift Electronic Control (VTEC) solenoid valve connector Oil filter adapter Oil pan Oil pump pickup tube Oil pump To install:

Apply liquid gasket along the broken line. 9302MG75

Apply liquid gasket to the inner threads of the bolt holes and the engine block along the area indicated by the broken line—MDX

9302MG76

>Use new gaskets and O-ring seals for assembly.

4. Apply liquid gasket to the oil pump and to the bolt hole threads. 5. Install or connect the following: . Oil pump. Tighten the bolts to 105 inch Ibs. (12 Nm). Oil pump pickup tube. Tighten the bolts to 105 inch Ibs. (12 Nm). Oil pan Oil filter adapter VTEC solenoid valve connector Crankshaft timing sprocket CKP sensor Timing belt idler pulley Timing belt Front cover Accessory drive belts Negative battery cable 6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks.

Oil pan tightening sequence—MDX

5. Tighten the bolts in sequence to 105 inch Ibs. (12 Nm). 6. Install or connect the following: ¢ Torque converter cover, if removed e Exhaust front pipe e Subframe center beam, if removed ¢ HO02S sensor connector e Front splash shield ¢ Negative battery cable

6

x 1.0mm 12 Nem (1.2 kgf-m, 8.7 Ibf-ft)

o-zB

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil.

93552605

Exploded view of the oil pump assembly

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ACURA MDX

NNN

5-11 7

eee

e Transaxle 4. Check the fluid levels. 5. Start the engine and check for leaks.

Rear Main Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transaxle ¢ Clutch pressure plate and disc, if equipped e Flywheel e Oil seal To install: 3. Install or connect the following: e (il seal. Drive the seal square into the seal case. e Flywheel. Tighten the bolts in a crossing pattern to 54 ft. Ibs. (73 Nm). ¢ Clutch pressure plate and disc, if equipped

Piston and Ring

POSITIONING SECOND RING GAP

DO NOT position any ring gap at iy thrust surfaces.

Approx, 90°

OIL RING GAP

Approx.

TOP RING GAP

15°

DO NOT | position any ring gap in line with piston pin hole.

9302AG06

SPACER GAP

OIL RING GAP 93552G06

Ring end gap positioning

Compression ring identification—3.5L engine

FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance, but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines: e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area.

¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

2. 3. 4. sation 5.

Disconnect the negative battery cable. Remove the fuel filler cap. Place a shop towel over the fuel puldamper. Loosen the fuel pulsation damper 1

turn.

6. When service is completed, replace the sealing washer and tighten the pulsation damper to 16 ft. Ibs. (22 Nm). 7. Replace the fuel filler cap. 8. Connect the negative battery cable. 9. Start the engine and check for leaks.

Fuel System Pressure RELIEVING

REMOVAL & INSTALLATION

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

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Driver's side second row seat and cut the carpet along the dotted line. Be careful not to cut the wiring harness under the carpet. e Access panel e Fuel pump module 4. Disassemble the fuel pump module and remove the fuel filter. To install: 5. Install the fuel filter and assemble the fuel pump module. 6. Install or connect the following:

A 22 N-m (2.2 kgf-m, 16 Ibf-ft)

9302MG77

Use a wrench on the fuel pulsation damper (A). Place a rag over the damper (B) when relieving residual fuel pres-

Brake service is covered in Section 4 of this manual

5-1

ACURA MDX

Fuel Injector

Fuel Pump

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION —————

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following:

A. Bracket B. Fuel filter C. Fuel gauge sender D. Case E.Wire harness

F. Suction filter G. Fuel pump H. Connectors J. Alignment marks K. Fuel tank _L. Fuel pump module

9308MG26

Exploded view of the fuel pump module—

MDX

Fuel pump module Access panel Carpet and seat Negative battery cable 7. Start the engine and check for leaks.

Negative battery cable Driver's side second row seat and cut the carpet along the dotted line. Be careful not to cut the wiring harness under the carpet. Access panel Fuel pump module wiring connector Fuel supply and return lines Fuel pump locknut e Fuel pump module To install: 4. Install or connect the following: Fuel pump module. Use a new seal and align the matchmarks. Fuel pump locknut Fuel supply and return lines Fuel pump module wiring connector Access panel Carpet and seat Negative battery cable 5. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable . e Intake manifold e Fuel lines e Fuel injector connectors e Fuel pressure regulator vacuum line e Fuel supply manifold 4. Separate the fuel injectors from the fuel supply manifold. To install: 5. Install the fuel injectors to the fuel supply manifold with new cushion rings and O-rings. 6. Install new seal rings to the intake manifold. 7. Install or connect the following: Fuel supply manifold and injector assembly. Tighten the bolts to 86 inch lbs. (10 Nm). Fuel pressure regulator vacuum line Fuel injector connectors Fuel lines Intake manifold Negative battery cable 8. Start the engine and check for leaks.

DRIVE TRAIN 2. Drain the transaxle. 3. Drain the power steering system. 4. Remove the engine appearance cov-

Transaxle Assembly REMOVAL & INSTALLATION

ers.

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

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93552608

Support the engine while removing the transaxle—MDX

5. Remove the drivers side center console lower panel and pull back the cover to access steering joint cover. 6. Remove or disconnect the following: \ © Steering joint bolt Steering joint from the steering gearbox pinion shaft Air intake assembly Battery Battery tray Power steering pump hose and the clamp bolt Transmission breather tube Cooler hose from the clamp on the Starter Transaxle oil cooler lines Starter motor Shift control solenoid valve connectors

93552G09

Support the sub-frame with a 4 x 4 x 50 inch piece of wood and a jack

Transaxle ground cable 8P connector from the bracket and the connector Clutch pressure switch connectors Joint connector and transmission range switch connector from the brackets Countershaft speed sensor connector

: e Heated Oxygen (HO2S) sensor connectors — e Transmission housing mounting

bolts Nut from the front mount and the ground cable from the engine Bulkhead cover, windshield wiper arms, cowl cover sealing and cover Install a support fixture to the engine lifting eyes. Splash shield Front sub-frame stiffener Exhaust front pipe Lower control arms from the knuckle Stabilizer bar links Tie rod ends from the knuckle Left driveshaft from the differential Right driveshaft from the intermediate shaft Propeller shaft from the companion flange Shift cable cover and holder Shift control cable and lever 7. Install a6 x 1x 14mm bolt and nut on the cable cover, then reinstall the cable cover to the torque converter housing. If this is not done, the bolt-head of the cable cover may prevent torque converter removal. e Transfer assembly e Engine-to-torque converter bolts e Power steering pressure switch connection e Power steering hose clamp, then the hose from the pipe at the subframe e Transmission lower mount nuts 8. Matchmark the front subframe to the vehicle body. e Rear mount bracket bolts 9. Support the sub-frame with a 4 x 4 x 50 inch piece of wood and a jack. e Sub-frame Transaxle lower mounts Driveshafts from the differential and intermediate shaft Intermediate shaft Transmission front mount bracket Tranmission flange bolts e Transmission To install: e>Use new circlips, split pins and selflocking nuts for assembly.

10. Installation is the reverse of removal. Please note the following specifications: e Transmission housing bolts and harness clamp bolts to 47 ft. Ibs. (64 Nm)

mCURA B43 e Transmission housing bolts to 40 ft. Ibs. (54 Nm) e Front mount bracket bolts to 28 ft. lbs. (38 Nm) e Intermediate shaft bolts to 29 ft. lbs. (39 Nm) 11. Raise the subframe into position and align the matchmarks. Tighten the subframe bolts to 76 ft. Ibs. (103 Nm). Tighten the front subframe bracket bolts to 54 ft. Ibs. (74 Nm) and the rear bracket bolts to 86 ft. Ibs. (117 Nm). ¢ Rear engine mount bolts to 28 ft. lbs. (38 Nm) e Engine-to-torque converter bolts. Tighten the 6 x 1 mm bolts to 105 inch Ibs. (12 Nm), 10 x 1.25mm bolt to 28 ft. Ibs. (38 Nm). e Front motor mount nut to 40 ft. Ibs. 12. level. 13. leaks, 14. adjust

REMOVAL & INSTALLATION

Fill the transaxle to the correct

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle. 3. Remove or disconnect the following: e Negative battery cable e Front wheels e Spindle nut e Stabilizer bar link ¢ Lower ball joint 4. Pry the inboard joint from the transaxle or intermediate shaft. 5. Remove the outer C\V-joint stub shaft from the hub by tapping the stub shaft with a plastic hammer. To install:

Start the engine and check for

Use new circlips, split pins and selflocking nuts for assembly.

(54 Nn)

Check the wheel alignment and as necessary.

Transfer Assembly

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable

Heated Oxygen (HO2S) sensor connectors Front sub-frame stiffener e Exhaust front pipe Propeller shaft from the transfer assembly Transfer assembly bolts and the assembly To install: 3. Install or connect the following: e New O-ring on the transfer cover Dowel pin on the assembly Transfer assembly and tighten the bolts to 33 ft. lbs. (44 Nm) Propeller shaft Exhaust front pipe Front sub-frame stiffener and tighten the bolts to 40 ft. Ibs. (54 Nm) Heated Oxygen (HO2S) sensor connectors Negative battery cable

6. Install the outer CV-joint stub shaft into the hub. 7. Install the inner CV-joint to the transaxle or intermediate shaft until the circlip locks in the retaining groove. 8. Install or connect the following: e Lower ball joint. Tighten the nut to 43-51 ft. Ibs. (69-69 Nm). e Stabilizer bar link. Tighten the nut to 58 ft. Ibs. (78 Nm). e Spindle nut. Tighten the nut to 181 ft. Ibs. (245 Nm). e Front wheels e Negative battery cable 9. Fill the transaxle to the correct level and check for leaks.

OVERHAUL Front

OUTBOARD JOINT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Axle halfshaft from the vehicle and place it in a vise e Outboard joint boot clamps and push the boot back

e Outboard joint by driving it off the axle shaft with a brass drift and hammer e Outboard joint boot

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

Se 7

1) he

SET RING Replace.

RS a?

,

_-SaEEH Pack cavity with grease.

INBOARD JOINT

(Left driveshaft)

(Right driveshaft) INBOARD BOOT

Pack cavity with grease.

SNAP RING Replace.

DRIVESHAFT

OUTBOARD JOINT

‘ - .

a ‘

OUTBOARD BOOT y

= ares Pack cavity with grease.

ee

Front axle exploded view—MDX

:

g

To install:

Use

4

new circlips and boot clamps for

assembly.

4

3. Install the outboard joint boot and

!:

clamps to the axle shaft. 4. Fill the outboard joint with grease.

;

Install the outboard joint to the axle shaft.

INBOARD JOINT

To install:

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

LOE NAHAS SRE lowing: if

: race!

neiedin at

Tap the stub shaft with a brass hammer to seat the circlip. A 5. Fill the outboard joint boot with grease and install the boot clamps.

Ghareaat bagi satioardhiol ' ° joint housing from the axle » Rollers from the spider E :

vehicle.

e Inboard joint boot

6. Install the axle halfshaft to the

si hase the spider from the

e>Use new circlips and boot clamps for assembly.

3. Install or connect the following:

e Inboard joint boot and clamps to the axle shaft e Spider with a new snapring ¢ Rollers to the spider ‘ 4. Fill the joint housing with grease and install it. 5. Fill the inboard joint boot with grease and install the boot clamps. 6. Install the axle halfshaft to the vehicle.

ai

he oa he

rT

nS

ee eee

ve Ore

STEERING AND SUSPENSION disconnected from the steering column. Damage to the air bag wiring can result.

* CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service

on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety preCautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deploy-ment. Before servicing the vehicle, also make Sure to refer to the precautions in the beginning of this section as well.

DISARMING Disconnect and isolate the negative battery cable. Wait 3 minutes for the system capacitor to discharge before performing any Service.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION

Do not permit the steering wheelto turn whenever the steering gear Is

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Center the steering wheel and lock it in position. 3. Attach a support fixture to the engine lifting eyes. _ 4. Remove or disconnect the following: “Negative battery cable Air bag and steering wheel Steering joint cover Steering flexible joint Powerssteering fluid lines 10mm bolt on the engine side mount bracket Front wheels Outer tie rod ends Sub-frame stiffener Heated Oxygen (HO2S) sensor connectors 3 way catalytic converter from the mufflers Flange bolts from the exhaust rubber mount Power steering pressure switch connector Propeller shaft protector e Splash shield 5. Support the front subframe with a jack and support the transmission with a second jack. 6. Loosen the 14mm subframe bolts. 7. Lower the subframe about 1 %e

inches (30mm). 8. Remove or disconnect the following: e Four 12mm stiffener plate bolts 9. Support the transfer case by raising the transmission jack and remove the two 12mm bolts. ¢ Two 14mm bolts and the rear stiffener plats from the subframe 10. Lower the transmission jack until the front subframe has dropped about 1 ‘6 inch (50mm). e Power steering line brackets e Feed line e Return hose e Two 10mm bolts from the right side gearbox ¢ Mounting bracket and cushion

a ¢ Two.10mm bolts from the left side gearbox 11. Lower the transmission jack until the front subframe has dropped about 3 16 inch (100mm). e Gearbox stiffener bracket 12. Slide the gearbox between the body and front sub-frame towards the left and from the vehicle. To install: 13. Position the steering gear in the vehicle. 14. Install or connect the following: Left steering gear mounting bolts. Tighten the bolts to 43 ft. Ibs. (58 Nm). Right steering gear mounting bracket. Tighten the bolts to 29 ft. lbs. (39 Nm). Return hose Feed line Power steering line mounting brackets and tighten the bolts to 7 ft. Ibs. (10 Nm) 15. Raise the subframe into position. Tighten the 14mm bolts to 76 ft. Ibs. (103 Nm) and the 12mm bolts to 86 ft. Ibs. (117 Nm). 16. Install or connect the following: Front stiffener plates. Tighten the 14mm bolts to 76 ft. Ibs. (103 Nm) and the 12mm bolts to 54 ft. Ibs. (74 Nm). Splash shield Propeller shaft protector Power steering pressure switch 3 way catalytic converter and mufflers. Tighten the nuts to 25 ft. Ibs. (33 Nm) Rubber exhaust mount and tighten the bolts to 28 ft. Ibs. (38 Nm) HO2S sensor connectors Sub-frame stiffener plate 10mm flange bolts on the engine side mount bracket to 33 ft. Ibs. (44 Nm) Power steering hoses Outer tie rod ends Front wheels. Position the wheels straight-ahead. Steering flexible joint. Tighten the pinch bolts to 16 ft. Ibs. (22 Nm). Steering joint cover Negative battery cable 17. Fill the power steering system. 18. Check the wheel alignment and adjust as necessary.

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

54

hee he cee +|

a

ee

ee

ee

ACURA MDX

stat REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Wheel speed sensor wiring bracket e Brake hose bracket e Stabilizer bar link

4. Check the wheel alignment and adjust as necessary.

e Upper mount nuts e Strut to Install’

Shock Absorber

3. Install or connect the following: e Strut. Tighten the upper mount nuts to 43 ft. Ibs. (69 Nm). Strut pinch bolts. Tighten the nuts to 116 ft. Ibs. (157 Nm). Stabilizer bar link. Tighten the nut to 58 ft. Ibs. (78 Nm). Brake hose bracket Wheel speed sensor wiring bracket Front wheel

DAMPER MOUNTING WASHER arsine!

DAMPER MOUNTING BASE

UPPER SPRING SEAT

8

—

=

eS

REMOVAL & INSTALLATION Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle under the lower control arm.

aes SELF-LOCKING NUT -

12 x 1.25 mm

44N-m (4.5 kgf-m, 33 tbf-ft)

_2————

Replace.

DAMPER MOUNTING BEARING

Check for any play or roughness.

DUST COVER PLATE

SPRING MOUNTING RUBBER Check for deterioration and damage.

DUST COVER SLEEVE

BUMP STOP Check for weakness and damage.

DAMPER SPRING Check for weakened compression

and damage.

DAMPER UNIT.

Exploded view of the front strut assembly

93552611

el al SS

aE

a

er

3. Remove or disconnect the following: e Rear wheel e Upper shock absorber flange bolt e Lower shock absorber nut e Shock absorber To install: 4. Install or connect the following: e Shock absorber. Tighten the fasteners to 47 ft. Ibs. (64 Nm). e Rear wheel

Coil Spring REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut from the vehicle and install in a strut spring compressor. Compress the spring until the end of the spring comes away from the spring seat. 3. Remove the upper strut mount, spring seat and related components. 4. Remove the coil spring from the strut spring compressor. . To install: >Use a new self-locking nut.

5. Compress the spring and position the

ef

for weakness

and damag

pr ae

et

strut so that the end of the spring aligns with the notch in the spring seat. 6. Install the upper strut mounting coma and tighten the nut to 33 ft. Ibs. (44 m). 7. Install the strut to the vehicle. 8. Check the wheel alignment and adjust as necessary.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle under the lower control arm. 3. Remove or disconnect the following: e Rear wheel e Stabilizer link from the lower arm ° ei Guta sensor wiring harness from the lower arm. Do not disconnect the connector. e Upper shock absorber flange bolt e Lower control arm bolts 4. Lower the floor jack and remove the coil spring and spring seats. To install: >Use new self-locking nuts for assembly.

5. Place the coil spring and spring seats on the lower control arm and raise into position. Tighten the inboard bolt to 61 ft. lbs. and the outer bolt to 54 ft. Ibs. (74 Nm). 6. Install the rear wheel.

kgf-m, 29 Hbf-ft) SPRING SEAT

REMOVAL & INSTALLATION

Cheer tee oudeterioration an

mage.

The lower ball joints are replaced with the control arms as an assembly.

_— SPRING roe: at Check for Jength and damage.

- 4, Installation is the reverse of removal. Tighten the arm bolt to 47 ft. Ibs. (64 Nm) and the ball joint nut to 36-43 ft. Ibs. (49-59 Nm).

Lower Control Arm

REMOVAL & INSTALLATION

Rear

Ball Joint

10 x 1.25 mm

(4.0 ene

RRA

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Lower ball joint e Front inner flange bolt e Rear inner flange bolt e Lower control arm To install: >Use a new split pin for assembly.

3. Install or connect the following: e Lower control arm. Tighten the inner flange bolts to 69 ft. Ibs. (93 Nm). e Lower ball joint. Tighten the nut to 43-51 ft. Ibs. (659-69 Nm). e Front wheel 4. Check the wheel alignment and adjust as necessary. Rear

LOWER ARM (A) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Lower arm mounting bolt and nut e Lower arm 3. Installation is the reverse of removal. Tighten the bolt to 103 ft. Ibs. (140 Nm) and the nut to 47 ft. Ibs. (64 Nm).

Upper Control Arm REMOVAL & INSTALLATION

Cc a

ea 25mm

8 5kgfm, 47 Ibf-ft)

Rear

LOWER SPRING SEAT Check for deterioration and damage.

93552612

Exploded view of the rear spring assembly

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the control arm at the knuckle. 3. Remove or disconnect the following: e Wheel e Upper ball joint from the knuckle e Upper arm bolt and the arm

“ects

9

14x1.5mm

140 N-m

ia

(14.2 kaf-m,

103 Ibf-ft)

yh A 93552GB2

Rear lower arm (A) mounting

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

0-18

fox"

93552613

Rear lower arm (B) mounting’

LOWER ARM (B) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the control arm with a jack. 3. Remove or disconnect the following: e Wheel e Stabilizer link from the lower arm e Wheel speed sensor wiring harness from the lower arm. Do not disconnect the connector. e Flange bolts that attaches the lower arm to the knuckle 4. Spring assembly e Inner nuts and bolts and the arm 5. Install or connect the following: e Arm, inner bolt and loosely install the nut e Spring assembly 6. Raise the arm into position and install the flange bolt. 7. Raise the rear suspension with a floor jack to load the vehicle weight. e Tighten the flange bolt to 54 ft. Ibs. (74 Nm) and the inner nut and bolt to 61 ft. Ibs. (83 Nm). e Wheel speed sensor harness e Wheel 8. Check the vehicle alignment.

e Outer tie rod end. Tighten the nut to AQ ft. Ibs. (54 Nm). ¢ Wheel speed sensor, if equipped e Brake caliper and rotor e Brake hose e Spindle nut. Tighten the nut to 181 ft. Ibs. (245 Nm). e Front wheel 11. Check the wheel alignment and . adjust as necessary.

2. Remove or disconnect the following: Front wheel Brake hose mounting bolt Brake caliper Wheel speed sensor Spindle nut Brake rotor Outer tie rod end Lower ball joint Steering knuckle 3. Press the hub out of the wheel bear-

12 x 1.25 mm im (8.5 kgf-m, 61 Ibf-ft)

ing.

Rear

4, Remove the splash guard. 5. Remove the snapring and press the wheel bearing out of the steering knuckle. 6. If necessary, press the inner bearing race off of the hub.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Rear wheel Brake hose bracket mounting bolts from the trailing arm and the knuckle Brake caliper Wheel speed sensor Spindle nut Brake rotor Upper ball joint Lower arm (A) Lower arm (B) from the trailing arm 3. Support the lower arm (B) e Steering knuckle 4. Press the hub out of the wheel bearing.

To install:

>Use a new ball joint nut, split pin, snapring and spindle nut for assembly.

7. Press the bearing into the steering knuckle and install the snapring. 8. Install the splash guard. 9. Press the hub into the bearing. 10. Install or connect the following: e Steering knuckle. Tighten the ball joint nut to 43-51 ft. Ibs. (59-69 Nm) and the damper flange bolts to 116 ft. Ibs. (157 Nm). FLANGE NUTS i eee 16x 1.5mm a)

157 N-m (16.0 kgf-m, 116 Ibf-ft)

WHEEL BEARING a Replace.

SPLASH GUARD

oe RING

KNUCKLE

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arms as an assembly.

Wheel Bearings

SCRE WASHERS (0.95 kgf-m, 6.9 Ibf-ft)

ADJUSTMENT BRAKE DISC

ee

REMOVAL & INSTALLATION

Weasure valve clearance with the

engine cold.

79248613

Aligning the sub gear with the Gear Spring Lever J-42686

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the valve covers. 3. Check the valve clearance with the camshafts positioned as shown. Intake valve clearance should be 0.0091—0.0130 inches. Exhaust valve clearance should be 0.0098—0.0138 inches. 4. If adjustment is required, replace the shims as follows:

Cn.

|

a. Step 1: Position special tool J-42689 on the edge of the tappet. b. Step 2: Rotate the crankshaft until the maximum lift portion of the camshaft lobe contacts the upper edge of the speCial tool and presses the tappet down to create enough clearance between the adjustment shim and the camshaft forthe shim to be removed. c. Step 3: Replace shims as necessary to achieve correct valve clearance. d. Step 4: Repeat for each valve to be adjusted. 5. Replace the valve covers. Tighten the

bolts to 80 inch Ibs. (9 Nm).

2. Remove or disconnect the following: Negative battery cable Air cleaner assembly Upper fan shroud Accessory drive belt and tensioner Cooling fan and pulley Idler pulley Power steering pump and move it aside , Crankshaft pulley Timing belt cover Timing belt Ignition coils Valve covers Camshafts Valve shims and tappets ->Keep the valve shims and tappets in order for installation.

To install: 3. Install the valve tappets and shims in their original locations. 4. Using Gear Spring Lever J-42686, turn the sub gear clockwise to align the 5mm bolt holes in the sub gear and the camshaft driven gear. Tighten the 5mm bolt. 5. Install the camshafts. Align the timing marks as shown. Tighten the bolts in sequence to 89 inch Ibs. (10 Nm). 6. Install or connect the following: Valve covers Ignition coils Timing belt Timing belt cover Crankshaft pulley Power steering pump Idler pulley Cooling fan and pulley Accessory drive belt and tensioner Upper fan shroud Air cleaner assembly Negative battery cable

9302BG02

Cross section of the cylinder head. Note the position of the camshaft lobe (1), adjustment shim (2) and the tappet (3)

9302BG04

9302BG03

Valve clearance adjusting tool J-42689 (1)

Using the valve clearance adjusting tool to hold the tappet for shim replacement

Timing belt service is covered in Section 3 of this manual

;

Starter Motor

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Heated Oxygen Sensor (HO2S) connectors e Exhaust front pipe e Heat shield e Starter wiring connectors e Starter motor To install: 3. Install or connect the following: e Starter motor. Tighten the bolts to 30 ft. Ibs. (40 Nm). e Starter wiring connectors e Heat shield e Exhaust front pipe e HO2S connectors e Negative battery cable

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Front wheels Oil level dipstick Stone guard Radiator under fan shroud Suspension crossmember Flywheel dust cover Pitman arm Idler arm 4. |f equipped with 4 wheel drive, unbolt and lower the front axle housing assembly for clearance. e Qil pan e Lower crankcase To install: 5. Apply a bead of silicone sealant to the crankcase flange and install the crankcase. Tighten the fasteners in sequence to 89 inch Ibs. (10 Nm). 6. Apply a bead of silicone sealant to the oil pan flange and install the oil pan. Tighten the fasteners to 89 inch Ibs. (10 Nm). 7. lf equipped, raise the axle housing assembly into position. Tighten

9308BG01

Lower crankcase torque sequence

the axle case bolts to 61 ft. Ibs. (82 Nm) and the mounting bolts to 112 ft. Ibs. (152 Nm). 8. Install or connect the following: e Pitman arm. Tighten the nut to 159

ft. lbs. (216 Nm). Idler arm. Tighten the bolt to 33 ft. lbs. (44 Nm). Flywheel dust cover Suspension crossmember. Tighten the bolts to 58 ft. Ibs. (78 Nm). Radiator under fan shroud Stone guard Oil level dipstick Front wheels

e Negative battery cable 9. Fill the crankcase with engine oil. 10. Start the engine and check for leaks.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ 2. Remove or disconnect the following:

9308BG02

Oil pump torque sequence

eer mat

ee

ACURA

SLX

e Timing belt e Oil pan ¢ Oil pick-up tube © Oil filter adapter ¢ Oil pump To install: 3. Apply silicone sealant to the oil pump mounting surface and install the oi! pump. Tighten the bolts in sequence to 18 ft. Ibs. (25 Nm). 4. Install or connect the following: e Oil filter adapter ¢ Oil pickup tube e Oil pan e Timing belt

To install: 3. Install or connect the following: e New rear main seal, by lubricating it with engine oil e Flywheel, using new flywheel bolts. Tighten the bolts, in a 2-step crisscross pattern, to 40 ft. Ibs. (54 Nm). e Transmission Negative battery cable 4. Check the oil and refill as necesSary.

Oil ring side rail (Lower)

No.2 Compression

ring

6-9 No,1 Compression i ring Front mark

side rail

(Upper) 7924AG51

Piston ring end-gap spacing

Piston and Ring

POSITIONING

Rear Main Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the follow-ing: e Negative battery cable e Transmission’ ¢ Flywheel by loosening the flywheel bolts in a 2-Step crisscross sequence e Rear main seal, using a seal puller ->Do not damage the crankshaft sealing surface.

TOP RING

&

MARK =

S)

Use new nuts, bolts and split pins for assembly.

. Knuckle . Lower end . Nut and washer, rear . Bolt, rear . Nut and washer, front . Bolt, front . Lower control arm assembly . Torsion bar arm bracket . Bushing, rear AFP OANA WNH— 10. Bushing, front

7924BG34

Exploded view of the control arm and ball joint components

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

APT

aN!

Ye ¢

ee Mri

a

or

x

6 18 re i ‘Install or connect the following: e Upper ball joint. Tighten the mounting bolts to 42 ft. Ibs. (57 Nm) and the nut to 72 ft. Ibs. (96 Nm). :

e Wheel speed sensor

e Front wheel

Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm with a jackstand. 3. Remove or disconnect the following: e Front wheel e Disc brake caliper and support e Brake rotor and backing plate e Wheel speed sensor e Outer tie rod end e Upper ball joint

e Steering knuckle e Lower ball joint

To install: e>Use new nuts, bolts and split pins for assembly.

4. Install or connect the following: ¢ Lower ball joint. Tighten the mounting bolts to 76 ft. Ibs. (103 Nm). Steering knuckle. Tighten the lower ball joint nut to 108 ft. Ibs. (147 Nm). e Upper ball joint. Tighten the nut to 72 ft. Ibs. (98 Nm). e Outer tie rod end. Tighten the nut to 72 ft. Ibs. (98 Nm), e Wheel speed sensor Brake rotor and backing plate e Disc brake caliper and support. Tighten the support bolts to 115 ft. lbs. (155 Nm). Front wheel 5. Check the wheel alignment and adjust as necessary.

e Brake caliper e Upper ball joint e Upper control arm e>Note the alignment shim location for assembly.

To install: 4. Install or connect the following: Upper control arm Alignment shims in their original locations. Tighten the bolts to 112 ft. Ibs. (152 Nm). Upper ball joint. Tighten the nut to 72 ft. Ibs. (98 Nm). Brake caliper Wheel speed sensor Front wheel 5. Check the wheel arene and adjust as necessary.

Upper Control Arm CONTROL ARM BUSHING REPLACEMENT REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm with a jackstand. 3. Remove or disconnect the following: e Front wheel e Wheel speed sensor

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the upper control arm. 3. Remove the nuts and washers from the fulcrum pin. 4. Press the bushings out of the control

arm.

‘

1. Nut and cotter pin 2. Nut 3. Lower ball joint 4. Bolt

7924BG35

Exploded view of the lower ball joint mounting and related components

Bolt and Plate Camber Shims Caster Shims Nut Assembly

Upper Control Arm Assembly Fulcrum = WP On

Pin

Bushing Plate Nut OoOmon

10 11 12

Speed Sensor Cable Nut and Cotter Pin Upper Ball Joint 9308BG06

Upper control arm and related parts

oe ineg Ce ie

‘taf tee

MM

6-2

ae

eee

Sere Oy, Ree Ole eee

ACURA

SLX

To install: 5. Press the bushings into the control arm. 6. Install the fulcrum pin washers and nuts. 7. Install the upper control arm. 8. Raise the suspension so that there is 0.79 inches (20mm) between the bump stop and the lower control arm. Tighten the fulcrum pin nuts to 80 ft. Ibs. (108 Nm). 9. Check the wheel alignment and adjust as necessary. Lower Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Torsion bar e Lower ball joint e Stabilizer bar link e Shock absorber e Lower control arm To install: 3. Install or connect the following: ¢ Lower control arm e Shock absorber e Stabilizer bar link e Lower ball joint e Torsion bar e Front wheel 4. Raise the suspension so that there is 0.79 inches (20mm) between the bump stop and the lower control arm. Tighten the front control arm bolt to 116 ft. Ibs. (157 Nm) and tighten the rear control arm bolt to 145 ft. Ibs. (196 Nm). 5. Check the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Lower control arm e Bushings, press them from the control arm, using Remover/Installer J-36833 for the front bushing and Remover/Installer J-36834 for the rear bushing. To install: 3. Install or connect the following: e New bushings e Lower control arm

Wheel Bearings

ADJUSTMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Brake caliper and pads e Hub dust cap e Snapring and shim e Hub flange e Lockscrew and washer 3. Tighten the hub nut to 22 ft. Ibs. (29 Nm) to seat the bearings and then fully loosen the nut. 4. Tighten the hub nut to achieve a bearing preload of 2.6—4.0 Ibs. (1.2-1.8 Kg) for used bearings. If the bearings were replaced, set the preload to 4.4—-5.5 Ibs. (2.0-2.5 Kg). 5. Install or connect the following: e Lock washer and screw ¢ Hub flange e Shim and snapring

e Hub dust cap. Tighten the bolts to 43 ft. Ibs. (59 Nm). e Brake caliper and pads e Front wheel

REMOVAL & INSTALLATION

—

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. : 2. Remove or disconnect the following: Front wheel Brake caliper and support Hub dust cap Snapring and shim Hub flange Lockscrew and washer Hub nut Brake rotor and hub assembly Wheel speed sensor ring Outer bearing Grease seal Inner bearing To install: 3. Clean and inspect the bearings. Replace if necessary. 4. Apply clean wheel bearing grease to the inner and outer bearings. 5. Apply grease in the hub. 6. Install the wheel bearings into the hub along with a new grease seal. 7. Install or connect the following: Wheel speed sensor ring. Tighten

the bolts to 13 ft. Ibs. (18 Nm). Brake rotor and hub assembly Hub nut. Set the bearing preload. Lockscrew and washer Hub flange Snapring and shim Hub dust cap Brake caliper and support. Tighten the support bolts to 115 ft. Ibs. (155 Nm). Front wheel

eee en | :

eg

era

3

gh ee tee oe ee ina on ff

BMW 2000 X5 DRIVE TRAIN ................... 7-11 ENGINE REPAIR.................. 7-2 FUEL SYSTEM.................. 7-10

Fel RUMP sinish die Be Het7-10 Removal & Installation.............. 7-10 Fuel System PreSSUure.........sc0ec 7-10

R | Rear Malit Seals, :.:1.;.-.s.dnmacenaen 7-8 Removal & Installation................ 7-8

STEERING AND

Fuel System Service

SHOCK ADSONDEN, 15.505. yesadeel tame! 7-14

A PY BAGS Yin Whee ite SH ARNE |i 7-13 SE Li Lge epee ean Se7-13

H HANTS Bt Ste tease cect Oy eae 7-12 Removal & Installation.............. 7-12

Stare ek sepa OR a eee 7-7 Removal & Installation... 7-7 SEU Rent re ocatre Lear eeeene 7-14

Vn Ye) whekdeg Oa i 7-2 - Removal & Installation.............. ioe C

PUTTUISUINOUIL. vars ec iced oie ae 7-2 take WAIMFOIA. css enpnne sesypunneeadesech 7-5 Removal & Installation............... 1-5

Timing Chain, Sprockets, Front Cover and Seal... 7-8 Removal & Installation... 7-8

Removal & Installation................ 7-6 Coil Spring............ gall poy Brice.AD7-14 Removal & Installation.............. 7-14)

Lower Ball Joint.......... he atiet alo Removal & Installation.............. 7-15 — LowemGontrol Artois. eM tte.asit.ne 7-15

Removal & Installation.............. fat] Transmission Assembly .............. Tt Removal & Installation............. 7-11

Removal & Installation.............. 7-15

Upper Control Arm .......ccccseeee 7-15

Engine ASS@MDIY ........sssseeeeeeesseeeee 7-3 Removal & Installation................ 7-3 Exhaust Manifold ....ccccccccccccccccccscosee 7-5

Oil Pare eeeer fy, AttLaoe aE.7-7 Removal & Installation................ 1-7 BING cilia phette Ai Me alee od (+7

V Valve LaShig abs kaa 7-7 AGIISUTIONE ARC Seay. aie 7-7

Removal & Installation... 7-5

Removal & Installation.............. ier P

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PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

ae e>Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer systems and may require the computer to undergo a relearning process.

Ignition Timing ADJUSTMENT

The Digital Motor Electronics (DME) control, unit controls all ignition and fuel injection functions. Ignition timing is fully electronically controlled; there is no vacuum advance or manual adjustment. Ignition functions are calculated from internal maps and from the same sensors used for the fuel injection system. On vehicles with an automatic transmission, the control unit will

~ brake fluid internally, seek medical assistance IMMEDIATELY. -e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as Soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. e Always wear Safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You

ENGINE REPAIR retard ignition timing briefly when the transmission is about to shift up or down. For this reason, there is a data link between the DME control unit and the transmission control unit. Since the ignition timing is controlled by the DME, checking and adjusting the timing is impossible. There is no method of setting dynamic or static timing.

Alternator

REMOVAL & INSTALLATION e>When the battery is disconnected the radio code, on-board computer and clock settings will be lost. The radio code should be obtained before disconnecting the battery or radio. Once the

| should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con_ tact with a painted surface; it will damage the paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt and to the: timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. e Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

| battery has been reconnected, the radio will not function unless the code is keyed in.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ‘ 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Drive belt Fan cowling Alternator bolts Alternator electrical connectors Alternator roller by releasing the Screw Alternator To install: 4. Replace the sealing ring for the alternator.

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5. Install or connect the following: e Alternator. Torque the bolts to 31 ft. * Ibs. (43 Nm). e Alternator roller e Alternator electrical connectors e Fan cowling e Drive belt e Negative battery cable : i Fill the cooling system to the proper evel, 7. Start the vehicle and check for leaks, repair if necessary.

Engine Assembly

REMOVAL & INSTALLATION 1. Fully open the hood and properly secure it in place. 2. Properly relieve the fuel system pressure. ‘ 3. Evacuate and recover the A/C sysem. 4. Drain the cooling system. 5. Drain the engine oil. 6. Drain the power steering fluid. 7. Before servicing the vehicle, refer to the precautions in the beginning of this section. 8. Remove or disconnect the following: Negative battery cable Engine cover Throttle cable from the intake filter housing Intake filter housing Mass Air Flow (MAF) sensor Windshield washer reservoir Brake booster hose from the suction jet pump Fuel feed line from the injection pipe Engine splash shield and reinforcement plate Drive belt

Power steering pump A/C system lines between the compressor and condenser A/C suction line Transmission Starter electrical connectors and heat shield e Starter Oil lines to the transmission on the

heat exchanger Radiator Coolant hoses on the alternator and thermostat housing Coolant hoses from the coolant manifold

e Heating valve and hoses e Fuel tank vent hose e Engine wire harness from the control unit box e Transmission wire harness from the control unit box e Oxygen (02S) sensor wiring and place all wires on top of the engine e Expansion tank ¢ Supply reservoir from the carrier Ground strap from the oil filter housing Left and right swivel bearings Output shafts Propeller shaft Partition wall Ground tape from the right side engine support Upper nuts from the left and right side engine mounts and install an engine removal tool to the locating lugs Engine from the vehicle To install: 9. Carefully lower the engine into the engine compartment. 10. Install or connect the following: Engine mounts. Torque the bolts to 32 ft. Ibs. (45 Nm). Ground tape Partition wall Propeller shafts Output shafts Left and right swivel bearings Ground strap to the oil filter housing Supply reservoir Expansion tank 02S sensor electrical connector Engine and transmission wire harness to the control unit box Fuel tank vent hose Heater valve and hoses Coolant hoses to the manifold and thermostat housing Radiator Transmission Oil lines to the transmission. Torque the nuts to 25 ft. Ibs. (34 Nm). e Starter and electrical connectors e A/C lines e Power steering pump e Drive belt e Engine splash shield and reinforcement plate Fuel feed line to the injection pipe Brake booster vacuum hose Windshield washer reservoir

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MAF sensor Intake filter housing Throttle cable to the filter housing Engine cover Negative battery cable 11. Fill and bleed the power steering system. 12. Fill and bleed the coolant system. 13. Recharge the A/C system. 14. Fill the engine with clean oil.

15. Start the vehicle and check for leaks, repair if necessary.

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REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect: e Negative battery cable e Vibration damper e Thermostat housing e Water pump pulley

¢ Coolant hoses e Water pump and discard the seal To install: 4. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump. 5. Install the water pump with a new gasket. Torque the bolts as follows: a. M6 bolts: 78 inch Ibs. (9 Nm). b. M7 bolts: 89 inch Ibs. (10 Nm). c. M8 bolts: 16 ft. Ibs. (22 Nm). 6. Install or connect the following: e Coolant hoses to the water pump e Water pump pulley e Thermostat housing e Vibration damper e Negative battery cable 7. Fill and bleed the cooling system

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8. Start the vehicle, check for leaks and repair as necessary.

Cylinder Head REMOVAL & INSTALLATION Left Side

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Left side exhaust manifold e Cylinder head cover e Spark plugs e Intake manifold Coolant manifold Left side camshaft adjustment unit

5. Install special tool 11-5-180 and

pull back until the flywheel is no longer secured. 6. Lift the timing chain and hold it under tension. 7. Crank the engine at the central bolt against the direction of rotation to 45 degrees Before Top Dead Center (BTDC). 8. Remove the special tools. 9. Remove or disconnect the following: e Guide rail from the cylinder head e Cylinder head bolts in the proper sequence

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10. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap. 11. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts, apply oil to the threads and torque the bolts in the following

sequence: a. Step 1: 22 ft. Ibs. (30 Nm). b. Step 2: 80 degrees. c. Step 3: 80 degrees. 12. Install or connect the following: e Guide rail screw and rotate the camshafts until the markings face upward ¢ Camshaft sprockets and the timing chain tensioner. Torque the bolts to

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e Coolant manifold e Spark plugs * ¢ Cylinder head cover. Torque the bolts to 10 ft. Ibs. (15 Nm). e Left side exhaust manifold e Negative battery cable 13. Fill and bleed the cooling system. 14. Change the engine oil and filter. 15. Start the vehicle, check for leaks and repair as necessary. Right Side 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure.

3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Right side exhaust manifold Cylinder head cover Spark plugs Fan clutch and impeller Intake manifold

Coolant manifold Right side cam adjustment unit 5. Install special tool 11-5-180 and pull back until the flywheel is no longer secured. 6. Lift the timing chain and hold it under tension. 7. Crank the engine at the central bolt against the direction of rotation to 45 degrees Before Top Dead Center (BTDC). 8. Remove the special tools. 9. Remove or disconnect the following: e Guide rail from the cylinder head e Cylinder head bolts in the proper

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a. Step 1: 22 ft. Ibs. (30 Nm). b. Step 2: 80 degrees. c. Step 3: 80 degrees. 12. Install or connect the following: e Guide rail screw and rotate the camshafts until the markings face upward Camshaft sprockets and the timing chain tensioner. Torque the bolts to 11 ft. Ibs. (15 Nm). Left side camshaft adjustment unit Coolant manifold Spark plugs Cylinder head cover. Torque the bolts to 10 ft. Ibs. (15 Nm). Left side exhaust manifold Negative battery cable 13. Fill and bleed the cooling system.

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Acoustic cover Ignition coil electrical connectors Throttle bellows Intake filter housing Mass Air Flow (MAF) sensor Wiring harness from the intake manifold Air injection vacuum control hoses Throttle body vacuum hose Fuel feed line from the injection pipe Engine ventilation hose from the cylinder head cover Engine ventilation hose from the oil separator

Brake booster vacuum hose Oil separator from the cover Decoupling elements from under the intake manifold Oil drain hose from the rear cover after raising the intake manifold slightly Intake manifold

14. Change, the engine oil and filter. 15. Start the vehicle and check for leaks, repair if necessary.

>The intake manifold is vibrationally separated from the cylinder head by decoupling elements and gaskets.

Intake Manifold

REMOVAL & INSTALLATION

To install: 4. Install or connect the following: Decoupling elements to the cylinder head Intake manifold Remaining components of the decoupling elements. Torque the M6 nuts to 89 inch Ibs. (10 Nm), the M7 nuts to 10 ft. Ibs. (15 Nm) and the M8 nuts to 16 ft. Ibs. (22 Nm). Oil drain hose to the rear cover Oil separator Brake booster vacuum hose Engine vent hose to the oil separator and the cylinder head Fuel feed line to the injection pipe Throttle body vacuum hose Air injection vacuum control hoses Wiring harness to the intake manifold MAF sensor Intake filter housing Throttle bellows Ignition coil electrical connectors Acoustic cover Both battery cables

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pres-

Sure. 3. Remove or disconnect the following: e Both battery cables

sequence e Cylinder head To install: 10. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap. e>Referto Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

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11. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts, apply oil to the threads and torque the bolts in the following sequence:

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Exhaust Manifold

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

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2. Remove or disconnect the following: _e Negative battery cable . Exhaust system Reinforcement plate Propeller shaft, left side manifold only Screw connection at the exhaust manifold Exhaust manifold downward and discard the gaskets To install: 3, Remove the old gasket off of the cylinder head and exhaust manifold and replace the gasket. The gasket beads face the exhaust manifolds. 4. Install or connect the following: Exhaust manifold with new gaskets. Torque the bolts to 10 ft. Ibs. (15 Nm). Screw connection at the exhaust manifold Propeller shaft, left side manifold only Reinforcement plate Exhaust system Negative battery cable

Camshaft and Valve Lifters

REMOVAL & INSTALLATION Pay CAMSHAFT (CYLINDER BANK

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 02. Remove or disconnect the following: Negative battery cable Splash guard Left and right cylinder head covers

Spark plugs Timing chain tensioning piston Top left timing case cover Left camshaft adjustment unit and distributor Oil lines to the left and right cylinder head 3. Install special tool 11-2-300 and pull. back on it until the flywheel is no longer secured in position. _ 4. Lift the timing chain and hold it under tension. 5. Crank the engine counter-engine wise on the central screw into the 45 degrees Before Top Dead Center (BTDC) position. 6. Rotate the exhaust camshaft at the hex head until the cam at cylinder No. 6 faces upward. 7. Rotate the inlet camshaft at the hex

head until the cam at cylinder No. 8 faces upward. 8. Evenly release the bearing covers on the exhaust and inlet camshafts in Yaturn steps from the outside working in. 9. Remove the bearing covers and remove the camshafts. 10. Remove the hydraulic valve lifters. To remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring. To install: 11. If the lifters were removed, install them with tool No. 11-32-250. 12. Lubricate and install the camshafts in their correct position. 13. Install or connect the following: e Exhaust and inlet camshafts and rotate them until exhaust cam at cylinder No. 6 faces up and inlet cam at cylinder No. 8 faces up Bearing caps. The exhaust camshaft bearing covers are marked A1 to Ad and the inlet covers are marked E1 to E5. Evenly tighten the bearing covers in ¥2 turn steps from the outside working in. 14. Torque the camshaft bearing covers as follows: a. M6 to 89 inch Ibs. (10 Nm). b. M7 to 9 ft. lbs. (14 Nm). c. M8 to 15 ft. Ibs. (20 Nm). 15. Rotate the camshafts until the markings face upwards. 16. Using special tools 11—2-446 and 11-—2-442 align the inlet and exhaust camshafts with an open-end wrench so the tools rest without a gap on the cylinder head. 17. Crank the engine from the 45 degrees BTDC position in the direction of rotation up to the TDC position. 18. Hold the crankshaft and install the distributor on the camshaft adjustment unit. 19. Install or connect the following: e Camshaft adjustment unit e Left timing case cover ¢ Timing chain tensioning piston ¢ Spark plugs Cylinder head covers Splash guard Negative battery cable

RIGHT CAMSHAFT 1-4)

(CYLINDER BANK

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

e Negative battery cable e Splash guard .

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e Left and right cylinder head COVers Spark plugs Timing chain tensioning piston

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Top right timing case cover Right camshaft adjustment unit and distributor ¢ Oil lines to the left and right cylinder head

3. Install special tool 11-2-300 and pull back on it until the flywheel is no longer secured in position. 4. Lift the timing chain and hold it under tension. 5. Crank the engine counter-engine wise on the central screw into the 45 degrees Before Top Dead Center (BTDC) position. 6. Rotate the exhaust camshaft at the hex head until the cam at cylinder No. 6 faces upward. 7. Rotate the inlet camshaft at the hex head until the cam at cylinder No. 8 faces upward. 8. Evenly release the bearing covers on the exhaust and inlet camshafts in Yeturn steps from the outside working in. 9. Remove the bearing covers and remove the camshafts. 10. Remove the hydraulic valve lifters. To _ remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring. To install: 11. If the lifters were removed, install them with tool No. 11-32-250. 12. Lubricate and install the camshafts in their correct position. 13. Install or connect the following: e Exhaust and inlet camshafts and rotate them until exhaust cam at cylinder No. 6 faces up and inlet cam at cylinder No. 8 faces up Bearing caps. The exhaust camshaft bearing covers are marked A1 to A5 and the inlet covers are marked E1 to ES. Evenly tighten the bearing covers in ¥2 turn steps from the outside working in. 14. Torque the camshaft bearing covers as follows: a. M6 to 89 inch Ibs. (10 Nm). b. M7 to 9 ft. Ibs. (14 Nm). C. M8 to 15 ft. Ibs. (20 Nm). 15. Rotate the camshafts until the markings face upwards. 16. Using special tools 11-2-446 and 11-2--442 align the inlet and exhaust

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tools rest without a gap on the cylinder . head. 17. Crank the engine from the 45 degrees BIDC position in the direction of rotation up to the TDC position. 18. Hold the crankshaft and install the distributor on the camshaft adjustment unit. 19. Install or connect the following: e Camshaft adjustment unit ¢ Both timing case covers Timing chain tensioning piston Spark plugs Cylinder head covers Splash guard Negative battery cable Valve Lash

ADJUSTMENT All engines are equipped with hydraulic valve lash adjusters. This design does not permit adjustments nor are adjustments possible.

REMOVAL & INSTALLATION e>When the battery is disconnected, the radio code, on-board computer and clock settings will be lost. The radio code should be obtained before disconnecting the battery or radio. Once the battery has been reconnected, the radio will not function unless the code is keyed in.

1. If needed, read the stored fault memories from the control module. 2. Relieve the fuel system pressure. 3. Set the ignition switch to the OFF position. 4. Before servicing the vehicle, refer to the precautions in the beginning of this section. 5. Remove or disconnect the following: Negative battery cable Reinforcement plate Positive battery cable from the starter Starter electrical connectors e Heat shield Starter from the transmission mount Starter To install: 6. Install or connect the following:

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e Starter to the transmission mount e Heat shield. Torque the bolts to 38 ft. Ibs. (47 Nm). e Starter electrical connectors e Positive battery cable to the starter ¢ Reinforcement plate e Negative battery cable

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Reinforcement plate e Oil level switch plug e Cable guide clips e Lower oil pan section >To remove the upper section of the oil pan, proceed with the following steps.

4, Remove or disconnect the following: Upper nuts on the left and right engine mounts Front splash guard Positive battery cable from the starter Left and right swivel bearings Output shafts Bearing pedestal from the right output shaft Propeller shaft Steering spindle from the steering gear and support the front axle Front axle support from the engine carrier and slightly lower the axle support Drive belt Vane pump from the oil pan Adjustable plate from the oil pan after releasing the tension from the A/C compressor belt Guide tube for the oil dipstick Oil return line from the oil separator to the oil pan Oil pump snorkel Cable guide for the positive lead Upper oil pan section towards the rear of the vehicle To install: 5. Clean the mounting surfaces. 6. Check the seals on the oil pipes and replace it if necessary. Lubricate the seals with oil.

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7. Install or connect the following: Install upper oil pan. Torque the

bolts to 89 inch Ibs. (10 Nm) and lower the engine Cable guide for the positive lead Banjo bolt for the oil return pipe from the oil filter at the oil pan Drive belt Left and right engine mounts Torque the bottom bolts to 32 ft. lbs. (43 Nm). . Lower oil pan with a new gasket. Torque the bolts, beginning in the middle and working to the outside to 89 inch Ibs. (10 Nm). . Plug for the level switch, making sure to replace the O-ring Steering spindle to the steering gear e Propeller shaft e Bearing pedestal e Output shafts e Positive battery cable Engine splash guards Oil dipstick guide tube, making sure to replace the O-ring e Reinforcement plate e Negative battery cable 8. Fill the engine with clean oil. 9. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Oil pan e Oil pump sprocket wheel and chain e Oil pump To install: 4. Check the seals on the oil pipes and replace it if necessary. Lubricate the seals with oil. 5. Check the seal in the oil pump and replace it if necessary. Screw the hexagon adapter back into the oil pump until it stops. 6. Install or connect the following: e (Oil pump. Torque the bolts to 17 ft. lbs. (22 Nm). e Oil pump sprocket wheel and chain. Torque the nut to 36 ft. Ibs. (47 Nm). e Oil pan

Timing belt service is covered in Section 3 of this manual

e Negative battery cable 7. Fill the engine with clean oil. 8. Start the vehicle and check for leaks, repair if necessary. Rear Main Seal

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REMOVAL & INSTALLATION The rear main bearing oil seal can be replaced after the transmission and flywheel has been removed from the engine. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: e Negative battery cable e Transmission e Flywheel assembly e Oil seal, using a Suitable seal removal tool To install: 4. Coat the sealing lips of the new seal with oil. 5. Install or connect the following: e New seal into the end cover housing with a suitable seal installation tool e Flywheel e Transmission e Negative battery cable 6. Fill the transmission with new fluid. 7. Start the engine and check that oil pressure is present; if the oil pressure lamp does not extinguish within 5-7 seconds of starting the engine, turn the engine OFF. 8. Check and top off all fluid levels.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Spark plugs e Cylinder head covers e>in the Top Dead Center (TDC) firing position, the inlet camshaft twists in the splines of the camshaft adjustment unit.

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Remove or disconnect the follow¢ Oil lines from the cylinder head e Vibration damper and rotate the

engine at the central bolt so that the first cylinder is at the TDC position. e Timing chain tensioning piston ¢ Both top timing case covers ¢ Left hand threaded nut from the sensor gear on cylinder bank 1-4 e Left hand threaded nut from the sensor gear on cylinder bank 5-8 5. Slacken the screw connection for the exhaust camshaft on cylinder bank 5-8 by Ya turn. 6. Slacken the screw connection for the exhaust camshaft on cylinder bank 1-4 by Va turn. 7. Slacken the screw connection for the inlet camshaft on cylinder bank 5-8 by Vo turn. 8. Slacken the screw connection for the inlet camshaft on cylinder bank 1—4 by Va tur. 9. Align the camshafts and install special tool 11-2—445/441 to the camshafts on cylinder bank 1-4. 10. Align the camshafts and install special tool 11-2—446/442 to the camshafts on cylinder bank 5-8. 11. Remove or disconnect the following: Central bolt and hub from the vibration damper ¢ Oil pump Water pump and thermostat housing Bottom timing case cover Tensioning rail and oil guide Timing chain from the camshaft adjustment unit To install: 12. Install or connect the following: e Timing chain over the reversing rail, camshaft adjustment unit and crankshaft sprocket wheel for cylinder bank 5-8 e Timing chain inside screw-in pin e Timing chain onto the camshaft adjustment unit for cylinder bank 1-4 13. Raise the timing chain slightly by the guide rail and slide the rail over the pin until the retaining lug can be heard snapping into place on the lower guide pin. 14. Align the timing chain to the guide rail. 15. Install the oil guide for the bow cover in the pivot rail. 16. Install the tensioning rail screw. Press the cover against the timing chain and secure the cover with the plastic strap. 17. Install or connect the following: e Upper oil pan section and secure the crankshaft in the TDC position with special tool 11-5-180 ¢ Special tool 11—-7-380 to the right

side cylinder bank and install special tool 11-4-230 e Adjustment screw into the tension-

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ing rail and hand tighten ¢ Special tool 11-6—440 to the camshaft adjustment unit on cylinder bank 5-8 and move it 31 ft. lbs. (40 Nm) to the left hand stop. 18. Tighten the screw connection on the inlet camshaft on cylinder bank 5-8 to 10 ft. lbs. (15 Nm) and back off by % turn. 19. Tighten the screw connection on the exhaust camshaft on cylinder bank 5-8 to 10 ft. Ibs. (15 Nm) and back off by % turn. 20. Special tool 11-6—440 to the camshaft adjustment unit on cylinder bank 1—4 and move it 31 ft. Ibs. (40 Nm) to the left hand stop. 21. Tighten the screw connection on the inlet camshaft on cylinder bank 14 to 10 ft. lbs. (15 Nm) and back off by % turn. 22. Tighten the screw connection on the exhaust camshaft on cylinder bank 1-4 to 10 ft. Ibs. (15 Nm) and back off by Yq turn. 23. Tighten the tensioning rail by turning the adjusting screw on special tool

11-4-230 When the timing chain is pretensioned, the camshaft adjustment unit moves and must be reset to the left hand stop.

24. Tighten the inlet camshaft screw connection on cylinder bank 5-8 to 85 ft.

Ibs. (110 Nm). 20. Tighten the exhaust camshaft screw connection on cylinder bank 5-8 to 85 ft.

lbs. (110 Nm). 26. Install special tool 11-6—451 to the camshaft adjustment unit on cylinder bank

1-4 and move it 31 ft. Ibs. (40 Nm)to the left hand stop. 27. Tighten the inlet camshaft screw connection on cylinder bank 1—4 to 85 ft. lbs. (110 Nm). 28. Tighten the exhaust camshaft screw connection on cylinder bank 1-4 to 85 ft. lbs. (110 Nm). 29. Install the sensor gear to cylinder bank 1—4 and hand tighten the nut. 30. Align the locating bore on the sensor gear to the positioning pin on special tool 11-6-451. Press the tool downward and align it to the cylinder head. Torque the sensor gear screw to 30 ft. Ibs. (40 Nm). Remove the special tool. 31. Install special tool 11-6—-452 to the camshaft adjustment unit on cylinder bank 9-8 and move it 31 ft. Ibs. (40 Nm) to the left hand stop. 32. Tighten the inlet camshaft screw

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BMW X5

connection on cylinder bank 5-8 to 86 ft. lbs. (110 Nm). 33. Tighten the exhaust camshaft screw connection on cylinder bank 5-8 to 85 ft. lbs. (110 Nm). 34. Install the sensor gear to cylinder bank 5-8 and hand tighten the nut. 35. Align the locating bore on the sensor gear to the positioning pin on special tool 11-6—-452. Press the tool downward and align it to the cylinder head. Torque the sensor gear screw to 30 ft. Ibs. (40 Nm). Remove the special tool. 36. Check for the correct seating of the dowel sleeves. Clean the sealing surfaces thoroughly, and then place a new gasket on the lower cover. 37. Trim the protruding ends of the gasket, making sure the cutting tool is level. Do not allow the pieces to fall into the engine. 38. Position the lower cover and install the mounting bolts with an even distribution of pressure. Tighten the 6mm bolts to 84 inch lbs. (10 Nm), 8mm bolts to 16 ft. Ibs. (22 Nm) and 10mm bolts to 35 ft. Ibs. (47 Nm). 39. Install the oil seal in the timing case

cover using tool No. 11-1-220. Make sure the seal is flush with the cover. 40. Install the vibration damper hub and install the mounting bolt. Tighten the hub bolt to: a. Step 1: 74 ft. Ibs. (100 Nm). b. Step 2: turn an additional 60 degrees. c. Step 3: turn an additional 60 degrees. d. Step 4: turn an additional 30 degrees. 41. Position the vibration damper pulleys and install the mounting bolts for the damper. 42. Install or connect the following: e Water pump pulley e Drive belt and the cooling fan. Rotate the fan counterclockwise to install. Intake hose between the throttle body and the air volume meter Battery positive cable for the alternator and install the protective tube mounting fasteners and connect the remaining wires to the alternator

e Oil filter housing and the return pipe and replace the housing cover e Alternator and cylinder head cover e Negative battery cable 43. Fill the engine with clean oil. 44. Start the vehicle and check for leaks, repair if necessary

Piston and Ring Positioning

7923AGB3

BMW engines Piston ring end-gap spacing

OW, a i

es 7923AG05 7923AG06

BMW engines compression and oil control ring locations

BMW engines connecting rod-to-piston positioning

Heater Core replacement is covered in Section 2 of this manual

7

Fuel System Service Precautions

| |

i |

Safety is the most important factor when performing not only fuel system maintenance but also any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. 1. To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. 2. Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Fuel under pressure may penetrate the skin or any part of the body that it contacts. 3. Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. 4. Always keep a dry chemical (Class B) fire extinguisher near the work area. 5. Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. 6. Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications. 7. Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

Fuel System Pressure RELIEVING To relieve the pressure in the system, locate fuel pump relay located on the cowl. The relay can sometimes be distinguished by the orange color of the housing. Unplug and remove the relay, and place it in a safe location. With the fuel pump relay removed, start the engine and operate it until it stalls.

Crank the engine for 10 seconds after it Stalls to remove any residual pressure.

Fuel Filter

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel pressure regulator and seal the fuel line before and after the filter with special tool 13-3-010 e Clips and fuel line from the filter e Fuel filter 4. Install or connect the following: To install: e New fuel filter e Fuel lines onto the correct fittings. Tighten the fuel line clamps until tight, but not to the point where the fuel lines become excessively pinched or damaged, then tighten the mounting bracket until snug. e Negative battery cable and cycle the ignition ON and OFF several times to build fuel pressure 5. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the fuel tank. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Rear seat bench Rubber plug above the sender unit and fold the rubber mat back Metal cover Fuel gauge level sending unit electrical connector Fuel lines Rotary connection with special tool 16-1020 5. Raise the fuel level sensor and expose the spiral hose. 6. Remove the fuel level sensor and fuel pump from the tank.

To install: e>Always use a new seal or gasket when installing the fuel pump or fuel level gauge sending unit assembly.

7. Install or connect the following: ¢ Fuel pump into the fuel tank taking care not to bend or damage the fuel sending unit assembly ¢ New seal and torque the sealing ring using tool No. 16-1-020 as follows: a. Metal sealing rings: 26 ft. Ibs. (35 Nm). b. Plastic sealing rings: 41 ft. Ibs. (55 Nm). 8. Install or connect the following: e Fuel lines e Fuel gauge level sending unit electrical connector Metal cover Rubber plug above the sender unit Rear seat bench Negative battery cable 9. Start the vehicle and check for leaks, repair if necessary.

Fuel Injector(s) REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Acoustic cover ¢ Knock Sensor (KS) electrical connector from the cable strips Changeover valve electrical connector Camshaft (CMP) sensor electrical connector Left side cylinder head ‘onitien Coil cover Ignition coil electrical connects Ignition coil cover Cable strip from the fuel injectors Vacuum accumulator lines Fuel line Both fuel injection pipe retaining brackets e Fuel injectors from the fuel pipe 4, Check the O-rings on the fuel injectors and replace if damaged. To install: 9. lf the O-rings are being replaced, coat the new O-ring with petroleum jelly.

6. Install or connect the following: «

° Fuel injectors to the fuel pipe © Fuel line . e Vacuum lines to the vacuum accumulator Cable strip to the fuel injectors Ignition coil electrical connectors Ignition coil cover

CMP sensor electrical connector Changeover valve electrical connector KS electrical connector Acoustic cover e Negative battery cable 7. Start the vehicle and check for leaks, repair if necessary.

9308KG05

Remove the fuel injector from the injection pipe~4.4L engine

DRIVE TRAIN e Cable connector from the transmis-

Transmission Assembly

sion case

REMOVAL & INSTALLATION Automatic Transmission 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the transmission fluid. 3. Remove or disconnect the following: Negative battery cable Exhaust system Front splash guard Reinforcement plate Heat shields and unclip the Oxygen (2S) sensor Stabilizer bar and slide it forward Rear heat shield Front propeller shaft and unclip the vent line from the transmission Retaining plate and brace the clamping bush Bracket for the oil lines at the oil pan Power steering pump oil line bracket Oil line and banjo bolt e Union screw on the oil return line and properly support the transmission and transfer case assembly 02S cable from the transmission crossmember Transmission crossmember Nuts for the center bearing after bracing the propeller shaft ->Do not allow the propeller shaft to damage the CV-joints. e Transmission output flange by bending the propeller shaft downward at the center bearing

e Impulse sensor electrical connector e Torque converter retaining screws 4. Support the engine at the front housing and turn the front wheel to the right lock position. 5. Remove the remaining screws and remove the transmission and transfer case assembly. To install: 6. Align the transmission/transfer case as an assembly. 7. Torque the transmission to engine screws as follows: a. M8 Hex screws: 18 ft. Ibs. (24 Nm). b. M10 Hex screws: 33 ft. Ibs. (45 Nm). c. M12 Hex screws: 60 ft. Ibs. (82 Nm). d. M8 Torx bolts: 16 ft. Ibs. (21 Nm). e. M10 Torx bolts: 31 ft. Ibs. (42 Nm). f. M12 Torx bolts: 54 ft. Ibs. (72 Nm). 8. Install or connect the following: Torque converter. Torque the bolts to 30 ft. Ibs. (40 Nm). Impulse sensor electrical connector Transmission case cable connector Transmission output flange Center bearing. Torque the bolts to 16 ft. Ibs. (21 Nm). Transmission crossmember. Torque the bolts to 16 ft. Ibs. (21 Nm). 02S cable to the crossmember Union screw to the oil return line. Torque the screw to 21 ft. Ibs. (28 Nm). Oil line and banjo bolt. Torque the bolt to 21 ft. Ibs. (28 Nm).

Oil line bracket for the power steering pump Retaining plate Front propeller shaft. Torque the bolts to 47 ft. Ibs. (64 Nm) and clip the vent line to the transmission. Rear heat shield Stabilizer bar. Torque the bolts to 16 ft. Ibs. (22 Nm). Front heat shields O2S connector Reinforcement plate Front splash guard Exhaust system Negative battery cable 9. Fill the transmission with the proper fluid to the proper level. 10. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: Negative battery cable Exhaust system Front splash guard Reinforcement plate Heat shields and unclip the Oxygen (02S) sensor Stabilizer bar and slide it forward e Rear heat shield Front propeller shaft and unclip the vent line from the transmission. Properly support the transmission.

Brake service is covered in Section 4 of this manual

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e 02S cable from the transmission crossmember Transmission crossmember » ~ e QoS cable from the transfer case e Center bearing after bracing the properller shaft. Do not allow the propeller shaft to damage the CVjoints. e Transmission output flange by bending the propeller shaft downward at the center bearing Transfer case from the transmission To install: 4. Connect the transfer case to the transmission. Torque the bolts as follows: a. M8 Hex screws: 18 ft. Ibs. (24 Nm). b. M10 Hex screws: 33 ft. Ibs. (45 Nm). c. M12 Hex screws: 60 ft. Ibs. (82 Nm). - d. M8 Torx bolts: 16 ft. Ibs. (21 Nm). e. M10 Torx bolts: 31 ft. Ibs. (42 Nm). f. M12 Torx bolts: 54 ft. Ibs. (72 Nm). 5. Install or connect the following: e Transmission output flange e Center bearing. Torque the bolts to 16 ft. Ibs. (21 Nm). e Transmission crossmember. Torque the bolts to 16 ft. Ibs. (21 Nm). ¢ (2S cable to the crossmember Union screw to the oil return line. Torque the screw to 21 ft. Ibs. (28 Nm). e Front propeller shaft. Torque the

bolts to 47 ft. Ibs. (64 Nm) and clip

|

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3. Install or connect the following: e New output shaft radial seal e New snap ring on the output shaft e Press the output shaft in by pushing it in over the resistance of the snap ring e Swivel bearing e Front splash guard e Reinforcement plate

Negative battery cable Front wheel Reinforcement plate Front splash guard Swivel bearing Output shaft from the differential by pressing it out with special tool 31-5-110 To install: e e e e e e

.

9308KG09

:

Exploded view of the front axle assembly-X5 Series

the vent line to the transmission. Rear heat shield

“= -@ 2 Stabilizer bar. Torque the bolts to Spite

16 ft. Ibs. (22 Nm). Front heat shields

02S connector Reinforcement plate Front splash guard Exhaust system Negative battery cable 6. Fill the transmission with the proper fluid to the proper level. 7. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

—seneko0g Exploded view of the rear halfshaft and suspension system-X5 Series

iis

hh" AHCCCS SAY,

9308KG08

9308KG07

Halfshaft removal tools Nos. 33-2-116, 33-4-201, 201 and 203

e Front wheel e Negative battery cable Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. r 2. Remove or disconnect the following: e Negative battery cable e Rear tire and wheel assembly e Collar nut e Brake disc e ABS sensor . ¢ Retaining nut from the output flange. Remove the drive flange hub

|

Drive flange hub tool Nos. 33-2-115, 116 and 118 used for drive flange installation

e>The wheel bearing will be destroyed when the flange is removed. The wheel bearing must be replaced.

e Halfshaft from the vehicle by removing the shaft from the final drive output flange and by pressing the halfshaft out of the drive flange hub using tool Nos. 33-2-116, 201, 202 and 203 3. Press out the drive flange hub. 4, Pull out the seal with a suitable tool. 5. If the bearing inner race is damaged, pull it off of the drive flange hub with tool No. 33-3--240. To install: 6. Using an appropriate bearing

installer, install the wheel bearing assembly, install the seal, then insert the snapring, and install the drive flange hub. 7. Install or connect the following: Axle shaft seal Output shaft, using tool Nos. 33-2115, 116 and 118 Output shaft to the final drive. Torque the bolts to 61 ft. Ibs. (83 Nm). Outer nut with bearing surface lightly oiled. Torque the nut to 310 ft. Ibs. (420 Nm). Brake disc ABS sensor Rear tire and wheel assembly Negative battery cable

STEERING AND SUSPENSION

PaaS

The vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. ' 1. Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. 3. Place the inflator module on a bench or other surface with the bag and trim cover facing up. 4. With the inflator module on the bench, never place anything on or close to

the module that may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the ignition switch in the OFF position. 3. Disconnect the negative battery terminal and cover the battery terminal to prevent accidental contact. 4. Once the battery has been disconnected, wait for a period of approximately 5 seconds allowing the capacitor in the control unit to discharge. Once the capacitor is

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

714 a

m

the screws to 74 ft. Ibs. (100 Nm). Self-locking nuts. Torque the nuts to 74 ft. Ibs. (100 Nm). Tie rod. Torque the castle nut to 58 ft. lps. (80 Nm).

discharged, a trigger pulse cannot be generated inadvertently.

REARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the ignition switch in the OFF position. 3. Attach the sensors, the steering column connector and the seat belt tensioner connectors. 4. Connect the negative battery terminal. 5. Place the ignition switch in the ON position. Check that the SRS light illuminates for 6 seconds and extinguishes. If it illuminates in any other pattern, check the components and their connections for proper operation and recheck operation of the warning light.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Set the steering gear in the straight ahead position by aligning the marks on the steering gear and spindle. 3. Drain the power steering fluid. — 4. Remove or disconnect the following: Negative battery cable Front wheels Reinforcement plate Nuts from the left and right engine support arms and raise the engine slightly Lower clamping screw Steering gear clamps Tie rod by pressing it off with special tool 32-3-090 Self-locking nuts and brace the front axle support Banjo bolts and slide the steering gear out through the left wheel opening To install: 5. Install the steering gear through the left side wheel opening 6. Install new sealing rings and banjo bolts. Torque the bolts as follows: a. M10: 7ft. Ibs. (12 Nm). b. M14: 25 ft. Ibs. (35 Nm). c. M16: 29 ft. Ibs. (40 Nm). d. M18: 34 ft. Ibs. (45 Nm). 7. Install or connect the following: e Front axle support screws. Torque

Steering gear to the spindle. Torque the fastener to 18 ft. Ibs. (24 Nm). Steering gear clamp Engine support arm nuts. Torque the nuts to 60 ft. Ibs. (85 Nm). Reinforcement plate Splash guard Both front wheels Negative battery cable 8. Fill and bleed the power steering system.

9. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Mark the position of the threaded pin to the wheel arch to retain the camber setting when installed. 3. Remove or disconnect the following: Negative battery cable Tire and wheel assembly Two of the nuts on the spring strut support bearing Center strut bracket nut Speed sensor/brake wear cable and disconnect the plug housing Swivel bearing and tie it aside Remaining nut on the spring strut support bearing Strut assembly To install: 4. Install or connect the following: Strut assembly One nut to the spring strut support bearing and hand tighten at this time Swivel bearing. Torque the new self-locking nut to 176 ft. Ibs. (250 Nm). Speed sensor/brake wear cable and connect the housing plug Center strut bracket. Torque the nut to 74 ft. Ibs. (100 Nm). 5. Align the three upper spring strut support bearing nuts and match the threaded pin with the mark made during the removal procedure. When aligned properly torque the nuts to 25ft. Ibs. (34 Nm).

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6. Install or connect the following: ¢ Tire and wheel assembly e Negative battery cable

Shock Absorber _ REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec“tion. 2. Remove or disconnect the following: Fuse in the air supply system Negative battery cable Rear wheel Nuts and expansion rivets and luggage compartment trim 3 upper nuts after supporting the wheel carrier Shock absorber from the swinging arm and insert a bushing into the bore of the arm Thrust bearing after bracing the piston rod with a ring spanner Upper nut and remove the shock absorber To install: 3. Install or connect the following: Shock absorber to the swinging arm. Torque the bolt to 41 ft. Ibs. (56 Nm). Thrust bearing. Torque the nut to 18 ft. Ibs. (25 Nm). Upper nuts. Torque the nuts to 41 ft. Ibs. (66 Nm). New expansion rivets and nuts Luggage compartment trim Rear wheel Negative battery cable Fuse for the air supply system

REMOVAL & INSTALLATION Front

+2 CAUTION This procedure calls for the spring to be compressed. A compressed spring has high potential energy and if released suddenly can cause severe damage and personal injury. 1. Before servicing the vehicle, referto the precautions in the beginning of this section. 2. disconnect the negative battery cable.

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3. Remove the strut from the vehicle and mount in a vise using a strut holder. This will prevent damage to the strut tube 4. Using a proper spring compressor, compress the spring until the stress on the thrust bearing is released. 5. Remove the top nut of the strut mount. Counterhold the strut rod during

(33 4191)” So

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6. Pull the strut mount off the strut rod. Note the positioning of the spacers and washer for replacement. 7. Pull the spring off the strut and place aside in a Safe area. 8. slowly release the compression of the spring. To install: 9. Install or connect the following: ¢ Spring in the compressor and compress e Spring and strut mount with all the spacers and washers in their original positions. Torque the new strut rod nut: 47 ft. Ibs. (65 , Nm). , 10. Release the spring slowly and check that it seats in the spring holders. Install the strut in the vehicle. 11. Connect the negative battery cable. Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Push rod/integral link assembly and properly support the wheel carrier Shock absorber from the swinging arm e Circlip 3. Using special tool 33-4-191, 192, 193 and 33-3-333 pull the ball joint out of the steering knuckle. To install: 4. Install or connect the following: ¢ Ball joint into the steering knuckle with special tools 33-4-191, 192, 194 and 33-3-333 e New circlip e Shock absorber and remove the support from the wheel carrier

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9308KG10

Remove the lower ball joint from the steering knuckle—-X5 Series

e Push rod/integral link e Negative battery cable

Lower Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheel e Control arm from the front axle Support and loosen the nut from the control arm to swivel bearing

e Control arm from the swivel bearing by pressing it off with special tool 31-2-240 To install: 3. Install or connect the following: e Lower control arm to the swivel bearing. Torque the nut to 58 ft. Ibs. (80 Nm). e Lower control arm to the front axle support. Torque the nut to 74 ft. lbs. (100 Nm) plus an additional 90 degrees. e Front wheel e Negative battery cable 4. Check and adjust the front end alignment as needed.

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

2. Remove or disconnect the following: e Negative battery cable e Control arm and tie it back to prevent damage to the ball joint ¢ Control arm bushing by installing special tools 31-1-051, 052, 33-3-051, 052, 054 and 310 To install: 3. Install or connect the following: e Control arm bushing by installing special tools 31-1-051, 052, 33-3-051, 052, 054 and 310 e Control arm e Negative battery cable

Upper Control Arm

REMOVAL & INSTALLATION

cee pe

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Wheel assembly Fuse for the air supply system, if equipped with air suspension and loosen the pipes on the distributor block Upper control arm from the steering knuckle Plastic shim and unhook the lines Upper control arm To install: 3. Install or connect the following: e Upper control arm. Torque the bolt to 74 ft. Ibs. (100 Nm).

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

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tools 33-2-116, 150 and

84-20

e Bearing inner race from the flange

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the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Swivel bearing and clamp it ina vise e Drive flange by installing special

Upper control arm to the steering knuckle. Torque the bolt to 122 ft. lbs. (165 Nm). e Fuse for the air supply system and tighten the pipes on the distributor block e Wheel assembly e Negative battery cable

ri

ADJUSTMENT 1 Se

. Wheel bearings can not be adjusted and must be replaced as a unit and never be reused once removed. ey

REMOVAL & INSTALLATION Front

>The wheel bearings are only removed if they are worn. They cannot be removed without destroying them (due to side thrust created by the bearing puller). They cannot be disassembled, repacked or adjusted.

4 Swivel bearing e Negative battery cable

1. Before servicing the vehicle, refer to

Plastic shim and connect the lines

° Circlip e Snap ring e Bearing by installing special tools

es? 33-3-261, 262 and ‘ : To install: 3. Install or connect the following: Wheel bearing with the wider camfer facing the swivel bearing to the drive flange with special tools 33-2-261, 264, 268 and 31-2-113 Snap ring and circlip inner race to the drive flange Drive flange to the swivel bearing by using special tool 33-3-261, 266, 268 and 31-2-113

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable e Wheel assembly e Collar nut Brake disc Drive flange by installing special tool 33-2-116, 334-201, 202 and 203 -e Inner race from the drive flange — e Wheel bearing To install: 3. Install or connect the following: e Wheel bearing Inner race to the drive flange. Torque the bolts to 74 ft. Ibs. (100 Nm). Drive flange to the axle shaft. Torque the collar nut to 310 ft. Ibs. (420 Nm). Brake disc Wheel assembly Negative battery cable

CHRYSLER CORP. 1998-02 Dodge-Durango DRIVE TRAIN ................... 8-24) - FuekPomp tion ebas chose aay 8-23

Removal & Installation.............. 8-17

FUEL SYSTEM.................. 8-22 GASOLINE ENGINE REPAIR ....8-2 PRECAUTIONS ................... 8-2 STEERING AND SUSPENSION “SARINVea TNE8-26

Removal & Installation... Fuel System Pressure... Reteviig 22). SHR? OrBl Bes Fuel System Service Precautions........... eens ee

8-22

Recirculating Ball Power Steering Gear. 4. 008 2 ee 8-27 Removal & Installation.............. 8-27 Rocker Ariis/Stialts'. vss. raccnatere 8-9 Removal & Het a sie 8-9

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Shock Absorber............. >. oles: 8-27 Removal & Installation.............. 8-27

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HONITIOAL TIMING. cere arierareceitenssss 8-3

Removal & Installation................ 8-3 Axle Shaft, Bearing and Seeal.......... 8-95 Removal & Installation.............. 8-25

AGUIUSITIONI. (35.408 taskbar 8-3 Intake Manifold......c.ccceeeeeen 8-10 Removal & Installation.............. 8-10

c Camshaft and Valve Lifters ............ 8-13

; L Leaf Spring.......... se 2 ee Ene 828

Removal & Installation... 8-13 CoibhSoriig!t) se Santen mie’ WG8-28 Removal & Installation............. 8-28 Mie 6225

Removal & Installation............. 8-28 Lower Ball Joint.......... Poipu ite 8-29 Removal & Installation............ 8-29 LowemContfob Arn. veo ae Oe 8-29

Removal & Installation............... 8-5

Removal & Installation.............. 8-29

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Control Arm Bushing Replacement............-ceeseenss 8-29

0 6 1A OR aoa mR a ene 8-15, Removal & Installation............. 8-15 OUP INID As Je toca oe arietnne |8-16

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Removal & Installation.............. 8-16

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Removal & Installation........0...... Oe ee RN OCG carceeenncrareme mice esO20. Exhaust Manifold... 8-12 eee Installation.............. ae iaui........b.. :

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Fuel Filter sere Pt once 8-23 Removal & Installation.............. 8-23 Fuel Injectoriec:. Seale... 8-23

PHSTOMPANO

RING aznernsrynancsss-eaecesenvs -

POSIOMNU A. MROMiaThe rotor will rotate clockwise as the gears engage.

2. Position the rotor slightly counterclockwise of the matchmark made during removal. 3. Install the distributor. 4. Align the distributor housing and intake manifold matchmarks and check that the distributor housing matchmark and rotor are also aligned. , 5. Install or connect the following: e Distributor housing clamp and bolt. Tighten the bolt to 17 ft. Ibs. (23 Nm). e CMP sensor connector e Distributor cap e Air cleaner tube e Negative battery cable Timing Disturbed

CHRYSLER CORP. 2. Set the engine at Top Dead Center (TDC) of the No. 1 cylinder compression ~ stroke.

3. Install the distributor, clamp and bolt. 4. Rotate the distributor so that the rotor aligns with the No. 1 cylinder mark on the Camshaft Position (CMP) sensor. Tighten the clamp bolt to 17 ft. Ibs. (23 Nm). 5. Install or connect the following: e CMP sensor connector e Distributor cap e Air cleaner tube e Negative battery cable 6. The final distributor position must be set with a scan tool. Follow the instructions supplied by. the scan too! manufacturer. Alternator

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Alternator harness connectors e Alternator 3. Installation is the reverse of removal. Tighten the bolts to the following specifications: a. 4.7L engine: Vertical bolt 41 ft. Ibs. (56 Nm), long horizontal bolt to 55 ft. lbs. (74 Nm) and short horizontal bolt to 55 ft. Ibs. (74 Nm). b. 3.9L, 5.2L, 5.9L engines: 30 ft. Ibs. (41 Nm).

3.9L, 5.2L AND 5.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Ignition Timing ADJUSTMENT The ignition timing is controlled by the

Powertrain Control Module (PCM) and is

CAMSHAFT POSITION SENSOR AUGNMENT MARK

not adjustable.

Engine Assembly REMOVAL & INSTALLATION 3.9L, 5.2L & 5.9L Engines DISTRIBUTOR 9308PG01

Distributor rotor alignment—3.9L, 5.2L and 5.9L engines

a

DURANGO

¢ Distributor cap «

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil.

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4. Relieve the fuel system pressure. 5. Remove or disconnect the following: — Negative battery cable Hood Upper crossmember and top core support Radiator hoses Cooling fan and shroud Radiator Accelerator cable Cruise control cable, if equipped Transmission cable, if equipped Heater hoses Intake manifold vacuum lines Accessory drive belt Power steering pump A/C compressor, if equipped Engine control sensor harness connectors Engine block heater, if equipped Fuel line Exhaust front pipe Starter motor Torque converter, if equipped Transmission oil cooler lines, if equipped Engine mounts e Transmission flange bolts. Support the transmission. Engine

Do not lift the engine by the intake manifold. Damage to the manifold may result. To install: 6. Install or connect the following: Engine. Tighten the engine mount bolts to 70 ft. Ibs. (95 Nm). Transmission flange bolts. Tighten

the bolts to 40-45 ft. Ibs. (54-61

.

Nm). Transmission oil cooler lines, if equipped Torque converter, if equipped. Tighten the bolts to 23 ft. Ibs. (31 Nm).

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Starter motor Exhaust front pipe Fuel line Engine block heater, if equipped Engine control sensor harness connectors

A/C compressor, if equipped Power steering pump Accessory drive belt Intake manifold vacuum lines Heater hoses

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e Hood e Negative battery cable

e On 4wd, the bracket locknuts: 30 ft. lbs. (41 Nm) e Transmission-to-engine bolts: 30 ft. Ibs. (41 Nm) ->The structural cover has a specific torque sequence.

Water Pump

7. Fill the crankcase to the correct level.

REMOVAL & INSTALLATION

8. Fill the cooling system. 9. Start the engine and check for leaks.

4.7L Engine

4.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system and engine oil. 3. Remove or disconnect the following: Negative battery cable Battery and tray Exhaust crossover pipe On 4wd, the axle vent tube Left and right engine mount through bolts On 4wd, the left and right engine mount bracket locknuts Ground straps CKP sensor On 4wd, the axle isolator bracket Structural cover Starter Torque converter bolts Transmission-to-engine bolts Engine block heater Resonator and air inlet Throttle and speed control cables Crankcase breathers A/C compressor Shroud and fan assemblies Transmission.cooler lines Radiator hoses Radiator Alternator Heater hoses Engine harness Vacuum lines Fuel system pressure Fuel line at the rail Power steering pump 4. Install lifting eyes and take up the weight of the engine with a crane. 5. Support the transmission with a jack. 6. Remove the engine. 7. Installation is the reverse of removal. Observe the following: e Left and right engine mount through bolts: 2wd 70 ft. Ibs. (95 Nm); 4wd 75 ft. Ibs. (102 Nm)

|

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Fan and fan drive assembly from the pump. Don't attempt to remove it from the vehicle, yet. elf a new pump is being installed, don’t separate the fan from the drive. e Shroud and fan

Keep the fan upright to avoid fluid loss from the drive.

e Accessory drive belt e Lower radiator hose e Water pump 4. Installation is the reverse of removal. tighten the bolts in sequence to 40 ft. Ibs. (54 Nm). 3.9L, 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Engine cooling fan and shroud e>Do not store the fan clutch assembly horizontally, silicone may leak into the bearing grease and cause contamination.

e Accessory drive belt e Water pump pulley e Lower radiator hose e Heater hose and tube e Bypass hose e Water pump To install: 4. Install or connect the following: e Water pump, using a new gasket. Tighten the bolts to 30 ft. Ibs. (40 Nm).

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Water pump torque sequence—4.7L engine

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e>Keep all valvetrain components in order for assembly. e Rocker arms e Pushrods

e Cylinder heads To install:

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WATER PUMP MOUNTING BOLTS 7924DG03

Water pump mounting bolt locations—3.9L, 5.2L and 5.9L engines

Bypass hose Heater hose dnd tube. Use a new O-ring seal. . Lower radiator hose Water pump pulley. Tighten the bolts to 20 ft. Ibs. (27 Nm). Accessory drive belt Engine cooling fan and shroud Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

Accelerator linkage Cruise control cable, if equipped Transmission cable, if equipped Spark plug wires Distributor Ignition coil harness connectors Engine Coolant Temperature (ECT)

sensor connector Heater hoses Bypass hose

Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down. 5. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows: a. Step 1: 50 ft. Ibs. (68 Nm). b. Step 2: 105 ft. Ibs. (143 Nm). c. Step 3: 105 ft. Ibs. (143 Nm). 6. Install or connect the following: e Pushrods in their original locations e Rocker arms in their original locations. Tighten the bolts to 21 ft. Ibs. (28 Nm).

Cylinder Head REMOVAL & INSTALLATION

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2. Relieve the fuel pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Accessory drive belt Alternator

A/C compressor, if equipped Alternator and A/C compressor bracket Air injection pump, if equipped Closed Crankcase Ventilation

(CCV) system Air cleaner and hose Fuel line

7924DG06

Cylinder head torque sequence—3.9L engine

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Exhaust manifolds Exhaust front pipe Intake manifold Valve covers Fuel injector harness connectors Intake manifold vacuum lines Bypass hose Heater hoses ECT sensor connector Ignition coil harness connectors Distributor Spark plug wires Transmission cable, if equipped Cruise control cable, if equipped Accelerator linkage Fuel line

Air cleaner and hose CCV system Air injection pump, if equipped @ ee eeeee#eeeeeoeoeeeeeee#eee# Alternator and A/C compressor bracket Alternator

A/C compressor Accessory drive belt Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks.

1 - TIMING CHAIN COVER 2 — CRANKSHAFT TIMING MARKS

4.7L Engine

9308PG04

1998-99 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the cooling system. 3. Remove or disconnect the following:

Crankshaft timing marks—4.7L engine

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Negative battery cable Exhaust Y-pipe Intake manifold Valve covers Engine cooling fan and shroud

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Accessory drive belt Oil fill housing Power steering pump Rocker arms 4. Rotate the crankshaft so that the

12 O'CLOCK

9302PG08

Camshaft positioning—4.7L engine

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Cylinder head access plug locations—4.7L

crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V8 marks on the camshaft sprock-

ets are at 12 o'clock as shown.

6. Matchmark the secondary timing chains to the camshaft sprockets. 7. Remove or disconnect the follow-

ing:

e Crankshaft damper e Front cover 5.Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8515.

Secondary timing chain tensioners Cylinder head access plugs Secondary timing chain guides Camshaft sprockets Cylinder heads

e>Each cylinder head is retained by ten 11mm bolts and four 8mm bolts.

To install: 8. Check the cylinder head bolts for signs of stretching and replace as necesSary. 9. Lubricate the threads of the 11mm bolts with clean engine oil. 10. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive. 11. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows: a. Step 1: Bolts 1-10 to 15 ft. Ibs. (20 Nm = b. Step 2: Bolts 1-10 to 35 ft. Ibs. (47 Nm). c. Step 3: Bolts 11-14 to 18 ft. Ibs. (25 Nm). d. Step 4: Bolts 1-10 plus % (90 degree) turn. e. Step 5: Bolts 11-14 to 22 ft. Ibs. (30 Nm). 12. Install or connect the following: e Camshaft sprockets. Align the secondary chain matchmarks and tighten the bolts to 90 ft. Ibs. (122 Nm). e Secondary timing chain guides e Cylinder head access plugs e Secondary timing chain tensioners. Refer to the timing chain procedure in this section. 13. Remove the Timing Chain Locking tool 8515. 14. Install or connect the following: Front cover Crankshaft damper. Tighten the bolt

to 130 ft. Ibs. (175 Nm). Rocker arms Power steering pump Oil fill housing

SPECIAL TOOL 8515

IDLER SPROCKET

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Accessory drive belt Engine cooling fan and shroud Valve covers Intake manifold Exhaust Y-pipe Negative battery cable 15. Fill the cooling system. 16. Start the engine and check for leaks.

2000-02, LEFT SIDE

SECONDARY CHAINS RETAINING PINS (4) 9302PG07

Use the special tool to lock the timing chains on the idler gear—4.7L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Exhaust pipe

Timing belt service is covered in Section 3 of this manual

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the idler sprocket with tool 8515, or equivaYee4 lent. 7. Mark the secondary timing chain, on link on either side of the V8 mark on the cam sprocket. 8. Remove the left side secondary chain : tensioner. 9. Remove the cylinder head access plug. 10. Remove the chain guide.

11. Remove the camshaft sprocket. >There are 4 smaller bolts at the front of the head. Don’t overlook these. 12. Remove the head bolts and head.

Don’t lay the head on its sealing surface. Due to the design of the head

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¢ INDICATES SEALER APPLIED TO THREADS

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Cylinder head torque sequence—4.7L engine, right cylinder head shown

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2. Drain the cooling system. 3. Remove or disconnect the following:

e Negative battery cable

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e Intake manifold Cylinder head cover e Fan shroud and fan ¢ Oil filler housing

Accessory drive belt 4. Rotate the crankshaft until the

damper mark is aligned with the TDC mark

Verify that the V8 mark on the camshaft sprocket is at the 12 o'clock position.

5. Remove or disconnect the following: ¢ Vibration damper e Timing chain cover 6. Lock the secondary timing chains to idler sprocket with tool 8515, or equiva-

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plug.

10. Remove the chain guide. 11. Remove the camshaft sprocket.

ck WARNING Do not pry on the target wheel for ‘ any reason! ->There are 4 smaller bolts at the front of the head. Don’t overlook these.

12. Remove the head bolts and head.

Don’t lay the head on its sealing surface. Due to the design of the head gasket, any distortion to the head sealing surface will result in leaks. 13. Installation is the reverse of removal. Observe the following: e Check the head bolts. If any necking is observed, replace the bolt. e The 4 small bolts must be coated with sealer. « e The head bolts are tightened in the following sequence: Step 1: Bolts 1-10 to 15 ft. Ibs. (20 Nm) Step 2: Bolts 1-10 to 35 ft. Ibs. (47 Nm) Step 3: Bolts 11-14 to 18 ft. Ibs. (25 Nm) Step 4: Bolts 1-10 90 degrees Step 5: Bolts 11-14 to 22 ft. Ibs. 5.2L and 5.9L Engines

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(4) 7924DG07

Cylinder head torque sequence—5.2L and 5.9L engines

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Heater hoses Bypass hose Upper radiator hose Intake manifold Valve covers

->Keep valvetrain components in order for reassembly. e Rocker arms e Pushrods e Exhaust manifolds

e Spark plugs e Cylinder heads To install:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Alternator

Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installa-

A/C compressor, if equipped

tion. Wait 5 minutes for the hydraulic

Air injection pump, if equipped Air cleaner assembly Closed Crankcase Ventilation (CCV) system Evaporative emissions control system Fuel line Accelerator linkage Cruise control cable Transmission cable Distributor cap and wires Ignition coil wiring Engine Coolant Temperature (ECT) sensor connector

lash adjusters to bleed down. 4. Install the cylinder heads. Use new gaskets and tighten the bolts in sequence as follows: a. Step 1: 50 ft. Ibs. (68 Nm). b. Step 2: 105 ft. Ibs. (143 Nm). c. Step 3: 105 ft. Ibs. (143 Nm). 5. Install or connect the following: e Spark plugs e Exhaust manifolds e Pushrods and rocker arms in their original positions e Valve covers

Intake manifold Upper radiator hose Bypass hose Heater hoses ECT sensor connector Ignition coil wiring Distributor cap and wires Transmission cable Cruise control cable Accelerator linkage Fuel line Evaporative emissions control system CCV system Air cleaner assembly A/C compressor, if equipped Air injection pump, if equipped Alternator Accessory drive belt Negative battery cable 6. Fill the cooling system. Ti Start the engine and check for leaks.

Rocker Arms/Shafts

REMOVAL & INSTALLATION 3.9L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Valve covers e Rocker arms

Heater Core replacement is covered in Section 2 of this manual

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e>Keep all valvetrain components in

order for assembly. To install: 3. Rotate the crankshaft so that the V6 mark on the crankshaft damper aligns with

the timing mark on the front cover. The V6 mark is located 147 degrees AFTER Top Dead Center (TDC). 4. Install the rocker arms in their original positions and tighten the bolts to 21 ft.

Ibs. (28 Nm).

ok CAUTION Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down. 5. Install or connect the following:

e Valve covers e Negative battery cable

3. Rotate the crankshaft so that the piston of the cylinder to be serviced is at Bottom Dead Center (BDC) and both valves are closed. 4. Use special tool 8516 to depress the valve and remove the rocker arm. 5. Repeat for each rocker arm to be serviced. e>Keep valvetrain components in order for reassembly.

To install: 6. Rotate the crankshaft so that the piston of the cylinder to be serviced is at BDC. 7. Compress the valve spring and install each rocker arm in its original position. 8. Repeat for each rocker arm to be installed. 9. Install or connect the following: e Cylinder head cover e Negative battery cable 5.2L and 5.9L Engines

4.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Valve covers

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Valve covers e Rocker arms Keep valvetrain components in order for reassembly.

To install: 3. Rotate the crankshaft so that the V8 mark on the crankshaft damper aligns with the timing mark on the front cover. The V8 mark is located 147 degrees AFTER Top Dead Center (TDC). 4. Install the rocker arms in their original positions and tighten the bolts to 21 ft. lbs. (28 Nm).

*: CAUTION

9302PG13

Rocker arm service—4.7L engine

Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down.

5. Install or connect the following: ¢ Valve covers ¢ Negative battery cable

ROCKER ARMS

Intake Manifold

REMOVAL & INSTALLATION RETAINER

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3.9L Engine 7924DG55

Exploded view of the rocker arm assembly—8.0L engine

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

2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Alternator A/C compressor Alternator and A/C compressor bracket Air cleaner assembly Fuel line Fuel supply manifold Accelerator cable Transmission cable Cruise control cable Distributor cap and wires Ignition coil wiring Engine Coolant Temperature (ECT) sensor connector

Heater hose Upper radiator hose Bypass hose Closed Crankcase Ventilation (CCV) system Evaporative emissions system Intake manifold To install: 4. Install the intake manifold. Use a new gasket and tighten the bolts in sequence as follows: a. Step 1: Bolts 1-2 to 72 inch lbs. (8 Nm) using 12 inch Ib. (1.4 Nm) increments. b. Step 2: Bolts 3-12 to 72 inch Ibs. (8 Nm). c. Step 3: Bolts 1-12 to 72 inch Ibs. (8 Nm). d. Step 4: Bolts 1-12 to 12 ft. Ibs. (16 Nm). é. Step 5: Bolts 1-12 to 12 ft. Ibs. (16 Nm). 5. Install or connect the following: Evaporative emissions system CCV system Bypass hose Upper radiator hose Heater hose ECT sensor connector Ignition coil wiring Distributor cap and wires Cruise control cable Transmission cable Accelerator cable Fuel supply manifold Fuel line Air cleaner assembly Alternator and A/C compressor bracket A/C compressor Alternator Accessory drive belt Negative battery cable

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Throttle body and mounting bracket Cowl seal Right engine lifting stud Intake manifold. Remove the fasteners in reverse of the tightening sequence. To install: 4. Install or connect the following; Intake manifold using new gaskets. Tighten the bolts, in sequence, to 105 inch Ibs. (12 Nm). Right engine lifting stud Cowl seal Throttle body and mounting bracket Fuel supply manifold Fuel line Oil dipstick tube Ignition coil towers Engine ground straps A/C compressor Alternator Accessory drive belt Cruise control servo hose Brake booster vacuum line Canister purge vacuum line PCV valve and hose ECT sensor IAC valve connector TP sensor connector IAT sensor connector MAP sensor connector Cruise control cable Accelerator cable

INTAKE

FRONT OF ENGINE Intake manifold torque sequence—3.9L engine

6. Fill the cooling system. 7. Start the engine and check for leaks.

Engine ground straps Ignition coil towers

4.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Air cleaner assembly Accelerator cable Cruise control cable Manifold Absolute Pressure (MAP) sensor connector Intake Air Temperature (IAT) sensor connector Throttle Position (TP) sensor connector Idle Air Control (IAC) valve connector Engine Coolant Temperature (ECT) sensor Positive Crankcase Ventilation

Fuel supply manifold

* INDICATES STUD LOCATIONS

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(PCV) valve and hose Canister purge vacuum line Brake booster vacuum line Cruise control servo hose Accessory drive belt Alternator A/C compressor

9302PG14

Intake manifold torque sequence—4.7L engine

Brake service is covered in Section 4 of this manual

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DURANGO e Air cleaner assembly

e Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

; 5.2L and 5.9L Engines te 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable m e Accessory drive belt

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° Fuel line ° Air cleaner assembly ¢ Alternator and A/C compressor bracket

Transmission cable Cruise control cable capand wires Distributor Ignition coi! wiring

° A/C compressor

nectors

° Alternator ° Accessory drive belt ° Negative battery cable 6. Fill the cooling system.

e Exhaust manifold heat shields e Exhaust front pipe e Exhaust manifolds To install:

7. Start the engine and check for leaks.

e Evaporative emissions system

: nam manifold To install:

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Intake manifold torque sequence—5.2L and 5.9L engines

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79240611

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lf the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.

3. Install oreconnect the following: Exhaust manifolds. Tighten the fasteners to 20 ft. Ibs. (27 Nm), starting with the center nuts and work out to the ends. Exhaust Y-pipe EGR tube Exhaust manifold heat shields Negative battery cable 4. Fill the cooling system. °. Start the engine and check for leaks. Camshaft and Valve Lifters

Exhaust Y-pipe Exhaust manifold heat shields Heater hoses

RVRHLRARE Gs mate

REMOVAL & INSTALLATION 4.7L Engine

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

3. Set the engine at Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 4. Install Timing Chain Wedge 8350 to ‘retain the chain tensioners. 5. Matchmark the timing chains to the

camshaft sprockets. 6. Install Camshaft Holding Tool 6958 and Adapter Pins 8346 to the left camshaft sprocket. 7. Remove or disconnect the following: e Right camshaft timing sprocket and target wheel ¢ Left camshaft sprocket e Camshaft bearing caps, by reversing the tightening sequence e Camshafts To install: 8. Install or connect the following: e Camshafts. Tighten the bearing cap bolts in % turn increments, in sequence, to 100 inch Ibs. (11 Nm). e Target wheel to the right camshaft e Camshaft timing sprockets and chains, by aligning the matchmarks 9. Remove the tensioner wedges and tighten the camshaft sprocket bolts to 90 ft. lbs. (122 Nm). 10. Install or connect the following: = ek

RIGHT CYLINDER HEAD

5.2L and 5.9L Engines a

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

SPECIAL TOOL 8350

e Negative battery cable e Exhaust manifold heat shields e Exhaust Gas Recirculation (EGR)

tube e Exhaust Y-pipe e Exhaust manifolds

9302PG15

Chain Tensioner Retaining Wedges—4.7L engine

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

“CHRYSLER CORP,

_ DURANGO

ter (TDC) of the compression stroke for the

No. 1 cylinder. 5. Remove or disconnect the following: Negative battery cable Accessory drive belt Power steering pump Water pump Radiator

TORQUE WRENCH

A/C condenser Grille Crankshaft damper Front cover Valve covers Distributor Intake manifold ->Keep all valvetrain components in order for assembly. 9302PG20 e

Hold the left camshaft sprocket with a spanner wrench while removing or installing the camshaft sprocket bolts—4.7L engine

Rocker arms and pushrods

; Hydraulic lifters

Timing chain and sprockets Camshaft thrust plate and chain oil tab Camshatt To install: 6. Install or connect the following: Camshaft Camshaft Holding Tool C-3509 Camshaft thrust plate and chain oil tab. Tighten the bolts to 18 ft. Ibs. (24Nm).. Timing chain and sprockets. Tighten the camshaft sprocket bolt to 50 ft. Ibs. (68 Nm). e e

~-9300P6t7 Camshaft bearing cap bolt tightening sequence—4.7L engine

CAMSHAFT SPROCKET

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3.9L, 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Recover the A/C refrigerant, if equipped with air conditioning. 4. Set the crankshaft to Top Dead Cen-

AND CHAIN

7. Remove the camshaft holding tool. 8. Install or connect the following: Hydraulic lifters in their original positions Rocker arms and pushrods in their original positions Intake manifold Distributor Valve covers Front cover Crankshaft damper Grille

9302PG16

Turn the camshaft with pliers, if needed, to align the dowel in the sprocket—4.7L engine

¢ Hydraulic lash adjusters in their original locations ¢ Rocker arms in their original locations e Cylinder head covers ¢ Negative battery cable

DISTRIBUTOR >

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7924DG63

Exploded view of the oil pump assembly—3.9L, 5.2L and 5.9L engines

5. Fill the crankcase to the correct level.

6. Start the engine and check for leaks.

Rear Main Seal

REMOVAL & INSTALLATION 4.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning ofthis section. 2. Remove or disconnect the following: e Transmission e Flexplate 3. Thread Oil Seal Remover 8506 into the rear main seal as far as possible and remove the rear main seal. To install: 4. Install or connect the following:

e Seal Guide 8349-2 onto the crankshaft e Rear main seal on the seal guide e Rear main seal, using the Crankshaft Rear Oil Seal Installer 8349 and Driver Handle C-4171; tap it into place until the installer is flush with the cylinder block e Flexplate. Tighten the bolts to 45 ft. lbs. (60 Nm). e Transmission 5. Start the engine and check for leaks. 3.9L, 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Oil pan

.25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR MAIN CAP 7924DG24

Sealant application locations —3.9L, 5.2L and 5.9L engines

8-17

e Oil pump e Rear main bearing cap 4, Loosen the other main bearing cap bolts for clearance and remove the rear main seal halfs. To install: 5. Install or connect the following: ¢ New upper seal half to the cylinder block e New lower seal half to the bearing cap 6. Apply sealant to the rear main bearing cap. 7. Install or connect the following: e Rear main bearing cap. Tighten all main bearing cap bolts to 85 ft. Ibs. (115 Nm). e Oil pump and oil pan 8. Fill the engine. 9. Start the engine and check for leaks.

Timing Chain, Sprockets, Front Cover and Seal _ REMOVAL & INSTALLATION 3.9L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Radiator Cooling fan Water pump Crankshaft pulley Front crankshaft seal Front cover Timing chain and gears To install: 4. Install or connect the following: Timing chain and gears. Align the timing marks and tighten the camshaft sprocket bolt to 35 ft. Ibs. (47 Nm). Front cover. Tighten the bolts to 30 ft. Ibs. (41 Nm). Front crankshaft seal Crankshaft pulley. Tighten the bolt to 135 ft. Ibs. (183 Nm). Water pump Cooling fan Radiator Accessory drive belt Negative battery cable

For Tire, Wheel and Ball Joint specifications, see Section 7 of this manual

|

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e Secondary timing chain guides 6. Compress the primary timing chain tensioner and install a lockpin. 7. Remove the secondary timing chain tensioners. 8. Hold the left camshaft with adjustable pliers and remove the sprocket and chain. Rotate the left camshaft 15 degrees clockwise to the neutral position. 9. Hold the right camshaft with adjustable pliers and remove the camshaft sprocket. Rotate the right camshaft 45 degrees counterclockwise to the neutral

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10. Remove the primary timing chain

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and sprockets. To install:

11. Use a small prytoo! to hold the ratchet pawl and compress the secondary

timing chain tensioners in a vise and install

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locking pins. >The black bolts fasten the guide to the engine block and the silver bolts fasten the guide to the cylinder head.

12. Install or connect the following:

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¢ Secondary timing chain guides.

79240667 Timing chain alignment marks—3.9L, 5.2L, and 5.9L engines

Tighten the bolts to 21 ft. Ibs. (28

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5. Fill the cooling system. 6. Start the engine and check for leaks. 4.7L Engine

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Valve covers e Camshaft Position (CMP) sensor e Engine cooling fan and shroud e Accessory drive belt e Heater hoses e Lower radiator hose ¢ Power steering pump 4. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V8 marks on the camshaft sprockets are at 12 o'clock. 5. Remove or disconnect the following: e Crankshaft damper Oil fill housing e Accessory drive belt tensioner ¢ Alternator

» A/C compressor

1 - TIMING CHAIN COVER

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2 — CRANKSHAFT TIMING MARKS

Front cover

¢ Front crankshaft seal ¢ Cylinder head access plugs

9308°G04 Crankshaft timing marks—4.7L engine

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ing tool 8515 as shown. 14. Align the primary chain double plated links with the idler sprocket timing mark and the single plated link with the crankshaft sprocket timing mark. 15. Install the primary chain and sprockets. Tighten the idler sprocket bolt to 25 ft. Ibs. (34 Nm). 16. Align the secondary chain single plated links with the timing marks on the

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secondary sprockets. Align the dot at the L ok 4

Compress and lock the primary chain tensioner—4.7L engine

e through the slots in the primary idler sprocket ae ‘ 13. Lock the secondary timing chains to

mark on the left sprocket with the plated link on the left chain and the dot at the R mark

For Wheel Alignment specifications, see Section 1 of this manual

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on the right sprocket with the plated link on the right chain. 17. Rotate the camshafts back from the neutral position and install the camshaft

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19. Remove the primary and secondary timing chain tensioner locking pins. 20. Hold the camshaft sprockets with a Spanner wrench and tighten the retaining bolts to 90 ft. Ibs. (122 Nm). 21. Install or connect the following: e Front cover. Tighten the bolts, in

|

sequence, to 40 ft. Ibs. (54 Nm). Front crankshaft seal Cylinder head access plugs

A/C compressor Alternator Accessory drive belt tensioner. Tighten the bolt to 40 ft. Ibs. (54 Nm).

SECONDARY

IDLER

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CHAINS

SPROCKET

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RETAINING

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PINS (4)

Lower radiator hose Heater hoses Accessory drive belt Engine cooling fan and shroud

9302PG07

Use the Timing Chain Locking tool to lock the timing chains on the idler gear—4.7L engine

RIGHT

SECONDARY TIMING CHAIN

CAMSHAFT

TENSIONER

SECONDARY TENSIONER ARM

LEFT CAMSHAFT SPROCKET

SPROCKET AND SECONDARY CHAIN

AND SECONDARY CHAIN

CHAIN GUIDE

SECONDARY TENSIONER ARM

TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN PRIMARY CHAIN TENSIONER

TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN

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Timing chain system and alignment marks—4.7L engine

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POSITIONING

7924AG34

Piston to engine positioning—3.9L, 5.2L, 5.9L engines

TIMING CHAIN COVER ASSEMBLY

OIL RING SPACER GAP

TOP COMPRESSION RING GAP

COMPRESSION

RING GAP OIL RING RAIL GAP (TOP)

9302PG26

Timing chain cover bolt torque sequence—4.7L engine

e Camshaft Position (CMP) sensor e Valve covers e Negative battery cable 22. Fill the cooling system. 23. Start the engine and check for leaks. 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable © Accessory drive belt

e Cooling fan and shroud e Water pump

© Power steering pump

Crankshaft damper Front crankshaft seal e Front cover 4. Rotate the crankshaft so that the camshaft sprocket and crankshaft sprocket timing marks are aligned.

5. Remove the timing chain and sprockets. To install: 6. Install the timing chain and sprockets with the timing marks aligned. Tighten the camshaft sprocket bolt to 50 ft. Ibs. (68 Nm). 7. Install or connect the following: Front cover. Tighten the cover bolts to 30 ft. Ibs. (41 Nm) and the oil pan bolts to 18 ft. Ibs. (24 Nm). Front crankshaft seal e Crankshaft damper. Tighten the bolt

OIL RING RAIL GAP (BOTTOM)

7924AG28

Piston ring end-gap spacing—3.9L, 5.2L, 5.9L engines

to 135 ft. Ibs. (183 Nm).

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shroud Accessory drive belt Negative battery cable 8. Fill the cooling system. 9. Start the engine and check for leaks.

NO. 2 RING

“EXPANDER GAP.

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Piston ring end-gap spacing. Position raised “F” on piston towards front of engine—4.7L engine

For Maintenance Interval recommendations, see Section 1 of this manual

:

8-22

CHRYSLER CORP. DURANGO

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system presSure prior to detaching any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. ¢ Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open

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Fuel pressure test port—3.9L engine

VACUUM

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flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping.

¢ Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed. Before servicing the vehicle, also make sure to refer to the precautions in the beginning of this section as well.

Fuel System Pressure RELIEVING

1998-99 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

7924DG34

Fuel pressure test port—5.2L engine, 5.9L engine is similar

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2. Disconnect the negative battery cable. 3. Remove the fuel tank filler cap to release any fuel tank pressure. . Unscrew the plastic cap from the pressure test port on the fuel rail. 5. Obtain a fuel pressure gauge/hose from a fuel pressure gauge tool set No. 5069, or equivalent. Remove the gauge, then place the gauge end of the hose into a Suitable gasoline container. : Place a shop towel under the test port. 7. Screw the other end of the hose onto the fuel pressure port to relieve the pressure. 8. When the pressure has been relieved, remove the hose and cap the port.

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8-23

FUEL FILTER/FUEL PRESSURE REGULATOR

7924DG35

2000-02 1. 2. power _3. 4.

Pull and twist the filter/regulator to remove it from the top of the fuel pump module

Remove the fuel filler cap. Remove the fuel pump relay from the distribution center. Run the engine until it stalls. Turn the key to OFF.

Fuel Filter

REMOVAL & INSTALLATION These engines are equipped with a fuel filter/pressure regulator. This unit is not a regularly maintained unit and is serviced only when a DTC indicates a fault. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel tank 4. Pull the filter/regulator out of the rubber grommet. Cut the hose clamp and remove the fuel line. To install: 5. Install the filter/requiator with a new clamp and push it into the rubber grommet. 6. Install or connect the following: e Fuel tank e Negative battery cable 7. Start the engine and check for leaks.

| Fuel Pump

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

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7924DG82

Fuel pump module locknut removal

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel pump module harness connector e Fuel line e Fuel tank e Fuel pump module locknut e Fuel pump module To install: 4. Install or connect the following: e Fuel pump module e Fuel pump module locknut e Fuel tank e Fuel line e Fuel pump module harness connector e Negative battery cable 5. Start the engine and check for leaks.

Fuel Injector

REMOVAL & INSTALLATION 4.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Air intake assembly Alternator wiring connectors Fuel line Throttle body vacuum lines and electrical connectors Fuel injector connectors Manifold Absolute Pressure (MAP)

sensor connector

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

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CHRYSLER CORP.

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e Intake Air Temperature (IAT) sensor connector e Ignition coils ¢ Fuel supply manifold with injectors attached e Fuel injectors To install: 4. Install or connect the following: Fuel injectors, using new O-rings Fuel supply manifold with injectors — attached. Tighten the bolts to 20 ft. lbs. (27 Nm). Ignition coils IAT sensor connector MAP sensor connector Fuel injector connectors Throttle body vacuum lines and electrical connectors

Fuel line e Alternator wiring connectors

e Air intake assembly Negative battery cable 5. Start the engine and check for leaks. 3.9L, 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Air intake tube Throttle body A/C compressor bracket Fuel injector connectors

Fuel line - Fuel supply manifold with injectors Fuel injectors

To install: 4. Install or connect the following: Fuel injectors with new O-ring seals Fuel supply manifold with injectors. Tighten the bolts to 17 ft. Ibs. (23 Nm). Fuel line Fuel injector connectors A/C compressor bracket Throttle body Air intake tube Negative battery cable tart the engine and check for leaks. ”one eeeee

DRIVE TRAIN Transmission Assembly

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Rear driveshaft Crankshaft Position (CKP) sensor Exhaust front pipe Transmission braces, if equipped Starter motor Transmission oil cooler lines Torque converter access cover Torque converter Transmission oil dipstick tube Vehicle Speed (VSS) sensor connector Park/Neutral switch connector Shift cable Throttle valve cable Transmission mount and crossmember. Support the transmission. Front driveshaft and transfer case, if equipped Transmission flange bolts Transmission To install: 3. Install or connect the following: Transmission. Tighten the flange bolts to 65 ft. Ibs. (87 Nm). Front driveshaft and transfer case, if equipped Transmission mount and crossmember Throttle valve cable Shift cable Park/Neutral switch connector

VSS sensor connector Transmission oil dipstick tube Torque converter. Tighten the bolts to 23 ft. Ibs. (31 Nm) for 10.75 inch converters and to 35 ft. Ibs. (47 Nm) for 12.2 inch converters. Torque converter access cover Transmission oil cooler lines Starter motor Transmission braces, if anne Tighten the bolts to 30 ft. Ibs. (41 Nm). Exhaust front pipe CKP sensor Rear driveshaft Negative battery cable

Transfer Case Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Shift the transfer case into N. 3. Remove or disconnect the following: Front and rear driveshafts Transmission mount and crossmember. Support the transmission. Vehicle Speed (VSS) sensor connector Shift linkage Vent hose Vacuum hose Indicator switch connector Transfer case attaching nuts Transfer case To install: 4. Install or connect the following: Transfer case. Tighten the nuts to 26 ft. Ibs. (35 Nm).

TRANSFER CASE

7924DG84

Typical transfer case mounting

Indicator switch connector Vacuum hose Vent hose Shift linkage VSS sensor connector Transmission mount and crossmember Front and rear driveshafts

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Skid plate, if equipped Front wheel Split pin Nut lock Spring washer Hub nut Brake caliper and rotor Wheel speed sensor, if equipped Wheel bearing and hub assembly

CHRYSLER CORP. DURANGO

8-95

¢ Wheel speed sensor, if equipped e Brake caliper and rotor ¢ Front wheel

SEAL

COTTER PIN 79240685 To separate the halfshaft from the hub, remove the cotter pin, nut lock and spring washer from the axle shaft

3. Pry the inner tripod joint out of the differential and remove the axle halfshaft. To install: 4. Install the axle halfshaft so that the snapring is felt to seat in the joint housing groove. 5. Install or connect the following: Wheel bearing and hub assembly Wheel speed sensor, if equipped Brake caliper and rotor Hub nut. Tighten the nut to 180 ft. lbs. (244 Nm). Spring washer Nut lock Split pin Front wheel Skid plate, if equipped

CV-Joints

2. Remove or disconnect the following: e Axle halfshaft from the vehicle e Inner tripod joint boot clamps e Tripod joint housing e Snapring e Circlip’ ¢ Tripod joint To install: >Use new snaprings, clips, and boot clamps for assembly.

3. Install or connect the following: e Tripod joint e Circlip e Snapring e Tripod joint housing 4. Fill the tripod joint housing and boot with grease and tighten the boot clamps. 5. Install the axle halfshaft.

Axle Shaft, Bearing and Seal

OVERHAUL

REMOVAL & INSTALLATION

Outer CV-Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Axle halfshaft from the vehicle e CV\-joint boot and clamps

e Snapring e CV-joint To install: 3. Install or connect the following: e CV-joint e Snapring e C\-joint boot and clamps 4. Fill the joint housing and boot with grease and tighten the boot clamps. 5. Install the axle halfshaft. Inner Tripod Joint 1. Before servicing the vehicle, refer tothe precautions in the beginning of this section.

Front

AXLE SHAFT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Brake caliper and rotor e Wheel speed sensor, if equipped e Axle hub nut e Wheel bearing and hub assembly e Axle shaft To install: 3. Install or connect the following: e Axle shaft e Wheel bearing and hub assembly e Axle hub nut. Tighten the nut to 175 ft. Ibs. (237 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ; e Front axle shafts e Differential cover e Differential and ring gear assembly e Axle seals To install: 3. Press the axle seals into the differential housing with Turnbuckle 6797 and Disc set 8110. 4. Install or connect the following: e Differential and ring gear assembly. Tighten the bearing cap bolts to 45 . ft. Ibs. (61 Nm). e Differential cover. Tighten the bolts to 30 ft. Ibs. (41 Nm). e Front axle shafts 5. Fill the axle assembly with gear oil and check for leaks. Rear

C-CLIP TYPE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Rear wheel Brake drum Differential cover Differential gear shaft retainer Differential gear shaft C-clip Axle shaft Axle seal ®e eeeeeeee#ee Axle bearing To install: 3. Install or connect the following: Axle bearing Axle seal Axle shaft C-clip Differential gear shaft. Use Loctite® and tighten the retainer to 14 ft. Ibs. (19 Nm). Differential cover. Tighten the bolts to 30 ft. Ibs. (41 Nm). e Brake drum e Rear wheel 4. Fill the axle assembly with gear oil and check for leaks.

For complete service labor times, order the Chilton Labor Guide

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NON C-CLIP TYPE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Rear wheel heen " et Teee Brake eee drum, if equipped CUI

e Axle retainer nuts

;

See ee ue ae bly 3. Split the bearing retainer with a chisel and remove the retainer ring. 4. Press the bearing off the axle shaft. 5. Remove the axle seal and retaining plate. To install: 6. Install the retaining plate and axle seal onto the axle shaft. 7. Pack the wheel bearing with axle ae and press the bearing on to the axle 8. Press the retaining ring onto the axle shaft. 9. Install or connect the following: e Axle shaft, seal and bearing assembly. Tighten the nuts to 45 ft. Ibs. (61 Nm). e Brake caliper and rotor, if equipped e Brake drum, if equipped e Rear wheel 10. Fill the axle assembly with gear oil and check for leaks.

REMOVAL & INSTALLATION C-Clip Type 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels e Brake drums e Driveshaft

3. Check the bearing preload with an inch |b. torque wrench. 4. Remove the pinion flange and seal. To install: e>Use a new pinion nut for assembly.

5. Install the new pinion seal and Tighten the nut to 210 ft. Ibs. (285 flange. Nm) 6. Check the bearing preload. The bear-

ing preload should be equal to the reading taken earlier, plus 5 inch Ibs. 7. If the preload torque is low, tighten the pinion nut in 5 inch Ib. increments until the torque value is reached. Do not exceed 350 ft. Ibs. (474 Nm) pinion nut torque. 8. If the pinion bearing preload torque cannot be attained at maximum pinion nut torque, replace the collapsible spacer. 9. Install or connect the following: e+ Driveshaft keds e Wheels 10. Fill the axle assembly with gear oil and check for leaks.

Non C-Clip Type

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels e Brake rotors e Driveshaft 3. Check the bearing preload with an inch lb. torque wrench. 4. Remove the pinion flange and seal. To install: >Use a new pinion nut for assembly.

5. Install the new pinion seal and flange. Tighten the nut to 160 ft. Ibs. (217 N m). 6. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch Ibs.

STEERING AND SUSPENSION

+k CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sen-

7. Ifthe preload torque is low, tighten the pinion nut in 5 inch Ib. increments until the torque value is reached. Do not exceed 260 ft. Ibs. (353 Nm) pinion nut torque. 8. If the pinion bearing preload torque can not be attained at maximum pinion nut torque, replace the collapsible spacer. 9. Install or connect the following: ef rivestiatl

sors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid

e Brake rotors

e Wheels 10. Fill the axle assembly with gear oil and check for leaks.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels ' e«. Brake rotors or drums Drieshal 3. Check the bearing preload with an inch |b. torque wrench. 4. Remove the pinion flange and seal. To install: >Use a new pinion nut for assembly.

5. Install the new pinion seal and flange. Tighten the nut to 160 ft. Ibs. (217 Nm). 6. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch Ibs. 7. lf the preload torque is low, tighten the pinion nut in 5 inch Ib. increments until the torque value is reached. Do not exceed 260 ft. Ibs. (353 Nm) pinion nut torque. 8. If the pinion bearing preload torque can not be attained at maximum pinion nut torque, remove one or more pinion preload shims. 9. Install or connect the following: e Driveshaft ¢ Brake rotors or drums e Wheels 10. Fill the axle assembly with gear oil and check for leaks.

/ accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up.

:

CHRYSLER CORP. _ DURANGO

e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment. Before servicing the vehicle, also make sure to refer to the precautions in the beginning of this section as well.

DISARMING 1. Disconnect and isolate the negative battery cable. Wait2minutes for the system capacitor to discharge before performing any service. 2. When repairs are completed, connect the negative battery cable.

Rack and Pinion Steering Gear

3. Install or connect the following: Steering gear. Tighten the bolts to 190 ft. Ibs. (258 Nm). | Power steering hoses. Tighten the fittings to 25 ft. Ibs. (35 Nm). Steering shaft coupler. Tighten the bolt to 36 ft. Ibs. (49 Nm). Outer tie rod ends. Tighten the nuts to 65 ft. Ibs. (88 Nm). Front wheels

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheels e Outer tie rod ends e Steering shaft coupler e Power steering hoses e Steering gear

8-27

Shock Absorber

REMOVAL & INSTALLATION

RACK AND PINION STEERING GEAR

Front

Recirculating Ball Power Steering Gear

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Power steering pressure and return lines e |ntermediate shaft e Pitman arm e Steering gear To install: 3. Install or connect the following: Steering gear. Tighten the bolts to 100 ft. Ibs. (136 Nm). Pitman arm. Tighten the nut to 175 ft. Ibs. (237 Nm). Intermediate shaft. Tighten the pinch bolt to 36 ft. Ibs. (49 Nm). Power steering pressure and return lines e Negative battery cable 4. Fill the power steering fluid reservoir. _ 5. Start the engine and check for leaks.

BUSHING 7924DG42

Rack and pinion steering gear mounting used on the 2WD models

1. Before servicing the vehicle, refer to " the precautions in the beginning of this section. : 2. Remove or disconnect the following: 3. Install or connect the following: e Front wheel e Upper mount nut e Lower mount bolt e Shock absorber

NUT me RETAINER GROMMET

79240641 7924DG86

Typical recirculating ball power steering gear mounting

Front shock absorber mounting—4WD models

Please visit our web site at www.chiltonsonline.com

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2. Support the lower control arm ona floor jack. y 3. Remove or disconnect the following: e Front wheel e Shock absorber e Stabilizer bar link e Lower ball joint. 4. Lower the jack and remove the coil spring. To install: 5. Install the coil spring and raise the control arm into position. 6. Install or connect the following: e Lower ball joint. Tighten the nut to 135 ft. Ibs. (183 Nm). e Stabilizer bar link e Shock absorber e Front wheel

RETAINER

GROMMET

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Front shock absorber mounting—2WD models

To install: 4. Install or connect the following: e Shock absorber. Tighten the lower bolt to 100 ft. Ibs. (136 Nm) and the upper nut to 30 ft. Ibs. (41 Nm). e Front wheel

Leaf Spring

REMOVAL & INSTALLATION REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle at the frame rails.

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

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle. 3. Remove or disconnect the following: e Upper bolt e Lower bolt e Shock absorber To install: 4. Install the bolts through the brackets and shock and tighten them as follows: Tighten the lower bolt and nut to 60 ft. Ibs. (81 Nm) and the upper bracket nuts to 20 ft. lbs. (27 Nm)

SUSPENSION / ARM

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Front suspension components—4WD models

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SUSPENSION ARM 79240G91

Cc SPRING 7924DG46

Rear shock absorber mounting

Front suspension components—2WD models

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CHRYSLER CORP. DURANGO

3. Support the rear axle with a jack. 4. Remove or disconnect the following. e Rear wheel e Stabilizer bar link e Axle U-bolts e Spring bracket e Leaf spring To install: >The weight of the vehicle must be supported by the springs when the spring eye and stabilizer bar fasteners are tightened.

5. Install or connect the following: e Leaf spring e Spring bracket e Axle U-bolts. Tighten the nuts to 52 ft. Ibs. (70 Nm). e Stabilizer bar link e Rear wheel 6. Tighten the front spring eye bolt and nut to 115 ft. Ibs. (156 Nm). Tighten the rear spring eye bolt and nut to 80 ft. Ibs. (108 Nm). Tighten the stabilizer bar nuts 55 ft. Ibs. (74 Nm). Torsion Bar

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the adjustment bolt to remove spring load. Note the number of turns for installation. 3. Remove or disconnect the follow-

ing: e Adjustment bolt, swivel and bearing e Torsion bar and anchor 4. Separate the torsion bar and anchor. To install: 5. Assemble the torsion bar and anchor. 6. Install or connect the following: e Torsion bar and anchor e Adjustment bolt, swivel and bearing 7. Tighten the adjustment bolt the recorded number of turns.

Upper Ball Joint REMOVAL & INSTALLATION Durango models utilize an upper control arm with an integral ball joint. If the ball

joint is damaged or worn, the upper control arm must be replaced, Lower Ball Joint

REMOVAL & INSTALLATION Durango models utilize a lower control arm with an integral ball joint. If the ball joint is damaged or worn, the upper control arm must be replaced.

Upper Control Arm REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Support tHe lower control arm.

3. Remove or disconnect the following: e Front wheel e Brake hose brackets e Upper ball joint e Pivot mounting nuts e Upper control arm To install: 4. Install or connect the following: e Upper control arm. Tighten the pivot nuts to 155 ft. Ibs. (210 Nm). e Upper ball joint. Tighten the nut to 60 ft. Ibs. (81 Nm). e Brake hose brackets e Front wheel 5. Check the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly.

Lower Control Arm

REMOVAL & INSTALLATION 2 wheel drive

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Shock absorber e Brake caliper and rotor e Stabilizer bar link

e Coil spring e Inner mounting bolts e Lower control arm

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3. Install or connect the following: Lower control arm. Tighten the. front bolt to 130 ft. Ibs. (175 Nm) and the rear bolt to 80 ft. Ibs. (108 Nm). Coil spring. Tighten the lower ball joint nut to 94 ft. Ibs. (127 Nm). Stabilizer bar link Brake caliper and rotor Shock absorber Front wheel 4 wheel drive

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Front driveshaft e Torsion bar e Shock absorber e Stabilizer bar e Lower ball joint e Pivot bolts e Lower control arm To install: 3. Install or connect the following: Lower control arm. Tighten the front pivot bolt to 80 ft. Ibs. (108 Nm) and the rear bolt to 140 ft. Ibs. (190 Nm). Lower ball joint. Tighten the nut to 135 ft. Ibs. (183 Nm). Stabilizer bar Shock absorber Torsion bar Front driveshaft Front wheel

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly.

Wheel Bearings ADJUSTMENT Durango models utilize a hub/bearing assembly which is not adjustable.

REMOVAL & INSTALLATION 2 wheel drive

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

Timing belt service is covered in Section 3 of this manual

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_ Hub/bearing assembly—2 wheel drive Wasa 2.

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(166 Nm).

3. Install or connect the following: e Hub and bearing assembly

¢ Spindle nut. Tighten the nut to 185 ft. lbs. (251 Nm).

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FORD/MAZDA 2001 Escape * Tribute

DRIVE TRAIN .............00006 9-16

ENGINE REPAIR.................. 9-2

Removal & Installation... 9-8

FUEL SYSTEM ..............008 9-15

Front Crankshaft Seal .............sccsee 9-9

STEERING AND SUSPENSION .................. 9-19

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PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

proper operation of the brake system. You brake fluid internally, IMMEDIATELY seek should always buy the correct type of brake medical assistance. fluid for your vehicle. Ifthe brake fluid e The EPA warns that prolonged contact becomes contaminated, completely flush the with used engine oil may cause a number of system with new fluid. Never reuse any brake skin disorders, including cancer! You fluid. Any brake fluid that is removed from should make every effort to minimize your the system should be discarded. Also, do not exposure to used engine oil. Protective allow any brake fluid to come in contact with gloves should be worn when changing oil. ~ a painted surface; it will damage the paint. Wash your hands and any other exposed ¢ Never operate the engine without the skin areas as soon as possible after expoproper amount and type of engine oil; doing Sure to used engine oil. Soap and water, or so WILL result in severe engine damage. waterless hand cleaner should be used. e Timing belt maintenance is extremely e All new vehicles are now equipped important! Many models utilize an interferwith an air bag system, often referred to as a ence-type, non-freewheeling engine. If the Supplemental Restraint System (SRS) or timing belt breaks, the valves in the cylinder Supplemental Inflatable Restraint (SIR) syshead may strike the pistons, causing potentem. The system must be disabled before tially serious (also time-consuming and performing service on or around system ‘expensive) engine damage. Refer to the components, steering column, instrument maintenance interval charts in the front of panel components, wiring and sensors. this manual for the recommended replaceFailure to follow safety and disabling procement interval for the timing belt, and to the dures could result in accidental air bag timing belt section for belt replacement and deployment, possible personal injury and inspection. unnecessary system repairs. e Always wear safety goggles when e Disconnecting the negative battery working with, or around, the air bag system. cable on some vehicles may interfere with When carrying a non-deployed air bag, be the functions of the on-board computer syssure the bag and trim cover are pointed tem(s) and may require the computer to away from your body. When placing a nonundergo a relearning process once the negdeployed air bag on a work surface, always ative battery cable is reconnected. face the bag and trim cover upward, away e When servicing drum brakes, only disfrom the surface. This will reduce the assemble and assemble one side at a time, motion of the module if it is accidentally leaving the remaining side intact for referdeployed. Refer to the additional air bag ence. system precautions later in this section. ¢ Only an MVAC-trained, EPA-certified ¢ Clean, high quality brake fluid from a automotive technician should service the air sealed container is essential to the safe and conditioning system or its components.

ENGINE REPAIR Distributor The Escape uses a Direct Ignition System (DIS), no distributor is used.

Alternator

REMOVAL 2.0L Engine Remove or disconnect the following: e Negative battery cable ¢ Drive belt e Alternator electrical connectors and loosen the upper alternator bolt

while moving the alternator to the rear of the engine ¢ Alternator. Torque the mounting and adjusting bolts to 33 ft. Ibs. (45Nm). 3.0L Engine

Remove or disconnect the following: Negative battery cable Right side intermediate axle shaft Right side splash shield and retainers Drive belt Alternator electrical connectors Alternator. Torque the mounting and adjusting bolts to 35 ft. Ibs. (48Nm),

INSTALLATION 2.0L Engine Install or connect the following: e Alternator with the upper bolt in the alternator before installation. Torque the bolts to 18 ft. Ibs. (25 Nm). e Alternator electrical connectors e Drive belt ¢ Negative battery cable

3.0L Engine Install or connect the following: e Alternator. Torque the bolts to 35 ft. lbs. (48 Nm).

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MANUAL TRANSMISSION

Wire harness connector Power distribution board electrical connectors Evaporative emissions (EVAP) canister vacuum lines Upper radiator hose Power steering line bracket Upper power steering pump bolts Coolant hose Heater hoses Speed control unit, if equipped Catalytic converter A/C compressor Both halfshafts Shifter linkages Block heater electrical connector, if equipped Front transmission through bolt Engine-to-transmission bolts Lower (adiator hose

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly recover the air conditioning system refrigerant. 3. Properly relieve the fuel system pressure. 4. Drain the cooling system. 5. Drain the engine oil. 6. Remove or disconnect the following: Hood Battery and battery tray Air cleaner housing Fuel lines Throttle cable and speed control cable, if equipped Exhaust Gas Recirculation (EGR) vacuum valve regulator EGR electrical connectors and vacuum hoses Brake booster vacuum hose Powertrain Control Module (PCM) wire harness and ground

Power Steering pump Clutch slave cylinder line from the bracket and move it aside Rear transmission mount Left side transmission mount Lower ground cable Engine mount upper bracket Engine and transmission as an assembly by using a proper lifting device Alternator electrical connectors Knock Sensor (KS) electrical connector Oil pressure sender electrical connector Starter electrical connector Vehicle Speed Sensor (VSS) electrical connector Park Neutral Position (PNP) electrical connector Fuel charging wire harness electrical connector PCM wire harness from the bracket

« e Negative battery cable

Ignition Timing

ADJUSTMENT Ignition timing is controlled by the Powertrain Control Module (PCM). No adjustment is necessary or possible.

Engine Assembly

REMOVAL & INSTALLATION 2.0L Engine

9-3 a,

PCM ground wire , Back up lamp switch electrical connector Wire harness Differential Pressure Feedback (DPFEE) EGR sensor 7. Separate the engine from the transmission. 4 8. Lock the flywheel to the engine. 9. Clutch pressure plate and disc. 10. Flywheel and rear cover plates. To install: 11. Install or connect the following: Flywheel. Torque the bolts to 83 ft. lbs. (112 Nm). Clutch disc to the flywheel Pressure plate to the flywheel. Torque the bolts in the proper sequence to 18 ft. Ibs. (25 Nm). Transmission to the engine. Torque the bolts to 33 ft. Ibs. (45 Nm). Starter. Torque the bolts to 18 ft. lbs. (25 Nm). Wire harness and attach it to the powertrain assembly DPFEE sensor electrical connector Reverse lamp switch electrical connector Ground wire. Torque the bolt to 80 inch Ibs. (9 Nm). PCM wire harness to the bracket Fuel charging wire harness electrical connector PNP switch electrical connector VSS electrical connector KS, Oil pressure sender and starter electrical connector. Torque the fasteners to 9 ft. Ibs. (12 Nm). Alternator electrical connectors. Torque the fasteners to 71 inch Ibs. (8 Nm). Powertrain assembly in the vehicle Left side transmission: mount. Torque the side bolts to 41 ft. Ibs.

9308TG07

Tighten the pressure plate bolts in the proper sequence-2.0L engine

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(55 Nm) and the center bolt to 66

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ft. Ibs. (90 Nm). Engine mount upper bracket.

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Torque the side bolts to 72 ft. Ibs. (98 Nm) and the center bolt to 57

|

ft. Ibs. (77 Nm). Ground wire. Torque the bolt to 25 ft. Ibs. (34 Nm). Rear transmission mount. Torque the bolts to 41 ft. Ibs. (65 Nm). Speed control unit, if equipped. Torque the bolts to 89 inch Ibs. (10 Nm). Power steering pump and hand tighten the bolts

For complete service labor times, order the Chilton Labor Guide

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Lower power steering line bracket. ~ Torque the bolt to 89 inch Ibs. (10 Nm). Upper power steering line bolt. Torque the bolt to 15 ft. Ibs. (20 Nm). Slave cylinder line and clip. Torque the bolts to 16 ft. Ibs. (22 Nm). Power steering lines. Torque the retaining bolts to 89 inch Ibs. (10 Nm). Torque the power steering pump bolts to 18 ft. Ibs. (25 Nm). Lower radiator hose Engine-to-transmission bolts. Torque the bolts to 33 ft. Ibs. (45 Nm). Front transmission through bolt. Torque the bolt to 66 ft. Ibs. (90 Nm). Block heater electrical connector Shifter linkages. Torque the upper bolt to 33 ft. Ibs. (45 Nm) and the lower bolt to 15 ft. Ibs. (20 Nm). Coolant hose Catalytic converter Heater hoses Upper radiator hose EVAP canister vacuum lines Power distribution box electrical connector. Torque the fastener to 9 ft. Ibs. (12. Nm). Wire harness electrical connector Ground wires PCM wire harness and ground Brake booster vacuum supply hose to the intake manifold EGR vacuum regulator valve hoses and electrical connector Throttle cable and speed control cable, if equipped Fuel lines Battery tray and battery Air cleaner Hood Fill the engine with clean oil. Fill and bleed the cooling system. Recharge the A/C system. Start the vehicle, check for leaks and if necessary.

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly recover the air conditioning system refrigerant. 3. Properly relieve the fuel system pressure. 4. Drain the cooling system. 5. Drain the engine oil. 6. Remove or disconnect the following;

Hood Battery and battery tray Air cleaner outlet tube and housing Lower radiator air deflectors Fuel lines Water pump drive belt Accelerator cable and speed control cable, if equipped Vapor Management Valve (VMV) Powertrain Control Module (PCM) PCM ground wire Thermostat housing and hose assembly and move them aside Power distribution box electrical connector Power distribution box cover Nuts and cables from inside the power distribution box Transmission linkage Brake booster vacuum hose Heater hoses Power steering return line Power Steering Pressure (PSP) switch electrical connector Power steering supply line Oil level indicator Catalytic converter A/C compressor Both front wheels Intermediate drive shaft, if equipped 7. Separate both side ball joints. 8. Separate both side tie rod ends from the steering knuckles. 9. Separate both sway bar links from the strut mounts. 10. Separate the struts from the steering knuckles. 11. Remove or disconnect the following: Both wheel speed sensors, if equipped Brake calipers from the steering knuckles and properly support the struts Steering shaft from the rack Transmission line bracket bolt Transmission cooler lines Torque converter inspection cover Torque converter nuts Block heater wiring, if equipped 12. Install a powertrain lifting devise and raise the vehicle. Engine support bracket Transmission support 2 rear subframe bolts 2 subframe side bolts Motor mount support bolts Engine and transmission as an assembly Heated Oxygen (HO2S) sensor Transmission Range (TR) sensor Transmission harness electronic

control switch

Transmission control harness from the bracket Starter and wire harness

Knock Sensor (KS) electrical connector

—

Output Shaft Speed (OSS) sensor electrical connector HO2S sensor and Exhaust Gas

Recirculation (EGR) tube from the exhaust manifold Alternator and electrical connectors Right side exhaust manifold and gasket Halfshaft support bracket and move it aside 13. Separate the engine from the transmission assembly To install: 14. Install or connect the following: Powertrain assembly on the subframe Transmission-to-engine bolts. Torque the bolts to 30 ft. Ibs. (40 Nm). . Halfshaft bracket. Torque the bolts to 18 ft. Ibs. (25 Nm). Right side exhaust manifold and new gasket. Torque the bolts to 15 ft. Ibs. (25 Nm). Alternator. Torque the larger bolts

to 18 ft. Ibs. (25 Nm) and smaller bolt to 89 inch Ibs. (10 Nm). EGR tube and HO2S sensor electrical connectors OSS sensor electrical connector e KS jumper electrical connector Starter. Torque the bolts to 18 ft. lbs. (25 Nm). Transmission control harness to the bracket. Torque the bolt to 18 ft. lbs. (25 Nm). Transmission harness Transmission range sensor Powertrain assembly Motor mount support. Torque the — bolts to 66 ft. Ibs. (90 Nm). Subframe side nuts. Torque the nuts to 76 ft. Ibs. (103 Nm). Raise the vehicle and support the powertrain assembly with a lifting device. Transmission mount. Torque the bolts to side bolts to 66 ft. Ibs. (90 Nm) and the other bolts to 76 ft. lbs. (103 Nm). Motor mount. Torque the bolts to side bolts to 66 ft. Ibs. (90 Nm) and the other bolts to 76 ft. Ibs. (103 Nm). Remove the powertrain lift. Block heater electrical connector, if equipped Torque converter. Torque the nuts

to 27 ft. Ibs. (37 Nm).

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FORD/MAZDA ESCAPE ¢ TRIBUTE e Transmission cover plate and plug Transmission cooler lines e Transmission cooler line bracket. Torque the bolt to 15 ft. Ibs. (20 Nm). Steering shaft to the rack. Torque the bolt to 18 ft. Ibs. (25 Nm). Struts to the steering knuckles. Torque the bolts to 75 ft. Ibs. (102 Nm). Brake calipers to the steering knuckles Wheel speed sensors, if equipped. Torque the bolts to 89 inch Ibs. (10

Nm).

;

Sway bar links to the strut mount. Torque the bolts to 41 ft. Ibs. (65 Nm). Tie rods to the steering knuckles. Torque the bolts to 41 ft. Ibs. (5 Nm). Ball joints. Torque the bolts to 52 ft. Ibs. (70 Nm). Intermediate drive shaft, if equipped Both front wheels A/C compressor Lower radiator air deflectors Catalytic converter Oil level indicator dipstick tube Power steering line and bracket. Torque the bolt to 13 ft. Ibs. (17 Nm). PSP switch electrical connector Power steering return line Heater hoses Vacuum lines Transmission linkage Wire harness cables and nuts to the power distribution box. Torque the nuts to 89 inch Ibs. (10 Nm). Power distribution box wire harness Thermostat housing and connect the hoses Ground wire. Torque the bolt to 89 inch lbs. (10 Nm). PCM electrical connector VMV electrical connector Accelerator cable and speed control cable, if equipped Air cleaner assembly Water pump drive belt Battery and tray 15. Fill and bleed the cooling system. 16. Fill the engine with clean oil. 17. Recharge the A/C system. 18. Inspect and top off the power steering fluid. 19. Start the vehicle, check for leaks and repair if necessary.

Water Pump

REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Right front wheel e Splash shield e Drive belt e Water pump pulley e Water pump To install: 4. Install or connect the following:

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To install: 4. Install or connect the following: e Water pump to the housing. Torque the bolts to 89 inch Ibs. (10 Nm). e Water pump. Torque the bolts to 89 inch Ibs. (10 Nm). Coolant hoses Water pump belt tensioner Air cleaner outlet tube Negative battery cable 5. Refill the cooling system. 6 Start the vehicle and check for leaks, repair if necessary.

Cylinder Head REMOVAL & INSTALLATION

Water pump. Torque the bolts to 89 inch Ibs. (10 Nm). Water pump pulley. Torque the bolts to 89 inch Ibs. (10 Nm). Drive belt Splash shield

Right front wheel Negative battery cable 5. Refill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary.

9308TG08

Exploded view of the water pump-2.0L engine

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Water pump belt tensioner Coolant hoses Water pump Water pump from the housing

2.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the engine oil. 4 Remove or disconnect the following: Negative battery cable Ignition coil bracket Thermostat housing Positive Crankcase Ventilation (PCV) tube Intake manifold Exhaust manifold Power steering bracket and move it aside Valve tappets Engine mount lower bracket Engine mount upper bracket Cylinder head bolts in the proper sequence and discard the gasket To install: 5. Install a new head gasket and the cylinder head. 6. Lubricate the cylinder head bolt threads. 7. Torque the cylinder head bolts in the proper sequence as follows: a. Step 1: 15 ft. Ibs. (20 Nm). b. Step 2: 30 ft. Ibs. (40 Nm). c. »Step 3: Plus an additional 90 degrees. 8. Install or connect the following: e Engine mount upper bracket. Torque the 2 upper bolts to 72 ft. lbs. (98 Nm) and the center bolt to 57 ft. Ibs. (77 Nm). e Engine mount lower bracket.

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ESCAPE e TRIBUTE e Cylinder head and discard the gasket To install: 4. \nstall a new head gasket and the cylinder head. 5. Lubricate the cylinder head bolt threads. 6. Torque the cylinder head bolts in the proper sequence as follows: a. Step 1: 30 ft. Ibs. (40 Nm). b. Step 2: Additional 90 degrees. c. Step 3: Loosen the bolts one full turn.

_ d. Step 4: 30 ft. Ibs. (40 Nm). e. Step 5: Plus an additional 90 degrees. f. Step 6: Plus an additional 90 degrees. 7. Install or connect the following:

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Cylinder head bolt torque sequence 2.0L engine Torque the bolts to 37 ft. Ibs. (50 Nm). Valve tappets Power steering pump bracket. Torque the bolts to 20 ft. Ibs. (28 Nm). Exhaust manifold Intake manifold PCV tube Thermostat housing Ignition coil bracket Negative battery cable 9. Fill the engine with clean oil and replace the filter. 10. Start the vehicle and check for leaks, repair if necessary.

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Hydraulic lash adjusters Camshaft followers Camshaft Exhaust manifold. Torque the bolts

3.0L Engine 9308TG05

The procedure for the left side cylinder head and right side are similar. Changes in the procedure will be noted for either side cylinder head. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. e Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Camshaft Exhaust Gas Recirculation (EGR) tube, right side only Exhaust manifold Camshaft followers Hydraulic lash adjusters and matchmark them for proper installation Cylinder head bolts in sequence and discard them

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Be careful not to damage the seal surface of the cover.

To install: 3. Install or connect the following: e New front crankshaft oil seal ¢ Timing belt guide and crankshaft sprocket e Timing belt e Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary.

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2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Camshaft timing sprocket and verify the valve clearance e Camshaft journal cap bolts by loosening them in several passes in the proper sequence e Camshafts 3. Inspect the camshaft for wear and discard the oil seals To install: 4. Install or connect the following: Camshaft cam followers, lubricate the bearing journals thoroughly. Torque the caps to 14 ft. Ibs. (19 Nm). Exhaust camshaft oil seal Camshaft timing sprocket Negative battery cable

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9308TG14

Camshaft bearing cap tightening sequence-2.0L engine

3.0L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Water pump belt ¢ Timing drive components

¢ Camshaft oil seal ¢ Camshaft oil seal retainer

¢ Camshaft cap bolts by loosening them in sequence e Camshafts To install: 3. Install or connect the following: e Camshaft bearing caps in their original position ¢ Align the camshafts ¢ Bearing thrust caps and hand tighten the bolts. When aligned properly, torque the bolts to 89 inch Ibs. (10 Nm). * Timing drive components

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Valve Lash

ADJUSTMENT OP

2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Timing belt 3. Measure each valve's clearance at the base circle with the lobe facing away from the tappet. 4. Use a feeler gauge to measure and record each valve's clearance 5. Remove or disconnect the following: e Camshafts e Valve tappets from the cylinder head 6. A mid range clearance is recommended as follows: a. Intake: 0.006 inch (0.15mm). b. Exhaust: 0.012 inch (0.3mm).

pene Remove and install the left side camshaft bearing caps in sequence-3.0L engine

e e e e e

To install: 7. Install or connect the following:

Camshaft oil seal retainer Crankshaft oil seal Water pump drive pulley Water pump belt Negative battery cable

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Timing drive components e Camshaft cap bolts by loosening them in sequence e Camshafts caps e Camshafts To install: 3. Install or connect the following: e Camshaft bearing caps in their original position e Align the camshafts e Bearing caps and hand tighten the bolts e Bearing thrust caps and hand

ome

tighten the bolts. When aligned

properly, torque the bolts to 89

inch Ibs. (10 Nm).

Remove and install the right side camshaft bearing caps in sequence—-3.0L engine

Brake service is covered in Section 4 of this manual

9-42 “

FaRDsmazoa

ESCAPE ¢ TRIBUTE

e \Valve tappets after lubricating them with clean engine oil e Camshafts and verify each valve's clearance at the base circle with the lobe facing away from the tappet e Timing belt e Negative battery cable 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Camshaft followers e Hydraulic lash adjusters e>Mark the position of the hydraulic lash adjusters to assure they are assembled in their original position

3. Inspect the adjusters for scoring or uneven wear in the bore and replace them as required. To install: 4. Install or connect the following: e Hydraulic lash adjusters after lubricating them with clean engine oil

La .

— |

e Camshaft followers e Negative battery cable

REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Starter bolts e Exhaust system, AWD vehicles only e Halfshaft support bracket bolts e Starter electrical connectors ° Starter To install: 3. Install or connect the following: Starter. Torque bolts to 20 ft. Ibs. (27 Nm). Starter electrical connectors Halfshaft support bracket. Torque the bolts to 11 ft. Ibs. (15 Nm), Exhaust system on AWD vehicles. Torque the bolts to 18 ft. Ibs. (25 Nm). Negative battery cable

93087617

Removal of the starter motor—2.0L engine

2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Air cleaner outlet tube e Coolant hoses and move the thermostat aside e Starter electrical connectors e Starter To install: 4. Install or connect the following: e Starter. Torque bolts to 20 ft. Ibs. (27 Nm). e Starter electrical connectors and reposition the thermostat e Connect the 4 coolant hoses e Air cleaner outlet tube e Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle and check for leaks, repair if necessary.

2. Drain the engine oil. 3. Support the powertrain assembly. 4, Remove or disconnect the following: e Negative battery cable e Catalytic converter e (Oil pan and gasket 5. Thoroughly clean the gasket mating surfaces. To install: 6. Apply silicone sealer to the oil pan. 7. Install a new gasket on the oil pan. 8. Oil pan. Torque the bolts in sequence to:

a. Step 1: 53 inch Ibs. (6 Nm). b. Step 2: 106 in Ibs. (12 Nm). 9. Install or connect the following: e Catalytic converter ¢ Negative battery cable 10. Fill the engine with clean oil. 11. Start the engine and check for leaks, repair if necessary. 3.0L Engine

REMOVAL & INSTALLATION

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

2. Drain the engine oil. 2.0L Engine

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

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

9308TG18

Tighten the oil pan bolts in sequence-2.0L engine

.

3. Remove or disconnect the following: e Negative battery cable e Flexible exhaust pipe ¢ Downstream catalyst monitor sensor ¢ Oil pan and gasket

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a

Se

aE aS Se

_FORD/MAZDA ESCAPE ¢ TRIBUTE

ae

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9-13

4. Thoroughly clean the gasket mating Surfaces. Jo install: 5. Apply silicone sealer to the oil pan. 6. Install or connect the following: e New gasket on the oil pan ¢ Qil pan. Torque the bolts in sequence to 18 ft. Ibs. (25 Nm). e Flexible exhaust pipe ¢ Downstream catalyst monitor sen-

Sor e Negative battery cable 7. Fill the engine with clean oil. 8. Start the vehicle and check for leaks, repair if necessary.

9308TG19

Remove the oil pump bolts in the proper sequence-3.0L engine

OS LOR’

REMOVAL & INSTALLATION 2.0L Engine _ 1. Before servicing the vehicle, referto the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Oil pan e Oil pump screen cover and tube e Qil pump and discard the gasket 4. Thoroughly clean the gasket mating surfaces. To install: 5. Install or connect the following: e Qil pump Screen cover and tube with a new gasket. Torque the bolts to 89 inch Ibs. (10 Nm). e Qil pump to the oil pan e Oil pan e Negative battery cable 6. Refill the engine with clean oil. 7. Start the engine and check for leaks; repair if necessary.

9308TG20

Install the oil pump bolts in the proper sequence-3.0L engine

4. Thoroughly clean the gasket mating surfaces. To install: 5. Install or connect the following: e Oil pump and bolts in the proper sequence. Torque the bolts to 89 inch lbs. (10 Nm). e Crankshaft sprockets e Oil pump screen cover and tube e Timing drive components e Negative battery cable 6. Refill the engine with clean oil. 7. Start the engine and check for leaks; repair if necessary.

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Timing drive components e Oil pump screen cover and tube ¢ Damper bolt and crankshaft sprockets e Oil pump bolts in the proper sequence

Rear Main Seal

REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions inthe beginning of this section. 2. Remove or disconnect the following: e Negative battery cable

e Flywheel e Rear main seal To install: 3. Coat the oil seal with clean engine 0)il, 4. Install or connect the following: e Crankshaft rear oil seal e Flywheel e Negative battery cable 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Flexplate e Rear main oil seal To install: 3. Coat the oil seal with clean engine Ol

4. Install or connect the following: e Crankshaft rear oil seal e Flywheel e Negative battery cable

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

9-14

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FORD/MAZDA

Cal He

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ESCAPE ¢ TRIBUTE

Timing Gears, Front Cover and Seal

REMOVAL & INSTALLATION 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Engine front cover e Ignition pulse wheel and install a damper bolt e Spark plugs 3. Rotate the crankshaft clockwise to position the keyway at the 11 o'clock position and the camshafts in the correct positions. The No. 1 cylinder will be at Top Dead Center (TDC). 4. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the right side camshafts in the neutral position. 5. Remove or disconnect the following: e Right side timing chain and tensioner e Tensioner arm and timing chain uide 6. Rotate the crankshaft clockwise 2 times to position the keyway at the 11 o'clock position. This will position the left side camshafts in the neutral position. 7. Verify that the left side crankshafts are in the neutral position and mark the link position on the crankshaft sprocket. 8. Remove or disconnect the following: e Left side timing chain and tensioner

e Tensioner arm and timing chain guide e Damper bolt and crankshaft sprockets To install: 9. Install the crankshaft sprockets. 10. Position the timing chain tensioner in a soft jaw vise. Hold the ratchet lock mechainsm away from the ratchet stem and Slowly compress the timing chain tensioner 11. If the timing marks on the chain are not visible, use a permanent marker to mark the left and right side timing chains. Mark the timing chains in the following sequence: a. Mark any link to use as the crankshaft timing mark. b. Count 29 links from the crankshaft timing mark and mark the link as the exhaust cam sprocket timing mark. c. Continue counting to 42 and mark the link as the intake sprocket timing mark 12. Install the guide. Torque the bolts to 18 ft. Ibs. (25 Nm). 13. Install the left side timing chain and align the chain in the following sequence: a. Mark any link to use as the crankshaft timing mark. b. Count 29 links from the crankshaft timing mark and mark the link as the exhaust cam sprocket timing mark. c. Continue counting to 42 and mark the link as the intake sprocket timing mark 14. Install or connect the following: ¢ Left side timing chain and tensioner arm. Torque the bolts to 18 ft. Ibs. (25 Nm). e Crankshaft damper bolt and rotate the keyway to the 3 o'clock position

15. Verify that the right side camshafts are properly positioned and install the right side timing chain and guide. Torque the bolts to 18 ft. Ibs. (25 Nm). 16. Make certain that the timing chain aligns with the marks on the camshaft and crankshaft sprockets

ok CAUTION Install the pulse wheel with the key~ way in the slot stamped 20-25-34Y-30M (Color Blur). 17. Install or connect the following: Right side timing chain tensioner and arm. Torque the bolts to 18 ft. lbs. (25 Nm) and remove the damper bolt Ignition pulse wheel Spark plugs Engine front cover Negative battery cable

Piston and Ring

POSITIONING

9308TG24 9308TG21

Mark the timing chain in the proper sequence-3.0L engine

2.0L engine piston and connecting rod positioning ring end-gap spacing

FORD/MAZDA ESCAPE ¢ TRIBUTE

9-15

9308TG25

9308TG26

2.0L (VIN B) engine —piston ring end-gap spacing

3.0L (VIN 1) engine—piston ring end-gap spacing

i

Fuel System Service Precautions ~ Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and’ repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. 1. To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. _ 2. Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. 3. Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. 4. Always keep a dry chemical (Class B) fire extinguisher near the work area. 5. Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.

6. Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. 7. Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed. Before servicing the vehicle, make sure to refer to the precautions in the beginning of this section as well.

Fuel System Pressure RELIEVING 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Remove the fuel pump relay and start the engine. 4. After the engine stalls, crank the engine 2 more times to be certain that all fuel pressure has been relieved. 5. Turn the ignition switch to the OFFposition. 6. Install the fuel pump relay. 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Remove the schrader valve cap at the end of the fuel injection supply manifold and attach a fuel pressure gauge.

4. Open the manual valve slowly and drain the fuel into a suitable container. 5. Continue draining the fuel system to relieve fuel pressure.

Fuel Filter

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSUTe. 3. Remove or disconnect the following: e Negative battery cable e Fuel line to the fuel filter 4. Loosen the clamp and remove the filter To install: 5. Install or connect the following: e New clips to the fuel lines e Fuel filter and tighten the clamp e Fuel lines to the fuel filter e Negative battery cable 6. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure.

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

. a

GPG fonman

|

ESCAPE ¢ TRIBUTE

3. Remove or disconnect the following: e Negative battery cable e Gas cap to relieve any additional fuel pressure e Left rear seat cushion and lift the

access cover on the scuff plate

e Pin type retainers and move the carpet aside

hee ie tug) pump medie i e Fuel pump module electrical con nectors

¢ Fuel and vapor lines from the fuel

tank

' Fuel pump P module and discard the e sina eo ‘

.

f

° Retaining clips and gently twist the fuel injector out of the manifold 4. Check the O-rings and replace if damaged. yeae wviirg omits

5. Start the engine and check for leaks, repair if necessary.

Fuel Injectors

eee

JUN Beigre Servieln g the vehicle, refer to , the precautions in the beginning of this section. 9. Release the fuel system pressure. ine folloue di 3 R

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é Negative

-

. Install or

REMOVAL & INSTALLATION

eee

e cable ) ak pee battery e Fuel injection supply manifold

4

° iesee me new bos ubricated with clean engine oll r into the suoply mani‘ pPly an areas Te clips when the fuel Lite i Retaining inje tors are seated properly —

° Fuel injection supply manifold

Negative battery cable

6. Start the vehicle and check for leaks, repair if necessary.

To install: 4. Install or connect the following: e New fuel pump module gasket

¢ Fuel pump module. Torque the

module to 60 ft. Ibs. (81 Nm).

e Fuel and vapor lines to the fuel i i

tank e Fuel pump module electrical connectors e Fuel pump module access cover and tighten the screws securely e Pin type retainers and reposition the carpet Left rear seat cushion e Gas cap Negative battery cable

9308TG22

Remove the fuel injectors from the fuel supply manifold-—2.0L engine

DRIVE TRAIN Wire harness from the rear harness

gt Manual Transmission 1. Before servicing the vehicle, reter to the

bracket e Park Neutral Position (PNP) electrical connector e Rear wire harness bracket and move it aside ° Vehicle Speed Sensor (VSS) elec-

precautions in the beginning ofHid this section. 50 Diain'thaiPnernlssion 3, Remove or disconnect the following: « Battery cables » Battery and tray

Oh e ipa ClutchCONG slave cylinder line from the bracket and move it aside while properly supporting the engine ¢ Left side transmission support

REMOVAL & INSTALLATION

* Mass Air Flow (MAF) sensor elec-

We Be

c UP » ©

Haat ope hceleraton cable mont em acancasti sans bniect eee management tube and Chitinace Menta atin ritaaeGaia Waite Air cleaner housing Back-up lamp switch electrical connector

+ Front wite Narteselbeanienenrs Toueltasits

» Front wire harness bracket spacer

insulator and bracket e Rear transmission support insulator e Front transmission support insulaieaneae es e and move it aside ¢ Top transmission flywheel housing bolts eo + Front transmission flywheel housing bolts rake e Transfer case, if equipped e Left side halfshaft

¢ Rear transmission support insulator bracket

e

e Shifter linkage and stabilizer bar Transverse crossmember

Front to aft crossmeber

e Left side splash shield and properly support the transmission e Remaining transmission flywheel housing bolts ¢ Transmission and separate the right Side halfshaft from the transmisAS 7 To install: ' 4. Align the right side half shaft to the transmission and position the transmission to the engine.

5. Install or connect the following: e Transmission flywheel housing: bolts. Torque the bolts to 33 ft. Ibs. (45 Nm) and remove the transmission support e Left Sfie gash shield e Front-to-aft crossmember. Torque the bolts to 66 ft. Ibs. (90 Nm). e Transverse crossmember. Torque the bolts to 85 ft. Ibs. (115 Nm). ¢ Shifter linkage. Torque the bolt to

15 ft. Ibs. (20 Nm). e Stabilizer bar. Torque the bolt to 30

ft. Ibs. (40 Nm).

Rear transmission support bracket.

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Torque the bolts to 66 ft. Ibs. (90 Nm). Left side halfshaft Transfer case, if equipped Front transmission flywheel housing bolts. Torque the bolts to 33 ft. lbs. (45 Nm), Top transmission flywheel housing bolts. Torque the bolts to 33 ft. Ibs. (45 Nm). Starter. Torque the bolts to 33 ft. lbs. (45 Nm). Front transmission support insulator and bracket. Torque the lower bolt to 66 ft. Ibs. (90 Nm) and the 3 upper bolts to 41 ft. Ibs. (565 Nm). Rear transmission support insulator bolt. Torque the bolt to 66 ft. Ibs. (90 Nm). Left side transmission support insulator bracket. Torque the bolts to 66 ft. Ibs. (90 Nm). Left side transmission support insulator. Torque the large bolt to 66 ft.

Ibs. (90 Nm) and the 3 remaining bolts to 41 ft,Ibs. (55 Nm). Clutch slave cylinder. Torque the bolt to 15 ft. Ibs. (20 Nm). Clutch slave cylinder line to the bracket and install the retaining clip VSS electrical connector Rear wire harness bracket. Torque the bolts to 80 inch Ibs. (9 Nm). PNP switch electrical connector Wire harness to the rear bracket Front wire harness bracket spacer and bracket. Torque the bolt to 9 ft. lbs. (12 Nm). Back-up lamp switch electrical connector Air cleaner housing MAF sensor electrical connector Air cleaner outlet tube Crankcase ventilation hose Emission management tube and hose Accelerator cable to the air cleaner outlet tube Battery and tray Both battery cables 6. Fill the transmission to the proper level.

if Start the vehicle and check for leaks, repair if necessary. Automatic Transmission

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

_— FORD/MAZDA Q.4

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le

2. Remove or disconnect the following: Battery cables Battery and tray Breather tube Mass Air Flow (MAF) sensor Intake tube and air cleaner cover Air cleaner assembly Transmission Range (TR) sensor Heated Oxygen (H02S) sensors

Fluid cooler tube. Torque the bolt to 17 ft. Ibs. (23 Nm). OSS sensor TSS sensor Flexplate nuts. Torque the nuts to 27 ft. Ibs. (36 Nm). Access cover Cross brace. Torque the bolts to 96 ft. Ibs. (130 Nm). Transmission bracket. Torque the bolts to 30 ft. Ibs. (40 Nm). PTU vent tube Driveshaft. Torque the bolts to 15 ft. Ibs. (20 Nm). Exhaust pipe and flange. Torque the bolts to 21 ft. Ibs. (29 Nm). Exhaust pipe and rubber hanger. Torque the bolts to 21 ft. Ibs. (29 Nm). Left side halfshaft assembly Right side halfshaft and intermediate shaft assembly by aligning the matchmarks Splash shields Both front wheels and lower the

Transmission harness connector and bracket Wire harness bracket spacer and move the bracket aside Shift cable Shift cable bracket and move the bracket aside Starter electrical connectors e Starter Electrical connectors from the valve cover and install an engine support bar 4 Upper transmission retaining bolts

Left side upper transmission mounting plate Rear transmission mount Right side engine mount bolt and Slightly raise the engine Both front wheels and splash shields Right side halfshaft and intermediate shaft assembly after matchmarking them Cross brace Center exhaust pipe and rubber hanger Front exhaust pipe and flange Rear exhaust pipe flange Driveshaft PTU vent tube Lower transmission bracket Access cover Flexplate nuts Output Shaft Speed (OSS) sensor Turbine Shaft Speed (TSS) sensor Fluid cooler tube and move it aside Fluid cooler line and install a transmission jack ° Bolts from the PTU unit Transmission with the PTU unit attached

engine on to the right side engine mount Right side engine mount bolt.

Torque the bolt to 89 ft. Ibs. (120 Nm).

To install:

3. Install or connect the following: Transmission with the PTU unit. Torque the engine-to-transmission mounting bolts to 30 ft. Ibs. (40 Nm). Fluid cooler line. Torque the fastener to 17 ft. Ibs. (23 Nm) and remove the transmission jack.

EI

6 0. 0, NO. © o''\

Rear transmission mount. Torque the upper bolt to 89 ft. Ibs. (120 Nm) and the lower bolts to 35 ft. lbs. (45 Nm). Transmission mount assemble. Torque the bolts to 30 ft. Ibs. (40 Nm) and remove the engine support bar. Electrical connectors to the valve cover Starter. Torque the bolts to 20 ft. lbs. (27 Nm). Starter electrical connectors Shifter cable and bracket. Torque the bolt to 14 ft. Ibs. (19 Nm) and connect the shifter cable. Wire harness and install the harness bracket spacer Wire harness bracket. Torque the bolt to 89 inch Ibs. (10 Nm). H02S sensor TR sensor and make certain it is properly aligned Air cleaner assembly Intake tube and air cleaner cover Breather tube MAF sensor Battery tray Battery and cables

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

9-18 ~FORD/MAZDA _ ESCAPE ¢ TRIBUTE

4. to the 5. repair

Fill the transmission with clean fluid proper level. Start the vehicle and check for leaks, if necessary

9. Check the transmission fluid level and top off if necessary.

Hydraulic Clutch System BLEEDING

ADJUSTMENTS The clutch is hydraulically driven and therefore no adjustment is required.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable

e Transmission and lock the flywheel to the engine with special tool 303-103 e Pressure plate bolts by loosening them evenly e Clutch pressure plate and disc 3. Clean the pressure plate and inspect it for burn marks, scores, flatness or ridges, replace if damaged. 4. Inspect the pressure plate diaphragm finger for wear, replace if damaged. 5. Measure the depth of the rivet heads. Minimum depth is 0.012 inch (0.3mm). 6. Inspect the clutch disc for signs of wear and replace if needed. 7. Check the clutch disc runout. Replace the disc if not with specification: 0.027 inch (0.7mm). To install: 8. Install or connect the following: e Clutch disc to the flywheel e Pressure plate to the flywheel. Torque the bolts in sequence to 21 ft. Ibs. (29 Nm). e Transmission e Negative battery cable

The following procedure is recommended for bleeding the clutch hydraulic system installed on the vehicle. It is recommended that the original clutch tube, with quickconnect fitting be replaced when servicing the hydraulic system, because air can be trapped in the quick-connect fitting and prevent complete bleeding of the system. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Clean the dirt and grease from the dust cap. 3. Remove the cap and diaphragm and fill the reservoir 9 of the way with approved brake fluid C6AZ-19542-AB or DOT 3 equivalent fluid (ESA-M6C25-A). 4. Loosen the bleeder screw cover from the slave cylinder and attach a hose to the screw. 5. Place the hose in a container and slowly pump the clutch pedal several times. 6. With the clutch pedal depressed, loosen the bleeder screw to release the fluid and air. 7. Remove the hose and tighten the

bleeder screw. 8. Repeat this procedure until all the air is removed from the hydraulic system.

2.. Place the transmission in the NEUTRAL position. 3. Remove or disconnect the following: Negative battery cable Driveshaft Intermediate shaft Exhaust crossover pipe Right side exhaust manifold Heat shield Lower bracket Crossmember brace Transfer case bolts and vent tube Transfer case To install: 4. Install or connect the following: Transfer case with a new driven gear seal. Torque the bolts to 33 ft. lbs. (45 Nm). Transver case vent tube Crossmember brace. Torque the bolts to 30 ft. Ibs. (40 Nm). Lower bracket. Torque the bolts to 30 ft. Ibs. (40 Nm). Exhaust manifold Heat shield. Torque the bolts to 10 ft. Ibs. (14 Nm). Exhaust crossover pipe Intermediate shaft Driveshaft Negative battery cable 5. Check the transfer case fluid level and top off if necessary. 6. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION REMOVAL & INSTALLATION 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the transmission in the PARK position. 3. Remove or disconnect the following: Negative battery cable Front wheel Front brake disc

Front axle wheel hub nut and dis-

9308TGO7A

Torque the pressure plate bolts in the proper sequence

card the nut Tie rod end and separate the lower ball from the steering knuckle Halfshaft from the steering knuckle e Halfshatt To install: 4. When seated properly, the halfshaft bearing retainer circlip will snap into the differential side gear groove. 5. Position the halfshaft and joint so that the splines align with differential side gear splines. Push the halfshaft into side gear.

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:

6. Install or connect the following: e Halfshaft into the steering knuckle . © Lower ball joint to steering knuckle. Torque the pinch bolt to 52 ft. Ibs. (70 Nm). e Tie rod end. Torque the nut to 41 ft. lbs. (55 Nm). e New front axle wheel hub nut. Torque the nut to 214 ft. Ibs. (290 Nm). e Front brake disc Front wheel Negative battery cable 7. Check the fluid level and adjust as needed. CV-Joints

OVERHAUL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Halfshaft and secure it in a softjawed vise e Inboard halfshaft boot clamp e Boot from the inboard CV-joint housing

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Pe

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ae

¢ Tripod joint from the CV-joint housing and matchmark the tripod joint to the halfshaft e Snapring and boot from the halfshaft ¢ Outboard halfshaft boot clamps ¢ Outboard boot back to expose the CV-joint and matchmark the joint to the halfshaft ¢ Outboard CV-joint from the halfshaft Halfshaft retainer circlip and discard it ¢ Boot from the halfshaft To install: 3. Install or connect the following: Outboard CV-joint and boot New halfshaft bearing circlip Inboard C\V-joint to the halfshaft Outboard halfshaft boot forward on to the ourtboard CV-joint New outboard halfshaft boot clamps e Inboard halfshaft boot Tripod joint on the halfshaft by aligning the matchmarks New snapring to the tripod joint and lubricate the needle bearings while filling the housing with C\Vjoint grease, E43Z-19590-A Inboard halfshaft boot with new clamps

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e Halfshaft e Negative battery cable

Axle Housing

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Rotary blade coupling Rear halfshafts Axle assembly-to-front bracket bolts e Rear axle-to-side bracket bolts e Axle assembly To install: 3. Install or connect the following: e Axle assembly e Rear axle-to-side-bearing bolts. Torque the bolts to 59 ft. Ibs. (80 Nim). e Axle assembly-to-front bracket bolts. Torque the bolts to 59 ft. Ibs. (80 Nm). e Rotary blade coupling e Negative battery cable

STEERING AND SUSPENSION

Some vehicles are equipped with an air bag system. The system MUST BE disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.

wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands and ensure that the bag and trim cover are pointed away. 3. Place the inflator module on a bench or other surface with the bag and trim cover facing up. 4. With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment.

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury: 1. Never carry the inflator module by the

The positive battery cable must be disconnected for a minimum of 1 minute before beginning any air bag work to deenergize the back-up power supply. It is a good idea to disengage both the positive and negative battery cables to ensure that the Air Bag system is definitely discharged.

ARMING THE SYSTEM

DISARMING

i CAUTION

PRECAUTIONS

the air bag, resulting in unnecessary SIR system repairs and/or personal injury.

The Supplemental Inflatable Restraint (SIR) system must be disarmed before performing service around SIR system components or SIR system wiring. Failure to do so may cause accidental deployment of

If the air bag simulators have been used, the air bag simulators must be removed and the air bags recon-

nected when the system is reactivated to avoid non-deployment ina collision resulting in possible personal injury.

For Wheel Alignment specifications, see Section 7 of this manual

3

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9-20 Scares ratoure

1. Disconnect the positive battery cable. 2. Wait 1 minute, this is required for the back-up power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the air bag sliding contact connector at the top of the steering column. Reconnect the driver's side air bag module assembly. Position the driver's air bag module on the steering wheel and secure with the 2 bolts and washers. Tighten the bolt and washer assembly to 8-10 ft. Ibs. (10-14 Nm). 4. Connect the positive battery cable. 5. Turn the ignition switch from the OFF to RUN and visually monitor the air bag warning indicator. The light will illuminate continuously for approximately 6 seconds and then turn off. If a fault occurs, the air bag indicator will either fail to light, remain lighted continuously or flash. The flashing may not occur until approximately 30 seconds after the ignition switch has been turned from OFF to RUN. This is the time needed for the air bag diagnostic monitor to complete testing the system. If the air bag indicator is inoperative, an air bag system fault exists, a tone will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be serviced before further diagnostics can be done.

Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the steering wheel in the straight-ahead position. Lock the steering wheel in place, using a steering wheel holder. e>Locking the steering wheel keeps the clockspring in alignment position.

3. Drain the power steering fluid. 4. Remove or disconnect the following: Negative battery cable Rear transmission insulator Rear transmission insulator bracket, if equipped with an automatic transmission Both front wheels Rear transmission insulator bracket, if equipped with a manual transmission Tie rod end cotter pin and nut Tie rod end from the steering knuckle and record the number of turns required to remove the tie rod end

e Antilock Brake System (ABS) harness from the strut assembly and move the brake hose bracket aside Stabilizer bar link nut and move the bar aside Strut to steering knuckle bolts and

e Steering gear coupling pinch bolt e Power steering pressure and return

lines and bracket Steering gear mounting bolts e Steering gear and separate the steering coupling from the steering gear shaft Steering gear To install: 5 Slide the steering gear rearward to connect the steering coupling to the steering gear shaft 6. Install or connect the following: Steering gear mounting bolts. Torque the bolts to 93 ft. Ibs. (126 Nm). Pressure and return lines and bracket. Torque the bracket bolts to 89 inch Ibs. (10 Nm). Power steering pressure and return lines to the steering gear. Torque the bolt to 18 ft. Ibs. (25 Nm). Steering gear pinch bolt and reposition the boot. Torque the bolt to 18 ft. Ibs. (25 Nm). Tie rod end to the tie rod using the number of turns required to remove the tie rod end Jam nuts. Torque the nuts to 35 ft. lbs. (47 Nm). Tie rod end to the steering knuckle. Torque the nut to 41 ft. Ibs. (57 Nm) and install a new cotter pin Rear transmission insulator bracket. Torque the bolts to 66 ft. lbs. (90 Nm). Both front wheels Rear transmission insulator bracket. Torque the bolts to 66 ft. lbs. (90 Nm). Rear transmission insulator. Torque

the bolts to 66 ft. Ibs. (90 Nm). Negative battery cable 7. Fill and bleed the power steering system.

8. Start the vehicle and check for leaks, repair if necessary. 9. Check and adjust the front end alignment.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install or connect the following: ¢ Negative battery cable ¢ Front wheel e Brake hose grommet from the bracket

support the strut assembly Upper strut nuts Strut and coil spring assembly To install: 3. Install or connect the following: Strut and spring assembly. Torque

the upper nuts to 59 ft. Ibs. (80 Nm). Lower strut assembly to the steering knuckle. Torque the lower bolts to 85 ft. Ibs. (115 Nm). Stabilizer bar into position. Torque the bolts to 35 ft. Ibs. (48 Nm). Brake hose bracket. Torque the bolts to 14 ft. Ibs. (18 Nm). ABS harness to the strut assembly, if equipped Brake hose grommet to the bracket e Front wheel Negative battery cable

Shock Absorber

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear quarter trim panel ¢ Upper shock absorber nut and raise the vehicle enough to relax the suspension ¢ Lower shock absorber nut. e Shock absorber To install: 3. Install or connect the following: ¢ Shock absorber. Torque the lower nut to 85 ft. Ibs. (115 Nm). ¢ Upper shock absorber nut. Torque the nut to 13 ft. Ibs. (18 Nm). ¢ Rear quarter trim panel e Negative battery cable

Coil Spring REMOVAL & INSTALLATION nS

Front

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

FORD/MAZDA ESCAPE ¢ TRIBUTE

—

Inside upper and lower arm bolts. Torque the bolts to 85 ft. Ibs. (115 Nm). ABS sensor bracket, if equipped. Torque the bolts to 80 inch Ibs. (9 Nm). Brake line bracket. Torque the bolt to 15 ft. Ibs. (20 Nm). Brake line to the wheel cylinder. Torque the fastener to 11 ft. Ibs. (15 Nm) and remove the lug nut Wheel Negative battery cable

Metal sheet plate Upper strut mount Thrust bearing plate

Thrust bearing Upper spring seat Upper spring seat isolator

Spring Dust boot WwW -& oa on N o

Rubber bump stopper

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Lower spring seat

9-21

Upper Control Arm

REMOVAL & INSTALLATION

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Disassemble the strut assembly in the proper sequence

2. Install or connect the following: e Negative battery cable e Front wheel e Strut and spring assembly and mount the strut assembly in a holding fixture and compress the coil spring using a suitable tool e Strut piston rod nut 3. Coil spring by disassembling the strut in the following sequence: a. Step 1: Metal sheet plate. b. Step 2: Upper strut mount. c. Step 3: Thrust bearing plate. d. Step 4: Thrust bearing. e. Step 5: Upper spring seat. if Step 6: Upper spring seat isolator. g. Step 7: Coil spring. h. Step 8: Dust boot. i Step 9: Rubber bump stopper. j. Step 10: Lower spring seat.

To install:

4 Assemble the strut assembly in the

reverse order of the removal procedure 5. Install or connect the following: e Strut piston rod nut. Torque the nut to 76 ft. Ibs. (103 Nm) and remove

the assembly from the holding fixture e Strut and spring assembly ° Front wheel e Negative battery cable Rear 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Wheel and install 1 lug nut to retain the brake drum Brake line from the wheel cylinder Brake line bracket Bolts from the Antilock Braking System (ABS) sensor bracket and move the sensor aside, if equipped Rear knuckle and loosen the inside upper and lower arm bolts

e Shock absorber lower nut © Spring

To install:

3. Install or connect the following: : Spring to the shock absorber Lower shock absorber nut. Torque the nut to 85 ft. Ibs. (115 Nm).

The upper and lower ball joints are an integral part of the control arms and are not a serviceable components. Replacement of the ball joint requires replacing the appropriate control arm. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable e Rear wheel Upper control arm from the knuckle while holding the ball joint stud from turning Upper ball joint nut Upper control arm Upper control arm inner bolt To install: 3. Install or connect the following: Upper control arm inner bolt Upper contro! arm. Torque the bolts to 85 ft. Ibs. (115 Nm). Upper ball joint nut Upper control arm to the knuckle. Torque the ball joint nut to 86 ft. lbs. (115 Nm). Rear wheel Negative battery cable

Lower Control Arm

REMOVAL & INSTALLATION Front

1. Remove or disconnect the following: e Negative battery cable e Front wheel e Lower ball joint from the knuckle and support the subframe e Lower control arm

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To install: 2. Install or connect the following: e Lower control arm bolts and hand tighten them e Pich bolt to the wheel knuckle. Torque the nut to 52 ft. Ibs. (70 Nm) and remove the subframe support e Front wheel and jounce the vehicle 3. Torque the inner lower control arm bolt to 148 ft. Ibs. (200 Nm) and outer bolt

89 ft. Ibs. (115 Nm). Rear

1. Remove or disconnect the following: Negative battery cable Front wheel Lower ball joint from the knuckle while holding the ball joint stud from moving Lower ball joint nut Lower control arm Lower control arm inner bolt To install: 2. Install or connect the following: Lower control arm inner bolt Lower control arm. Torque the bolts

nut

Rear

the ball joint nut to 85 ft. Ibs. (115 Nm). Rear wheel

2WD VEHICLES

REMOVAL & INSTALLATION Front

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

2. Remove or disconnect the following:

e Negative battery cable Front wheel Brake disc

Wheel hub nut Tie rod end cotter pin and nut Tie rod end from the knuckle Antilock Brake System (ABS) sensor bolt and move the sensor aside, if equipped Lower ball joint from the knuckle Halfshaft from the knuckle and properly support the halfshaft Steering knuckle 3. Press the hub from the wheel bearing and knuckle

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

2. Remove or disconnect the following: Negative battery cable Rear wheel Rear brake drum Wheel hub nut Wheel hub Inner wheel bearing race from the hub Snapring Wheel bearing outer race from the knuckle

To install: 3. Install or connect the following: ¢ Wheel bearing in to the knuckle

Snapring Wheel hub into the wheel bearing Wheel hub nut. Torque the nut to 214 ft. Ibs. (290 Nm). Brake drum Rear wheel Negative battery cable

4WD VEHICLES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

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Wheel hub. Torque the nut to 214 ft. Ibs. (290 Nm). Brake disc Front wheel Negative battery cable

Lower ball joint nut Lower ball joint the knuckle. Torque

Wheel Bearings

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4. Press the inner wheel bearing race from the knuckle and remove the snapring 5. Press the outer wheel bearing race from the knuckle To install: 6. Install or connect the following: Wheel bearing into the steering knuckle e Snapring e Wheel hub into the wheel bearing by using a press Steering knuckle. Torque the bolts to 85 ft. Ibs. (115 Nm). Halfshaft into the wheel hub Pinch bolt to knuckle. Torque the nut to 52 ft. Ibs. (70 Nm). Ball joint stud into the knuckle ABS sensor. Torque the bolt to 80 inch Ibs. (9 Nm), if equipped Tie rod end to the knuckle. Torque the nut to 41 ft. Ibs. (565 Nm). New cotter pin to the tie rod end

to 85 ft. Ibs. (115 Nm).

Negative battery cable

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2. Remove or disconnect the following: ¢ Negative battery cable e Rear wheel e Rear brake shoes e Rear halfshaft nut and loosen the halfshaft from the hub Wheel hub and place it in a vise Inner wheel bearing race from the hub e Antilock Brake System (ABS) sensor bracket and move the sensor aside, if equipped Parking brake cable from the steering knuckle Brake line from the wheel cylinder ° and support the knuckle Lower shock absorber nut Lower ball joint by holding the ball joint stud Upper ball joint Coil spring while noting the location of the insulator Steering knuckle cam Steering knuckle Snapring and press out the outer wheel bearing race from the knuckle To install: 3. Install or connect the following: New wheel bearing into the steering knuckle Snapring to the knuckle Wheel hub Steering knuckle cam and hand tighten the bolt Coil spring Shock absorber lower nut. Torque the nut to 85 ft. Ibs. (115 Nm). Upper ball joint. Torque the nut to 85 ft. Ibs. (115 Nm). Lower ball joint. Torque the nut to 85 ft. Ibs. (115 Nm). Align the Steering knuckle cam and torque the bolt to 85 ft. Ibs. (115 Nm). Brake line to the wheel cylinder. Torque the brake line bracket bolt

to 15 ft. Ibs. (20 Nm) and the brake line fastener to 11 ft. Ibs. (15 Nm) © Parking brake cable to the backing

plate. Torque the bolt to 16 ft. Ibs. (22 Nm). ABS sensor bracket. Torque the bolt to 80 inch Ibs. (9 Nm), if equipped Halfshaft nut. Torque the nut to 214 ft. Ibs. (290 Nm). Brake shoes Rear wheel Negative battery cable 4. Fill and bleed the brake system. 9. Check and adjust the wheel alignment as needed.

|

FORD MOTOR CO. 1998-02

Ford-Explorer * Explorer Sport * Explorer Sport Trac * Mercury-Mountaineer DRIVE TRAIN.................. 10-27 ENGINE REPAIR ................ 10-2 FUEL SYSTEM ................ 10-26 PRECAUTIONS.................. 10-2 STEERING AND SUSPENSION er i 10-38

Fuel Imjechors eitiasioumletoct itieul 10-26

Power Rack and Pinion

Removal & Installation............ 10-26

Steering Gear...

FuelsPurnipeiendc Reade ah ae 10-26

Removal & Hag Lk

Removal & Installation............ 10-26

nbd eeerece ere 10-38 Arming The System ............... 10-38 Disarming The System............ 10-38

HaliSndic ct cette 10-33 Removal & Installation............ 10-33

Rear Axle Shaft, Bearing and Seal ............ Removal & Installation Rear Main Seal ............... Removal & Installation

Hydraulic Clutch System ............. 10-30

Rear Wheel Bearings........

PGC AUH Of Sarveacuwetlstvotnt. neni 10-38

BIRC GUNG sissshcapdey ciara 10-30

ILGING[0]fo

Fuel System Service Precautions........... ice Saar 10-26

nw ar aee eer eae 10-2

Removal & nae es ela atl 10-2

ETUIELOhssl HTNING msccaredead eee,deen made 10-3 AGiUSHM@M tess.isrccbieet Hiraelets ten, 10-3

Camshaft and Valve-Lifters .......... 10-17 Removal & Installation............ 10-17 Churches see Be.” 0 10-29 ACUStMentos: Soria 00810-30 Removal & Installation............ 10-29

Intake Manifold... cee 10-11 Removal & Installation............ 10-11

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wera ater iiecete 10-40

Removal & Installation............ 10-40 ON eee Rete cat nat ser asianen10-34 Ovepthaliacates awetes a se Sy 10-34

CVIMACE BAC gis. cilid boxtotie akds10-6 Removal & Bala ese art 10-6

Engine ASS@MDIY .............ccssesseee 10-3 Removal & Installation.............. 10-3 Exhaust Mantfold............ccceese. 10-15 Removal & ieee Tes 10-15

Front Axle Tube Bearing............... 10-35 Removal & Installation............ 10-35 Front Wheel Bearings ..............00. 10-41 TACT STARTER lacey Aa10-41 Removal & Installation............ 10-41 UIT)(citracastte glean Rape ene 10-26 Removal & Installation............ 10-26

heabbSpnings aasthisiiucue. to. iw. Removal & Installation............ Locking Hubs: 224 ste Dee whe Removal & Installation... LowerBait JoInt sc Bee Removal & Installation............ Lower Control APM uu... cece

10-40 10-40 10-35 10-35 10-40 10-40 10-40

Removal & Installation

Relieving Fuel System PReSSUNGRe Pet hlieeo. acs3 Rocker Arms/Roller Followers ....... Removal & ee

Timing Chain, Sprockets,

Lower Control Arm Bushing Replacement .......ccccssererseeee 10-41

Front Cover and Seal...... Removal & Installation TORSION Dal ce nae Removal & Installation Transfer Case Assembly... Removal & Installation

Removal & Se

Transmission Assembly...

sha Gace 10-40

Removal & ean OM Tale eraseects 10-19 Removal & Installation............ 10-19

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wih nea ene 10-21

Removal & atl Ran 10-21 Pinion Seal ...........0. AMS MU nas10-36 Removal & Installation............ 10-36 ISTOrenCr MMO soar teense ota 10-25

POST NOcaatash getcacameas 10-25

Upper Ball Joint............... Removal & Installation Upper Control Arm.......... Removal & Installation

Upper Control Arm Bushing Replacement............. W Water Pump Removal & Installation

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PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically: designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol

ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. ¢ The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as Soon as possible after expoSure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface: This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. Ifthe brake fluid ~ becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from ~ the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; itwill damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference,

ENGINE REPAIR Alternator

REMOVAL & INSTALLATION 4.0L OHV and 5.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Drive belt Electrical connectors from the alternator

A/C manifold and tube bracket e

aside, 5.0L engine only Wiring harness to alternator push pin Alternator

To install: 3. Install or connect the following: Alternator. Torque the bolts to 40 ft. Ibs. (55 Nm). Push pin for the alternator wiring harness A/C manifold and tube bracket, 5.0L engine only. Torque the bolt to 106 inch Ibs. (12 Nm). Electrical connectors to the alternator Drive belt Air cleaner outlet tube Negative battery cable

4.0L OHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Negative battery cable Air cleaner outlet tube Accessory drive belt Electrical connectors Wiring harness-to-generator pintype retainer Stud bolt, the bolts and the alternator

3. To install, reverse the removal procedure. Torque all mounting bolts to 35 ft. Ibs. (47Nm). 4.6L Engine

1. Before servicing the vehicle, refer to Hhprecautions in the beginning of this secion. 2. Remove or disconnect the following: e Negative battery cable e Drive belt ¢ Electrical connectors

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Ignition Timing

ADJUSTMENT

Fuel lines Power steering pressure and return hoses

Block heater, if equipped Engine ground cable Automatic transmission harness connectors, if equipped Heated Oxygen (HO2S) sensor, if equipped e Starter

The ignition timing is preset to 10 degrees Before Top Dead Center (BTDC) and is not adjustable.

Engine Assembly

REMOVAL & INSTALLATION 4.0L OHV Engines _ 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Properly discharge the A/C system. 6. Remove or disconnect the following: Both battery cables Mass Air Flow (MAF) sensor Air cleaner outlet tube Drive belt Accelerator control splash shield Upper and lower radiator hoses Fan guard/shroud Radiator overflow tube Radiator Transmission cooler lines, if equipped Heater hoses Alternator electrical connectors Vacuum reservoir connection Throttle body heater hose

A/C cycling switch Powertrain Control Module (PCM) connector

Ground wire from the PCM Power steering cut-out switch Peanut fitting from the A/C condenser core A/C high pressure cut-out switch A/C manifold hose Accelerator and speed control cables Brake booster vacuum hose and tube from the intake manifold Vacuum reservoir line

Catalytic converter Torque converter bolts, if equipped and properly support the transmission Differential pressure feedback sensor and support the engine with a floor crane Exhaust Gas Recirculation (EGR) transducer Upper transmission-to-engine bolts Engine from the vehicle Clutch/ flywheel, if equipped To install: 7. Install or connect the following: Flywheel. Torque the bolts to 64 ft. lbs. (87 Nm). Engine. Torque the mounting bolts to 85 ft. Ibs. (115 Nm). HO2S sensor Upper transmission-to-engine bolts. Torque the bolts to 38 ft. Ibs. (51 Nm). EGR transducer and remove the floor jack from the transmission Torque converter-to-engine bolts. Torque the bolts to 38 ft. Ibs. (51 Nm). Catalytic converter Transmission wiring harness connectors Engine ground cable. Torque the bolt to 106 inch Ibs. (12 Nm). Block heater, if equipped A/C high pressure cut out switch A/C manifold to the evaporator core Power steering cut-out switch Power steering pressure and return lines Engine sensor control wiring harness to the A/C compressor Fuel lines 42 pin connector Vacuum reservoir vacuum line Brake booster vacuum hose and tube Accelerator cable Ground strap. Torque the bolt to 106 inch Ibs. (12 Nm).

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e PCM ground strap. Torque the bolt to 106 inch Ibs. (12 Nm), e PCM wire harness bracket bolt. Torque the bolt to 61 inch Ibs. (7 Nm).

A/C low pressure cut-out switch Throttle body heater hose Fan clutch and water pump pulley. Torque the bolt 17 ft. Ibs. (23 Nm). Drive belt Alternator electrical connectors Inlet and outlet heater hoses Fuel charging wiring Radiator and fan shroud Transmission cooler lines, if equipped Upper, lower and overflow hoses to the radiator Accelerator control splash shield. Torque the bolts to 89 inch Ibs. 10 Nm). Drive belt Air cleaner outlet tube MAF sensor Both battery cables 8. Recharge the A/C system. 9. Fill the cooling system. 10. Fill the engine with clean oil. 11. Run the engine and check for leaks and proper operation. 12. Check and adjust the front end alignment. 4.0L OHC Engines

“kk CAUTION If the fuel supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold. Accelerator cable from engine Speed control cable from engine Radiator, the fan blade, and the fan shroud Accessory bracket bolts and position bracket aside Alternator wiring Wiring harness retainer and position generator wiring away from engine Engine electrical connector PCM connector PCM ground wire Engine ground wire Brake booster vacuum hose A/C high pressure switch electrical connector

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e Bolt and position the A/C lines aside ->Heater hose will be removed with

engine.

Heater hoses Fuel line Starter motor Engine oil Oil drain plug Transmission portion of wiring harness RH and LH heated oxygen sensor connectors Transmission control connector Output shaft speed sensor connector Digital transmission range sensor connector Catalyst monitor sensor electrical connector Transmission/transfer case portion of the wiring harness from any routing clips or pushpins. Route transmission/transfer case portion of the wiring harness to top of engine. Bolt, and position the transmission cooling line bracket aside A/C line bracket nut and position it aside Power steering return hose Power steering pressure hose Vapor management valve hose connector Eight bolts and the LH and the RH engine support insulator nuts >The lifting eyes should be installed on the exhaust manifold studs for number three and number four cylinders.

1. Install the lifting eyes. 2. Install the spreader bar to the lifting eyes. 3. Attach a floor crane to the spreader bar and remove the engine. 4. Installation is the reverse of removal. Observe the following torques: e Left and right engine insulator nuts: 81 ft. Ibs. (110 Nm) e Engine mount nuts: 59 ft. Ibs. (80Nm) e Transmission-to-engine bolts: 35 ft. Ibs. (47Nm) e Torque converter nuts: 35 ft. Ibs. (47Nm)

4.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. 3. 4. 5. 6.

Relieve the fuel system pressure. Drain the cooling system. Drain the engine oil. Properly discharge the A/C system. Remove or disconnect the following: Battery ground cable e Hood Accelerator cable from the throttle

body and all clips Speed control cable from the throttle body and all clips Air cleaner and the air cleaner out-

let pipe Radiator and transmission cooler A/C condenser core Access the heater control valve bracket through the wheel well.

Heater control valve bracket bolt Coolant hoses All vacuum hoses. Position the heater control valve assembly aside. A/C tubes from the A/C compressor Fuel charging wiring harness connections Fuel charging wiring harness from the clips on the bulkhead. Release the fuel charging wiring harness pin-type retainer. All connections from the evaporative emissions (EVAP) canister purge solenoid Brake booster vacuum hose

Fuel tube Alternator connections and the wiring anchors Wiring harness side of the left and right heated exhaust gas oxygen (HEGO) sensor connectors Power steering return hose. Plug the power steering reservoir. Power steering pressure tube from the power steering pump Brackets Oil pressure sender electrical connector CKP sensor electrical connector and the wiring anchor A/C compressor electrical connector and the wiring anchor Wiring harness routing clip and wiring anchor Starter On 4x4 vehicles, the bolt from the right side axle housing bushing bolt Right side and the left side stabilizer bar bracket nuts Left side lower axle housing bushing bolt

+ Left side upper axle housing bushing bolt e Right lower mount nut and washer e Left lower mount nut and washer e Transmission inspection cover, torque converter bolts and the transmission-to-engine block bolts 7. Install the right side Lifting Eye. 8. Install the left side Lifting Eye. 9. Install the Spreader Bar to the Lifting ~ Eyes. 10. Attach a floor crane to the Spreader Bar and remove the engine. e>lf engine disassembly is to be carried out, remove the rear crankshaft oil seal slinger and the crankshaft rear oil seal.

11. Installation is the reverse of removal. Observe the following torques: e Lower mount nuts: 59 ft. Ibs. (81Nm) Left side upper axle housing bushing bolt: 49 ft. Ibs. (66Nm) e Left side axle housing bushing bolt: 49 ft. Ibs. (66Nm) e Stabilizer bar bracket nuts: 30 ft. lbs. (40Nm) Right side axle housing bushing bolt: 49 ft. Ibs. (66Nm) 5.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Properly discharge the A/C system. 6. Remove or disconnect the following: Battery Drive belt Fan shroud Air cleaner outlet tube

A/C condenser core Upper radiator hose Power steering reservoir and move it aside 4 Power steering pump Spark plug wire bracket from the A/C compressor

A/C compressor and bracket Alternator Wide-open A/C cut-off switch electrical connector Vapor Management Valve (VMV) hose Lower steering column. shaft and move It aside Left and right hand side vacuum connections

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- Accelerator and speed control cables Accelerator cable bracket e Powertrain Control Module (PCM) connector

Transmission cooler lines to the

retainer by the right si mount eae st e Battery-to-starter relay cable ¢ Ground strap to the engine front

cover

¢ PCM ground connector

e Engine bulkhead connector

e Ground strap to the rear of the

¢ Transmission fill tube * Power steering cooler and move it

¢ Ground cable to the engine front cover

+ Ground cable from theengine front

* transmission fill tube

° Ground strap from the lower intake

° Engine bulkhead connector. Torque

° Transmission cooler lines from the retainer on the right engine mount © Starter

¢ PCM and body ground connectors. Torque the bolt to 89 inch Ibs. (10 Nm).

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4.0L OHV Engines 1. Before servicing the vehicle, refer to

the precautions in the beginning of this section, 2. Drain the cooling system.

3. Remove or disconnect the following: + Negative battery cable

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* Accelerator cable bracket. Torque

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* Lower radiator hose

cables,tothe clip

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assembly and move them aside

the upper bolts to 15 ft. Ibs. (20

* Water pump

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¢ Accelerator and speed control

° Torque converter nuts

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REMOVAL & INSTALLATION

° Heater hoses

° Transmission inspection cover

10-5

Water Pump

lower intake manifold

e Heater hoses

To install:

° to Transmission bulkhead connec¢ Brake booster vacuum supply line

sped control cables ¢ to Accelerator the throttleandlinkage ¢ Accelerator control shield. Torque

surfaces the matingto the Clean attaches engine.where the water4. pump 9. Install or connect the following:

e Low oil level sensor electrical connectar

e Left and right side vacuum connecAsns

106 in Ibs. (12 Nm). e A/C compressor mounting bracket.

e Oil bypass filter e Lower radiator hose el guchmeniolds

e Lower power steering column shaft. Torque the bolt to 40 ft. Ibs. (65 Nm).

Torque the bolts to 44 ft. Ibs. (61 Nm). e Water pump pulley. Torque the

at the left upper intake manifold

° Left and right side motor mounts

and install the lifting brackets to the

exhaust manifold studbolts on No. 1-No. 8 cylinders ¢ Engine from the vehicle ¢ Flywheel, if equipped

To install: 7. Install or connect the following: Flywheel. Torque the new bolts to 85 ft. Ibs. (115 Nm). Engine. Torque the motor mount bolts to 109 ft. Ibs. (148 Nm). Exhaust manifolds e Lower radiator hose e Oil bypass filter e Brake booster vacuum supply line to the left side upper intake connection e Transmission bulkhead connector e Left and right HO2S sensor connectors Transmission Torque converter bolts. Torque the bolts to 38 ft. Ibs. (51 Nm). Transmission inspection cover Starter

the bolt to 106 inch Ibs. (12 Nm).

* Water pump. Torque the bolts to

bolts to 20 ft. Ibs. (28 Nm).

« VMV hose

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* * * *

¢ Wide-open A/C cutoff switch electrical connector e Alternator and electrical connectors ¢ A/C compressor e Spark plug wire bracket. Torque the nut to 89 inch Ibs. (10 Nm). Power steering pump. Torque the bolts to 21 ft. Ibs. (29 Nm). Power steering reservoir. Torque the bolts to 106 inch Ibs. (12 Nm). e Upper radiator hose e Fan blade e Drive belt e A/C condenser core e Air cleaner outlet tube e Battery and cables 8. Recharge the A/C system. 9. Fill the cooling system. 10. Fill the engine with clean oil. 11. Run the engine and check for leaks and proper operation. 12. Check and adjust the front end alignment.

Heater hose Lower radiator hose Fan and shroud Air cleaner outlet tube

+ Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair if necessary.

4.0L OHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Fan shroud Accessory drive belt Idler pulley Water bypass hose Heater hose Lower radiator hose Water pump pulley Water pump

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WARNING Use care when scraping the water pump-to-engine block mating surfaces. Gouges in the aluminum could form leak paths. 4. Clean all the sealing surfaces. 5. To install, reverse the removal procedure. Torque the water pump bolts to 89 inch lbs. (10Nm). Torque the pulley bolts to 18 ft. Ibs. (25Nm). 4.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Engine cooling fan e Drive belt e Water pump pulley e Water pump 4. Discard the O-ring seal. 5. To install, reverse the removal procedure. Install a new O-ring seal and lubricate with engine coolant. 6. Torque the pump and pulley bolts to 18 ft. Ibs. (25Nm). 5.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Fan shroud Drive belt Water bypass hose Heater hose from the water pump Engine control sensor wiring and move it aside Water pump pulley Water pump from the engine front cover Water pump inlet hose e Water pump To install: 4. Clean the mounting surfaces of the pump and front cover thoroughly. Remove all traces of gasket material. 5. Install or connect the following: ° Apply adhesive gasket sealer to both sides of a new gasket and place the gasket on the pump. e Inlet hose to the water pump. Torque the clamps to 11 ft. Ibs. (15 Nm). e Water pump. Torque the bolts to 20 ft. Ibs. (28 Nm).

Water pump pulley. Torque the bolts to 20 ft. Ibs. (28 Nm). Engine control sensor wiring Heater hose Water bypass tube. Torque the clamps to 11 ft. Ibs. (15 Nm). e Dive belt e Fan shroud Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair if necessary.

Cylinder Head

REMOVAL & INSTALLATION 4.0L OHV Engine ->New cylinder head bolts must be used when installing the cylinder head on the 4.0L OHV engine.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure.

3. Evacuate the A/C system. 4. Drain the cooling system. 5. Drain the engine oil. 6. Remove or disconnect the following: Negative battery cable Drive belt Separate the A/C manifold tube from the A/C compressor A/C compressor electrical connectors A/C compressor mounting bracket and move it aside

e Alternator electrical connectors

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Heater hose and move it aside Alternator mounting bracket Lower intake manifold Both exhaust manifolds 7. Gradually loosen the rocker arm shafts and remove them. e Matchmark the position of the push rods and remove them e Cylinder head and gasket To install: To install: 8. Clean the mating surface where the cylinder head attaches to the engine. 9. Install a new cylinder head gasket and the cylinder head to the engine. 10. Torque the new cylinder head bolts in sequence, as follows: a. Step 1: 25 ft. Ibs. (34 Nm). b. Step 2: 53 ft. Ibs. (72 Nm). c. Step 3: Plus an additional 90 degrees. 11. Install or connect the following: Push rods Rocker arm shafts gradually. Torque the bolts to 24 ft Ibs. (33 Nm) plus an additional 90 degrees Exhaust manifolds Lower intake manifold Alternator bracket. Torque the bolts to 35 ft. Ibs. (47 Nm). Heater hose retaining clip Alternator electrical connectors A/C compressor mounting bracket. Torque the bolts to 35 ft. Ibs. (47 Nm). A/C compressor electrical connectors

9308EG04

Cylinder head bolt torque sequence 4.0L OHV engine

FORD MOTOR CO.

EXPLORER © EXPLORER SPORT ¢ EXPLORER SPORT TRAC ¢ MOUNTAINEER

¢ Camshaft holding tool T97T-6256C

e A/C manifold tube to the A/C compressor « ¢ Drive belt ¢ Negative battery cable 12. Fill the cooling system. 13. Fill the engine with clean oil. A filter replacement is also recommended. 14. Recharge the A/C system.

e Crankshaft holding tool T97T6303-A e Camshaft holding tool adapter T97T-6256-D 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable

e>WWhen the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven about 10 miles (16 km) or more to relearn the strategy.

Lower intake manifold Fan blade and shroud Valve cover Roller followers, if equipped Drive belt Upper radiator hose and tube Alternator electrical connectors Alternator mounting bracket Engine accessory bracket and move it aside Camshaft Position (CMP) electrical connector Crankshaft Position (CKP) sensor electrical connector Engine Coolant Temperature (ECT) sensor electrical connector Coil pack electrical connector Exhaust Gas Recirculation (EGR) valve electrical connector EGR valve bracket and move it aside e Heater hoses

15. Start the engine and check for leaks. 4.0L SOHC Engine elf only one cylinder head is to be removed, only follow the procedures that apply. The following tools, or their equivalents are absolutely necessary to properly perform this procedure:

Cam Chain Tensioner tool T97T6K254-A Cam Gear Removal tool T97T6256-F Cam Gear Torque adapter 197T6256-G Camshaft Gear Positioning/Holding tool 197T-6256-B Camshaft Gear Positioning/Holding tool adapter T97T-6256-A

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Fuel injector electrical connectors Water bypass hose Thermostat housing Spark plug wires Fuel injection supply manifold Fuel injectors Crankcase vent separator spring Oil dipstick housing Exhaust manifold Hydraulic chain tensioner Cassette retaining bolt Camshaft sprocket Cylinder head and discard the gasket To install: 5. Thoroughly clean all gasket mating surfaces. Remove all traces of old gasket material, oil, grease or dirt. 6. Insure that the rubber band is holding the right-hand chain to the cassette. 7. Install a new head gasket and the cylinder head. 8. Torque the new cylinder head bolts in sequence as follows:

1998-99 e Step 1: 26 ft. Ibs. (34 Nm). e Step 2: Plus 90 degrees. e Step 3: Plus an additional 90 degrees. 2000-01 e Step 1: 28 ft. Ibs. (38 Nm). e Step 2: Plus 90 degrees. e Step 3: Plus an additional 90 degrees. 2002 e Step 1: 24 ft. Ibs. (32 Nm). e Step 2: Plus 90 degrees. 9. Install or connect the following: Camshaft sprocket in the cassette and make certain that the camshaft sprocket turns freely on the camshaft Cassette retaining bolt. Torque the bolt to 89 inch Ibs. (10 Nm). Exhaust manifold Oil level indicator tube. Torque the bolt to 18 ft. Ibs. (25 Nm). Crankcase vent separator and spring Thermostat housing. Torque the bolts to 8 ft. Ibs. (11 Nm). Water bypass hose Heater hoses eee @ EGR bracket. Torque the bolt to 89 inch lbs. (10 Nm). EGR tube. Torque the nut to 30 ft. lbs. (40 Nm). ECT sensor electrical connector Electrical harness retainer. Torque the bolt to 89 inch Ibs. (10 Nm). CKP and CMP electrical connectors

Timing belt service is covered in Section 3 of this manual

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e Accessory bracket. Torque the bolts to 31 ft. Ibs. (42 Nm). Alternator mounting bracket. Torque the bolts to 31 ft. Ibs. (42 Nm). Alternator and electrical connectors Drive belt Fan shroud Roller followers Valve cover Lower intake manifold Negative battery cable 10. Change the engine oil and filter. 11. Refill the cooling system. 12. Start the engine and check for leaks, repair if necessary. 4.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Intake manifold e Timing chains Exhaust manifolds Water heater tube back and remove.

9355EG01

Discard the O-ring seal. t

t

e>The cylinder head bolts must be dis-

Left cylinder head bolt torque sequence 4.6L engine

carded with new bolts installed. They

are tighten-to-yield designed and cannot be reused. Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

e Bolts and the RH cylinder head e Bolts and the LH cylinder head 4. Installation is the reverse of removal. Observe the following notes and torques: a. Install the cylinder head on the head gasket and loosely install the bolts. b. Make sure to tighten the bolts in alte in six stages. © Step 1: Tighten to 40 Nm (30 ft. Ibs.). Step 2: Tighten an additional 85-95 degrees. Step 3: Back out all bolts one full turn (360 degrees). Step 4: Tighten to 40 Nm (30 ft. Ibs.). Step 5: Tighten an additional 85-95 degrees. Step 6: Tighten an additional 85-95 degrees. lop). Install a new O-ring seal and posi-

§ 9355EG07

Right cylinder head bolt torque sequence 4.6L engine

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a. Step 1: 30 ft. Ibs. (40 Nm). b. Step 2: 50 ft. Ibs. (68 Nm). C. Step 3: Plus an additional 90 degrees. 7. Install or connect the following: Lubricate and install the push rods in their original positions Rocker arms and fulcrum guides Rocker arm fulcrums. Torque the bolts to 25 ft. Ibs. (34 Nm). Valve cover Transmission oil fill tube. Torque the bolt to 25 ft. Ibs. (34 Nm). Alternator bracket, if removed. Torque the bolts to 48 ft. Ibs. (65 Nm). Alternator electrical connectors, if

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79246614

Tighten upper intake manifold bolts in the sequence shown—5.0L engine

tion the water heater tube forward. Lubri-

cate the O-ring seal with premium engine coolant.

;

5.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Lower intake manifold Valve cover Matchmark the rocker arms and push rods to ease installation and remove the rocker arm fulcrums e Rocker arms and fulcrum guides e Exhaust manifold

e A/C compressor and power steer-

ing bracket, left side cylinder head only Alternator electrical connectors, right side cylinder head only Transmission oil fill tube from the rear of the right side cylinder head Push rods and make certain to matchmark them Cylinder head and discard the gasket To install: 4. Thoroughly clean all the gasket mating surfaces. 5. Position a new cylinder head gasket to the engine block, then install the cylinder head. 6. Install new cylinder head bolts, and torque in 3 steps:

removed Exhaust manifold Lower intake manifold Negative battery cable 8. Fill the cooling system 9. Fill the engine with clean oil and replace the filter. 10. Start the engine and check for leaks, repair if necessary.

Rocker Arms/Roller Followers

REMOVAL & INSTALLATION 4.0L SOHC Engines e>A special tool is required to compress the valve spring.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the valve cover. 4, Rotate the camshaft so that the base circle of the cam is against the cam follower you intend to remove. e>lf removing more than one cam follower, label them so they can be returned to their original position.

7924EG05

Cylinder head bolt torque sequence 5.0L engine

5. Using special tool T97T-6565-A depress the valve spring. Slide the cam follower over the lash adjuster and out from under the camshaft. To install: 6. Compress the valve spring and slide the roller follower into position. 7. Release the tension from the spring. 8. Install the valve cover and connect the negative battery cable.

Heater Core replacement is covered in Section 2 of this manual

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Rocker Arm Shaft Support

5.0L Engines

:

Rocker Arm Shaft Spring

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

2. Remove or disconnect the follow-

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Retaining Pin

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e Negative battery cable e Rocker arm covers e Retaining bolt at each rocker arm 3. The rocker arm and pushrod may then be removed from the engine. Keep all rocker arms and pushrods in order so they may be installed in their original locations. To install:

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covers and connect the negative battery cable.

Rocker arm and shaft assembly—4.0L SOHC engine

4.6L Engine

1. Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2. Remove the valve cover. 3. Position the piston of the cylinder being repaired at the bottom of the stroke. 4. Install the special tool between the valve spring coils to prevent valve stem seal damage.

e Compress the valve springs and k

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5. Installation is the reverse of removal.

4.0L OHV Engine 1. Befor ini @ servicing the vehicle, refer to

the precautions in the beginning ofthis sec-

tion.

>The roller followers are positional. Mark the followers for installation in their original locations.

1. Rocker arm bolt

2. Rocker arm fulcrum 3. Rocker arm

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9355EG06

Install this tool to prevent seal damage— 4.6L engine

Exploded view of the rocker arm assembly. Notice the fulcrum guide between the pedestals used for extra stability—5.0L engine

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EXPLORER ¢ EXPLORER SPORT ¢ EXPLORER SPORT TRAC © MOUNTAINEER

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REMOVAL & INSTALLATION

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Rocker arm and shaft assembly—4.0L OHV engine

2. Remove or disconnect the following: e Negative battery cable e Rocker arm covers e Rocker arm shaft stand attaching bolts by loosening the bolts 2 turns at a time, in sequence (from the end of the shaft to the middle of the shaft) e Rocker arm and shaft assembly To install: 3. If equipped, loosen the valve lash adjusting screws a few turns. Apply engine oil to the assembly to provide initial lubrication. 4. Install or connect the following: e Rocker arm shaft assembly to the cylinder head and guide adjusting screws on to the pushrods e Rocker arm stand. Torque the bolts to 46-82 ft. Ibs. (62-70 Nm), 2 turns at a time, in sequence (from

The intake manifold is a 4-piece assembly, consisting of the upper intake manifold, the throttle body, the fuel supply manifold, and the lower intake manifold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Accelerator cable splash shield Spark plug wires from the ignition coil Ignition coil and radio interference capacitor electrical connectors Throttle Position (TP) sensor electrical connector Idle Air Control (IAC) valve electrical connector Brake booster vacuum hose Positive Crankcase Ventilation (PCV) hose Canister purge line from the throttle body

23 Nm (17 Ib-ft}

Tighten the upper manifold bolts in the sequence shown—4.0L OHV engine

Brake service is covered in Section 4 of this manual

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FORD) MOTOR co. 12 EXPLORER ¢ EXPLORER SPORT + 10e Fuel line bracket e Upper intake manifold and discard the gasket To install: 3. Install or connect the following: New gasket and the upper manifold. Torque the nuts to 18 ft. Ibs. (25 Nm). Fuel line bracket Canister purge line to the throttle body Brake booster vacuum hose IAC valve electrical connector TP sensor electrical connector Ignition coil and radio interference capacitor electrical connectors Spark plug wires to the proper spark plug Accelerator cable and speed control cable, if equipped Accelerator cable splash shield Air cleaner outlet tube Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary.

LOWER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Radiator overflow hose and set it aside e Upper intake manifold e Water bypass hose e Engine Coolant Temperature (ECT) electrical connector e Wire harness retainer nut e Heater hoses e Positive Crankcase Ventilation (PCV) hoses e Upper radiator hose e Fuel injector electrical connectors e Ground strap at the rear of the lower intake manifold

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7924EG07

Tighten the lower manifold bolts in the sequence shown—4.0L OHV engine

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e Water temperature indicator sender electrical connector e Camshaft Position (CMP) sensor and the camshaft synchronizer e Bolts from the lower intake manifold Lower intake manifold and discard the gaskets To install: 4. Ensure that all of the gasket mating surfaces are clean and free of grease, oil or dirt. Also ensure that the EGR passages in the manifolds and heads are clear. 5. Apply a “e in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads. 6. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylin-

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the bolt to 18 ft. Ibs. (25 Nm). ECT electrical connector ¢ Water heater bypass hose to the heater tube PCV hoses to the heater tube Upper intake manifold Radiator overflow hose Negative battery cable 10. Fill the cooling system. 11. Start the vehicle and check for leaks, repair if necessary. 4.0L SOHC Engine

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1998-01 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner-to-intake tube Accelerator splash shield Accelerator and, if equipped with cruise control, speed control cables from the throttle control cam Accelerator cable retaining bracket from the upper intake manifold Label and disengage all vacuum and electrical connections on the intake manifold. Upper intake manifold attaching bolts Lift up on the manifold and remove both fuel Vapor Management Valve (VMV) hoses Intake manifold and discard the gasket To install: e>Ford does not specify a sequence for either upper or lower intake manifolds, but it is recommended that you start tightening in the middle and work your way out to the ends. Repeat the tightening sequence several times until the bolts will no longer turn at the specified torque.

3. Install the lower intake manifold. Torque the bolts to 10 ft. Ibs. (13 Nm) for 1998-00, and 13 ft. Ibs. (18 Nm) for 2001. 4. Position the upper manifold on the lower manifold. 9. Install or connect the following: e Attach both VMV hoses to the manifold ¢ Upper manifold attaching bolts. Torque the bolts to 62 inch Ibs. (7 Nm). e Attach any vacuum and electrical connections that were removed

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Accelerator cable bracket to the intake and the cable (or cables if « quipped with cruise control) to the throttle cam e Accelerator splash shield e Air cleaner-to-intake supply tube ¢ Negative battery cable 6. Start the vehicle and check for leaks, repair if necessary.

2002 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Splash shield Air cleaner outlet pipe Accelerator and speed control cables from the throttle body Accelerator cable and the speed contro! cable from the bracket. Position the cables away from the intake manifold. All the vacuum hoses KS electrical connector IAC valve electrical connector TP sensor electrical connector EGR transducer electrical connector Wiring anchor EGR tube from the EGR valve Wiring harness pin-type retainer Spark plug wires Intake manifold retainers, then slightly reposition the manifold to access the EGR vacuum regulator (EVR) solenoid. EVR solenoid vacuum and electrical connections Intake manifold To install, reverse the removal procedure. Torque the bolts to 89 inch lbs. (10 Nm). There is no particular sequence. 4.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Throttle body Ignition coils Fuel injection supply manifold Upper radiator hose and the heater hose Alternator Accelerator cable bracket Throttle body adapter

9355EG03

Tighten the manifold bolts in the sequence shown—4.6L engine

Thermostat housing Intake manifold bolts Intake manifold. Tilt the manifold to Slide it out from underneath the exhaust gas recirculation (EGR) tube. To install, reverse the removal procedure. Tighten retaining bolts is sequence shown.

5.0L Engine

UPPER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Idle Air Control (IAC) valve electrical connector Accelerator contro! splash shield Throttle Position (TP) sensor electrical connector Accelerator cable and if equipped, speed control cable from the throttle linkage Accelerator cable bracket

Fuel pressure regulator vacuum connection Pressure transducer hoses Upper Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tubing Engine Vacuum Regulator (EVR) electrical connector EVR vacuum connector EGR back pressure electrical connector Ignition coil bracket Accelerator cable from the upper intake manifold clips Intake cover plate Vacuum connections from the front of the manifold Vapor Management Valve (VMV) purge line Brake booster vacuum supply line Positive Crankcase Ventilation (PCV) hose PCV heater hoses Upper intake manifold and discard the gasket To install: 3. Ensure that all of the gasket mating Surfaces are clean and free of grease, oil or

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

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sure the silicone sealer will not fall into the engine and possibly block oil passages. 7. Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads. Also, ensure that the water pump bypass hose is installed at the same time. 8. Install or connect the following: Intake manifold and new gasket and hand tighten the bolts Upper intake vacuum connections PCV tube and heater hoses Brake booster vacuum supply line Torque the intake manifold bolts to 18 ft. Ibs. (25 Nm). Intake manifold cover plate. Torque the bolts to 15 ft. Ibs. (20 Nm). Accelerator cable bracket. Torque the upper bolt to 15 ft. Ibs. (20 Nm) and lower bolt to 80 inch Ibs. (9 Nm). Accelerator cable and speed control cable to the throttle linkage, if equipped Ignition coils and bracket EVR electrical connector EVR vacuum connector EGR valve vacuum connector Fuel pressure regulator vacuum

9355EG04

Loosen the upper manifold bolts in the sequence shown—5.0L engine

connector

e Upper EGR valve-to-exhaust mani-

dirt. Also ensure that the EGR passages in the manifolds and heads are clear.

heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gas-

kets are aligned with the holes in the cylin-

° EGR back pressure transducer elec-

cone sealer to the points where the cylinder block rails meet the cylinder heads. 5. Position new seals on the cylinder

der heads. 6. Apply a Ye in. (1.6mm) bead of sealer to the outer end of each intake mani-

trical connector ¢ TP sensor electrical connector e IAC valve electrical connector

4. Apply a Ye in. (1.6mm) bead of sili-

block and new gaskets on the cylinder

fold seal for the full width of the seal. Make

fold connector. Torque the fastener to 25 ft. Ibs. (34 Nm).

¢ Accelerator control splash shield.

Torque the bolt to 89 inch Ibs. (10 Nm). Air cleaner outlet tube e Negative battery cable

LOWER

7924EG14

Tighten the upper manifold bolts in the sequence shown—5.0L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the folkowing: Negative battery cable Radiator overflow hose and set it aside Upper intake manifold Water bypass hose Engine Coolant Temperature (ECT) electrical connector Wire harness retainer nut Heater hoses Positive Crankcase Ventilation (PCV) hoses Upper radiator hose Fuel injector electrical connectors

FORD MOTOR co. 1 0-1 5

EXPLORER ¢ EXPLORER SPORT ¢ EXPLORER SPORT TRAC © MOUNTAINEER

Wire harness retainer nut. Torque to the bolt to 18 ft. Ibs. (25 Nm). ECT electrical connector Water heater bypass hose to the heater tube PCV hoses to the heater tube Upper intake manifold Radiator overflow hose Negative battery cable 10. Fill the cooling system. 11. Start the vehicle and check for leaks, repair if necessary.

Exhaust Manifold

REMOVAL & INSTALLATION 4.0L OHV Engine

7924EG13

Tighten the lower manifold bolts in the sequence shown—5.0L engine

Ground strap at the rear of the

lower intake manifold Water temperature indicator sender electrical connector Camshaft Position (CMP) sensor and the camshaft synchronizer Bolts from the lower intake manifold Lower intake manifold and discard the gaskets To install: 4 Ensure that all of the gasket mating Surfaces are clean and free of grease, oil or dirt. Also ensure that the EGR passages in the manifolds and heads are clear. 5. Apply a Ye in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads. 6. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads. 7. Apply a Ve in. (1.6mm) bead of Sealer to the outer end of each intake manifold seal for the full width of the seal. Make sure the silicone sealer will not fall into the engine and possibly block oil passages. 8. Install the lower intake manifold and tighten the bolts in 2 steps as follows: a. 89 inch Ibs. (10 Nm). b. 24 ft. Ibs. (32 Nm).

9. Install or connect the following: CMP sensor and camshaft synchronizer Water temperature indicator sender electrical connector Fuel injector electrical connectors Fuel line Water bypass hose Upper radiator hose Heater hoses

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Oil level indicator tube and bracket Exhaust pipe-to-manifold bolts Power steering pump hoses, if removing the left-hand manifold Hot air intake shroud that is bolted around the manifold, if removing the right-hand manifold Exhaust manifold and gasket To install: 3. Clean all mating surfaces for the exhaust manifold and cylinder head. 4. Install or connect the following:

9308EG10

Tighten the right side exhaust manifold in sequence

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

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EXPLORER ¢ EXPLORER SPORT ¢ EXPLORER SPORT TRAC © MOUNTAINEER

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e Exhaust manifold heat shield e Exhaust gas recirculation tube from the exhaust manifold e Eight nuts and the exhaust manifold 3. Installation is the reverse of removal. Tighten the exhaust manifold nuts in the sequence shown.

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front fender splash shield Engine oil runoff Lower steering column shaft pinch bolt. Position the lower steering column shaft aside. Exhaust manifold heat shield 8 nuts and the exhaust manifold To install, reverse the removal procedure.

9308EG11

Tighten the left side exhaust manifold in sequence

e New gasket and the exhaust manifold. Torque the right side bolts to 18 ft. Ibs. (25 Nm) and the left side bolts to 16 ft. Ibs. (22 Nm). e Exhaust pipe to the manifold e Oil level bracket. Torque the bolt to 17 ft. Ibs. (23 Nm). e Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary. 4.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Exhaust inlet pipe-to-manifold attaching bolts e Differential Pressure Feedback EGR (DPFE) transducer hoses, left side manifold only e Exhaust Gas Recirculation (EGR) tube from the manifold and valve, left side manifold only e Exhaust manifold and discard the gasket To install: 3. Clean the gasket mating surfaces. 4. Install or connect the following: ¢ New gasket and the exhaust manifold. Torque the bolts to 16 ft. Ibs. (22 Nm). ¢ EGR tube to the manifold. Torque the fastener to 30 ft. Ibs. (40 Nm) left side manifold only e DPFE transducer hoses, left side manifold only e Exhaust inlet pipe-to-manifold

attaching bolts. Torque the bolts to 30 ft. Ibs. (40 Nm). e Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

5.0L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Discharge and recover the A/C system. 3. Remove or disconnect the following: e Negative battery cable e Spark plug wires and retaining brackets e A/C manifold and tube e Condenser to evaporator tube from the A/C condenser core

4.6L engine

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front fender splash shield e Heater control valve bracket bolt e Vacuum hose and heater hose. Position the heater control valve assembly aside.

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Exhaust manifold torque sequence—4.6L engine

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Oil level indicator tube Left wheel Wheel well apron pin retainers Exhaust manifold and discard the gasket To install: 4. Clean the gasket mating surfaces. 5. Install or connect the following; e New gasket and the exhaust manifold. Torque the bolts to 30 ft. Ibs.

(40 Nm). ¢ Wheel well pin retainers e Left wheel Oil level indicator tube. Torque the bolt to 18 ft. Ibs. (25 Nm). Condenser to evaporator tube A/C manifold and tube Spark plug wires and brackets Negative battery cable 6. Recharge the A/C system. 7. Start the vehicle and check for leaks, repair if necessary.

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

2. Remove or disconnect the following:

Negative battery cable Air cleaner outlet tube Drive belt tensioner Alternator electrical connectors Alternator and bracket Exhaust flange Right front wheel Wheel well apron pin retainers Exhaust Gas Recirculation (EGR) valve from the manifold tube Spark plug wires and retaining brackets Exhaust manifold heat shield Exhaust manifold and discard the gasket To install: 3. Clean the gasket mating surfaces. 4. Install or connect the following: New gasket and the exhaust manifold. Torque the bolts to 30 ft. Ibs. (40 Nm). Exhaust manifold heat shield. Torque the bolts to 61 inch Ibs. (7 Nm). Spark plug wires and retaining brackets EGR valve to the manifold tube Wheel well apron pin retainers Right front wheel Exhaust flange. Torque the nuts to 26 ft. Ibs. (34 Nm).

5. Install the alternator and bracket. Torque the bolts in sequence as follows: a. Bolts NO. 1-2 to 26 ft. Ibs. (34 Nm). b. Bolt NO. 3 to 48 ft. Ibs. (65 Nm). c. Torque the remaining bolt to 26 ft. lbs. (34 Nm). 6. Install or connect the following: e Drive belt tensioner e Air cleaner outlet tube e Negative battery cable 7. Start the vehicle and check for leaks, repair if necessary. Camshaft and Valve Lifters e>Although Ford suggests that this component is removable while the engine is installed in the vehicle, depending on the particular options with which your truck is equipped, working clearance may be extremely tight and this procedure may be much easier to perform with the engine removed. Before commencing, read through this procedure and make certain enough clearance, or working room, exists with the engine in the vehicle; if there is not enough space, the engine should be removed.

REMOVAL & INSTALLATION 4.0L OHV Engine e>it is necessary to replace the oil pan gasket when removing and installing the engine front cover. It will also be necessary to remove the transmission to properly reseal the oil pan.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Evacuate the A/C system. 5. Relieve fuel system pressure. 6. Remove or disconnect the following: Negative battery cable Radiator A/C compressor. Do not disconnect the lines

A/C condenser Fan, spacer and shroud Air cleaner hoses Spark plug wires Ignition coil and bracket Crankshaft pulley and damper Oil pump drive ee eoeeee#eeeoee Alternator

Fuel lines at the supply manifold Upper and lower intake manifold Rocker arm covers Rocker arm shafts . Pushrods and identify them for installation Tappets and identify them for installation e Oil pan Engine front cover Water pump 7. Turn the engine by hand until the timing marks align at Top dead Center (TDC) of the power stroke on No.1 piston. 8. Place the timing chain tensioner in the retracted position and install the retaining clip. 9. Check the camshaft end-play. If excessive, you'll have to replace the thrust plate. 10. Remove the camshaft gear attaching bolt and washer, then slide the gear off the camshaft. 11. Remove the camshaft thrust plate. 12. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings. To install: 13. Lubricate the camshaft using a good assembly lubricant. 14. Install or connect the following: e Camshaft using caution to avoid any damage to the camshaft bearings e Thrust plate. Make sure that it covers the main oil gallery. Torque the screws to 84-120 inch Ibs. (9-13 Nm). 15. Rotate the camshaft and crankshaft, as necessary, to align the timing marks. e Camshaft gear and chain. Torque

the bolt to 44-50 ft. Ibs. (60-68 Nm). 16. Remove the clip from the chain tensioner e Engine front cover and water pump e Crankshaft damper/pulley. Torque the bolt to 33 ft. Ibs. +90 degrees, for 1998, or 46-49 ft. Ibs. +90 degrees for 1999-01. e Oil pan 17. Coat the tappets with SOW engine oil and place them in their original locations. 18. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations. e Tappets e Rocker arm shafts and covers e Upper and lower intake manifolds

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

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e Fuel lines to the fuel supply manifold Alternator and electrical connectors Oil pump drive Ignition coil and bracket Spark plug wires Air cleaner hoses Fan, spacer and shroud

A/C condenser A/C compressor Radiator Negative battery cable 19. Fill the cooling system. 20. Recharge the A/C system. 21. Replace the oil filter and refill the engine with clean oil. 22. Start the engine and check the ignition timing and idle speed; adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks.

4.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable for safety e Valve cover e Hydraulic camshaft tensioner >The right-hand camshaft sprocket bolt uses left-hand threads.

3, For the right-hand camshaft use the Cam Gear Torque Adapter too! T971-6256-F, to remove the camshaft sprocket bolt. 4. For the left-hand camshaft, remove the sprocket bolt. When removing the followers, label them so that they may be returned to their original positions.

5. Using the Valve Spring Compressor tool ST1330-A, remove the camshaft roller followers. 6. Install or connect the following: e Camshaft bearing cap bolts and the oil rail e Camshaft To install: 7. Lubricate all of the moving parts with SAE 50W engine oil. 8. Install camshaft onto the cylinder head. 9. Position the oil rail and install the bearing caps and bolts. Torque the bolts in 2 Steps: a. Step 1—53.5 inch Ibs. (6 Nm). b. Step 2—11-12.5 ft. Ibs. (15-17 Nm). 10. Install or connect the following: e Camshaft followers

7924EG15

Use the proper sequence to prevent damage to the camshaft both when installing and removing the bearing caps—4.0L SOHC engine

e Camshaft sprocket bolt and hand tighten the bolt e Camshaft Chain Tensioner 197T6K254-A in the hole that the hydraulic chain tensioner was in 11. Turn the crankshaft one revolution clockwise until No. 1 piston is Top Dead Center (TDC). 12. Install or connect the following: e Crankshaft Holding tool T97T6303-A on the crankshaft to keep it from turning Position the timing slot on the rear of the camshaft to fit Camshaft Holding tool T97T-6256-C and install the holding tool on the rear of the head Camshaft Gear Holding tool T97T6256-B and Camshaft Gear Holding tool T97T-6256-A on the front of the cylinder head to securely hold the camshaft gear Tighten the camshaft sprocket bolt to 63 ft. Ibs. (85 Nm). 13. Remove the Camshaft Chain Tensioner tool and install the hydraulic chain tensioner, tighten the tensioner to 35-39 ft. lbs. (47-53 Nm), 14. Remove the special tools from the engine. 15. Install or connect the following: e Valve cover e Negative battery cable 16. Start the engine check for leaks and repair if necessary. 4.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following:

At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. e Timing chains

e Camshaft roller followers e Camshaft sprocket e The 13 camshaft bearing cap bolts e Camshaft bearing caps ladders e Camshaft from the cylinder head ->The valve tappets are positional. Mark each valve tappet for installation in its original location.

e Valve tappets To install: 3. Lubricate the camshaft journals with clean engine oil. 4. Install the camshaft onto the cylinder head. 5. Lubricate the camshaft bearing caps with clean engine oil. 6. Install the camshaft bearing caps and loosely install the bolts. 7. Tighten the bolts in the sequence shown. 8. Install the camshaft sprocket. Tighten the sprocket bolt in two stages. ° re 1: Tighten to 40 Nm (30 ft. S. e Step 2: Tighten an additional 90 degrees. 9. Install the roller followers 10. Install the timing chains

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¢ Camshaft 5. Apply SAE 50W engine oil to the camshaft thrust plate. Position the thrust plate with the groove toward the block and install the retaining bolts. Torque to 10-12 ft. Ibs. (13-16 Nm). 6. Apply SAE SOW engine oil to the valve tappets and install them. If reusing the old lifters, place them in their original positions. 7. Install or connect the following: Pushrods to their original positions Rocker arms Valve covers Lower and upper intake manifolds Camshaft sprocket and chain assembly. Ensure that the timing marks on the cam and crankshaft sprockets are aligned. e Timing chain cover Negative battery cable 8. Start the engine, check for leaks and repair if necessary.

REMOVAL & INSTALLATION 4.0L OHV Engine 9355EG13

Camshaft bearing bolt torque sequence—4.6L engine

5.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable e Timing chain cover

Camshaft sprocket and chain assembly Upper and lower intake manifolds Both valve covers Loosen the rocker arm bolts and rotate the rocker arms to the side Pushrods in sequence so that they may be installed to their original positions Lifters Camshaft thrust plate bolts and the plate Camshaft from the engine, taking care not to damage the bearings,

Review the complete service procedure before starting this repair.

MEASURE CLEARANCE

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BLOCK 7924EG16

To install:

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The correct spacer must be used to extend the mounting surface of the oil pan so it is flush with the mounting surface of the engine block-4.0L OHV engine

For Wheel Alignment specifications, see Section 1 of this manual

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4 0-20 foro motor co. EXPLORER e EXPLORER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Engine from the vehicle and mount the engine on a suitable engine Stand with the oil pan facing up e Qil pan attaching bolts (note location of 2 spacers) and remove the pan from the engine block e Oil pan gasket and crankshaft rear main bearing cap wedge seal 4. Clean all gasket surfaces on the engine and oil pan. Remove all traces of old gasket and/or sealer. To install: 5. Install or connect the following: New crankshaft rear main bearing cap wedge seal. The seal should fit snugly into the sides of the rear main bearing cap New oil pan gasket to the engine block and place the oil pan in correct position on the 4 locating studs. Torque the bolts EVENLY to 60-84 inch Ibs. (7-10 Nm), Transmission bolts to the engine and oil pan. There are 2 spacers on the rear of the oil pan to allow proper mating of the transmission and oil pan. Spacers to the mounting pads on the rear of the oil pan before bolting the engine and transmission together Engine to the vehicle Negative battery cable 6. Fill the engine with clean oil. e Start the vehicle and check for leaks, repair if necessary.

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surfaces. These may cause scratches and gouges resulting in leak paths. Use

4.6L Engine

surfaces.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Front axle e Oil pan

4. Remove and discard the oil pan gasket. Clean the sealing surfaces with metal surface cleaner. Allow the surfaces to dry for four minutes or until there is no sign of wetness, whichever is longer. Failure to do so

a plastic scraper to clean the sealing

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can cause future oil leaks, To install:

e>If the oil pan and gasket are not secured within four minutes of sealer

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9355EG12

4.0L SOHC Engine >The 4.0L SOHC engine does not use an oil pan in the conventional sense. There is a separate access panel that unbolts from what would be considered the oil pan (which is now known as the ladder frame).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following; e Negative battery cable ¢ Qil pan and discard the gasket To install: 4. Install or connect the following: e New gasket and oil pan. Torque the bolts to 80 inch Ibs. (9 Nm). e Negative battery cable 5. Fill the engine with clean oil.

Q355EG11 Sealant application—4.6L engine

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EXPLORER ¢ EXPLORER SPORT ¢ EXPLORER SPORT TRAC * MOUNTAINEER application, the sealant must be removed and the sealing surfaces cleaned with metal surface cleaner.

5. Apply silicone gasket and sealant in the two places shown. 6. Position the new oil pan gasket and the oil pan and loosely install the bolts. 7. Tighten the bolts in three stages in the sequence shown. © Step 1: Tighten to 2 Nm (18 inch Ibs.) e Step 2: Tighten to 20 Nm (15 ft. Ibs.) ¢ Step 3: Tighten an additional 60 degrees. 8. Install the front axle. 5.0L Engine e>The oil pan cannot be removed with the engine in the vehicle.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Engine from the vehicle e Qil pan and discard the gasket To install: 4. Install or connect.the following: e Qil pan with a new gasket. Torque the bolts to 18 ft. Ibs. (25 Nm). e Engine to the vehicle e Negative battery cable 5. Fill the engine with clean oil. 6. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 4.0L OHV Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Oil pan e Oil pick-up and tube assembly from the pump e Oil pump retainer bolts and the oil pump To install: 4. Prime the oil pump with clean engine oil by filling either the inlet or outlet port. Rotate the pump shaft to distribute the oil within the pump body. 5. Install the oil pump and tighten the mounting bolts to 13-15 ft. Ibs. (18-20 Nm).

WARNING Do not force the oil pump if it does not seat readily. The oil pump driveshaft may be misaligned with the distributor or shaft assembly. If the pump is tightened down with the driveshaft misaligned, damage to the pump could occur. To align, rotate the intermediate driveshaft into a new position.

10. Fill the engine with clean oil. 11. Start the vehicle and check for leaks, © repair if necessary.

4.6L Engines

6. Install or connect the following: ¢ Qil pick-up and tube assembly e Oil pan 7. Fill the engine with clean oil. 8. Start the vehicle and check for leaks, repair if necessary.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Timing chains e Oil pan e Three bolts and the oil pump screen cover and tube ¢ Oil pump To install:

4.0L SOHC and 5.0L Engines

e>Lubricate the new O-ring seal with clean engine oil.

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Engine from the vehicle e Qil pan e Unbolt the oil pick-up tube 4. On the 4.0L engine, perform the following: a. Remove the 8 ladder frame bolts that were under the oil pan. b. Remove the 2 rear outer ladder frame bolts. c. Remove the 7 left-hand and the 8 right-hand ladder frame bolts. d. Lift the ladder frame from the engine. 5. Remove the 2 oil pump attaching bolts and the pump. To install: 6. Submerge the pump in clean engine oil to prime it. 7. On the 4.0L engine, do the following: a. Position the ladder frame on the engine. b. Install the 8 right-hand and 7 lefthand ladder frame bolts. c. Install the 2 rear outer and the 8 frame bolts under the pan. 8. Install the oil pump. Torque the bolts to: a. 4.0L; 13-15 ft. Ibs. (17-21 Nm). b. 5.0L: 23-31 ft. Ibs. (30-43 Nm). 9. Install or connect the following: Oil pick-up tube Oil pan Engine to the vehicle Negative battery cable

4. Clean and inspect the mating surfaces. Install a new O-ring seal. 5. Position the oil pump. 6. Loosely install the bolts. 7. Tighten the bolts to 89 inch Ibs. (10Nm). 8. Install the three oil pump screen and cover bolts. Torque the bolts to 18 ft. Ibs. (25Nm). 9. Install the timing chains. 10. Install the oil pan.

Rear Main Seal

REMOVAL & INSTALLATION 4.0L OHV and 5.0L Engines

1. Remove the flexplate or flywheel.

Use care to avoid scratching or damaging the oil seal surface or leakage may occur. 2. Using a sharp awl, punch one hole into the crankshaft rear oil seal metal surface

between the seal lip and the cylinder block. 3. Screw the threaded end of the special tool into the oil seal. Use the special tool to remove the crankshaft rear oil seal. To install: 4. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil. 5. Using the special tool, install the crankshaft rear oil seal. Alternate bolt tightening to correctly seat the crankshaft rear oil seal. 6. Install the flexplate or flywheel.

For Maintenance Interval recommendations, see Section 1 of this manual

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4.0L OHC Engine 1. Remove the flexplate or flywheel.

Kos WARNING Avoid scratching or damaging the oil crankshaft seal running surface during removal of the crankshaft rear oil seal. 2. Using the special tool, remove the crankshaft rear oil seal. To install: ->Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear Sealing surface, use extra-fine emery cloth or extra-fine 0000 steel! wool with metal surface cleaner.

3. Lubricate the crankshaft rear oil seal with clean engine oil and install on the special tool. 4. Using the special tool, install the crankshaft rear oil seal. 5. Install the flexplate or flywheel. 4.6L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Flexplate e Crankshaft rear oil seal slinger with a slide hammer ¢ Rear oil seal with a slide hammer 3. Installation is the reverse of removal. Note the following: e Lubricate the inner lip of the rear crankshaft seal with clean engine oil. e Use the two Crankshaft Rear Oil Seal Installers to install the rear oil seal.

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e Timing chain tensioner e Sprocket bolt ¢ Timing chain, camshaft sprocket and crankshaft sprocket as an assembly To install: 3. Install or connect the following: e Timing chain, camshaft and crankshaft sprockets as an assembly 4. Align the timing marks. 5. Install or connect the following: e Timing chain tensioner e Sprocket bolt. Torque the bolt to 51 ft. Ibs. (70 Nm). e Engine front cover e Negative battery cable

4.0L OHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Engine from the vehicle e Oil pan e Engine front cover e Cylinder heads 4, Lock the jackshaft tensioner by

installing a pin.

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e Left front cassette retaining bolt e Cassette chain and tensioner assembly

Rear jackshaft plug fromni the engine e Right rear cassette retaining bolt and spacer e Right rear cassette chain and tensioner e Timing chain (s) To install: 5. Install or connect the following: e Timing chain(s) e Right rear cassette chain, tensioner and sprocket ¢ Jackshaft sprocket and chain on the engine and remove the tensioner pin 6. Torque the jackshaft sprocket bolt in 2 stages: a. 32-35 ft. Ibs. (43-47 Nm). b. Turn an additional 65 degrees. 7. Install or connect the following: e Cylinder heads e Front cover e Oil pan e Engine to the vehicle e Negative battery cable 8. Fill the engine with clean oil. 9. Start the vehicle, check for leaks and repair if necessary.

4.6L Engine

SEAL ONLY

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

e Using the two Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear oil slinger.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 4.0L OHV Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Engine front cover e Rotate the crankshaft and align the timing marks

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Remove the jackshaft sprocket-4.0L SOHC Engine

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2. Remove or disconnect the following: ¢ Crankshaft pulley «© Front oil seal with a puller To install: 3. Lubricate the front cover and the front oil seal inner lip with clean engine oil. 4. Use a seal driver to install the front Oil seal into the engine front cover. 5. Install the crankshaft pulley.

FRONT COVER

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil and coolant. 3. Remove or disconnect the following: e Battery ground cable e Both valve covers Radiator and the transmission cooler Drive belt Water pump

CMP sensor Upper radiator hose bracket EGR vacuum regulator solenoid Drive belt tensioner Idler pulleys Crankshaft pulley

¢ Coolant hose clamps e CKP sensor ¢ Oil pan to front cover bolts e Crankshaft front oil seal e Timing cover bolts and studs e Front cover from the cylinder block To install: ->lf the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

4. Apply silicone gasket and sealant along the cylinder head to block surface and the oil pan to cylinder block surface. 5. Install the engine front cover on the front cover to cylinder block dowel and loosely install the bolts. 6. Tighten the front cover bolts and stud bolts in the sequence shown. 7. Install a neW crankshaft front oil seal. 8. Loosely install the pan-to-cover bolts, then, tighten the bolts in two stages, inner bolts first. e Step 1: Tighten to 20 Nm (15 ft. lbs.) e Step 2: Tighten an additional 90 degrees

TALC MBHURERECE 10-23 9. The remainder of installation is the reverse of removal.

TIMING CHAINS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur. e Front cover e Crankshaft sensor ring from the crankshaft 3. Rotate the crankshaft until both camshaft key ways are 90 degrees from the valve cover surface. Make sure the copper links line up with the dots on the camshaft sprocket.

4. Install the special tools 303-380 and 303-413 on the camshaft. 5. Remove or disconnect the following: e LH timing chain tensioner e RH timing chain tensioner

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9355EG10

Front cover bolt torque sequence—4.6L engine

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

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Do not compress the ratchet assembly. This will damage the ratchet assembly.

9355EG08

6. Compress the tensioner plunger, using an edge of a vise. 7. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 8. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 9. Install a paper clip into the hole in » the tensioner housing to hold the ratchet assembly and plunger in during installation. elf the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.

10. Install or connect the following: Crankshaft sprocket, making sure the timing mark faces forward Timing chain guides LH (inner) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket LH (inner) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket RH (outer) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket RH (outer) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket 11. Make sure that the copper marks on the timing chain are lined up with the corresponding dots on the crankshaft sprockets and the camshaft sprockets. 12. Make sure that the camshaft sprocket keyway is 90 degrees from the valve cover mounting surface.

y 9355EG01

Left cylinder head bolt torque sequence 4.6L engine

>The LH timing chain tensioner arm has a bump near the dowel hole, for identification.

9355EG09

Sprocket alignment—4.6L engine

13. Position the LH and RH timing chain tensioner arm on the dowel pins. 14. Position the RH timing chain tensioner and install the bolts.

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15. Position the LH timing chain ten‘

sioner and install the bolts. +6. Remove both the RH and LH retaining pins from the timing chain tensioner. 17. Remove the special tools from the camshaft.

25.4 mm

(1 INCH)

(A)

25.4mm

(1 INCH)

18. Install the crankshaft sensor ring on the crankshaft. 19. Install the engine front cover. 5.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. : 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Engine front cover 4. Rotate the crankshaft and align the timing marks.

7924AG21

Bagel

Piston and connecting rod positioning on

Piston ring endxgap spacing

5. Remove or disconnect the following: @ Camshaft sprocket bolt e Timing chain, camshaft sprocket

4.6L

TOP COMPRESSION SEGMENT Ott

and crankshaft sprocket as an

BOTTOM

CONTROL RING

assembly To install: 6. Install or connect the following: ¢ Timing chain, camshaft and crankshaft sprockets as an assembly 7. Align the timing marks. e Camshaft sprocket bolt. Torque the bolt to 45 ft. Ibs. (61 Nm). e Engine front cover e Negative battery cable

COMPRESSION

RING

OIL CONTROL RING

ARROW PISTON ENGINE $Qu RT

PISTON

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PISTON PIN

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Piston and Ring

7924AG16

POSITIONING

Piston and connecting rod positioning on 4.0L

Upper Compression Ring

Oil Control

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2nd Compression Ring

During this move, to avoid damage, do not allow the transmission to get into a nose down position as this will cause the converter to move forward and disengage from the pump gear.

10. Install or connect the following: ¢ Converter housing to engine.

64 ft. Ibs. (87 Nm). Crossmember. Torque the bolts to 87 ft. Ibs. (118 Nm). Transmission mount. Torque the bolts to 81 ft. Ibs. (110 Nm). Transmission cooler lines. Torque the bolts to 23 ft. Ibs. (31 Nm). Starter. Torque the bolts to 30 ft.

Ibs. (40 Nm). Transmission wire harness HO2S sensor Transmission connector TR sensor connector Shift cable and bracket

Driveshaft. Torque the bolts to 95

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ft. Ibs. (129 Nm). Shroud. Torque the bolts to 71 inch lbs. (8 Nm). Fluid level indicator e Negative battery cable 11. Fill the transmission to the proper level. 12. Start the vehicle and check for leaks, repair if necessary.

2002 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the transmission in Neutral. 3. Remove or disconnect the following: e Negative battery cable e Transfer case e Three-way catalytic converter 4. If transmission disassembly is necessary, drain the transmission fluid. 5. Support the transmission with a transmission jack. 6. Remove or disconnect the following: ¢ RH heat shield ‘ LH heat shield bolt Plastic cover from the right side of the frame rail Plastic shield on the right side of the crossmember near the fuel tank The two upper crossmember bolts (two on each side) e RH side lower crossmember bolts e LH side lower crossmember bolts Transmission support insulator nuts and remove the crossmember The two bolts and remove the transmission support insulator Shift cable and bracket

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EXPLORER ¢ EXPLORER SPORT ¢ EXPLORER SPORT TRAC ¢ MOUNTAINEER e Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors ->Clean the area around connector to

prevent contamination of the solenoid body connector.

7. Remove or disconnect the following: Screw from the solenoid body connector and disconnect the connector Harness retainers Left side heated oxygen sensor (HO2S) connector from the bracket Digital transmission range (TR) sensor connector Starter

WARNING

vehicle was equipped with a fluid filter, install a new filter (XC3Z-7B155-AB). 16. Connect the battery ground cable. 17. Verify that the shift cable is correctly adjusted.

14. Install and lubricate new O-ring seals on the transmission connector and connect the connector. 15. Install or connect the following; Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed (ISS) sensor electrical connectors. Shift cable and bracket Three-way catalytic converter Transmission support insulator. Torque to 68 ft. Ibs. (QONm). Crossmember in place and loosely install the two nuts to hold up the

REMOVAL & INSTALLATION 1998-00 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Clutch hydraulic system master cylinder from the clutch pedal ° Starter e Hydraulic coupling at the transmission e Transmission from the vehicle 3. Mark the assembled position of the pressure plate in relation to the flywheel to aid during reassemble. e Loosen the pressure plate and cover attaching bolts evenly until the pressure plate springs are expanded e Pressure plate and cover assembly and the clutch disc from the flywheel e Pilot bearing, only if replacing

crossmember.

Do not damage the cooler tubes ' e Transmission cooler tubes

e Access cover

contamination of the solenoid body connector. Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.

—

e>Make an identifying mark on the nut, stud, and adapter plate to allow for correct installation. .

e The 4 torque converter nuts e The 7 engine-to-transmission retaining bolts 8. Lower the transmission from the vehicle. To install: 9. Raise and position the transmission. 10. Align the flexplate to converter marks made at removal. 11. Install seven engine to transmission retaining bolts. Torque to 35 ft. Ibs. (48Nm). 12. Install the four torque converter nuts. Torque to 28 ft. Ibs. (48Nm). 13. Install or connect the following: Access cover Transmission cooler tubes

Crossmember bolts. Torque to 52 ft. Ibs. (70Nm). Rear transmission support nuts. Torque to 52 ft. Ibs. (70Nm). Heat shields Plastic cover to the right side of the frame rail Plastic shield on the right side of the crossmember near the fuel tank Transfer case elf the vehicle was not equipped with a fluid filter, install a Fluid Filter Service Kit (XC3Z-7B155-AA). Follow the instructions supplied in the kit. If the

FLYWHEEL

TRANSMISSION

Starter Digital transmission range (TR) sensor connector Left side heated oxygen sensor

(HO2S) to the bracket Wire harness, and install the retainers

+ WARNING Damage will occur to the solenoid body assembly if the screw is tight-

ened above 44 inch Ibs. (5Nm).

Always install new O-ring seals on vehicle harness connector. Clean the area around connector to prevent

BOLT 21-32 Nem (15-24 FT-LB) CLUTCH PLATE AND COVER

-27 Nem

(15-20 FT-LB)

CLUTCH SLAVE CYLINDER ASSEMBLY 7924EG17

Clutch disc, pressure plate and bearing assembly

Timing belt service is covered in Section 3 of this manual

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7924EG18

Tighten the bolts gradually in the correct sequence to avoid warping the pressure plate

To install: 4. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft tool T74P-7137-K can enter the clutch pilot bearing and align the disc. 5. When reinstalling the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. 6. Install or connect the following: e Pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Torque the bolts to 15-25 ft. Ibs. (21-35 Nm) in the proper sequence. Remove the clutch disc pilot tool Transmission into the vehicle Starter Coupling by pushing the male coupling into the slave cylinder Hydraulic clutch master cylinder pushrod to the clutch pedal e Negative battery cable 7. Bleed the hydraulic clutch system

2001-02 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transmission e>if the parts are to be reused, indexmark the clutch pressure plate to the flywheel.

¢ Bolts, clutch pressure plate and the clutch disc To install: 3. Lubricate the transmission input shaft pilot bearing with grease.

4. Adjust the clutch pressure plate: a. Using a Suitable press, press downward on the fingers until the adjusting ring moves freely. b. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. c. Release the pressure on the fingers. The adjusting ring will stay in the reset position. 5. Position the clutch disc on the flywheel. 6. Align the clutch disc and the clutch pressure plate. Install the bolts and tighten ina star pattern sequence. Torque to 21 ft. lbs. (28Nm). An “L” is stamped by three bolt holes on the clutch pressure plate. Tighten these to specification first to ensure correct clutch alignment. 7. Install the transmission.

ADJUSTMENT

Because the clutch is hydraulically driven, there is no adjustment required. In the event the clutch pedal develops a squeak or uneven feel when depressing, spray the pedal bushing assembly with penetrating oil and work the pedal back-andforth.

Hydraulic Clutch System BLEEDING The following procedure is recommended for bleeding the clutch hydraulic system installed on the vehicle. It is recommended that the original clutch tube, with quickconnect fitting be replaced when servicing the hydraulic system, because air can be trapped in the quick-connect fitting and prevent complete bleeding of the system. The replacement tube does not include a quickconnect fitting. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Clean the dirt and grease from the dust cap. 3. Remove the cap and diaphragm and fill the reservoir to the top with approved brake fluid C6AZ-19542-AA or BA, (ESAM6C25-A). e>To keep brake fluid from entering the clutch housing, route a suitable rubber tube of appropriate inside diameter from the bleed screw to a container.

4. Loosen the bleed screw, located in the slave cylinder body, next to the inlet connection. Fluid will now begin to move from the master cylinder down the tube to the slave cylinder. ->The reservoir must be kept full at all times during the bleeding operation, to ensure no additional air enters the system.

5. Observe the bleed screw outlet. When the slave cylinder is full, a steady stream of fluid will flow from the outlet port. Tighten the bleed screw. 6. Depress the clutch pedal to the floor and hold for 1-2 seconds. Release the pedal as rapidly as possible. The pedal must be released completely. Pause for 1-2 seconds. Repeat 10 times. 7. Check the fluid level in the reservoir. ' The fluid should be level with the step when the diaphragm is removed. 8. Hold the pedal to the floor, slightly open the bleed screw to allow any additional air to escape. Close the bleed screw, then release the pedal. ' 9. Check the fluid in the reservoir. The hydraulic system should now be fully bled, and should actuate the clutch. 10. Check the vehicle by starting, pushing the clutch pedal to the floor and selecting reverse gear. There should be no grating of gears. If there is, and the hydraulic system still contains air; repeat the bleeding procedure.

Transfer Case Assembly REMOVAL & INSTALLATION 1998-00 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

7924EG21

Transfer case-to-extension bolt torque sequence

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7924EG19

Exploded view of the 13-54 mechanical shift transfer case-to-transmission mounting

TO TRANSMISSION EXTENSION GASKET

TRANSFER CASE

TRANSMISSION

SPEEDOMETER DRIVEN GEAR FROM THIS POINT

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Exploded view of the 13-54 electronic shift transfer case-to-transmission mounting—44-05 model is similar

Heater Core replacement is covered in Section 2 of this manual

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2. Place the transmission in Neutral. 3. Drain the transfer case. 4. Remove or disconnect the following: Negative battery cable Skid plate Damper, if equipped Wire connector from rear of the transfer case, on electronic-shift models Front driveshaft from the axle input yoke Clamp retaining the front driveshaft boot to the transfer case, and pull the driveshaft and front boot assembly out of the transfer case front output shaft, if equipped Rear driveshaft from the transfer case output shaft yoke Speedometer driven gear from the transfer case rear cover, if equipped Electrical plug from the Vehicle Speed Sensor (VSS), if equipped Vent hose 5. On manual-shift models, perform the following: a. Remove the shift lever retaining nut and remove the lever. b. Remove the bolts that retains the shifter to the extension housing. Note the size and location of the bolts to aid during installation. Remove the lever assembly and bushing. 6. If equipped, remove the heat shield from the transfer case. 7. Support the transfer case with a transmission jack. 8. Install or connect the following: e 5 bolts (6 bolts on the AWD transfer case) retaining the transfer case to the transmission and the extension housing Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Gasket from between the transfer case and extension housing To install: 9. Install or connect the following: e Heat shield onto the transfer case, if equipped e New gasket between the transfer case and adapter 10. Align the output shaft with the splined transfer case input shaft. Slide the transfer case forward on to the transmission output shaft and onto the dowel pin. Torque the bolts to 25-35 ft. Ibs. (34-47 Nm). Shifter to the extension housing Vent tube VSS plug, if equipped

Speedometer driven gear to the rear cover, if equipped Driveshaft front boot, if equipped Front driveshaft to the axle input yoke Wire connector to the rear of the transfer case Damper, if equipped Skid plate Negative battery cable 11. Fill the transfer case to the proper

level.

:

12. Start the vehicle and check for leaks, repair if necessary.

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

2. Place the transmission in Neutral.

3. cable. 4. shafts. 5. . essary, fluid. 6. ing:

Disconnect the negative battery

Matchmark the front and rear driveIf transfer case disassembly is necremove the drain plug and drain the Remove or disconnect the follow-

2001-02 AUTOMATIC SHIFT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the transmission in Neutral. 3. Remove or disconnect the following: e Negative battery cable e Skid plate ->Drain the transfer case if disassembly is necessary.

e>Match-mark the front and rear driveshaft yokes and pinion flange and the rear driveshaft yoke and rear output flange.

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Rear driveshaft Front driveshaft Vent tube Shift motor electrical connector 4. Using a suitable high lift jack, support the transfer case. 5. Remove or disconnect the following: RH crossmember cover, then the four bolts The four LH crossmember bolts Heat shields from the crossmember Transmission mount nuts The seven bolts and separate the transfer case from the extension housing 6. Lower the transfer case from the vehicle. 7. Remove and discard the transfer case-to-extension housing gasket. Clean the gasket surfaces. 8. To install, reverse the removal procedure. Use a new transfer case gasket. 9. Torque the transfer case-to-extension housing bolts to 30 ft. Ibs. (40Nm). 10. Torque the crossmember bolts to 46 ft. Ibs. (63Nm). 11. Torque the mount nuts to 72 ft. Ibs. (98Nm).

Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft ‘and the boot can and cause the boot to tear.

Front driveshaft Rear driveshaft Skid plate Hose from the vent The two bolts retaining the heat shield to the crossmember. Loosen, but do not remove, the two nuts retaining the transmission mount to the crossmember. The three bolts and the heat Shield

7. Position a high lift jack under the transfer case. 8. Remove or disconnect the following:

e The four upper nuts and bolts retaining the crossmember to the frame

e The two lower bolts retaining the crossmember to the frame The two nuts retaining the transmission mount to the crossmember e The crossmember The two bolts, the transmission mount, and the exhaust hanger

e>Support the transmission.

e The seven bolts retaining the transfer case to the transmission 9. Separate the transfer case from the extension housing and the output shaft. 10. Lower the transfer case from the vehicle. 11. Remove and discard the gasket, and clean the mating surfaces. 12. To install, reverse the removal procedure. Note the following:

FORD MOTOR CO.

EXPLORER e EXPLORER SPORT ¢ EXPLORER SPORT TRAC ¢ MOUNTAINEER J 0-33 Install a new gasket on the transfer case. Watch for obstructions when installing the transfer case in the vehicle. Install the original transfer case to transmission bolts. If new bolts are required, be sure to install only the specific Ford transfer case to transmission bolts. Transfer case-to-extension: 30 ft. lbs. (40Nm)

2001-02 FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Loosen the front axle wheel hub retainer. Wheel and tire assembly Hub retainer and the washer. Discard the front axle wheel hub retainer. The two bolts and position the disc brake caliper aside Tie-rod end from the knuckle. Discard the nut. e Stabilizer bar link. Discard the nut.

Transmission mount bolts: 66 ft. lbs. (90Nm) Crossmember bolts/nuts: 52 ft. Ibs. (70Nm) ¢ Heat shield: 18 ft. Ibs. (25Nm)

+

WARNING

REMOVAL & INSTALLATION

Do not allow the knuckle to hang

1998-00

freely. It is possible to overextend and internally separate each inner CV joint from its housing.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Front wheel Manual locking hub assembly from the rotor by pulling straight outward Plastic stub shaft retainer Front disc brake caliper from the anchor and move it aside. Support the front suspension lower arm. Upper ball joint from the steering knuckle Outboard front driveshaft from the hub Halfshaft from the axle housing Driveshaft and joint from the axle housing To install: 3. Install or connect the following: Halfshaft and joint to the axle housing Outboard front driveshaft to the hub

Upper ball joint to the steering knuckle Brake caliper to the anchor and remove the front suspension support New stub shaft retainer Locking hub to the brake rotor Front wheel Negative battery cable

e Upper ball joint from the knuckle

Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components may result.

4. Press the outboard CV joint until it is loose in the hub. 5. Remove the outboard CV joint from the hub.

Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing. e>A circlip retains the inboard CV joint housing to the differential side gear in the axle.

6. On the left side, pry the LH inboard CV joint housing from the differential side gear. 7. On the right side, disengage the RH inboard CV joint housing from the axle tube. 8. Pull the halfshaft and the axle shaft away from the axle tube, and separate the inboard CV joint housing from the axle shaft. 9. Remove the halfshaft assembly from the vehicle.

Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV joint housing, or the axle shaft splines.

10. To install, reverse the removal procedure. 11. Always install the halfshaft with a new retainer circlip and a new front axle wheel hub retainer. 12. On the right side, check the retainer circlip engagement after reseating the axle shaft and after installing the halfshaft in the axle. On the LH side, check the retainer circlip engagement after installing the halfshaft in the axle. When seated, the retainer circlip will lock the axle shaft and the inboard CV joint housing to the axle.

Never use power tools to tighten the front axle wheel hub retainer. Torque the retainer to 184 ft. Ibs. (250 Nm). eit may be necessary to support the front suspension lower arm to be able to connect the upper ball joint to the knuckle.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.: 2. Remove or disconnect the following:

ck WARNING Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. e Wheel and tire assembly ->Have an assistant press the brake pedal to keep the axle from rotating.

Brake service is covered in Section 4 of this manual

Hub retainer and the washer Caliper. Position the disc brake caliper out of the way. Brake disc Bolt retaining the parking brake cable bracket to the frame

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Using a rubber hose approximately 37.5 mm (1.5 in) long, cover the stabilizer link bolt threads and nut to ‘prevent boot damage when removing the halfshaft assembly from the vehicle. ,

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The bolt that retains the upper ball joint to the knuckle is longer and it has fewer threads than the bolt that. retains the toe link to the knuckle. Switching these bolts during installation will prevent the pinch arms on the knuckle from correctly retaining the toe link to the knuckle. This may cause the toe link to separate from the knuckle during vehicle operation. Failureto follow these instructions may result in personal injury.

-e Pinch bolts and disconnect the toe link and upper ball joint from the knuckle

ok WARNING “Usinga wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension “upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle. ->Do not use a hammer to separate the outboard CV joint from the hub. Dam~age to the threads and internal CV joint

components may result. Once the outboard CV joint separates from the hub the knuckle will continue to pivot until the brake backing plate presses against the suspension lower arm. To prevent damage to the brake backing plate, immediately after separating the outboard CV joint from the hub, rest the knuckle on a cushioned support that is tall enough to keep the backing plate from pressing against the suspension lower arm.

3. Press the outboard CV joint until it is loose in the hub. 4. Separate the outboard CV joint from the hub. 5. Rest the knuckle on a cushioned Support.

Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.

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6. Using the special tool, disengage the inboard CV joint a | from the differential side gear.Pig ter .To set timing correctly, a remote starter should not be used. Use the ignition key only to start the vehicle. Disconnecting the start wire at the starter relay will cause the Ignition Control Module (ICM) to revert to “start mode timing” after the vehicle is started. Reconnecting the start wire after the vehicle is running will not correct the timing.

Accessory drive belt Engine air cleaner outlet tube Intake manifold assembly Bulkhead connector cover Bulkhead connector

6. With the engine running at the timing rpm specified, check the initial timing by aiming the timing light at the timing marks and pointer. Refer to the underhood Vehicle Emission Control Information (VEC!) label for specific specifications. 7. Ifthe marks do not align, shut the engine OFF and loosen the distributor hold-down clamp bolt. Start the engine, and while watching the timing marks with the timing light, turn the’distributor until the marks are correctly aligned. Shut the engine OFF, then tighten the distributor hold-down clamp bolt to 17-25 ft. Ibs. (23-34 Nm). 8. Reattach the single wire inline spout connector or reinstall the shorting bar on the double wire spout connector. Check the timing advance to verify the distributor is advancing beyond the initial setting. 9. Remove the timing light and tachometer.

Engine Assembly REMOVAL & INSTALLATION

>< CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Both battery cables, negative cable first e Hood

e Coolant

radiator

The 3 power steering reservoir bracket retaining bolts and move the reservoir aside The 2 Differential Pressure Feedback (DPFE) transducer hoses Upper and lower Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube fittings and the tube Heater water hose Ignitian coil, radio capacitor and Camshaft Position (CMP) sensor electrical harness connectors Both ignition coils and mounting bracket bolts, the coil and bracket assemblies Starter motor The 3 lower radiator air deflector

Screws 5 clips and remove the air deflector Air conditioning compressor electrical harness connector Air conditioning manifold-to-compressor bolt, the manifold and tube assembly The 3 air conditioning compressor retaining bolts and the air conditioning compressor Fluid cooler hoses from the block mounted clip Inspection cover, torque converter bolts and transmission-to-engine retaining bolts, on vehicles with automatic transmissions Upper and lower power steering pump bolts and move the power steering pump aside Exhaust system from the exhaust manifolds and support with wire hung from the crossmember Right-hand and left-hand engine

support insulator (mount) throughbolts 4. Install a suitable engine lifting bracket and connect suitable engine lifting equipment to the lifting brackets. 5. Carefully raise the engine out of the

11-5

To install: 6. Install the engine lifting brackets. Support the engine using a suitable floor crane installed to the lifting equipment and remove the engine from the work stand. 7. Carefully lower the engine into the engine compartment. Start the converter pilot into the flywheel and align the paint marks on the flywheel and torque converter. Be sure the studs on the torque converter align with the holes in the flywheel. 8. Fully engage the engine to the transmission and lower onto the engine support insulators. 9. Remove the engine lifting equipment and brackets. 10. Raise and safely support the vehicle. 11. Install or connect the following: The 6 engine-to-transmission retaining bolts and tighten to 30-44 ft. Ibs. (40-60 Nm) The engine support insulator through-bolts and tighten to 15-22 ft. Ibs. (20-30 Nm) The 4 torque converter retaining nuts and tighten to 22—25 ft. Ibs. (20-30 Nm) Transmission housing cover to the cylinder block Exhaust pipes to the exhaust manifolds and tighten to 30 ft. Ibs. (41 Nm) Power steering pump in position on the cylinder block and install 4 retaining nuts. Tighten to 15-20 ft. Ibs. (20-30 Nm). Starter motor Transmission fluid cooler hoses into the cylinder block mounted clip Air conditioning compressor in position and install the 3 retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm). Air conditioning manifold and tube assembly on the compressor and install the retaining bolt. Tighten the bolt to 14-18 ft. Ibs. (18-24 Nm). Air conditioning compressor clutch electrical harness connector Lower radiator air deflector Ignition coil and bracket assemblies. Tighten the retaining nuts to 15-23 ft. Ibs. (20-30 Nm). Ignition coil, radio capacitor and CMP sensor electrical harness con-

engine compartment and place on a work stand. Remove the engine lifting equipment.

Please visit our web site at www.chiltonsonline.com

nectors Rear heater water hose and com-

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FORD MOTOR CO.

EXCURSION ¢ EXPEDITION

press and slide the clamp in position e EGR valve-to-exhaust manifold tube and tighten the upper and lower fittings to 26-33 ft. Ibs. (35-45 Nm) e DPFE transducer hoses e Power steering pump reservoir in position and install the 3 retaining bolts. Tighten the bolts to 71-107 inch Ibs. (8-12 Nm). e Engine bulkhead connector and install the retaining bolt. Tighten the bolt to 36-50 inch Ibs. (4-6 Nm). e Bulkhead connector cover e Intake manifold assembly e Accessory drive belt e Radiator, cooling fan and shroud e Engine air cleaner outlet tube 12. Fill the engine with the correct amount and type of engine oil. 13. Fill and bleed the engine cooling system. 14. Connect both battery cables, nega-

tive cable last. 15. Start the engine and allow to reach normal operating temperature while checking for leaks. 16. Check all fluid levels. 17. Properly evacuate and recharge the aif conditioning system using approved equipment. 18. Install the hood, aligning the marks that were made during removal. 19. Road test the vehicle and check the engine and transmission for proper operation.

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NAVIGATOR

20-30 Nm (15-22 Ib/ft) 7924FG02

Exploded view of the water pump mounting—4.6L, 5.4L and 6.8L engines

To install: 3. Before installing the water pump, be sure to completely clean the water pump mounting surfaces of all dirt, grime and old gasket material. >All water pump housing bolts, nuts and studs are tightened to 15-22 ft. Ibs. (20-30 Nm).

4. \nstall or connect the following: e Water pump onto the engine with a new gasket. Install the water pump stud bolt temporarily finger-tight. Water pump mounting nuts and bolts temporarily finger-tight, then tighten all water pump housing fas-

teners to 15-22 ft. Ibs. (20-30 Nm). Water outlet tube for the heater, if equipped

e Water pump pulley and accessory drive belt e Fan shroud, fan blade assembly and the radiator e Coolant e Negative battery cable 5. Start the engine and check for any fluid leaks. 6. If necessary, bleed the cooling system.

Cylinder Head

6

REMOVAL & INSTALLATION

Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system

Water Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Radiator, fan blade assembly and fan shroud Accessory drive belt Water pump pulley Heater hose from the water pump Water pump bolts and nuts. Note the locations of the bolts if different lengths. Water pump stud bolt, the water pump and the water pump housing gasket. Discard the water pump housing gasket.

7924FG04

Tighten the cylinder head bolts using 3 steps in this sequence—4.6L and 5.4L engine

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FORD MOTOR CO.

EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

11-7.

e Timing chains e Intake manifold e Cylinder head covers ¢ Refrigerant e Engine oil e Coolant e Negative battery cable 8. Start the engine and check for any fluid or vacuum leaks,

REMOVAL & INSTALLATION 4.6L and 5.4L Engines 7924FG81

Tighten the cylinder head bolts using 3 steps in this sequence—6.8L engine

pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. >To correctly tighten the cylinder head bolts an angle torque wrench is needed. .

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Air conditioning system, using approved equipment Negative battery cable Cylinder head covers Intake manifold Timing chains from the engine Exhaust manifolds The 2 heater hose retaining bolts, then compress and slide the hose clamp back to remove the heater water hose The cylinder head bolts, then lift the cylinder head from the engine block 3. Discard the cylinder head gasket and clean the engine block surface. To install:

block. Loosely install NEW cylinder head bolts. i Be sure to tighten the head bolts in 3 steps.

6. Tighten the cylinder head bolts in the correct Sequence using 3 steps, as follows: a. Step 1: 27-382 ft. lbs. (37-43 Nm). b. Step 2: tighten an additional 85-95 degrees. ¢. Step 3: tighten another 85-95 degrees. 7. Install or connect the following: e Heater hose e Exhaust manifolds

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the camshaft covers. 4. Position the piston of the cylinder being serviced at the bottom of its travel. ->Two different valve spring compressor tools are used for this procedure. Valve Spring Compressor (T91P-6565-

A) is used on the exhaust camshaft and Valve Spring Compressor (T93P-6565A) is used on the intake camshaft. 5. Compress the valve spring and remove the rocker arm. To install: 6. Position the piston of the cylinder being serviced at the bottom of its travel.

VALVE SPRING COMPRESSOR

VALVE SPRING SPACER

Cylinder head bolts must be replaced with new ones. They are torque-toyield designed and cannot be reused. 4. Turn the crankshaft to position the keyway at the 12 o'clock position. 5. Clean and inspect the cylinder head for damage or warpage. Install the cylinder head gasket over the dowel pins. Then, install the cylinder head onto the engine

VALVE SPRING SPACER

7924FG37

Using the proper tool, compress the valve spring and remove the rocker arm—4.6L and 5.4L

engine

Timing belt service is covered in Section 3 of this manual

iE eat Oe AN AP a a ally rt i, inte -44- (FoRDMotoR co. ; EXCURSION « EXPEDITION » NAVIGATOR Engine air cleaner outlet tube Accelerator cable from the bracket

7924FG82

Compress the valve spring and remove the rocker arm—6.8L engine

7. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore. Valve tappet should have no more than “ce inch (1.5mm) of travel before installing the rocker arm.

8. Compress the valve spring using the correct tool and install the rocker arm.

6.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ‘2. Disconnect the negative battery cable. 3. Remove the camshaft covers. 4. Position the base circle of the camshaft lobe on the rocker arm to be serviced. Also, be sure the piston is not at the top of its travel near the valve. 5. Compress the valve spring and remove the rocker arm. To install: 6. Position the base circle of the camshaft lobe over the place where the rocker arm is to be installed. 7. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore. 8. Compress the valve using the special tool and install the rocker arm. 9. Install the rocker arm covers and the remaining components.

been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Fuel system pressure e Coolant e Upper radiator hose from the intake manifold

and the throttle body cam Speed control actuator cable from the throttle body ; All vacuum hoses, fuel lines and electrical wires from the throttle body and intake manifold Brake booster vacuum hose bracket Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tube Fuel injector electrical connectors Radio interference capacitors from the left side of the intake manifold, on the 6.8L engine Spark plug wires, if necessary Accessory drive belt Alternator Power steering oil reservoir bracket and set aside. Heater hose from the intake manifold Intake manifold bolts Intake manifold from the engine, then detach the Intake Manifold Tuning Valve (IMTV) electrical connector. Remove and discard the upper intake manifold gaskets.

Intake Manifold

REMOVAL & INSTALLATION e>When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy.

stk CAUTION Fuel injection systems remain under pressure, even after the engine has

. 7924FG10

Tighten the lower intake manifold bolts in 2 steps using this sequence—4.6L shown, 5.4L engine similar

FORD MOTOR CO. 1 1-9 |

EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

e Upper-to-lower intake manifold bolts, then separate the upper ~ intake manifold from the lower intake manifold. Discard the old gasket. To install: 3. Position the lower intake manifold. gasket and the upper intake manifold onto the lower intake manifold, then loosely install the upper-to-lower intake manifold bolts. e>Be sure to tighten the lower-to-upper manifold bolts in 2 steps.

4. Tighten the 8 lower-to-upper intake manifold bolts in 2 steps following the tightening sequence as follows: a. Step 1: 18 inch Ibs. (2 Nm). b. Step 2: 72-96 inch Ibs. (8-12 Nm). 5. Position the 2 upper intake manifold gaskets on the cylinder heads. Set the upper intake manifold in place on the engine, then loosely install the 9 intake manifold-tocylinder head bolts. 6. Attach the IMTV electrical connector. 7924FG11

Tighten the upper intake manifold bolts using this sequence—4.6L shown, 5.4L engine similar

e>Check that the thermostat housing is in the correct position before the thermostat housing is installed.

7. Install the thermostat housing and start the 2 housing bolts. e>Make certain to tighten the intake manifold in 2 steps.

8. Tighten the intake manifold bolts using the sequence shown, in 2 steps. a. Step 1: 18 inch Ibs. (2 Nm). b. Step 2: 15-22 ft. Ibs. (20-30 Nm).

9. Install or connect the following:

7924FG83

Tighten the upper-to-lower intake manifold bolts using this sequence—6.8L engines

Heater water hose Power steering bracket and the power steering pump bracket bolts. Tighten to 71-107 inch Ibs. (8-12 Nm). All electrical connections, fuel lines, vacuum tubes and coolant hoses to the intake manifold, fuel injectors and throttle body assembly Alternator and the accessory drive belt Spark plug wires EGR valve-to-exhaust manifold tube. The tube fittings should be tightened to 26-33 ft. Ibs. (35-45 Nm). Speed actuator cable, if equipped, and the accelerator cable to the throttle body

Heater Core replacement is.covered in Section 2 of this manual

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EXCURSION e EXPEDITION ¢ NAVIGATOR

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DIESEL ENGINE REPAIR Alternator

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Battery ground cable e Connectors from the alternator e Drive belt from the alternator pulley. e Alternator retaining bolts e Alternator from the vehicle

INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install or connect the following: e Alternator and the retaining bolts. Tighten the retaining bolts to

15-21 ft. Ibs. (21-29 Nm). e Drive belt. e Alternator connectors e Battery ground cable

Engine Assembly REMOVAL & INSTALLATION

kk CAUTION The fuel system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Hood Coolant Engine oil Negative battery cable Air cleaner and intake duct assembly Upper grille support bracket Upper air conditioning condenser mounting bracket Refrigerant, using approved equipment to remove the condenser Radiator fan shroud halves Fan and clutch assembly Radiator hoses and the transmission cooler lines, if equipped

¢ Condenser. Cap all openings immediately! Radiator Power steering pump and position it out of the way Fuel supply line heater and alternator wires at the alternator Oil pressure sending unit wire at the sending unit

Sender from the firewall and lay it on the engine Accelerator cable and the speed control cable, if equipped, from the injection pump Accelerator cable bracket with the cables attached, from the intake manifold and position it out of the way Transmission kickdown rod from the injection pump, if equipped Main wiring harness connector from the right side of the engine and the ground strap from the rear of the engine Fuel system pressure Fuel return hose from the left rear of the engine The 2 upper transmission-toengine attaching bolts Heater hoses Water temperature sender wire Overheat light switch wire and position the wire out of the way Battery ground cables from the front of the engine and the cables from the starter Fuel inlet line, and plug the fuel line at the fuel pump Exhaust pipe at the exhaust manifold Engine insulators from the no. 1 crossmember Flywheel inspection plate and the 4 converter-to-flywheel attaching nuts, if equipped with automatic transmission 3. Support the transmission on a jack. 4. Remove the 4 lower transmission attaching bolts. 5. Attach an engine lifting sling and remove the engine from the vehicle. To install: 6. Lower the engine into vehicle. 7. Align the converter to the flexplate and the engine dowels to the transmission. 8. Install the engine mount bolts and tighten them to 80 ft. Ibs. (109 Nm). 9. Remove the engine lifting sling. 10. Install the 4 lower transmission attaching bolts. Tighten the bolts to 65 ft. lbs. (88 Nm).

11. Remove transmission jack. 12. Raise and support the front end. 13. Install or connect the following: -e A4converter-to-flywheel attaching nuts, if equipped with an automatic transmission. Tighten the nuts to 34 ft. Ibs. (47 Nm). Flywheel inspection plate. Tighten the bolts to 60-90 inch Ibs. (6.7-10 Nm). Exhaust pipe at the exhaust manifold Fuel inlet line Battery ground cables to the front of the engine Starter cables at the starter Overheat light switch wire Water temperature sender wire Heater hoses The 2 upper transmission-toengine attaching bolts. Tighten the bolts to 65 ft. Ibs. (88 Nm). Fuel return hose at the left rear of the engine Main wiring harness connector at the right side of the engine and the ground strap from the rear of the engine. Transmission kickdown rod at the injection pump, if equipped Accelerator cable and the speed control cable, if equipped, at the injection pump. Cable bracket with the cables attached, to the intake manifold Oil pressure sending unit Oil pressure sending unit wire at the sending unit Fuel supply line heater and alternator wires at the alternator Power steering pump Radiator Condenser Radiator hoses and the transmission cooler lines, if equipped. Fan and clutch assembly Radiator fan shroud halves Upper grille support bracket and upper air conditioning condenser mounting bracket. Air cleaner and intake duct assembly 14. Refill the engine oil with the recommended type of engine oil and the correct amount.

15. 16. charge 17. 18.

Connect the negative battery cable. If equipped with air conditioning, the system. Fill the cooling system. Install the hood.

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FORD MOTOR CO. 44 4 e

EXCURSION © EXPEDITION ¢ NAVIGATOR

WATER PUMP

e Drive belt e Tighten the pulley retaining bolts to 12-18 ft. Ibs. (16-24 Nm) e Fan and fan shroud assembly 6. Fill and bleed the cooling system. 7. Connect the battery ground cables. 8. Start the engine and check for leaks.

REMOVAL & INSTALLATION

:< CAUTION The red-striped wiring harness carries 115v direct current. Severe electrical shock may be received. DO NOT pierce.

NO. 3 OR EQUIVALENT TO THESE BOLTS &

® THESE BOLTS 2 3/4 IN. LONG ALL OTHERS ARE 1 1/2 IN. LONG 7924FG56

Apply RTV sealant tothe bolts indicated—7.3L diesel engine

Water Pum |

REMOVAL &INSTALLATION. ;

cables.

e Water pump attaching bolts. Tighten the bolts to 15 ft. Ibs. (20 Nm).

* Heater hose to the pump e ECT sensor connector

.

2. Drain the cooling system. 3. Remove or disconnect the following: e Radiator shroud, fan clutch and fan

>The fan clutch bolts are right-hand

water pump pulley bolts

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rocker arm cover e Glow plug electrical leads using a pair of pliers e Glow plugs by unscrewing them from the cylinder head with a 10mm socket and wrench 3. Inspect the tips of the plugs for any evidence of distortion or missing tip ends; replace them if necessary.

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19 Nm

(14 lb/ft)

thread. Remove them by turning counter-clockwise.

Water pump pulley bolts, loosen only at this time Drive belt Water pump pulley bolts and the pulley Engine Coolant Temperature (ECT) sensor connector Heater hose from the water pump Bolts attaching the water pump to the front cover and lift off the pump To install: 4. Thoroughly clean the mating surfaces of the pump and front cover. 5. Install or connect the following: e New gasket ¢ Water pump over the dowel pins and into place on the front cover

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7924FG57

Tighten the glow plugs to 14 ft. Ibs. (19 Nm) and attach the connector—7.3L engine

For Maintenance Interval recommendations, see Section 1 of this manual

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EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

To install: 4. Install or connect the following: e Glow plug into the cylinder head. Tighten the glow plugs to 14 ft. Ibs. (19 Nm). e Glow plug electrical connector. Be sure that the glow plug wiring Is routed to avoid moving components in the engine bay. e Rocker arm cover e>When the battery is disengaged and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn this strategy.

e Negative battery cable

Cylinder Head REMOVAL & INSTALLATION Right Cylinder Head

*¢ CAUTION The fuel system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

~ e Exhaust back pressure line e Three glow plug relay bracket nuts and the ground wire Heater hose from the cylinder head Outer half of the heater distribution box Four outboard fuel injector holddown bolts, retaining screws and four oil deflectors ack WARNING Remove the oil drain plugs prior to removing the injectors or oil could enter the combustion chamber which could result in hydrostatic lock and severe engine damage. ' e (il rail drain plugs e Fuel injectors using Injector Remover No. T94T—9000—AH1, or equivalent. Position the tool's fulcrum beneath the fuel injector hold-down plate and over the edge of the cylinder head. Install the remover screw in the threaded hole of the fuel injector plate (see illustration). Tighten the screw to lift out the injector from its bore. Place the injector in a Suitable protective Sleeve such as Rotunda Injector Protective Sleeve, No.

014-00933-2, and set the injector ina suitable holding rack. 4. Use a suitable vacuum tool, such as Rotunda Vacuum Pump, No. 021-00037, or equivalent to remove the oil and fuel left over in the injector bores. 5. Remove or disconnect the following: Rocker arms and pushrods, KEEP EVERYTHING IN ORDER Four glow plugs Right turbo exhaust inlet pipe Ground strap from the rear of the cylinder head Fuel return line at the front of the cylinder head Four inboard fuel injector shoulder bolts Cylinder head bolts and attach a Rotunda Cylinder Head Lifting Bracket, 014-00932-2, or equivalent 6. Carefully lift the cylinder head out of the engine compartment and remove the head gaskets. To install: >To prepare a good seat for the fuel injector O-rings, use a suitable injector sleeve brush to clean any debris from the bore.

7. Carefully clean the cylinder block and head mating surfaces. 8. Install or connect the following:

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

tion.

2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cables Radiator Turbocharger assembly Fuel lines from the rear of both cylinder heads and the fuel pump Wiring from the alternator Adjusting bolts and pivot bolts from the alternator and the vacuum pump and remove both units Alternator and its bracket Engine oil dipstick tube Manifold Absolute Pressure (MAP) sensor and position it aside Valve cover Connectors from the injectors and glow plugs Valve cover gasket High pressure oil pump supply line to the right cylinder head

9355FG01

Cylinder head torque sequence—diesel engines

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FORD MOTOR CO. 11-23

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EXCURSION © EXPEDITION ¢ NAVIGATOR

e Cylinder head gasket on the engine block and carefully lower the cylinder head in place e Cylinder head bolt and torque in 3 Steps using the sequence shown in the illustration as follows: a. Step 1: 65 ft. Ibs. (88 Nm). b. Step 2: 85 ft. Ibs. (115 Nm). C. Step 3: 95 ft. Ibs. (129 Nm).

e>Lubricate the threads and the mating Surfaces of the bolt heads and washers with engine oil.

¢ Fuel return line to the cylinder head ¢ Four inboard injector shoulder bolts. Tighten them to 9 ft. Ibs. (12 Nm). 9. Install the fuel injectors using speClal tools as follows: a. Lubricate the injectors with clean engine oil. Using new copper washers, carefully push the injectors square into the bore using hand pressure only to seat . the O-rings. b. Position the open end of Injector Replacer, No. T94T-9000—AH2, or equivalent betweerrthe fuel injector body and injector hold-down plate, while positioning the opposite end of the tool over the edge of the cylinder head. c. Align the hole in the tool with the threaded hole in the cylinder head and install the bolt from the tool kit. Tighten the bolt to fully seat the injector, then remove the bolt and tool. 10. Install or connect the following: e Four outboard fuel injector holddown bolts, the four oil deflectors and retaining screws. Tighten them to 9 ft. Ibs. (12 Nm). 11. Dip the pushrod ends in clean engine oil and install the pushrods with the copper colored ends toward the rocker arms, making sure the pushrods are fully seated in the tappet pushrod seats. e Rocker arms and posts in their original positions. Apply Lubriplate® grease to the valve stem tips. Turn the engine over by hand until the timing mark is at the 11 o'clock position as viewed from the front. ¢ Rocker arm posts, bolts and tighten to 27 ft. Ibs. (37 Nm) e Valve covers ¢ Fuel rail drain plugs, tightening them to 8 ft. Ibs. (17 Nm) © (il rail drain plugs, tightening them to 53 inch Ibs. (6 Nm)

¢ Heater distribution box e Heater hose to the cylinder head ° Glow plug relay bracket and ground wire e Exhaust back pressure line e Oil supply line to the cylinder head, tightening it to 19 ft. bs. (26 Nm) Dipstick tube MAP sensor and screws Valve cover gasket Wiring to the fuel injectors and glow plugs Valve cover, tightening the bolts to 8 ft. Ibs. (11 Nm) Injector wiring harness to the valve cover gasket Alternator, tightening the bracket bolts to 40-55 ft. Ibs. (64-75 Nm) Alternator wiring e Drive belt 12: “atheremainder of the installation is the reverse of the removal. Tighten the fuel pump-to-fuel line banjo bolt to 40 ft. Ibs. (54 Nm), 13. Connect both negative battery cables. 14. Refill and bleed the cooling system. 15. Run the engine and check for fuel, coolant and exhaust leaks.

Left Cylinder head

*k CAUTION The fuel system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Using approved equipment, recover

the refrigerant from the A/C system. 4. Remove or disconnect the following: Negative battery cables Radiator Turbocharger assembly Two crankcase breather screws and the breather Wiring from the air conditioning compressor Four left accessory bracket bolts Vacuum hose at the brake vacuum um A/C lines from the compressor Power steering lines from the pump

e Left accessory bracket and accessories as an assembly e Valve cover e Fuel line assembly between the cylinder heads and fuel pump = e Fuel line nut from the intake manifold stud e Fuel return line from the cylinder head High pressure oil pump supply line from the cylinder head 5. Raise the vehicle and support it Safely on jackstands. e Left turbo exhaust pipe from the manifold 6. Lower the vehicle. e Oil rail drain plugs e Four outboard fuel injector holddown bolts, retaining screws and four oil deflectors

“i WARNING Remove the oil drain plugs prior to removing the injectors or oil could enter the combustion chamber which: could result in hydrostatic lock and severe engine damage. cia

e Oil rail drain plugs a 7. Remove the fuel injectors using ©: » Injector Remover No. T94T—9000—AH1, or . equivalent. Position the tool’s fulcrum beneath the fuel injector hold-down plate and over the edge of the cylinder head. Install the remover screw in the threaded hole of the fuel injector plate. Tighten the screw to lift out the injector from its bore. Place the injector in a suitable protective sleeve such as Rotunda Injector Protective Sleeve, No. 014-00933-2, and set the injector in a Suitable holding rack. 8. Use a suitable vacuum tool, such as Rotunda Vacuum Pump, No. 02100037, or equivalent to remove the oil and fuel left over in the injector bores. 9. Remove or disconnect the following: Rocker arms and pushrods, KEEP EVERYTHING IN ORDER Four glow plugs Left turbo exhaust inlet pipe Main engine harness connectors in the left fender well and position the harness aside Four inboard fuel injector shoulder bolts Cylinder head bolts and attach a Rotunda Cylinder Head Lifting Bracket, 014-00932—2, or equivalent

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

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41-24 FORD moroR co.

EXCURSION ¢ EXPEDITION © NAVIGATOR

10. Carefully lift the cylinder head out of the engine compartment and remove the head gaskets. To install: >To prepare a good seat for the fuel

injector O-rings, use a suitable injector ~ sleeve brush to clean any debris from the bore.

11. Carefully clean the cylinder block and head mating surfaces. 12. Install or connect the following: e Cylinder head gasket on the engine block and carefully lower the cylinder head in place e Cylinder head bolt and torque in 3 steps using the sequence shown in the illustration as follows: a. Step 1: 65 ft. Ibs. (88 Nm). b. Step 2: 85 ft. Ibs. (115 Nm). c. Step 3: 95 ft. Ibs. (129 Nm). Lubricate the threads and the mating surfaces of the bolt heads and washers with engine oil.

13. Apply anti-seize paste and install the glow plugs, tightening them to 14 ft. Ibs. (19 Nm). 14. Install or connect the following: e Four outboard fuel injector holddown bolts, the four oil deflectors and retaining screws. Tighten them to 9 ft. Ibs. (12 Nm). 15. Dip the pushrod ends in clean engine oil and install the pushrods with the copper colored ends toward the rocker arms, making sure the pushrods are fully seated in the tappet pushrod seats. e Rocker arms and posts in their original positions. Apply Lubriplate® grease to the valve stem tips. Turn the engine over by hand until the timing mark is at the 11 o'clock position as viewed from the front. Rocker arm posts, bolts and tighten to 27 ft. Ibs. (37 Nm) Valve covers Four inboard injector shoulder bolts. Tighten them to 9 ft. Ibs. (12 Nm). 16. Install the fuel injectors using speCial tools as follows: a. Lubricate the injectors with clean engine oil. Using new copper washers, carefully push the injectors square into the bore using hand pressure only to seat the O-rings. b. Position the open end of Injector Replacer, No. 194T—9000-AH2, or equivalent between the fuel injector body and injector hold-down plate, while posi-

tioning the opposite end of the tool over the edge of the cylinder head. c. Align the hole in the tool with the threaded hole in the cylinder head and

install the bolt from the tool kit. Tighten

the bolt to fully seat the injector, then remove the bolt and tool. 17. Install or connect the following: Fuel rail drain plugs, tightening them to 8 ft. Ibs. (11 Nm) Oil rail drain plugs, tightening them to 53 inch Ibs. (6 Nm) Heater distribution box Valve cover gasket Wiring to the fuel injectors and glow plugs Valve cover, tightening the bolts to 8 ft. Ibs. (11 Nm) Engine wiring harness 18. Raise and safely support the vehicle on jackstands. 19. Loosely install the turbo exhaust pipe to the manifold. 20. Lower the vehicle. 21. The remainder of the installation is the reverse of the removal. Tighten the fuel pump-to-fuel line banjo bolt to 40 ft. Ibs. (54 Nm). 22. Connect both negative battery cables. 23. Refill and bleed the cooling system. 24. Run the engine and check for fuel, coolant and exhaust leaks.

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

2. Disconnect the ground cables from both batteries. 3. Remove the valve cover attaching Screws and remove both valve covers. 4. Remove the valve rocker arm post mounting bolts. Remove the rocker arms and posts in order and mark them with tape so they can be installed in their original positions. 5. If the cylinder heads are to be removed, then the pushrods can now be removed. Make a holder for the pushrods out of a piece of wood or cardboard and remove the pushrods in order. It is very important that the pushrods be reinstalled in their original order. The pushrods can remain in position if no further disassembly is required. To install: 6. If the pushrods were removed, install them in their original locations. Make sure they are fully seated in the tappet seats.

Item } Description Snap Retaining Clip valid Rocker Arm Pedestal

bite Rocker Arm Ball

:

[4 [Rockerarm bie: Sy Rocker Arm Assembly 7924FG58

Exploded view of the rocker arm assembly—diesel engines

>The copper colored end of the pushrod goes toward the rocker arm.

7. Apply a polyethylene grease to the valve stem tips. Install the rocker arms and posts in their original positions. 8. Turn the engine over by hand until the valve timing mark is at the 11 o'clock position, as viewed from the front of the engine. Install all of the rocker arm post attaching

bolts and tighten to 20 ft. Ibs. (27 Nm). 9. Install new valve cover gaskets and install the valve cover. 10. Install the battery cables, start the engine and check for leaks. .

Turbocharger

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ The 2 air intake tube assembly bolts, clamps at the turbocharger, crankcase breather assembly, engine air cleaner, air intake tube and hoses Exhaust outlet clamp from the turbocharger Engine charge exhaust pipe bolt from the transmission, if so equipped e Bolts and nuts from the catalytic

FORD MOTOR CO.

EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

COMPRESSOR MANIFOLD

11-25

Catalytic converter to the engine charge exhaust pipe bolts and nuts 2 right and left upper bolts (retaining the turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter) to 36 ft. Ibs. (49 Nm) Exhaust outlet clamp to the turbocharger Air intake tube and hose assembly Negative battery cable Intake Manifold

REMOVAL & INSTALLATION

CAUTION The fuel system remains under pressure, even after the engine has been

turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 7924FG59

After loosening the clamps, the compressor manifold can be removed—diesel engines

converter-to-engine charge exhaust pipe, if So equipped 2 bolts retaining the turbocharger exhaust inlet pipe to the left exhaust manifold, loosen only Bolts retaining the left turbocharger exhaust inlet pipe to the turbocharger exhaust inlet adapter, on automatic transmissions 2 bolts retaining the turbocharger exhaust inlet pipe to the right exhaust manifold, loosen only Lower bolt retaining the right turbocharger exhaust inlet pipe to the turbocharger exhaust inlet adapter Upper bolts retaining the right and left turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter, on automatic transmissions Right engine lift hook and bolt Air inlet hose clamp at the turbocharger, hose and lay aside Compressor manifold 4 bolts retaining the turbocharger pedestal assembly to the cylinder block Turbocharger assembly and all electrical connectors from it

e>if the turbocharger is not being removed for service, install the Fuel/Oil turbo Protector Cap Set T94T9395-AH.

e Oil gallery O-rings To install: 3. Install or connect the following: Oil gallery O-rings Turbocharger electrical connectors and the turbocharger assembly 4 bolts retaining the turbocharger pedestal assembly to the engine block. Tighten the bolts to 18 ft. lbs. (25 Nm). 4 bolts retaining the right and left turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter. Compressor manifold, intake manifold hoses and clamps. Be sure the compressor Outlet seal is in position. Right engine lift hook and bolt 2 right and left lower bolts (retaining the turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter) to 36 ft. Ibs. (49 Nm) 4 right and left bolts and nuts (retaining the turbocharger exhaust inlet pipes to the exhaust manifolds) to 36 ft. Ibs. (49 Nm)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Both battery ground cables e Air cleaner and install clean rags into the air intake of the intake manifold. It is important that no dirt or foreign objects get into the intake. Fuel system pressure Injection pump Fuel return hose from No. 7 and No. 8 rear nozzles Return hose to the fuel tank Engine wiring harness from the engine >The engine harness ground cables must be removed from the back of the left cylinder head.

e Bolts attaching the intake manifold to the cylinder heads and the manifold e Crankcase Depression Regulator (CDR) valve tube grommet from the valley pan e Bolts attaching the valley pan strap to the front of the engine block and the strap e Valley pan drain plug and the valley pan To install: 3. Apply a ¥% inch (3mm) bead of RTV Sealer to each end of the cylinder block.

For complete service labor times, order the Chilton Labor Guide

1 : -2 FORD MoTOR co.

EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

LINE SEQUENCE START HERE ->@& (STEP NO. 2)

STEP 1. TIGHTEN BOLTS TO 24 FTeLB IN NUMBERED SEQUENCE SHOWN ABOVE. STEP 2. TIGHTEN BOLTS TO 24 FTeLB IN LINE SEQUENCE

SHOWN

ABOVE.

7924FG25

Intake manifold bolt torque sequence—diesel engines

->The RTV sealer should be applied immediately prior to the valley pan installation.

4. Install or connect the following: Valley pan drain plug, CDR valve tube and new grommet into the valley pan New O-ring and new back-up ring on the CDR valve Valley pan strap on the front of the valley pan Intake manifold and tighten the bolts to 24 ft. Ibs. (33 Nm) using the tightening sequence Engine wiring harness and the engine ground wire located to the rear of the left cylinder head Injection pump No. 7 and No. 8 fuel return hoses and the fuel tank return hose Air cleaner Battery ground cables to both batteries

Exhaust Manifold

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the ground cables from both batteries. 3. Raise the vehicle and safely support it. 4. Disconnect the muffler inlet pipe from the exhaust manifolds.

5. If removing the right manifold, lower the vehicle. When removing the left manifold, raise the vehicle and remove the manifold from underneath. Bend the tabs on the manifold attaching bolts, then remove the bolts and manifold. To install: 6. Before installing, clean all mounting surfaces on the cylinder heads and the manifold. Apply an anti-seize compound on _ the manifold both threads and install the left manifold, using a new gasket and new locking tabs. 7. Tighten the bolts to 45 ft. Ibs. (61 Nm) and bend the tabs over the flats on the bolt heads to prevent the bolts from loosening. 8. Raise the vehicle to install the right manifold. Install the right manifold. 9. Connect the inlet pipes to the manifold and tighten. Lower the vehicle, connect the batteries and run the engine to check for exhaust leaks. Camshaft and Valve Lifters.

REMOVAL & INSTALLATION e->Ford recommends removing the diesel engine from the vehicle for camshaft removal.

1. Before servicing the vehicle, refer to.the precautions in the beginning of this section. 2. Remove or disconnect the following:

LINE SEQUENCE START HERE (STEP NO 2)

e>if necessary, purge the nozzle high pressure lines of air by loosening the connector % to 1 turn and cranking the engine until solid stream of fuel, devoid of any bubbles, flows from the connection.

5. Run the engine and check for oil and fuel leaks. 2

CAUTION

Keep eyes and hands away from the nozzle spray. Fuel spraying from the nozzle under high pressure can penetrate the skin. 6. Check and adjust the injection pump timing.

STEP1. TIGHTEN BOLTS TO 35 FT.LB. IN NUMBERED SEQUENCE SHOWN ABOVE STEP2. TIGHTEN BOLTS TO 35 FT.LB. IN LINE SEQUENCE SHOWN ABOVE 7924FG26

Tighten the manifold bolts in the proper sequence—diesel engines

FORD MOTOR CO. 1 1 -27

EXCURSION ¢ EXPEDITION ¢ NAVIGATOR Intake manifold and valley pan, if equipped Rocker covers Either the rocker arm shafts or loosen the rockers on their pivots and remove the pushrods. The pushrods must be reinstalled in their original positions. Valve lifters in sequence with a magnet. They must be replaced in their original positions. Timing gear cover, timing gear and sprockets eA camshaft removal tool, Ford part no. T65L-6250-a and adapter 14-0314 is needed to remove the diesel camshaft.

e Camshafts To install:

_ the parking brake and place blocks in back of the rear wheels. _ 4. Remove or disconnect the following: ¢ Wiring from the starter motor terminals e Starter motor retaining bolts, loosen e Starter retaining bolts while supporting the starter motor e Starter from the vehicle To install: 5. The installation is the reverse of removal. Tighten the starter retaining bolts to 15-20 ft. Ibs. (20-27 Nm)

To install: 6. Apply a % in. (3mm) bead of RTV Silicone sealant to the pan mating surfaces, and a 4 in. (6mm) bead on the front and rear covers and in the corners; you have 15 minutes within which to install the pan! 7. Install the locating dowels into position. 8. Position the pan on the engine and install the pan bolts loosely. 9. Remove the dowels. 10. Tighten the pan bolts to: e ¥Y% in.-20 bolts: 84 inch Ibs. (10 Nm) e %e in.-18 bolts: 14 ft. lbs. (19 Nm) e ¥ in.-16 bolts: 24 ft. lbs. (33 Nm) 11. Install the engine.

REMOVAL & INSTALLATION

3. Liberally coat the camshaft with oil before installing it. Slide the camshaft into the engine very carefully so as not to scratch the bearing bores with the camshaft lobes. Install the camshaft thrust plate and tighten the attaching screws to 10-12 ft.

1. Before servicing the vehicle, refer to the precautions’in the beginning of this section. 2. Remove the engine. 3. Remove the oil pan bolts. 4. Lower the oil pan.

lbs. (13-16 Nm). Measure the camshaft end-play. If the end-play is more than 0.009 inch (0.228mm), replace the thrust plate. Assemble the remaining components in the reverse order of removal. 4. Install or connect the following: e Timing gear and front cover e Valve lifters. They must be replaced in their original positions. Pushrods, the rocker arms and the rocker arm covers Intake manifold and valley pan, if equipped

>The oil pan is sealed to the crankcase with RTV silicone sealant in place of a gasket. It may be necessary to separate the pan from the crankcase with a utility knife. Also, the crankshaft may have to be turned to allow the pan to clear the crankshaft throws.

5. Clean the pan and crankcase mating surfaces thoroughly.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cables e Oil pan e Oil pick-up tube from the pump e Bolts and the oil pump To install: 3. Assemble the pick-up tube and pump. Use a new gasket. 4. Install or connect the following: e (Oil pump and tighten the bolts to 14 ft. Ibs. (19 Nm)

Valve Lash

ADJUSTMENT ’ Valve lash on the 7.3L diesel engine is not adjustable.

Starter Motor

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable 3. Raise the front of the truck and install jackstands beneath the frame. Firmly apply

OIL PUMP BODY PLATE The oil pump is mounted on the cylinder block with 4 bolts—diesel engine

Please visit our web site at www.chiltonsonline.com

7924FG62

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FORD MOTOR CO. EXCURSION ¢ EXPEDITION * NAVIGATOR e Seal retaining bolts e Flywheel e Transmission

e Oil pick up tube e Oil pan e Negative battery cables

REMOVAL & INSTALLATION REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission e Flywheel e Crankshaft rear oil seal bolts and the seal 3. Clean the seal mating surfaces. 4. lf installing the old seal, inspect it for damage. 5. Using crankshaft wear ring removal tool T941-6701-AH1, forcing screw 184T7025-B, remover tube T77J-7025-B and wear ring remover sleeve T94T-6701-Ah2 (refer to the illustration), remove the wear ring. To install: ‘6. Apply RTV silicone sealant to the seal retaining ring and the seal retaining bolts. 7. Using seal replacers 1941-6701-AH3 and T94T-AH4, driver sleeve T79T-6316-A4 (part of T79T-6316-A) and guide pins T94P7000-P install the wear ring and oil'seal. 8. Install or connect the following:

>The crankshaft gear sprocket is not serviced separately from the crankshaft. Do not try to remove the sprocket or you will damage the crankshaft.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cables e Camshaft e Sprocket from the camshaft using a press e Thrust plate and sprocket key 3. Inspect the camshaft and related parts for wear and damage. To install: 4 Clean the nose of the camshaft. 5. Install or connect the following: e Thrust plate e Key in the keyway on the camshaft

-T924FG64

Be sure the timing marks are aligned as illustrated—diesel engines

CAMSHAFT SPROCKET

CAMSHAFT \

MSY)

Item 1

| Description

|

| Crankshaft Wear Ring

2 | Crankshaft Rear Wear Ring

CYLINDER BLOCK

Remover 3

| Forc:ng Screw

4

Remover Tube

6)

Crankshaft Rear Wear Ring Remover Sieeve 7924FG61

Assemble the seal and wear ring removal tools, then remove the wear ring—diesel engine

7924FG63

The camshaft gear is removed with the camshaft, then pressed off-diesel engines

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7

FORD MOTOR CO.

EXCURSION e EXPEDITION ¢ NAVIGATOR. 6. Heat the sprocket in an oven to 500°F (260°C). 7, Remove the sprocket from the oven, align the sprocket keyway with the camshaft key and install the sprocket on the camshaft until it is fully seated. Allow the camshaft assembly to cool before installation e Camshaft in the engine and align

4 1 -29

TOWARD CAMSHAFT

the timing marks on the gears ¢ Negative battery cables CAMSIDE {

Piston and Ring Positioning 7924AG27

7.3L Diesel engines—piston-to-engine orientation

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance, but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to. come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary

stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

Fuel Filter

REMOVAL & INSTALLATION ->A fuel line disconnect tool is needed for this procedure.

Fuel System Pressure

RELIEVING e>A fuel pressure gauge is needed to correctly perform this procedure.

kt CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable and remove the fuel filler cap. 3. Remove the cap-from the pressure relief valve on the fuel supply manifold. Install a fuel pressure gauge to the pressure relief valve. 4. Direct the gauge drain hose into a Suitable container and depress the pressure relief button. 5. Remove the gauge and replace the cap on the pressure relief valve. e>As an alternate method, disconnect the inertia switch and crank the engine for 15-20 seconds until the pressure is relieved.

Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to

do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable 3. Relieve the fuel system pressure. e Fuel lines from the fuel filter. Have a drain pan handy to catch any residual fuel once the lines are separated. 4. On newer models, disconnect the fuel lines from the filter as follows: e Safety clip from the male hose

ome 7924FG65

Typical fuel filter mounting along an under vehicle frame rail

Timing belt service is covered in Section 3 of this manual

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| 41-30 fone. moraR co. EXCURSION ¢ EXPEDITION e Install and push the fuel line disconnect tool into the female fitting. Male and female fittings from the filter Inspect the fuel lines for any damage after the fuel is finished draining. Fuel filter from the bracket and the retainer, if equipped. Note the direction of the flow arrow so the replacement filter can be installed correctly. To install: 5. Install or connect the following: e Fuel filter into the mounting bracket with the flow arrow pointing in the correct direction Fuel lines to the fuel filter. Align and push the male tube into the female fitting until a click is heard. Pull on the fitting to ensure that it is fully engaged, then install the Safety clip. 6. Lower the vehicle to the ground. ->When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy.

7. Connect the negative battery cable.

REMOVAL & INSTALLATION

kk CAUTION Fuel injection systems remain under pressure, even after the engine has . been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Fuel pressure Fuel tank skid plate bolts and lower the skid plate Fuel Fuel tank filler pipe hose from the tank

¢ NAVIGATOR e Fuel tank filler pipe vent hose from the tank ¢ Fuel lines from the fuel pump Front fuel tank connections e Rear Evaporative Emissions (EVAP) hose clamp and the hose Electrical connector from the fuel pump

3. Support the fuel tank with a jack.

e Fuel tank support strap bolts and the fuel tank straps e Fuel tank e Fuel pump bolts e Fuel pump To install: 4. Install or connect the following: e Fuel pump e Fuel pump bolts. Tighten the pump bolts to 66-91 inch Ibs. (7.6—-10.4 Nm). e Fuel tank 5. Tighten the fuel tank strap bolts to 22-30 ft. Ibs. (29.7-40.7 Nm). 6. Tighten the skid plate bolts to 10-13 ft. lbs. (13-17 Nm). 7. Connect the negative battery.

Fuel Injector

REMOVAL & INSTALLATION

*k:« CAUTION Fuel injection systems remain under pressure, even after the engine has

been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Partially drain the engine cooling system. 4. Remove the engine air cleaner outlet tube from the throttle body. 5. Properly relieve the fuel system pressure. 6. Remove or disconnect the following: e 3 power steering reservoir retaining bolts and the reservoir bracket e Accelerator splash shield e Vacuum line at the fuel pressure regulator ¢ Fuel supply and return lines at the fuel injection supply manifold

e Flectrical harness connectors from each fuel injectors e Heater water inlet tube hose and position aside -e Brake booster bracket nut e Brake booster tube Positive Crankcase Ventilation (PCV) hose Exhaust Gas Recirculation (EGR) Differential Pressure Feedback (DPFE) transducer hoses from the EGR tube Upper and lower EGR tube fittings and remove the EGR valve to exhaust manifold tube Vapor management valve hose 4 fuel injection supply manifold retaining bolts Fuel injection supply manifold from the lower intake manifold 7. Remove the fuel injectors from the fuel injection supply manifold as follows: a. Grasp the injector body and pull while gently rocking the injector from side-to-side to remove the injector from the fuel injection supply manifold. Repeat the removal procedure for fuel injectors left in the intake manifold. 8. Inspect the fuel injector end cap, body and washer for signs of dirt and deterioration. 9. Discard the fuel injector O-rings. To install: 10. Lubricate new O-rings with clean engine oil and install 2 O-rings on each injector. Do not use silicone grease as it will clog the injectors. 11. Install the fuel injectors into the fuel injection supply manifold using a light, twisting, pushing motion.

12. Install or connect the following: e Fuel injection supply manifold, pushing it down to ensure all fuel injector O-rings are fully seated in the fuel rail cups and the intake manifold 4 fuel injection supply manifold retaining bolts while holding the manifold down. Tighten the retaining bolts to 71-106 inch Ibs. (8-12 Nm). Fuel supply and return lines to the fuel injection supply manifold Vacuum line to the fuel pressure regulator 13. With the fuel injector wiring disconnected, temporarily connect the negative battery cable and turn the ignition switch to the RUN position to allow the fuel pump to pressurize the fuel system.

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FORD MOTOR CO. 1 131 ;

EXCURSION © EXPEDITION ¢ NAVIGATOR

14. Check for fuel leaks. 15. Disconnect the negative battery cable. “16. Install or connect the following: Electrical harness connectors to each fuel injector e Vapor management valve hose e EGR valve to exhaust manifold tube. Tighten the fittings to 30 ft. lbs. (41 Nm). EGR DPFE hoses to the EGR tube

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. — Always follow the proper torque specifications.

e PCV hose e Brake booster tube and position 2 clamps. Tighten the retaining nut to 108 inch Ibs. (12 Nm). e Heater water inlet tube hose and properly position clamp ¢ Accelerator splash shield and tighten 3 retaining bolts to 3 ft. Ibs.

(4 Nm) ¢ 3 power steering reservoir bracket bolts

e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

Fuel System Pressure RELIEVING

4

kk CAUTION Before removing the fuel tank filler cap, turn the fuel tank filler cap 1% to ¥, turn counterclockwise and wait for the tank pressure to be relieved. Personal injury may result if the fuel tank filler cap is removed without the pressure fully relieved.

e Engine air cleaner outlet tube to the throttle body e Negative battery cable 17. Start the engine and allow to idle for several minutes while checking for leaks. 18. Turn the engine OFF and recheck for leaks. 19. Road test the vehicle and check for proper engine operation.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the fuel tank filler cap to relieve any pressure in the fuel tank. 3. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved.

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Idle Speed ADJUSTMENT 1. Before servicing the vehicle, refer to the . precautions in the beginning of this section. 2. Place the transmission in P. 3. Bring the engine up to normal operating temperature.

COLD START, ADVANCE TERMINAL

COLD IDLE SPEED — ADJUSTMENT

CURB IDLE See ADJUSTMENT 7924FG27

Raise or lower the curb idle speed by turning the curb idle speed adjusting screw—diesel engines

Heater Core replacement is covered in Section 2 of this manual

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11 -39 FORD MOTOR CO.

EXCURSION ¢ EXPEDITION * NAVIGATOR

e>|die speed is measured with the transmission in D.

4. Ensure that the curb idle adjusting screw is against the stop. If not, correct the vehicle linkage. 5. Check curb idle speed. Curb idle speed is specified on the Vehicle Emissions Control Information (VECI) decal on the underside of the vehicle’s hood. Adjust the idle speed to specification using the idle speed adjusting screw. 6. Place the transmission in P. Rev the engine momentarily, then place the transmission in the specified gear and recheck the idle speed. Adjust again if necessary. 7. Remove the tachometer and close the hood.

Fuel Filter/Water Separator DRAINING WATER

|} |FuetFuercao | Fuel Fiter Bevel Cut Gasket Fuel Filter Housing ead Giana

Drain water from the water separator manual drain valve whenever the warning light comes ON or every 5000 miles (8000km). The “Water in Fuel” light will glow when approximately 3.5 oz.

(103.5ml) of water accumulates in the separator.

40k CAUTION The fuel system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. The diesel engines are equipped with a fuel/water separator in the fuel supply line. A “Water in Fuel” indicator light is provided on the instrument panel to alert the driver. The light should glow when the ignition switch is in the start position to indicate proper light and water sensor function. If the light glows continuously while the engine is running, the water must be drained from the separator as soon as possible to prevent damage to the fuel injection system. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Shut the engine OFF. Failure to shut the engine OFF before draining the separator will cause air to enter the system.

Fuet Filter Element andCap Lockmg Taos 7924FG68

Use a prytool to remove the fuel filter cap to gain access to the filter element-diesel fuel systems

4. Unscrew the vent on the top center of the separator unit 2 Ye—3 turns. 5. Unscrew the drain screw on the bottom of the separator 1 %2~2 turns and drain the water into an appropriate container. 6. After the water is completely drained, close the water drain finger-tight. 7. Tighten the vent until snug, then turn

it an additional % turn. 8. Start the engine and check the “Water in Fuel” indicator light; it should not be lit. If it is lit and continues to stay so, there is a problem somewhere else in the fuel system.

REMOVAL & INSTALLATION

+ CAUTION The fuel system remains under pressure, even after the engine has been turned OFF. The fuel system pressure

must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

e Negative battery cable e Turbocharger assembly e Baffle and the air inlet crossover manifold 3. Place a suitable container under the drain hose and open the filter drain. e The 2 capscrews securing the fuel filter base to the crankcase ¢ Water drain hose from the filter 4. Relieve the fuel system pressure. Fuel outlet hose, located between the fuel and filter housing, and the fuel return hose from the fuel presSure regulator valve The 2 fuel supply hoses that connect the regulator block to the cylinder head fuel rails Clamp at the fuel pump end of the hose (loosen only), which connects the fuel filter to the inlet of high pressure stage at the fuel pump. Wiring harness from the right side of the filter housing Electrical connections from the Water In Fuel (WIF) sensor and the fuel heater e Fuel filter 5. Use a prybar to remove the fuel filter cap and the filter element will come out with the cap. 6. Depress the element locking tabs and remove the element from the cap. To install: 7. Clean the mating surfaces and install the filter element onto the cap, making sure the tabs engage. 8. Install or connect the following: Filter gap and press down firmly, but gently, to engage it Wiring connections to the fuel heater and WIF sensor Wiring harness to the filter housing Tighten the clamp at the fuel pump end of the hose, which connects the fuel filter to the inlet of high pressure stage at the fuel pump 2 fuel supply hoses that connect the regulator block to the cylinder head fuel rails Fuel outlet hose, located between the fuel and filter housing, and the fuel return hose from the fuel presSure regulator valve. Water drain hose to the filter The 2 capscrews securing the fuel filter base to the crankcase Air inlet crossover manifold and baffle Turbocharger assembly Negative battery cable

ave

:

EXCURSION « SPEHTIAR RACER 1 1 -33

.

i the pump out of the crankcase

REMOVAL & INSTALLATION

Hy

e Injection pump tappet from the crankcase bore

RENO NSE il wer eae

To install: ;

3. Rotate the engine so the injection

The fuel system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal

Injury.

pump eccentric is on the base Shes 4. Install or connect the following: ¢ Injection pump tappet in the base of the injection pump ¢ O-ring on the injection pump base

¢ Injection pump and tighten the

i

bolts to 19-27 ft. Ibs. (26-37 Nm

ks

CAUTION

Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a

i

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tire extinguisher near

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|. Before servicing the vehicle, refer to Pe Mra in the beginning of this sec-

° Fuel filter and ee water work area. Always keep fuel in a condrain hose tainer specifically designed for fuel

. 2. Remove or disconnect the follow-

e The 3 fuel hoses at the front of the injection pump

storage; also, always properly seal fuel containers to avoid the possibil-

Ing:

© The fuel line clamps and the fuel

ity of fire or explosion.

; Negative battery cable

filter retaining bolts

Turbocharger assembly e Fuel system pressure Fuel line banjo bolt at the pump Fuel line fittings at the rear of the cylinder Fuel | heads;

°

Fuel lines

Fuel line assembly and new seal rings at the rear of the pump

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

Fuel line fittings at the rear of the cylinder heads

tion.

e Fuel line banjo fitting at the pump.

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Tighten the bolt to 18 ft. Ibs. (24

* The 3 hose clamps at the injection

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pump fittings

e Turbocharger assembly

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RETAINING BOLT

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carry 115 volts DC. A severe electri-

pierce the wires.

FUEL PUMP

FUEL PUMP

The red-striped wires on the DI Turbo cal shock may be given. Do not

° Negative battery cable

e Filter and position it forward

CAUTION

~

Do not pierce the wires or damage to the harness could occur.

Special tools required:

° Slide Hammer, No. T50T-100-A,

se

or equivalent e Injector Remover, No. T94T-—9000-AH1, or equivalent e Injector Replacer, No. T94T-9000-AH2, or equivalent 2. Remove or disconnect the following: e Valve cover e Fuel injector electrical connector

Remove the oil drain plugs prior to removing the injectors or oil could enter the combustion chamber which could result in hydrostatic lock and severe engine damage. FUEL

TINE

LINE

e (il rail drain

BANJO FITTING

ASSEMBLY

plugs

° Retaining ei and oil deflector. 7924FG28

, , Injection pump assembly components—diesel engines

Brake service is covered in Section 4 of this manual

The shoulder bolt on the inboard sideof thefuelinjector does not 4 require removal.

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11-34

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FORD MOTOR CO. EXCURSION

EXPEDITION ¢ NAVIGATOR

e Qutboard fuel injector retaining bolt e Heater distribution box screws, nuts and clip e Outer half of the case (to service No. 4 fuel injector only) 3. Remove the fuel injector using Injector Remover No. T94T—-9000-AH1, or equivalent. Position the tool’s fulcrum beneath the fuel injector hold-down plate and over the edge of the cylinder head. Install the remover screw in the threaded hole of the fuel injector plate. Tighten the screw to lift out the injector from its bore. Place the injector in a suitable protective sleeve such as Rotunda Injector Protective Sleeve, No. 014—00933-2, and set the injector in a suitable holding rack. 4. Remove the fuel injector sleeves, if required. Insert the Injector Sleeve Tap Plug, 014-00934—3 into the injector Sleeve to prevent debris from entering the combustion chamber. Insert Injector Sleeve Tap Pilot into the fuel injector sleeve and tighten 1-1 1% turns. Attach Slide Hammer 1T501T—100-A to the Injector Sleeve Tap 014—-00934—1 and

014—00934-2 Injector Sleeve Tap Pilot and remove the fuel injector sleeve from the bore. 5. Use Rotunda Injector Sleeve Brush 104-00934-A, or equivalent to clean the injector bore of any sealant residue. Make sure to remove any debris. To install: 6. If removed, install the fuel injector sleeves using Rotunda Sleeve Replacer, No. 014-00934—4, or equivalent. Apply Threadlock, No. 262—E2FZ—19554-B, or equivalent to the fuel injector sleeves as shown (see illustration). Using a rubber mallet, tap on the tool to seat the injector bore. Remove the tool and remove any residue sealant. 7. Clean the fuel injector sleeve using a Suitable sleeve brush set. Clean any debris from the sleeve. 8. Clean the injector bore with a lintfree shop towel. 9. Install the fuel injectors using speCial tools as follows: a. Lubricate the injectors with clean engine oil. Using new copper washers, carefully push the injectors square into

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the bore using hand pressure only to seat the O-rings. b. Position the open end of Injector Replacer, No. T94T-9000—Ah2, or equivalent between the fuel injector body and injector hold-down plate, while positioning the opposite end of the tool over the edge of the cylinder head. c. Align the hole in the tool with the threaded hole in the cylinder head and install the bolt from the tool kit. Tighten the bolt to fully seat the injector, then remove the bolt and tool. 10. Install or connect the following: Outer half of the heater distribution box and retaining hardware (for No. 4 injector only) Oil deflector and bolt. Tighten the bolt to 108 inch Ibs. (12 Nm). Fuel rail drain plug, tightening it to 96 inch Ibs. (11 Nm) Oil rail drain plug, tightening it to 53 inch Ibs. (6 Nm) Heater distribution box Fuel injector wiring harness Valve cover

DRIVE TRAIN Transmission Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ 2. Remove or disconnect the following: Negative battery cable Front driveshaft and transfer case, on 4-wheel drive vehicles All cables, connectors and fluid lines that may interfere with transmission removal. Tag them if helpful for installation. The torque converter from the flexplate Shift linkage 3. Drain the transmission fluid. 4. Position a transmission jack under the transmission and safety-chain the case to the jack. 5. Remove or disconnect the following: e e e e

Driveshaft Transmission rear mount Crossmember The transmission-to-engine block bolts

«kt CAUTION The torque converter will fall out of the transmission if it is tilted forward. Keep a hand on it while lowering the transmission out of the vehicle. 6. Roll the transmission rearward until the input shaft clears, lower the jack and remove the transmission. To install: 7. Carefully raise the transmission to the engine or bell housing. 8. Roll the transmission forward and into position. 9. Install or connect the following: ¢ The transmission-to-engine block bolts. Tighten the bolts to 65 ft. lbs. (87 Nm) for the diesel or to 50 ft. Ibs. (67 Nm) for gasoline engines. Crossmember and tighten the bolts to 55 ft. Ibs. (74 Nm) Transmission rear insulator and lower retainer. Tighten the bolts to 60 ft. Ibs. (81 Nm). 10. The rest of the installation is the reverse of removal. 11. Refill all transmissions with the cor-

rect amount of Motorcraft MERCON® Automatic Transmission Fluid (ATF). 12. Connect the negative battery cable.

Transfer Case Assembly REMOVAL & INSTALLATION

ok CAUTION The catalytic converter is located beside the transfer case. Dueto the extreme high temperatures generated by the converter, be careful when removing the transfer case, or personal injury may result. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ 2. Remove or disconnect the following: Negative battery cable Fluid from the transfer case AWD indicator switch wire connector at the transfer case Skid plate from the frame, if equipped Front driveshaft from the front output yoke

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EXCURSION © EXPEDITION ¢ NAVIGATOR

DOWEL

1ST REMOVAL & INSTALLATION

6TH 4TH 7TH ~~ 2ND 7924FG30

Transfer case-to-adapter bolt torque

sequence—Borg-Warner model 13-45

Rear driveshaft from the rear output shaft yoke Speedometer driven gear from the transfer case rear bearing retainer Retaining rings and shift rod from the transfer case shift lever Vent hose from the transfer case Heat shield from the frame 3. Support the transfer case with a transmission jack. e Bolts retaining the transfer case to the transmission adapter e Transfer case from the vehicle To install: 4. When installing place a new gasket between the transfer case and the adapter. 5. Raise the transfer case with the transmission jack so the transmission output shaft aligns with the splined transfer case input shaft. Install the bolts retaining the transfer case to the adapter. 6. Remove the transmission jack from the transfer case. 7. Install or connect the following: Rear driveshaft to the rear output shaft yoke. Tighten the bolts to 15 ft. Ibs. (20 Nm). Shift lever to the transfer case and tighten the retaining nut Speedometer driven gear to the transfer case AWD indicator switch wire connector at the transfer case Front driveshaft to the front output yoke. Tighten the bolts to 15 ft. Ibs. (20 Nm). Heat shield to the frame crossmember and the mounting lug on the transfer case. Install and tighten the retaining bolts. Skid plate to the frame e Drain plug 8. Remove the filler plug and install 6 pints. (2.8L) of Dexron®ll transmission. 9. Connect the negative battery cable.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheels e Front hub cotter pin, retainer and nut 3. Using a floor hydraulic jack, support the lower suspension arm. ¢ Upper ball joint cotter pin and castle nut ¢ Knuckle from the front suspension upper arm 4. Lower the lower suspension arm and steering knuckle slightly to facilitate easier halfshaft remoyal. e 2 disc caliper mounting bolts, then lift the front disc caliper off of the front disc brake caliper anchor plate and position aside. Do not allow the caliper to hang by the brake hose; suspend it from the vehicle's frame with strong cord or wire. ¢ 6 front halfshaft-to-differential bolts

Use care to avoid damaging the hub seal when removing the front halfshaft.

11-35

e Inboard end of the halfshaft from the differential case or extension axle case. Separate the front halfshaft and joints from the hub, then remove the halfshaft and joints from the vehicle. To install: 5. Install or connect the following: e Halfshaft outboard end into the hub, making sure that the splines engage e Inboard end of the halfshaft against the front differential flange. e 6 halfshaft-to-differential bolts. Tighten the halfshaft bolts to 51-67 ft. Ibs. (68-92 Nm). e Front disc brake caliper onto the rotor and anchor plate e 2 caliper mounting bolts and tighten to 21-26 ft. Ibs. (28-36 Nm) 6. Lift the lower suspension arm and steering knuckle up until the upper ball joint stud is inserted into the steering knuckle. Install the upper ball joint castle nut and tighten to 57—76 ft. Ibs. (77-104 Nm). Install a new cotter pin. e Hub nut onto the halfshaft and tighten the hub nut to 188-254 ft. lbs. (255-345 Nm) e Hub nut retainer and a new cotter pin e Front wheels and tighten the lug nuts in a star-shaped sequence to 83-112 ft. Ibs. (113-153 Nm) 7. Lower the vehicle to the ground.

7924FG70

Halfshaft-to-differential mounting bolts (3 of the 6 bolts shown)

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

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EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

CV-Joint

OVERHAUL ->Before continuing with this proce-

dure, make sure to have available a new CV-joint boot kit, for each CV-joint being serviced. The outer CV-joint cannot be disassembled, only the boot can be replaced. Inner CV-Joint And Boot

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the halfshaft assembly from the vehicle. 3. Clamp the halfshaft in a vise equipped with jaw caps to prevent damage to machined surfaces. Do not allow the vise jaws to contact the boot or its clamp. 4. Slide 2 inboard clamp protectors off the boot clamps. 5. Carefully remove 2 boot clamps, and Slide the boot off the inner C\V-joint and housing. 6. Remove the CV-joint retaining ring and remove the housing. 7. Mark the inner race and the ball cage for assembly. 8. Remove 6 cage balls. 9. Remove the snapring. 10. Remove the inner race and ball cage. 11. Clean all parts in suitable parts cleaning solvent and inspect for wear. To install: 12. Place the boot and the small boot clamp and protector on the shaft. 13. Place the ball cage on the shaft with the tapered end toward the outer CV-joint. e>Line up the marks made at disassembly.

Cap

14. Position the inner race on the driveshaft in the position marked on disassembly. 15. Install the snapring. 16. Lubricate and position 6 balls with suitable CV-joint grease. 17. Place the boot protector and boot clamp on the CV-joint housing. Fill the housing with 8.29 ounces of suitable CVjoint grease. 18. Place the housing to the cage and bearings and install the retaining ring. 19. Remove any excess grease from the mating surface and position the boot and clamp. 20. Adjust the CV-joint to boot spacing to 16.43 in. (417.25mm). 21. After adjusting the CV-joint to boot spacing, insert a dull bladed screwdriver blade to relieve built up air pressure in the boot. 22. Use CV Boot Clamp Installer T95P3514-A or equivalent, to install the boot clamps. 23. Place the clamp protectors over the boot clamps. 24. Install the halfshaft into the vehicle. 25. Road test the vehicle and check for proper operation. Outer Boot

1. Remove the inner CV-joint and housing from the halfshaft. . 2. Remove the inner boot from the halfshaft. ) 3. Remove the outer boot clamp protectors and carefully remove the boot clamps. 4. Remove the outer boot from the halfshaft and inspect the grease for contamination. 5. If the grease is contaminated, clean and inspect the joint for wear. Replace the joint and shaft if worn or damaged.

Hub body

Snap-ring

Locking Hubs REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Remove or disconnect the following: e Tire e 3 screws and separate the cap from the body ¢ Lockring seated in the groove of the hub assembly ¢ Body assembly from the brake rotor/hub ¢ Snapring from the groove in the stub-shaft e 3 thrust washers from the stubshaft 4. Pull the cam assembly to remove it.

Plastic thrust

f Lockring

To install: 6. Place the new CV-joint boot on the shaft. 7. Using 5.82 ounces (165 grams) of suitable CV-joint grease, pack the outer CVjoint with grease, then spread the remaining grease inside the boot. 8. Clean the boot mounting surface and position the boot in the joint grooves. 9. Place the clamps in position and use ~ CV Boot Clamp Installer T95P-3514-A or equivalent, to install the boot clamps. 10. Place the clamp protectors over the boot clamps. 11. Install the inner boot on the halfshaft. _ 12. Install the inner CV-joint and housing on the halfshaft. 13. Install the halfshaft in the vehicle. 14. Road test the vehicle and check for proper operation.

Cam assembly

: 2026

Splined thrust washer

Steel thrust washer

Lockring 7924FG93

Exploded view of the typical automatic locking hub assembly

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FORD MOTOR CO. 44 37 |

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EXCURSION ¢ EXPEDITION ¢ NAVIGATOR To install: 5. Align the fixed cam retaining key on the cam assembly with the keyway on the spindle. Firmly push the cam assembly on the wheel retaining nut. 6. Install or connect the following: e Metal, plastic, then the splined washers on the stub-shaft ¢ Snapring in the groove of the stubshaft. It may be necessary to push the stub-shaft outward from the back of the knuckle assembly.

Do not pack the hub assembly with grease. Too much grease will damage the hub assembly. 7. Rotate the moving cam assembly to the 1 o'clock position in relation to the fixed cam retaining key. Use any 1 of the 3 stops. e Body assembly onto the hub by lining up the 3 legs with the 3 pockets in the cam assembly. Be sure the assembly is in far enough to see the groove in the hub. Large lockring in the groove on the

hub. Ensure the lockring is seated completely. Cap using the 3 screws. Tighten the screws to 35-53 inch Ibs. (4-6 Nm). Tire and lower the vehicle to the floor

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION Dana 50 Independent Front Suspension 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and support the front end on jackstands. 3. Remove or disconnect the following: Front wheels Calipers Hub/rotor assemblies Nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic mallet to remove it from the knuckle. e Splash shield 4. On the left side, pull the shaft from the carrier, through the knuckle. 5. On the right side, remove and discard the keystone clamp from the shaft and

joint assembly and the stub shaft. Slide the rubber boot onto the shaft and pull the shaft and joint assembly from the splines of the stub shaft. 6. Place the spindle in a soft-jawed vise clamped on the second step of the spindle. 7. Using a slide hammer and bearing

puller, remove the needle bearing from the spindle. 8. Inspect all parts. If the spindle is excessively corroded or pitted it must be replaced. If the U-joints are excessively loose or don’t move freely, they must be replaced. If any shaft is bent, it must be replaced. To install: 9. Clean all dirt and grease from the spindle bearing bore. The bore must be free of nicks and burrs. 10. Insert anew spindle bearing in its bore with the printing facing outward. Drive it into place with drive T80T—4000-S for F-150 and F-250, or T80T—4000-R for the F-350, or their equivalents. Install a new bearing seal with the lip facing away from the bearing. 11. Pack the bearing and hub seal with grease. Install the hub seal with a driver. 12. Install or connect the following: e Thrust washer on the axle shaft e New slinger on the axle shaft e Rubber V-seal on the slinger. The seal lip should face the spindle. e Plastic spacer on the axle shaft. The chamfered side of the spacer should be inboard against the axle shaft. 13. Pack the thrust face of the seal in the spindle bore and the V-seal on the axle shaft with heavy duty, high temperature, waterproof wheel bearing grease. 14. On the right side, install the rubber boot and new keystone clamps on the stub shaft and slip yoke. The splines permit only one way of meshing so you'll have to properly align the missing spline in the slip yoke with the gapless male spline on the shaft. Slide the right shaft and joint assembly into the slip yoke, making sure that the splines are fully engaged. Slide the boot over the assembly and crimp the keystone clamp. 15. On the left side, slide the shaft and joint assembly through the knuckle and engage the splines in the carrier. 16. Install or connect the following: e Splash shield and spindle on the knuckle. Tighten the spindle nuts to 60 ft. Ibs. (81 Nm). ¢ Rotor on the spindle

¢ Quter wheel bearing into the cup. Make sure that the grease seal lip totally encircles the spindle. e Wheel bearing, locknut, thrust bearing, snapring and locking hubs. e Caliper

Spindle and Front Axle Shaft

REMOVAL & INSTALLATION Dana 60 Monobeam

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and support the front end on jackstands. 3. Remove or disconnect the following: Caliper from the knuckle and wire it out of the way Free-running hub Front wheel bearings Hub and rotor assembly Spindle-to-knuckle bolts. Tap the spindle from the knuckle using a plastic mallet. Splash shield and caliper support 4. Pull the axle shaft out through the knuckle. 5. Using a slide hammer and bearing cup puller, remove the needle bearing from the spindle. 6. Clean the spindle bore thoroughly and make sure that it is free of nicks and burrs. If the bore is excessively pitted or scored, the spindle must be replaced. To install: 7. Insert a new spindle bearing in its bore with the printing facing outward. Drive it into place with driver T80T—4000-R, or its equivalent. Install a new bearing seal with the lip facing away from the bearing. 8. Pack the bearing with waterproof wheel bearing grease. 9. Pack the thrust face of the seal in the Spindle bore and the V-seal on the axle shaft with waterproof wheel bearing grease. 10. Carefully guide the axle shaft through the knuckle and into the housing. Align the splines and fully seat the shaft. 11. Install or connect the following: e Bronze spacer on the shaft. The chamfered side of the spacer must be inboard. e Splash shield and caliper support e Spindle on the knuckle and install the bolts. Tighten the bolts to 50-60 ft. Ibs. (68-81 Nm).

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

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4 138 FORD MOTOR co. e Flbifotor assembly on the spindle e Wheel bearings e Free-running hub

Right Side Slip Yoke and Stub Shaft, Carrier, Carrier Oil Seal and Bearing

REMOVAL & INSTALLATION Dana 50 Independent Front Axle -1. Before servicing the vehicle, refer to the precautions in the beginning of this section. >This procedure requires the use of special tools.

2. Raise and support the front end on jackstands. 3. Disconnect the front driveshaft from the carrier and wire it up out of the way. 4. Remove the left and right axle shafts and both spindles. 5. Support the carrier with a floor jack and unbolt the carrier from the support arm. 6. Place a drain pan under the carrier, separate the carrier from the support arm and drain the carrier. 7. Remove the carrier from thetruck. 8. Place the carrier in holding fixture T5/7L-500-B with adapters T80T—4000-8B. 9. Rotate the slip yoke and shaft assembly from the carrier. 10. Using a slide hammer/puller remove the caged needle bearing and oil seal as a unit. Discard the oil seal and bearing. To install: 11. Clean the bearing bore thoroughly and make sure that it is free of nicks and burrs. 12. Insert a new bearing in its bore with the printing facing outward. Drive it into place with driver T83T—1244—A, or its equivalent. Install a new bearing seal with the lip facing away from the bearing. Coat the bearing and seal with waterproof wheel bearing grease.

13. Install the slip yoke and shaft assembly into the carrier so that the groove in the shaft is visible in the differential case. 14. Install the snapring in the groove in the shaft. It may be necessary to force the snapring into place with a small prybar. Don't strike the snapring! 15. Remove the carrier from the holding fixture. 16. Clean all traces of sealant from the carrier and support arm. Make sure the mating surfaces are clean. Apply a % in. (6mm) wide bead of RTV sealant to the mating surface of the carrier. The bead must be continuous and should not pass through or outside of the holes. Install the carrier with 5 minutes of applying the sealer. 17. Position the carrier on the jack and raise it into position using guide pins to align it if you'd like. Install and hand-tighten the bolts. Tighten the bolts in a circular pattern to 30-40 ft. Ibs. (41-54 Nm). 18. Install the support arm tab bolts and tighten them to 85-100 ft. Ibs. (115-136 Nm). 19. Install all other parts in reverse order of removal.

REMOVAL & INSTALLATION Independent Front Axle 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. eA torque wrench capable of at least 225 ft. Ibs. (305 Nm) is required for pinion seal installation.

2. Raise and safely support the vehicle with jackstands under the frame rails. Allow the axle to drop to rebound position for working clearance. 3. Mark the companion flanges and Ujoints for correct reinstallation position.

STEERING AND SUSPENSION

ki CAUTION Some vehicles are equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling

procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. a

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EXCURSION ¢ EXPEDITION * NAVIGATOR

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PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury:

4. Remove the driveshaft. Use a suitable tool to hold the companion flange. Remove the pinion nut and companion flange. 5. Use a slide hammer and hook or sheet metal screw to remove the oil seal. To install: 6. Install a new pinion seal after lubricating the sealing surfaces. Use a suitable seal driver. Install the companion flange and pinion nut. Tighten the nut to 200-220 ft.

- Ibs. (271-298 Nm).

Monobeam Front Axle

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e>A torque wrench capable of at least 300 ft. Ibs. (407 Nm) is required for pinion seal installation.

2. Raise and support the truck on jackstands. 3. Allow the axle to hang freely. 4. Matchmark and disconnect the driveshaft from the front axle. 5. Using a tool such as 175T—4851-B,

or equivalent, hold the pinion flange while removing the pinion nut. 6. Using a puller, remove the pinion flange. 7. Use a puller to remove the seal, or punch the seal out using a pin punch. To install: 8. Thoroughly clean the seal bore and make sure that it is not damaged in any way. Coat the sealing edge of the new seal with a small amount of 80W/90 oil and drive the seal into the housing using a seal driver. 9. Coat the inside of the pinion flange with clean 80W/90 oil and install ie flange onto the pinion shaft. 10. Install the nut on the pinion shatt and tighten it to 250-300 ft. Ibs. (3839-407 Nm). 11. Connect the driveshaft.

| e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. ¢ With the inflator module on the bench,

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FORD MOTOR CO.

EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

never place anything on or close to the module, which may be thrown in the event of an accidental deployment.

DISARMING —_—__—_—_—_—_———

+ CAUTION The Supplemental Inflatable Restraint (SIR) system must be disarmed before performing service around SIR system components or

__ SIR system wiring. Failure to do so

may cause accidental deployment of the air bag, resulting in unnecessary SIR system repairs and/or personal injury.

The positive battery cable must be disconnected for a minimum of 1 minute before beginning any air bag work to deenergize the back-up power supply. It is a good idea to disengage both the positive and negative battery cables to ensure that the Air Bag system is definitely discharged.

ARMING THE SYSTEM

If the air bag simulators have been used, the air bag simulators must be removed and the air bags reconnected when the system is reactivated to avoid non-deployment in a collision resulting in possible personal injury.

1. Disconnect the positive battery cable. 2. Wait 1 minute, this is required for the back-up power supply in the air bag diagnostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the air bag sliding contact connector at the top of the steering column. Reconnect the driver's side air bag module assembly. Position the driver's air bag module on the steering wheel and secure with the 2 bolts and washers. Tighten the bolt and washer assembly to 8-10 ft. Ibs. (10-14 Nm). 4. Connect the positive battery cable. 5. Turn the ignition switch from the OFF to RUN and visually monitor the air bag warning indicator. The light will illuminate continuously for approximately 6 seconds and then turn off. If a fault occurs, the air bag indicator will either fail to light,

remain lighted continuously or flash. The flashing may not occur until approximately 30 seconds after the ignition switch has been turned from OFF to RUN. This is the time needed for the air bag diagnostic monitor to complete testing the system. If the air bag indicator is inoperative, an air bag system fault exists, a tone will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be apie before further diagnostics can be

one.

Steering Gear

REMOVAL & INSTALLATION Excursion

1. Before servicing the vehicle, refer to the precautionsin the beginning of this section. 2. Place the wheels in the straightahead position. 3. Remove or disconnect the following: Pressure and return lines. Cap the openings. Splash shield from the flex coupling Flex coupling at the gear Pitman arm from the sector shaft Steering gear mounting bolts Steering gear. It may be necessary to work it free of the flex coupling. To install: 4. Place the splash shield on the steering gear lugs. 5. Slide the flex coupling into place on the steering shaft. Be sure the steering wheel spokes are still horizontal. 6. Center the steering gear input shaft with the indexing flat facing downward. 7. Slide the steering gear input shaft into the flex coupling and into place on the frame side rail. Install the flex coupling bolt and tighten it to 30 ft. Ibs. (41 Nm). 8. Install or connect the following: e Steering gear mounting bolts and tighten them to 65 ft. Ibs. (88 Nm) e Pitman arm. Tighten the nut to 230 ft. Ibs. (312 Nm). e Pressure, then, the return lines. Tighten the pressure line to 25 ft. lbs. (34 Nm). e Flex coupling shield 9. Fill the steering reservoir. 10. Run the engine and turn the steering wheel lock-to-lock several times to expel air. Check for leaks.

11-39 er |

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Expedition & Navigator 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Skid plate Lower radiator air deflector Pitman arm cotter pin and castellated nut from the drag link Pitman arm from the drag link Dust cover from the steering shaft valve housing Intermediate shaft pinch bolt and slide the shaft off the steering gear input shaft Power steering pressure hoses at the steering gear Steering gear-to-frame rail retaining | bolts and the steering gear 3. If replacing or servicing the steering gear, match mark the sector shaft arm to the sector shaft and remove the steering gear sector shaft arm retaining nut and lockwasher. Remove the sector shaft arm. To install: 4. |f removed, install the steering gear sector shaft arm to the sector shaft aligning the match marks made during removal. Install the retaining nut and lockwasher and tighten to 170-228 ft. Ibs. (234-316 Nm). 5. Install or connect the following: Steering gear in position. Install the 3 retaining bolts and tighten them to 50-68 ft. Ibs. (68-92 Nm). Power steering pressure hoses to the steering gear using new seals, if necessary. Intermediate shaft on the steering gear input shaft and install the shaft pinch bolt. Tighten the pinch bolt to 30-42 ft. Ibs. (41-57 Nm). Dust cover over the steering shaft valve housing Pitman arm to the drag link. Install the castellated nut and tighten to 57-76 ft. Ibs. (77-104 Nm). Install a new cotter pin. Radiator air deflector and secure with the retaining screws and push clips Skid plate and secure it with the retaining bolts 6. Lower the vehicle. 7. Fill and bleed the power steering sysem. 8. Road test the vehicle and check the steering system for proper operation.

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

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41-40 FORD MOTOR CO. EXCURSION e EXPEDITION Shock Absorber

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. lf equipped with 2-wheel drive, perform the following: a. Hold the shock absorber stem and remove the nut from the top of the shock. b. Raise and safely support the vehicle. c. Remove the 2 lower retaining nuts and remove the shock absorber. 3. If equipped with 4-wheel drive, perform the following: a. Hold the shock absorber stem and remove the nut, washer and bushing from the top of the shock absorber stud. b. Raise and support the vehicle. c. Remove the lower retaining nut and bolt. d. Remove the shock absorber from the vehicle. To install: 4. On 4-wheel drive models, perform the following: a. Install the washer and bushing to the top stem of the shock absorber. b. Place the shock absorber up through the coil spring. c. Install the 2 lower retaining nuts. Tighten the nuts to 19-25 ft. Ibs. (26-34 Nm). d. Lower the vehicle. e. Install the bushing, washer and retaining nut to the top of the shock absorber stud. Tighten the nut to 34-46 ft. Ibs. (47-63 Nm). 5. On 2-wheel drive models, perform the following: a. Install the washer and bushing to the top stem of the shock absorber.

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b. Place the shock absorber up through the coil spring. c. Install the lower retaining nut and bolt. Tighten to 57-76 ft. Ibs. (77-104 Nm). d. Lower the vehicle. e. Install the shock absorber upper bushing, washer and retaining nut. Tighten the nut to 22-29 ft. Ibs. (30-40 Nm). 6. Road test the vehicle and check for proper operation. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise the vehicle and secure on support stands. 3. Remove the self-locking nut, steel washer, and rubber bushings at the upper end of the shock absorber. 4. Remove the bolt and nut at the lower end and remove the shock absorber. If needed, raise the rear axle assembly slightly with a jack. To install: 5. When installing a new shock absorber, use new rubber bushings. Position the shock absorber on the mounting brackets with the stud end at the top. Install the upper bushing, steel washer and selflocking nut at the upper end, and the bolt and nut at the lower end. 6. Tighten the upper mounting studs to 18-22 ft. Ibs. (24-30 Nm) and the lower mounting nuts to 40-60 ft. Ibs. (64-82 Nm).

REMOVAL & INSTALLATION Front

This procedure applies to 2-wheel drive vehicles only. In order to remove the coil

7924FG73

Lower shock absorber mounting—late models with torsion bar suspension

spring, the lower control arm must also be removed. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels Disc brake caliper and support aside with wire Disc brake adapter Rotor Rotor splash shield Shock absorber Bracket supporting the brake hose Sway bar link retaining nut and bushing from the lower control arm. Separate the sway bar link from the lower control arm. 3. Install a coil spring compressor and compress the coil spring enough to relieve the tension of the spring between the upper and lower contro! arms. e Cotter pin and castellated nut from the lower ball joint e Lower ball joint from the wheel spindle 4. Matchmark the lower control arm alignment cams for installation reference. e Lower control arm retaining nuts and bolts e Lower control arm and the compressed coil spring as an assembly 5. Loosen the coil spring compressor and remove the coil spring from the lower contro! arm. 6. Inspect the coil spring and replace as needed. To install: 7. Install or connect the following: ¢ Coil spring correctly in the saddle of the lower control arm ¢ Coil spring compressor and compress the coil spring. The end of the coil spring A, must cover the hole designated B and be visible in the second hole designated as C, for proper installation. ¢ Lower control arm to the frame e Retaining bolts, adjusting cams, and nuts 8. Align the match marks on the adjusting cams. The forward nut must be tightened first while the control arm is held at the curb position height. Tighten the nuts to 197-241 ft. Ibs. (270-330 Nm). ¢ Lower ball joint stud into the wheel spindle Castellated nut and tighten to 83-113 ft. Ibs. (113-153 Nm) New cotter pin Sway bar link to the lower control arm

FORD MOTOR CO. '1-41 a

EXCURSION ¢ EXPEDITION ¢ NAVIGATOR

7924FG75

Be sure the coil spring is mounted correctly in the lower control arm

¢ Bushing and retaining nut. Tighten to 15-21 ft. Ibs. (21-29 Nm). 9. Remove the coil spring compres-

SOr. e Shock absorber. Tighten the lower bolts to 22 ft. Ibs. (32 Nm) and the top nut to 45 ft. Ibs. (61 Nm). e Brake hose bracket Brake rotor splash shield 3 retaining bolts and tighten them to 90-107 inch Ibs. (10-14 Nm) Disc brake ysotor and caliper assemblies e Wheel and tire assembly 10. Lower the vehicle. 11. Pump the brake pedal several times to position the brake pads prior to moving the vehicle. 12. Check the alignment and adjust if out of specification. 13. Road test the vehicle and check for proper operation. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and support the vehicle. e Wheel and tire assembly e Rear driveshaft e Rear brake anti-lock sensor (ABS) electrical connector e»Make sure the parking brake control is fully released.

3. Pull the front parking brake cable and conduit. 4. Insert a suitable retainer into the parking brake control. 5. Remove or disconnect the following: e Rear parking brake cable and conduit from the rear axle e Rear parking brake cable and con-

duit from the rear axle bracket assembly e Cable from the caliper 6. Repeat for the other side. ¢ Disc brake caliper bolts 7. Repeat for the other side. e Axle vent tube e Stabilizer bar from the rear axle e Bolts from each stabilizer bar retainer e Retainers 8. Use a Suitable jack to support the rear axle. e Lower shock absorber nut and bolt 9. Repeat for the other side. e Rear axle-to-trackbar assembly bolt e Rear suspension lower arm assembly-to-axle bolt 10. Repeat for the other side. e Rear suspension upper arm assembly-to-rear axle bolt 11. Repeat for the other side. 12. Lower the rear axle and remove the coil spring. To install: Do not tighten any nuts or bolts until the rear suspension is raised so that the rear suspension lower arms are parallel to the ground. Once in position, tighten all the nuts and bolts to specification.

13. Install or connect the following: Rear coil spring Rear Suspension upper arm assemblies to the axle and the bolts Rear Suspension lower arm assemblies to the axle and the bolts Trackbar assembly to the axle and the bolts Shock absorbers to the axle and the bolts Stabilizer bar to the axle and the stabilizer bar retainers and bolts

Disc brake caliper and the bolts Parking brake cables and conduit to the axle Parking brake cable and conduit to the lever Parking brake cable and conduit to the rear axle bracket assembly Tire and wheel assembly Lug nuts and lower the vehicle Wheel cover. 14. Remove the pin from the parking brake control assembly. e Rear brake anti-lock sensor (ABS) electrical connector e Axle vent tube e Driveshaft 15. Lower the vehicle.

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

kk CAUTION The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the PASSENGER SIDE kick panel area.

Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 2. Raise and support the vehicle.

The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. 3. Remove or disconnect the following: Air suspension height sensor electrical connector Metal retaining tabs and remove the air suspension height sensor from the ball studs Passenger side trackbar bolt Driver's side trackbar nut and bolt Trackbar from the vehicle

For Wheel Alignment specifications, see Section 1 of this manual

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11-42

FORD MOTOR CO. EXCURSION e EXPEDITION ¢ NAVIGATOR

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To install: 4. The installation is the reverse of the removal.

Torsion Bars

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Matchmark and measure the length of the torsion bar being removed. Torsion bars are marked for left-hand or right-hand installation. If removing both torsion bars, make sure to reinstall in the correct position. If replacing a torsion bar, make sure that it is the correct torsion bar for the side being replaced.

4. Install Torsion Bar Adjuster T95T5310-A and Adapter Plates T96T-5310-A, or equivalents. 5. Tighten the adjuster tool until it touches the torsion bar adjuster. 6. Remove the torsion bar adjuster bolt and nut. 7. Remove 6 torsion bar crossmember retaining bolts. 8. Remove the crossmember support. 9. Remove the torsion bar from the vehicle. To install: 10. Place the torsion bar in position ensuring that it is the correct torsion bar for the side being installed. 11. Install the crossmember support and 6 retaining bolts. Tighten the retaining bolts to 40-50 ft. Ibs. (63-72 Nm). 12. Install the torsion bar adjuster bolt and nut, then remove the torsion bar adjuster tool and adapters. 13. Tighten the adjusting bolt until the match marks are in alignment. 14. Lower the vehicle. 15. Measure the ride height and adjust if necessary. 16. Check the alignment and adjust if not within specification. 17. Road test the vehicle and check for proper operation.

ADJUSTMENT 1. Place the vehicle on a level surface. 2. Bounce the front end to normalize the

ride height. 3. Measure the ride height on both sides of the vehicle from the frame to the ground.

4. Loosen the lock nut and add or delete turns until the vehicle is level and at the correct curb height. 5. Tighten the lock nut. 6. Road test the vehicle and recheck the measurements.

Upper Ball Joint

REMOVAL & INSTALLATION The upper ball joint is an integral part of the upper control arm and is not a serviceable component. Replacement of the ball joint requires replacing the upper control arm assembly. Lower Ball Joint

REMOVAL & INSTALLATION The lower ball joint is an integral part of the lower control arm and is not a serviceable component. Replacement of the ball joint requires replacing the lower control arm.

Upper Control Arm REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Remove the wheel and tire assembly. 4. Support the lower control arm with a transmission jack or equivalent adjustable jack. 5. Matchmark the upper contro! arm adjusting cams. 6. If equipped with 4-wheel ABS, remove the speed sensor harness bracket bolt and position the harness aside. 7. Remove the cotter pin and castellated nut from the upper ball joint. Discard the cotter pin. 8. Using Pitman Arm Puller T64P3590-F or equivalent, separate the ball joint from the wheel spindle. 9. Remove 2 nuts and bolts securing the upper control arm to the body brackets. 10. Remove the upper control arm and ball joint assembly from the vehicle. To install: 11. Align the matchmarks on the upper control arm adjusting cams.

12. Place the upper control arm in position to the body brackets and install 2 retaining bolts and nuts. Do not tighten at this time. 13. Install the ball joint stud to the wheel spindle and install the castellated nut. Tighten the nut to 56-77 ft. Ibs. (76-104 Nm). Install a new cotter pin. 14. Raise the lower control arm to position the control arms at normal curb height ~ and tighten the front upper control arm retaining nut first, to 84-112 ft. Ibs. (113-153 Nm). 15. With the vehicle still at curb height, tighten the rear upper control arm retaining nut to 84-112 ft. Ibs. (113-153 Nm). 16. Remove the transmission jack or equivalent from under the lower control arm. _ 17. If equipped with 4-wheel ABS brake system, position the speed sensor harness and install the bracket bolt. Tighten the speed sensor bracket bolt to 62—80 inch lbs. (7-9 Nm). 18. Install the wheel and tire assembly. Torque the lug nuts to 83-112 ft. Ibs. (113-153 Nm). 19. Lower the vehicle. 20. Check the alignment and adjust if not within specification. 21. Road test the vehicle and check for proper operation.

Upper Control Arm REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

-These vehicles require that the torsion bar tension be relieved before removing the lower control arm. If either the lower control arm or lower ball joint require replacement, the lower control arm and ball joint must be replaced as a unit. ‘

2. Raise and safely support the vehicle. 3. Matchmark and measure the length of the torsion bar being removed. Torsion bars are marked for left-hand or right-hand installation. If removing both torsion bars, make sure to reinstall in the correct position. If replacing a torsion bar, make sure that it is the correct torsion bar for the side being replaced.

FORD MOTOR CO.

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EXCURSION e EXPEDITION ¢ NAVIGATOR t 1 -43

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4. Install Torsion Bar Adjuster T95T5310-A and Adapter Plates T96T-5310-A, or equivalents. « 5. Tighten the adjuster tool until it touches the torsion bar adjuster. 6. Remove the torsion bar adjuster bolt and nut. 7. Remove 6 torsion bar crossmember retaining bolts. 8. Remove the crossmember support. 9. Remove the torsion bar from the vehicle. 10. If equipped with 4 wheel ABS, disconnect the sensor wire bracket bolt. 11. Remove the lower shock absorber retaining nut and bolt. 12. Disconnect the lower control arm castle nut and cotter pin and separate the ball joint from the steering knuckle. 13. Disconnect the stabilizer bar link from the lower control arm. 14. Remove the 2 lower control arm nuts and bolts. 15. Remove the lower arm and torsion bar. To install: 16. Install the lower control arm and torsion bar. Tighten the bolts to 150 ft. Ibs. (200 Nm). 17. Connect the lower ball joint and tighten the castle nut to 80-110 ft. Ibs. (113-153 Nm). 18. Connect the stabilizer bar link to the lower control arm. tighten the nut to 16-21 ft. lbs. (22-28 Nm). 19. Place the torsion bar in position ensuring that it is the correct torsion bar for the side being installed. 20. Install the lower shock absorber retaining nut and bolt. Tighten to 55-74 ft. lbs. (76-103 Nm). 21. Secure the ABS sensor bracket, if equipped. _ 22. Install the crossmember support and 6 retaining bolts. Tighten the retaining bolts to 40-50 ft. Ibs. (63-72 Nm). 23. Install the torsion bar adjuster bolt and nut, then remove the torsion bar adjuster tool and adapters. 24. Tighten the adjusting bolt until the match marks are in alignment. 25. Lower the vehicle. 26. Measure the ride height and adjust if necessary. 27. Check the alignment and adjust if not within specification. 28. Road test the vehicle and check for proper operation.

Front Wheel Bearings

ADJUSTMENT

-¢ CAUTION If equipped with the automatic air suspension system, the service switch near the right kick panel must be turned OFF before raising the vehicle for service. >On 4-wheel drive vehicles, the front wheel bearings are not adjustable.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Support the front end. 4. Remove the wheel cover, if equipped.

5. Remové the grease cap. o> Check the wheel bearings for sufficient grease.

6. Remove the cotter pin and retaining washer. Back off the spindle nut. Discard the cotter pin. 7. Adjust the wheel bearings as follows: a. Tighten the spindle nut to 17-24 ft. lbs. (23-34 Nm) while rotating the wheel and tire assembly to seat the wheel bearings. b. Back off the spindle nut no less than ¥ turn. c. Tighten the spindle nut to 17 inch lbs. (2 Nm). 8. Install the retaining washer so the castellations are aligned with the cotter pin hole. Install a new cotter pin. 9. Check the wheel and tire assembly for proper rotation, then install the grease cap. If the wheel still does not rotate properly, inspect and clean or replace the wheel bearings and cups. 10. Install the wheel cover, if equipped. 11. Lower the vehicle. 12. Road test the vehicle and check for proper operation.

REMOVAL & INSTALLATION 2-Wheel Drive

The hub is part of the disc brake rotor and cannot be serviced separately. The inner and outer wheel bearing and races are serviced individually. Be sure to have a new hub grease seal when servicing the wheel bearings.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheels Caliper Brake pads and anti-rattle clips Anchor plate Hub grease cap, cotter pin, retainer washer and the spindle nut Wheel bearing retainer washer and the outer wheel bearing Brake hub and rotor assembly Grease seal Inner wheel bearing 3. Clean and inspect the wheel bearings and races for unusual wear or damage. Replace parts as necessary. 4. Inspect the hub and brake rotor assembly. If required, the hub and brake rotor assembly must be replaced as a unit. To install: 5. If needed, pack the wheel bearing with a suitable high temperature wheel bearing grease before assembly. 6. Install or connect the following: e Inner wheel bearing in the hub and brake rotor assembly e New grease seal e Hub and rotor assembly on the wheel spindle e Outer wheel bearing e Retainer washer and the spindle nut 7. Adjust the wheel bearings as follows: a. Tighten the spindle nut to 17-24 ft. lbs. (23-34 Nm) while rotating the wheel and tire assembly to seat the wheel bear-

ings. b. Back off the spindle nut no less than ¥% turn. c. Tighten the spindle nut to 17 inch lbs. (2 Nm). 8. Install or connect the following: Retaining washer, so the castellations are aligned with the cotter pin hole. Install a new cotter pin. Anchor plate, and the 2 retaining bolts. Tighten the bolts to 125-168 ft. lbs. (170-230 Nm). Anti-rattle clips, and the disc brake pads Caliper Wheels. Tighten the lug nuts to 83-112 ft. Ibs. (113-153 Nm). 9. Check the wheel and tire assembly for proper rotation, then install the grease cap. 10. Lower the vehicle. 11. Road test the vehicle and check for proper operation.

For Maintenance Interval recommendations, see Section 7 of this manual

4-Wheel Drive —

,

The wheel bearings are of the cartridge design and are an integral part of the hub assembly. The bearings are permanently lubricated and require no maintenance or 5 adjustments. If required, a new hub assem-

__ bly must be installed. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels Caliper Brake pads and anti-rattle clips

Anchor plate Brake rotor Rotor shield Speed sensor retaining bolt and move the speed sensor and harness aside, if equipped with 4wheel ABS Hub nut cotter pin, retainer and the hub nut. Discard the cotter pin. The 3 hub assembly retaining bolts

from the inside of the steering knuckle e Hub assembly e>If necessary, use a suitable puller to separate the hub assembly from the CV-joint. Use care not to over extend the CV-joint and boot when removing the hub assembly.

e Grease seal from the steering knuckle To install: 3. Install or connect the following: e New grease seal e Hub assembly to the steering knuckle and secure with the 3 retaining bolts. Tighten the bolts to 110-145 ft. Ibs. (149-201 Nm). C\-joint into the hub assembly Speed sensor and secure with the retaining bolt, if equipped with 4wheel ABS. Tighten the bolt to 60-84 inch Ibs. (7-9 Nm). e Brake rotor shield and the 3

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bolts to 80-107 inch Ibs. oe Nm). ¢ Hub nut and tighten to 188-254 ft lbs. (255-345 Nm) ; e Hub nut retainer and a new cotter pin Brake rotor Anchor plate in position and install the 2 retaining bolts. Tighten the bolts to 125-168 ft. Ibs. (170-230 Nm). e Anti-rattle clips and the disc brake pads e Caliper e Wheels. Tighten the lug nuts to 83-112 ft. Ibs. (113-153 Nm). 4. Lower the vehicle. 5. Pump the brake pedal several times to position the brake pads prior to moving the vehicle. ' 6. Road test the vehicle and check for proper operation.

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PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury, and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. Ifthe brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from _ the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing S50 WILL result in severe engine damage. e Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

ENGINE REPAIR ->Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor

REMOVAL The 1.8L, 2.0L, 2.5L and 1999-01 1.6L Engines are equipped with a Distributorless Ignition System (DIS). 1998 1.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Negative battery cable e Distributor cap e Distributor wiring harness connector 3. Matchmark the rotor to the distributor housing and the distributor housing to the cylinder head. 4. Remove the distributor.

INSTALLATION Timing Not Disturbed Install or connect the following: e Distributor by aligning the matchmarks made during removal e Distributor wiring harness connector e Distributor cap e Negative battery cable

| Timing Disturbed

1. Set the engine to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 2. Install the distributor so that rotor is aligned with the No. 1 cylinder spark plug wire tower.

3. Install or connect the following: ’ ¢ Distributor wiring harness connector ¢ Distributor cap ¢ Negative battery cable

Alternator

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

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2. Remove or disconnect the following: e Negative battery cable * Evaporative Emission (EVAP) can* ister e Accessory drive belt _¢ Alternator harness connectors e Alternator mounting bracket e Alternator

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INSTALLATION Install or connect the following: e Alternator e Alternator mounting bracket. Tighten the bolts to 20 ft. Ibs. (27 Nm). e Alternator harness connectors e Accessory drive belt. Tighten the alternator bolts to 24 ft. Ibs. (33 Nm). e EVAP canister e Negative battery cable

6 1. Not Used 2. Diagnostic Request Terminal

3. 4. 5. 6.

Diagnostic Output Terminal Ground Terminal Test Switch Terminal Duty Check Terminal

5

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7924HG01

Duty Check Data Link Connector terminal identification for ignition timing

Ignition Timing

ADJUSTMENT

1999-01 1.6L Engine This engine is equipped with a Distributorless Ignition System (DIS). All timing functions are controlled by the Powertrain Control Module (PCM). No adjustment is possible.

1.8L, 2.0L, 2.5L and 1998 1.6L Engines ~The 1.8L, 2.0L and 2.5L engines use

a Camshaft Position (CMP) sensor that is rotated to set base timing. The procedure is the same as for the 1998 1.6L engine distributor. eCheck and adjust the ignition timing with the engine at normal operating temperature, all electrical accessories OFF and transmission in P, N for auto’ matic transmission or neutral for manual transmission.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. With the engine OFF, connect a jumper wire between terminals 4 and 5 of the Data Link Connector (DLC) for Tracker or between terminals D and E of the DLC for all others. 3. Connect a timing light to the No. 1 spark plug wire and start the engine. 4. \gnition timing at idle should be 4-6 degrees Before Top Dead Center (BTDC).

1. CMP sensor 2. Bolt 7924HG82

Camshaft position sensor—1.8L engine shown

5. Adjust the timing as necessary, then turn the engine OFF. 6. Remove the jumper wire from the DLC and remove the timing light.

Engine Assembly REMOVAL & INSTALLATION 1.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Relieve the fuel system pressure. 3. Drain the cooling system and engine Oil. 4 Remove or disconnect the following: Negative battery cable Hood

Strut tower bar, if equipped Cooling fan and shroud Heater hoses Radiator hoses Bypass hose Radiator Air intake tube Accelerator cable Transmission cable, if equipped

For complete service labor times, order the Chilton Labor Guide

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Brake booster vacuum line MAP sensor connector and vacuum line Alternator wiring connectors Injector harness connectors

Positive Crankcase Ventilation (PCV) valve and hose Exhaust Gas Recirculation (EGR) valve and temperature sensor EGR vacuum valve connector EGR bypass valve connector

A/C temperature switch, if equipped Temperature gauge sender connec-

Idle Air Control (IAC) valve hoses and connector Fuel lines Main engine control wiring harness connectors at the firewall Throttle Position (TP) sensor con-

tor ECT sensor connector HO2S sensor connectors TP sensor connector Main engine control wiring harness connectors at the firewall Fuel lines IAC valve hoses and connector

nector Heated Oxygen (HO2S) sensor connectors Engine Coolant Temperature (ECT) sensor connector Temperature gauge sender connector

EGR bypass valve connector EGR vacuum valve connector EGR valve and temperature sensor PCV valve and hose Transmission cable, if equipped

A/C temperature switch, if equipped Injector harness connectors Alternator wiring connectors Manifold Absolute Pressure (MAP) sensor connector and vacuum line Brake booster vacuum line Evaporative Emission (EVAP) canister and hoses Distributor, if equipped Front skidplate, if equipped Power steering hoses

A/C compressor, if equipped Flywheel access cover Torque converter, if equipped Clutch cable, if equipped Transmission cooler lines, if equipped Exhaust front pipe Starter motor Transmission flange fasteners and support the transmission Left and right engine mounts Engine To install: 5. Install or connect the following: Engine. Tighten the mount bolts to AQ ft. Ibs. (54 Nm). Transmission flange fasteners. Tighten them to 62 ft. Ibs. (85 Nm). Starter motor Exhaust front pipe Transmission cooler lines, if equipped Clutch cable, if equipped Torque converter, if equipped. Tighten the bolts to 40 ft. Ibs. (54 Nm). Flywheel access cover A/C compressor, if equipped Power steering hoses Front skidplate, if equipped Distributor, if equipped EVAP canister and hoses

Accelerator cable Air intake tube Radiator

Bypass hose Radiator hoses Heater hoses

Cooling fan and shroud Strut tower bar, if equipped Hood

Negative battery cable 6. Fill the crankcase to the correct level. 7. Fill the cooling system. 8. Start the engine and check for leaks.

1.8L, 2.0L and 2.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. 3. 4. 5.

Relieve the fuel system pressure. Drain the cooling system. Drain the engine oil. Remove or disconnect the following: Negative battery cable Hood Heater hoses Radiator hoses Cooling fan and shroud Radiator overflow tank Radiator Accelerator cable Transmission cable, if equipped Strut tower bar, if equipped Air intake assembly Engine oil dipstick tube Transmission oil dipstick tube, if equipped Ignition coil covers Ignition coil connectors Injector connectors Camshaft Position (CMP) sensor connector

Crankshaft Position (CKP) sensor connector . Throttle Position (TP) sensor connector Mass Air Flow (MAF) sensor connector

Idle Air Control (IAC) valve Intake manifold ground cable Evaporative Emission (EVAP) canister purge valve Exhaust Gas Recirculation (EGR) valve connector Heated Oxygen (HO2S) sensor connectors Engine Coolant Temperature (ECT) sensor connector Alternator wiring connectors Oil pressure gauge sender connector Power Steering Pressure (PSP) switch connector Alternator bracket ground cable Brake booster vacuum line Tank pressure control vacuum valve hose Fuel lines EVAP canister Power steering pump A/C compressor Steering shaft lower assembly Front differential housing, if

equipped Exhaust front pipe and bracket Transmission oil cooler lines, if equipped Transmission stiffener brackets, if equipped Flywheel access cover Torque converter, if equipped Starter motor Transmission flange fasteners and support the transmission Left and right engine mounts Engine

To install:

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6. Install or connect the following: Engine Left and right engine mounts. Tighten the nuts to 36 ft. Ibs. (50 Nm). Transmission flange fasteners. Tighten them to 58 ft. Ibs. (80 Nm). Starter motor Torque converter. Tighten the bolts to 47 ft. Ibs. (65 Nm), Flywheel access cover Transmission stiffener brackets. Tighten the bolts to 36 ft. Ibs. (50 Nm). Transmission oil cooler lines, if equipped Exhaust front pipe and bracket

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e Front differential housing, if equipped Steering shaft lower assembly

A/C compressor Power steering pump EVAP canister Fuel lines Tank pressure control vacuum valve hose Brake booster vacuum line Alternator bracket ground cable PSP switch connector Oil pressure gauge sender connector Alternator wiring connectors ECT sensor connector HO2S sensor connectors EGR valve connector EVAP canister purge valve Intake manifold ground cable IAC valve MAF sensor connector TP sensor connector CKP sensor connector CMP sensor connector Injector connectors Ignition coil-connectors Ignition coil-covers Transmission oil dipstick tube, if equipped Engine oil dipstick tube Air intake assembly Strut tower bar, if equipped Transmission cable, if equipped Accelerator cable Radiator Radiator overflow tank Cooling fan and shroud Radiator hoses Heater hoses Hood Negative battery cable . Fill the crankcase to the correct level. . Fill the cooling system. —~WN. Start the engine and check for leaks. OC Cc

Water Pump REMOVAL & INSTALLATION

1. Water pump 7924HG04

Exploded view of the water pump mounting—1.6L engines

e Front cover e Timing belt. Refer to the Timing Belt unit repair section. © Qil dipstick tube e Alternator bracket e Timing belt tensioner e Water pump To install: 4. Install or connect the following: e Water pump with a new gasket. Tighten the bolts to 106 inch Ibs. (12 Nm). Timing belt tensioner Alternator bracket Oil dipstick tube. Tighten the bolt to 97 inch Ibs. (11 Nm). Timing belt. Refer to the Timing Belt unit repair section. Front cover Cooling fan and shroud Accessory drive belts Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks. 1.8L and 2.0L Engines

1.6L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Accessory drive belts ¢ Cooling fan and shroud

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Radiator hose at the thermostat housing e Heater outlet pipe bolt e Alternator belt e Water pump

To install:

e>Use new water pump bolts for assembly.

4. Install or connect the following: e Water pump with a new O-ring seal. Tighten the bolts to 19 ft. Ibs. (27 Nm). e Alternator belt e Heater outlet pipe bolt e Radiator hose at the thermostat housing e Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Accessory drive belts e Front cover e Water pump To install: 4. Install or connect the following: e Water pump with a new O-ring seal. Tighten the bolts to 19 ft. Ibs. (27 Nm). e Front cover e Accessory drive belts e Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

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3. Drain the cooling system. 4. Remove or disconnect the following:

(5) 9308HG01

Cylinder head loosening sequence—1.6L engine

e Camshaft timing sprocket e Rear timing belt cover Distributor and spark plug wires, if equipped Ignition coils and wiring, if equipped with Distributorless Ignition System (DIS) e Valve cover Cylinder head. Loosen the bolts in the sequence shown. To install: 5. Install the cylinder head with a new gasket. 6. For 1998 engines, tighten the bolts in sequence as follows: a. Step 1: 26 ft. Ibs. (35 Nm) b. Step 2: 41 ft. Ibs. (55 Nm) c. Step 3: 52 ft. Ibs. (70 Nm) 7. For 1999-01 engines, tighten the bolts in sequence as follows: a. Step 1: 26 ft. Ibs. (35 Nm) b. Step 2: 41 ft. Ibs. (55 Nm) c. Step 3: Loosen all bolts to 0 ft. Ibs.

(0 Nm) d. Step 4: 26 ft. Ibs. (35 Nm) e. Step 5:52 ft Ibs. (70 Nm)

8. Install or connect the following: Valve cover Ignition coils and wiring, if equipped with DIS Distributor and spark plug wires, if equipped Rear timing belt cover Camshaft timing sprocket Timing belt Front cover Power steering pump

A/C compressor Exhaust manifold Exhaust front pipe Exhaust manifold bracket Exhaust manifold heat shield

HO2S sensor connectors Intake manifold Intake manifold brackets Alternator bracket Coolant bypass hose

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Cylinder head torque sequence—1.6L engine

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Evaporative Emission (EVAP) canister purge valve connector and hose Intake manifold ground cable

1.8L and 2.0L Engines

Heated Oxygen (HO2S) sensor connectors ¢ Camshaft Position (CMP) sensor

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Remove or disconnect the following: e Negative battery cable Strut tower brace Air intake tube Exhaust Gas Recirculation (EGR) valve connector Idle Air Control (IAC) valve connector Throttle Position (TP) sensor connector

connector

Engine Coolant Temperature (ECT) sensor connector

Fuel injector connectors Ignition coils Accelerator cable Transmission cable, if equipped Brake booster vacuum hose Radiator hose

Bypass hose Heater hose Fuel lines Intake manifold bracket Water pipe

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Crankshaft pulley side Flywheel side Bolt (M6) 7924HG09

Cylinder head loosening sequence—1.8L and 2.0L engines

6 MM BOLT 9308HGO7

e Valve cover Accessory drive belts Oil pan Front cover Timing chains Camshafts Exhaust front pipe Exhaust manifold bracket Cylinder head. Loosen the bolts in the sequence shown. To install: 6. Install the cylinder head with a new gasket. 7. For 1.8L engines, tighten the bolts in sequence as follows: a. Step 1: 38 ft. Ibs. (62 Nm) b. Step 2: 61 ft. Ibs. (84 Nm) c. Step 3: Loosen all bolts to 0 ft. Ibs. (0 Nm) d. Step 4: 27 ft. Ibs. (37 Nm) e. Step 5: 76 ft. Ibs. (105 Nm) f. Step 6: 6mm bolt to 96 inch Ibs. (8 Nm) 8. For 2.0L engines, tighten the bolts in sequence as follows: a. Step 1: 38 ft. Ibs. (62 Nm) b. Step 2: 61 ft. lbs. (84 Nm) c. Step 3: Loosen all bolts to 0 ft. Ibs. (0 Nm) d. Step 4: 38 ft. Ibs. (62 Nm) e. Step 5: 76 ft. Ibs. (105 Nm) f. Step 6: 6mm bolt to 96 inch Ibs. (8 Nm) 9. Install or connect the following: Exhaust manifold bracket Exhaust front pipe Camshafts Timing chains Front cover Oil pan Accessory drive belts Valve cover Water pipe Intake manifold bracket Fuel lines Heater hose Bypass hose Radiator hose Brake booster vacuum hose Transmission cable, if equipped Accelerator cable Ignition coils Fuel injector connectors ECT sensor connector CMP sensor connector HO2S sensor connectors Intake manifold ground cable EVAP canister purge valve connector and hose

Cylinder head torque sequence—1.8L and 2.0L engines

Timing belt service is covered in Section 3 of this manual

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TP sensor connector IAC valve connector EGR valve connector Air intake tube Strut tower brace

e Negative battery cable 10. Fill the crankcase to the correct level. 11. Fill the cooling system. 12. Start the engine and check for leaks. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system and engine oil. 4. Remove or disconnect the following: e Negative battery cable e Intake manifold e Ignition coil covers and ignition coils e Valve covers e Oil pan Timing chain cover and timing chains Camshaft Position (CMP) sensor Camshafts Exhaust manifolds Water outlet caps

Cylinder heads. Loosen the bolts in

the sequence shown. To install: 5. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows: a. Step 1: 38 ft. Ibs. (52 Nm) b. Step 2: 61 ft. Ibs. (84 Nm) c. Step 3: Loosen all bolts to 0 ft. Ibs. (0 Nm) d. Step 4: 38 ft. Ibs. (62 Nm) e. Step 5: 76 ft. Ibs. (105 Nm) f. Step 6: 6mm bolt to 96 inch Ibs. (8 Nm) 6. Install or connect the following: e Water outlet caps Exhaust manifolds

1. Hex hole bolt 2. Timing chain side 3. Flywheel side 9302HG01

Cylinder head loosening sequence—2.5L engine

RIGHT BANK

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Camshafts CMP sensor Timing chain cover and timing chains Oil pan Valve covers Ignition coil covers and ignition coils Intake manifold Negative battery cable 7. Fill the crankcase to the correct

8. Fill the cooling system. 9. Start the engine and check for 9308HG08

Cylinder head torque sequence—2.5L engine

GEO/CHEVROLET/SUZUKI TRACKER @ SIDEKICK © SIDEKICK SPORT ¢ X-90 © VITARA e GRAND VITARA

Rocker Arms/Shafts

REMOVAL & INSTALLATION 1.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belts Cooling fan and shroud Radiator and hoses Distributor, if equipped Camshaft Position (CMP) sensor, if equipped Valve cover Front cover Timing belt. Refer to the Timing Belt unit repair section. Camshaft Rocker arm shaft plug Rear timing belt cover

4. Loosen the rocker arm locknuts and back the valve adjusters off until all rocker arms move freely with no tension. ->Keep all valvetrain components in order for assembly.

5. Remove or disconnect the following: e Intake rocker arms and clips e Rocker arm shaft bolts 6. Push the rocker arm shaft towards the rear of the cylinder head and remove the rocker arm shaft O-ring.

7. Remove the exhaust rocker arms and springs by pulling the rocker arm shaft out of the front of the cylinder head. To install: 8. Insert the rocker arm shaft into the front of the cylinder head, while installing the exhaust rocker arms and springs in their original positions. 9. Push the end of the rocker arm shaft out of the rear of the cylinder head and install a new O-ring. 10. Install or connect the following: Rocker arm shaft bolts. Tighten them to 96 inch Ibs. (8 Nm). Intake rocker arms and clips in their original positions Rear timing belt cover Rocker arm shaft plug. Tighten it to 24 ft. Ibs. (33 Nm). e Camshaft Timing belt and adjust the valve clearafice Valve cover Front cover Distributor, if equipped CMP sensor, if equipped Radiator and hoses Cooling fan and shroud Accessory drive belts Negative battery cable 11. Fill the cooling system. 12. Start the engine and check for leaks. 1.8L, 2.0L and 2.5L Engines The 1.8L, 2.0L and 2.5L engines do not utilize rocker arms or rocker arm shafts.

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Rocker arm shaft and O-ring—1.6L engine

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intake Manifold REMOVAL & INSTALLATION 1.6L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: Negative battery cable Air intake pipe Accelerator cable and bracket Transmission cable, if equipped Throttle Position (TP) sensor connector Idle Air Control (IAC) valve connector and hoses Engine Coolant Temperature (ECT) sensor connector Coolant temperature gauge sender connector A/C coolant temperature switch connector, if equipped Evaporative Emission (EVAP) canister purge valve connector and vacuum line Exhaust Gas Recirculation (EGR) temperature sensor connector EGR vacuum valve connector EGR bypass valve connector EGR vacuum lines Fuel injector connectors Intake manifold ground cable Transmission vacuum line, if equipped Brake booster vacuum line Manifold Absolute Pressure (MAP) sensor vacuum line Fuel lines Upper radiator hose Coolant bypass hose Alternator bracket Intake manifold brackets Intake manifold To install: 5. Install or connect the following: Intake manifold with a new gasket. Tighten the nuts to 17 ft. Ibs. (23 Nm). Intake manifold brackets. Tighten the fasteners to 36 ft. Ibs. (50 Nm). Alternator bracket. Tighten the fasteners to 36 ft. Ibs. (650 Nm). Coolant bypass hose Upper radiator hose Fuel lines

Heater Core replacement is covered in Section 2 of this manual

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MAP sensor vacuum line Brake booster vacuum line Transmission vacuum line, if equipped Intake manifold ground cable Fuel injector connectors EGR vacuum lines EGR bypass valve connector EGR vacuum valve connector EGR temperature sensor connector

EVAP canister purge valve connector and vacuum line A/C coolant temperature switch connector, if equipped Coolant temperature gauge sender connector ECT sensor connector IAC valve connector and hoses TP sensor connector Transmission cable, if equipped Accelerator cable and bracket Air intake pipe

Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks. 1.8L and 2.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Air intake tube Exhaust Gas Recirculation (EGR) valve connector Idle Air Control (IAC) valve con-

nector Throttle Position (TP) sensor connector Evaporative Emissions (EVAP) canister purge valve connector and hose Intake manifold ground cable Manifold Absolute Pressure (MAP) sensor connector Accelerator cable Transmission cable, if equipped Brake booster vacuum hose Positive Crankcase Ventilation (PCV) valve and hose Fuel pressure regulator vacuum hose Intake manifold vacuum hose Throttle body coolant hoses Water bypass pipe Fuel lines Fuel supply manifold with injectors attached

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e Intake manifold support brackets e Intake manifold water pipe e Intake manifold To install: 5. Install or connect the Falowine Intake manifold with a new gasket. Tighten the fasteners to 17 ft. Ibs. (23 Nm). Intake manifold water pipe Intake manifold front support bracket. Tighten the bolts to 36 ft. lbs. (50 Nm). Intake manifold rear support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm). Fuel supply manifold with injectors attached Fuel lines Water bypass pipe Throttle body coolant hoses Intake manifold vacuum hose Fuel pressure regulator vacuum hose PCV valve and hose Brake booster vacuum hose Transmission cable, if equipped Accelerator cable MAP sensor connector Intake manifold ground cable EVAP canister purge valve connector and hose TP sensor connector IAC valve connector EGR valve connector Air intake tube Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Strut tower bar Intake Air Temperature (IAT) sensor connector Surge tank cover Air intake assembly Accelerator cable Transmission cable, if equipped Throttle body coolant hoses Fuel injector connectors Throttle Position (TP) sensor connector

Mass Air Flow (MAF) sensor connector

Idle Air Control (IAC) valve connector

Intake manifold ground cables Brake booster vacuum hose Evaporative Emissions (EVAP) canister purge valve connector and hoses Exhaust Gas Recirculation (EGR) valve connector Positive Crankcase Ventilation (PCV) valve and hose Heater hoses EGR pipe Fuel lines Throttle body and intake collector Intake manifold To install: 5. Install or connect the following: Intake manifold with new gaskets. Tighten the fasteners to 16 ft. Ibs. (23 Nm). Throttle body and intake collector with new gaskets. Tighten the fasteners to 102 inch Ibs. (12 Nm). Fuel lines EGR pipe Heater hoses PCV valve and hose EGR valve connector EVAP canister purge valve connector and hoses Brake booster vacuum hose Intake manifold ground cables IAC valve connector MAF sensor connector TP sensor connector Fuel injector connectors Throttle body coolant hoses Transmission cable, if equipped Accelerator cable Air intake assembly Surge tank cover IAT sensor connector Strut tower bar Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

Exhaust Manifold

REMOVAL & INSTALLATION 1.6L, 1.8L and 2.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Negative battery cable e Strut tower bar, if equipped e Air intake assembly and bracket e Heated Oxygen (HO2S) sensor connector

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, © Exhaust manifold bracket, if equipped e Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold with a new gasket. Tighten the fasteners to 13-20 ft. Ibs. (18-28 Nm). Exhaust manifold bracket, if equipped. Tighten the bolts to 36-43 ft. Ibs. (50-60 Nm). Exhaust manifold heat shield Exhaust front pipe. Tighten the fasteners to 29-43 ft. Ibs. (40-60 Nm). HO2S sensor connector Air intake assembly and bracket Strut tower bar, if equipped. Tighten the fasteners to 66 ft. Ibs. (90 Nm). Negative battery cable 4. Start the engine and check for leaks. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Strut tower bar Air intake assembly Heated Oxygen (HO2S) sensor connectors Oil dipstick tube Exhaust Gas.Recirculation (EGR) pipe Exhaust manifold heat shields Evaporative Emissions (EVAP) canister Front driveshaft, if equipped Exhaust front pipe Exhaust manifold brace Exhaust manifolds To install: 3. Install or connect the following: Exhaust manifolds with new gaskets. Tighten the nuts to 21 ft. Ibs. (30 Nm). Exhaust manifold brace Exhaust front pipe. Tighten the fasteners to 37 ft. Ibs. (50 Nm). Front driveshaft, if equipped EVAP canister Exhaust manifold heat shields EGR pipe Oil dipstick tube HO2S sensor connectors Air intake assembly Strut tower bar

Front Crankshaft Seal

e Negative battery cable 5. Start the engine and check for leaks.

Camshaft and Valve Lifters

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REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

1.6L Engine

1.6L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belts Cooling fan and shroud Water pump pulley Crankshaft pulley Front cover Timing belt. Refer to the Timing Belt unit repair section.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Radiator Accessory drive belts Crankshaft pulley Front cover Timing belt. Refer to the Timing Belt unit repair section. Camshaft sprocket Valve cover Distributor and case, if equipped Camshaft Position (CMP) sensor and case, if equipped 4. Loosen the rocker arm locknuts and back the valve adjusters off until all rocker arms move freely with no tension. 5. Remove or disconnect the following: e Camshaft bearing caps. Loosen the bolts in reverse of the tightening sequence. e Camshaft To install: 6. Install or connect the following: e Camshaft e Camshaft bearing caps. Tighten the

Crankshaft timing sprocket Front crankshaft seal To install: 4. Install or connect the following: Front crankshaft seal flush with the oil pump housing Crankshaft timing sprocket. Tighten the bolt to 94 ft. Ibs. (128

Nm). Timing belt Front cover Crankshaft pulley. Tighten the bolts to 12 ft. Ibs. (16 Nm). Water pump pulley Cooling fan and shroud Accessory drive belts

1. 2.

Oilseal Oil pump case 7924HG13

Install the new oil pump seal flush with the oil pump housing—1.6L engine

Brake service is covered in Section 4 of this manual

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SIDEKICK SPORT ¢ X-90 © VITARA © GRAND VITARA 1.8L and 2.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Oil pan Valve cover Accessory drive belts Crankshaft pulley Front cover Secondary timing chain Camshaft Position (CMP) sensor

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Keep all valvetrain components in order for installation.

1. Camshaft 2. Camshatt oil seal

e Camshaft bearing caps. Loosen the bolts: in several steps in reverse of the tightening sequence.

3. Rocker arm shaft

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6. Rocker arm (IN)

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Valve adjusting screw Clip Lock nut Rocker arm spring

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16. Vaive spring 17. Valve spring retainer 18. Valve cotter

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5. Install or connect the following:

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in several steps in sequence to 96 ‘

inch Ibs. (11 Nm). e CMP sensor ¢ Secondary timing chain

¢ Front cover e Crankshaft pulley. Tighten the bolt to 109 ft. Ibs. (148 Nm).

e Accessory drive belts 7924HG24

Exploded view of the valve train components—1.6L engine

bolts in sequence to 96 inch Ibs.

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Valve cover

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e Negative battery cable 6. Fill the crankcase to the correct level.

(11 Nm). e CMP sensor and case, if equipped Distributor and case, if equipped

Camshaft sprocket. Tighten the bolt to 44 ft. Ibs. (60 Nm). Timing belt and adjust the valve clearance Valve cover Front cover Crankshaft pulley. Tighten the bolts to 12 ft. Ibs. (16 Nm). Accessory drive belts Radiator e Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for

7924HG26

leaks. Camshaft housing torque sequence—1.8L and 2.0L engines

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7. Fill the cooling system. 8. Start the engine and check for leaks.

t WARNING Wait ’% hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in intera between the valves and pisons. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Intake manifold e Oil pan e Accessory drive belts _e Water pump pulley e Crankshaft pulley e Timing chain cover 5. Align the timing marks as shown.

Do not allow the crankshaft or camshafts to rotate once the timing chains have been removed. Valve or piston damage could result.

6. Remove or disconnect the following: e Left bank secondary timing chain e Primary timing chain e Valve covers

Sy Timing mark alignment—2.5L engine

e>Keep all valvetrain components in order for assembly.

e Right bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown. Right bank secondary timing chain, exhaust and intake camshafts as an assembly Camshaft Position (CMP) sensor Left bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown. e Left bank camshafts e Hydraulic lash adjusters To install: 7. Install or connect the following: e Hydraulic lash adjusters in their

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Left bank camshafts

Left bank camshaft housing loosening sequence—2.5L engine

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

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REMOVAL & INSTALLATION

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Right bank camshaft housing loosening sequence—2.5L engine

e Left bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm). e CMP sensor e Right bank secondary timing chain, exhaust and intake camshafts as an assembly e Right bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch Ibs. (12 Nm).

Wait 1% hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons. e Valve covers. Tighten the bolts to 90 inch Ibs. (10.5 Nm). Primary timing chain Left bank secondary timing chain Timing chain cover Crankshaft pulley. Tighten the bolt to 109 ft. Ibs. (148 Nm). Water pump pulley Accessory drive belts Oil pan Intake manifold Negative battery cable 8. Fill the crankcase to the correct level. 9. Fill the cooling system. 10. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the valve cover. 3. Set the engine to Top Dead Center (TDC) of the compression stroke for the cylinder to be adjusted. 4. Check the valve clearance. The valve clearance specifications are as follows: e Intake valves: 0.005—0.007 inches (0.13-0.17mm) e Exhaust valves: 0.005—0.007 inches (0.13-0.17mm) 5. After adjustment, tighten the locknuts to 11-14 ft. Ibs. (15-19 Nm). 6. Repeat for each valve to be adjusted. 1.8L, 2.0L and 2.5L Engines The 1.8L, 2.0L and 2.5L engines utilize automatic hydraulic lash adjusters to maintain proper valve lash at all times. Periodic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Starter motor wiring connectors e Starter motor To install: 3. Install or connect the following: e Starter motor. Tighten the bolts to 22 ft. Ibs. (30 Nm). e Starter motor wiring connectors. Tighten the solenoid nut to 11 ft. lbs. (15 Nm). e Negative battery cable

REMOVAL & INSTALLATION 1.6L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Front skidplate, if equipped e Front differential, if equipped

Valve Lash

ADJUSTMENT 1.6L Engines ->Measure valve clearance with the

. Oil pan . Oil pump strainer Seal . Drain plug gasket

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Exploded view of the oil pan and pump pickup mounting—1.6L engine

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5. Install or connect the following: Oil pan and oil pump pickup tube. Tighten the fasteners to 97 inch

lbs. (11 Nm), Left and right engine mounts. Tighten the nuts to 36 ft. Ibs. (50

Nm).

1. Oil pan »

A.

Sealant

Exhaust front pipe Flywheel access panel Left transmission stiffener bracket, if equipped Front differential, if equipped Steering gear Front skidplate, if equipped Front wheels Oil dipstick tube Negative battery cable 6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks.

2.5L Engine

7924HG79

Before installing the oil pan, apply a continuous bead of silicone sealant to the oil pan mating

flange—all engines

e Crankshaft Position (CKP) sensor

e Front skidplate, if equipped

e Steering gear

e Left transmission stiffener bracket,

¢ Front differential, if equipped

if equipped .

e Left transmission stiffener bracket,

e Flywheel actess panel

if equipped

° Oil pan and oil pump pickup tube

To install:

4. Apply abead ofsilicone sealant to the oil pan flange. 5. Install or connect the following: ¢ New oil pump pickup tube O-ring seal ¢ Oil pan and oil pump pickup tube. Tighten the fasteners to 97 inch

bs (11 Nm).

¢ Flywheel access panel

+ Exhaust front pipe e Left and right motor mounts and raise the engine about 1inch (25mm) for clearance ¢ Oil pan and oil pump pickup tube oe To peal rai 4.

Applya bead of silicone sealant to the

oil pan flange. Install new oil pump pickup

tube O-ring seals.

° Flywheel access panel

ies

1. Before Servicing the vehicle, refer lo

the precautions in the beginning of this section. 2. Drain the engine oil. oak

3. Removeordisconnect the following:

* Negative battery cable

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° Frontwheels : Eom sate if equipped Se ae eee : oh rate la Weg uippe : anid ny ponkith Se Meta ; BEES 4 fetSa et Ha wel ae inci rae Pal and. Olt PICKUP tbe :

eiInstall a new O-ring to the lower

Snes

e Left transmission stiffener bracket, if equipped e CKP sensor Front differential, if equipped Front skidplate, if equipped. Tighten the bolts to 40 ft. Ibs. (55 Nm). e Negative battery cable 6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks. 1.8L and 2.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following:

e Negative battery cable

1. O-ring

e Oil dipstick tube

e Front wheels

9302HG05

Lower crankcase O-ring seal

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

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-The oil pump bolts are different lengths. Note their location for assembly.

To install:

1: 97 Inch ilb. (11 Nm) ¢ 2: 20 Ft. Ibs. (27 Nm)

¢ Negative battery cable

as

Upper oil pan bolt torque values—2.5L engine

5. Apply a bead of silicone sealant to the upper oil pan flange. 6. Install or connect the following:

¢ New oil pump pickup tube O-ring

:

5. Install or connect the following: © Oil pump with a new gasket. Tighten the bolts to 97 inch Ibs. (11 Nm). Crankshaft timing sprocket. Tighten the bolt to 94 ft. Ibs. (130 Nm). Oil pan and oil pump pickup tube A/C compressor and bracket, if equipped Alternator and bracket Timing belt Front cover Crankshaft pulley. Tighten the bolts to 12 ft. Ibs. (16 Nm). Accessory drive belts ‘6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks. 1.8L and 2.0L Engines

° Front cover ¢ Timing belt. Refer to the Timing Belt unit repair section.

e Alternator and bracket

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

ee

2. Drain the engine oil.

3. Removeor disconnect the following: ° Negative battery cable

seals e Upper oil pan and oil pump pickup

and bracket, if e A/C compressor equipped

tube and tighten the fasteners as

¢ Oil pan and oil pump pickup tube

° Oil pan and pickup tube

© Oil pump

e Oil pump

shown

° Crankshaft timing sprocket

e Radiator outlet pipe Oil pickup tube bracket Lower oil pan. Tighten the bolts to 97 inch Ibs. (11 Nm). Front differential, if equipped Steering gear Front skidplate, if equipped Front wheels Oil dipstick tube Negative battery cable 7. Fill the crankcase to the correct level. 8. Start the engine and check for leaks.

* Oil pump sprocket cover

REMOVAL & INSTALLATION 1.6L Engines

2

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Remove ordisconnect the following:

e Negative battery cable

* Accessory drive belts ¢ Crankshaft pulley

:

'. No. 1 bolts (short)

2. No. 2 bolts (long) Oil pump housing short (1) and long bolt (2) locations—1.6L engines

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2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section, 2. Drain the cooling system. 3. Drain the engine oil. 4. Remove or disconnect the following: e Negative battery cable e Accessory drive belts e Intake manifold ¢ Qil pan and oil pickup tube e Front cover e Oil pump chain guide e Oil pump

7

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6

7

a—-9

Do not remove the sprocket from the oil pump. Damage to the oil pump center shaft and abnormal pump operation may result.

}-

o—10 s 1. Rotor plate

6. Pin

2. Inner rotor

7. Relief vaive

3. Outer rotor 4. Gasket 5. Pin

8. Spring 9. Retainer 10. Retainer ring 7924HG12

Exploded view of the oil pump housing—1.6L engines

To install: 5. Install or connect the following: e Oil pump. Tighten the bolts to 20 ft. lbs. (27 Nm). Oil pump chain guide. Tighten the bolts to 97 inch Ibs. (11 Nm). Front cover Oil pan and oil pickup tube Intake manifold Accessory drive belts Negative battery cable 6. Fill the crankcase to the correct level. 7. Fill the cooling system. 8. Start the engine and check for leaks.

Rear Main Seal

REMOVAL & INSTALLATION

1. 2.

Oil pump case No.1 Oil pump case No.2

3. Outer rotor

4.

Relief valve

5.

Relief spring

6.

Retainer 7924HG15

Exploded view of oil pump—1.8L, 2.0L and 2.5L engines

Do not remove the sprocket from the oil pump. Damage to the oil pump center shaft and abnormal pump operation may result.

To install: 4. Install or connect the following:

¢ Oil pump. Tighten the bolts to 20 ft. lbs. (27 Nm). e (Oil pump sprocket cover. Tighten the bolts to 108 inch Ibs. (12 Nm). e Oil pan and pickup tube e Negative battery cable 5. Fill the crankcase to the correct level. 6. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transmission e Clutch assembly, if equipped e Flywheel e Rear main seal To install: 3. Install or connect the following: e Rear main seal flush with the cylinder block e Flywheel. Tighten the bolts in a crossing pattern to 58 ft. Ibs. (79 Nm) for 1.6L engines or to 51 ft. lbs. (69 Nm) for all other engines. e Clutch assembly, if equipped

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

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e Transmission e Negative battery cable

Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION 1.8L and 2.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Remove or disconnect the following: Negative battery cable Oil pan and pickup tube Valve cover Bypass pipe and hose Accessory drive belts Cooling fan and shroud Water pump pulley Alternator belt tensioner and idler pulleys e Upper radiator hose e A/C compressor and bracket, if equipped e Crankshaft pulley e Front crankshaft seal

e Front cover 5. Rotate the crankshaft to align the timing marks as shown. | ack WARNING

e Camshaft sprockets and second timing chain e First timing chain tensioner

=

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6. Remove or disconnect the following, * Second timing chain tensioner

ae

Timing mark alignment—1.8L and 2.0L engines

e Timing chain idler sprocket and first timing chain with the matchmarks and colored links aligned as

e Timing chain idler sprocket and first timing chain To install: = 7. Prepare the timing chain tensioners for installation by releasing the latches, compressing the tensioner piston fully

shown e First timing chain tensioner. Tighten the bolts to 97 inch Ibs. (11 Nm). e Camshaft sprockets and second timing chain with the matchmarks

_iNto the bore and installing retaining pins.

and colored links aligned as shown ¢ Second timing chain tensioner.

8. Install or connect the following:

tf

1.

1. Crankshaft timing sprocket

3. 1st timing chain

2. Match mark

4.

Yellow plate

7924HG17 Crankshaft and first timing chain alignment—1.8L and 2.0L engines

Tighten the bolts to 97 inch Ibs.

Idler sprocket

2. Match mark on idler sprocket

3.

1st timing chain

4. Dark blue plate

Idler sprocket and first timing chain alignment—1.8L and 2.0L engines

7924616

GEO/CHEVROLET/SUZUKI

TRACKER ¢ SIDEKICK © SIDEKICK SPORT ¢ X-90 © VITARA © GRAND VITARA

12-19

(11 Nm) and the nut to 33 ft. Ibs. (45 Nm). 9. Tighten the camshaft sprocket bolts

to 59 ft. Ibs. (80 Nm).

Arrow Knock Knock Timing oad ge ip Ngee Timing

mark on idler sprocket pin of intake camshaft pin of exhaust camsaft mark of intake side

mark of exhaust side 7924HG19

Idler sprocket and camshaft alignment—1.8L and 2.0L engines

10. Remove the timing chain tensioner retaining pins. 11. Rotate the crankshaft two complete turns and check that the timing marks align. 12. Install or connect the following: Front cover. Apply sealant as shown. Front crankshaft seal Crankshaft pulley. Tighten the bolt to 109 ft. Ibs. (130 Nm). A/C compressor and bracket, if equipped Upper radiator hose Alternator belt tensioner and idler pulleys Water pump pulley Cooling fan and shroud Accessory drive belts Bypass pipe and hose Valve cover Oil pan and pickup tube Negative battery cable 13. Fill the crankcase to the correct level. 14. Fill the cooling system. 15. Start the engine and check for leaks. 2.5L Engine

1. Crank timing sprocket key 2. Timing mark 7924HG18

Crankshaft sprocket alignment—1.8L and 2.0L engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Remove or disconnect the following: Negative battery cable Intake manifold Ignition coils Valve covers Accessory drive belts

Cooling fan and shroud Water pump pulley Radiator Power steering pump and brackets Oil pan and pickup tube Crankshaft pulley Front crankshaft seal Crankshaft Position (CKP) sensor Front cover 5. Rotate the crankshaft so that the timing marks are aligned as shown. 1. 2.

Yellow plate Match mark of 2nd timing chain (Arrow mark) 7924HG20

Do not allow the crankshaft or camshafts to rotate once the timing

Idler sprocket and second timing chain alignment—1.8L and 2.0L engines

For Wheel Alignment specifications, see Section 1 of this manual

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camshafts. To install:

1. Dark blue

2. Arrow mark on intake camshaft timing sprocket 3. Arrow mark on exhaust camshaft timing sprocket

Camshaft sprocket and second timing chain alignment—1.8L and 2.0L engines

6. Remove or disconnect the following: Left bank No. 2 timing chain tensioner Left bank intake and exhaust camshaft sprockets with the No. 2 timing chain No. 1 timing chain guides No. 1 timing chain tensioner e Center idler sprocket and the No. 1 timing chain Right bank No. 1 timing chain sprocket 7. The right bank No. 2 timing chain is removed with the intake and exhaust

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8. Prepare the timing chain tensioners for installation by releasing the latches, compressing the tensioner piston fully into the bore and installing retaining pins.

1. Timing chain cover 2. Cylinder head 3. Cylinder block

Prior to installing the timing chain cover on the engine block and cylinder head, , apply silicone sili dah sealan t to the cover as ;indicated i 1.8L, 2.0L and 2.5L engines pply (areas marked A)—

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Preparing the No. 1 timing chain tensioner adjuster for installation—1.8L, 2.0L and 2.5L

1 2 -2 1

9. Align the timing chain sprocket matchmarks and colored chain links as shown during assembly. 10. Install or connect the following: Right bank intake and exhaust camshafts with the No. 2 timing chain Right bank No. 1 timing chain sprocket. Tighten the bolt to 58 ft. Ibs. (80 Nm). Center idler sprocket and the No. 1 timing chain. Tighten the fastener to 32 ft. Ibs. (45 Nm). e No. 1 timing chain tensioner and guides. Tighten the bolts to 97 inch lbs. (11 Nm).

Left bank intake and exhaust camshaft sprockets with the No. 2 timing chain. Tighten the bolts to 57 ft. Ibs. (80 Nm). Left bank No. 2 timing chain tensioner. Tighten the bolts to 97 inch lbs. (11 Nm). 11. Remove the retaining pins from the

timing chain tensioners. 12. Rotate the crankshaft two complete 1. Plunger 4 cae

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turns and check that the timing marks align. 13. Install or connect the following: e Front cover. Tighten the bolts to 97

inch lbs. (11 Nm).

e CKP sensor

No. 2 timing chain tensioner—left bank tensioner shown—1.8L, 2.0L and 2.5L engines

1. Crankshaft Keyway 2. Oil Jet 3. Right Bank No. 1 Chain Marks 4. Left Bank Intake Cam Marks 5. Left Bank Exhaust Cam Marks

6. Right Bank Intake and Exhaust Cam Marks

9302HG07

Timing chain alignment marks—2.5L engine

For Maintenance Interval recommendations, see Section 1 of this manual

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9302HG08

3. Match mark of RH bank 1st timing chain sprocket

5. Match mark of idler sprocket No.2

4. Silver plate (LH) of 1st timing chain

6. Silver plate (RH) of 1st timing chain

7. Match mark of crankshaft timing sprocket

8. Gold or Yellow plate of 1st timing chain

1. Crank timing pulley key

2. Oiljet 9302HG10

No. 1 timing chain alignment—2.5L engine

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Front crankshaft seal Crankshaft pulley. Tighten the bolt to 109 ft. Ibs. (148 Nm). Oil pan and pickup tube Power steering pump and brackets Radiator Water pump pulley Cooling fan and shroud Accessory drive belts Valve covers Ignition coils Intake manifold Negative battery cable 14. Fill the crankcase to the correct level. 15. Fill the cooling system. 16. Start the engine and check for leaks. i

Knock pin of LH bank intake camshaft Knock pin of LH bank exhaust camshaft

POSITIONING

Match mark of intake side = Match mark of exhaust side eae 9302HG11

Left bank camshaft alignment—2.5L engine

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.

Arrow mark string end ap 2ndring end gap and oil ring spacer gap Oil ring upper rail gap

. . wo NO > .

Oil ring lower rail gap Intake side Exhaust side 7924AG67

Piston ring end-gap spacing—All engines

—_

+ .

Istring 2nd ring ring

WN . Oil

7924AG68

Compression ring identification marks— All engines

7

Circlip

3 4

‘ore

1.

Silver plate

or

4, (b)

Align the left bank No. 2 chain silver links—2.5L engine

1, 2.

Piston Arrow mark

3.

Connecting rod

4. Oilhole

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2. Arrow mark on intake camshaft timing sprocket

3. Arrow mark on exhaust camshaft timing sprocket 4. Sprocket bolt

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Crankshaft pulley side

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Piston and connecting rod positioning— 1.6L engine

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

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Install so that circlip end gap comes within such range as indicated by arrow.

1, 2. 3. 4.

Piston Arrow mark Connecting rod Oil hole

No.1 No.2 No.3 No.4 Cylinder Cylinder Cylinder Cylinder

9302AG15

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Piston pin circlip installation—2.5L engine

Piston installation—1.6L engine

2

Crankshaft pulley side

&

Circlip

1, 2.

Piston Arrow mark

3. Connecting rod

Piston Cylinder block

4, 5.

Crank shaft pulley side Flywheel side

7924AG65

Piston identification—1.8L and 2.0L

Install so that circlip end gap comes within such range as indicated by arrow.

1. Piston 2, Arrow mark 3, Connecting rod 7924AG62

7924AG61

Piston and connecting rod positioning— 1.8L, 2.0L and 2.5L engines

1. 2.

3. Paint

Piston pin circlip installation—1.8L and 2.0L engines

engines Match pistons with “1” indicators to red cylinder paint marks

Match pistons with “2” indicators to blue cylinder paint marks

1

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No. 2 cylinder

No.iO. 4 cylinder

N 0. 6 cylinder

9302AG16

Piston identification—2.5L engine

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Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle fuel system components can be accomplished safely and effectively by ru to the following rules and guideines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system presSure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to-fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Detach the wiring harness connector from the fuel pump relay, located under the

a

ah

left-hand side of the instrument panel near the ECM. 3. Start the engine and run it until it Stops from lack of fuel. Crank the engine 2-3 times for a 3 second period. The fuel lines should now be depressurized. 4. After servicing, reattach the wiring harness connector to the fuel pump relay. Fuel Filter

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable ¢ Fuel lines from the fuel filter e Fuel filter To install: 4. Install or connect the following: e Fuel filter and tighten the bracket bolt. Note the fuel flow directional arrow. e Fuel lines to the fuel filter. e Negative battery cable 5. Start the engine and inspect the fuel filter connections for leaks.

Fuel Pump

12-25

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REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Fuel filler hose and vent hose Fuel tank inlet valve and drain the fuel tank Fuel filter inlet hose Evaporative Emissions (EVAP) vapor hose Fuel return line Fuel tank skidplate Fuel pump connector Fuel tank pressure sensor connector Fuel tank Fuel pump module To install: 4. Install or connect the following:

e Fuel pump module with a new seal. Tighten the bolts to 44 inch Ibs. (5 Nm). Fuel tank. Tighten the strap bolts to 37 ft. Ibs. (50 Nm), Fuel tank pressure sensor connector Fuel pump connector Fuel tank skidplate Fuel return line EVAP vapor hose Fuel filter inlet hose Fuel tank inlet valve and drain the fuel tank Fuel filler hose and vent hose Negative battery cable 5. Fill the fuel tank. 6. Start the engine and check for leaks.

Fuel Injector

ma

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REMOVAL & INSTALLATION 1.6L, 1.8L and 2.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable Front intake manifold bracket, if equipped Positive Crankcase Ventilation (PCV) valve and hose Fuel injector harness connectors Fuel line bracket Fuel supply manifold Fuel injectors To install: 4. Install or connect the following: e Fuel injectors with new O-ring seals e Fuel supply manifold. Tighten the bolts to 17 ft. Ibs. (23 Nm). Fuel line bracket Fuel injector harness connectors PCV valve and hose Front intake manifold bracket, if equipped Negative battery cable 5. Start the engine and check for leaks. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

For complete service labor times, order the Chilton Labor Guide

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VROLET/SUZUKI GEOICHE SIDEKICK e SIDEKICK SPORT ¢ X-90 ¢ VITAR A GRAND VITARA 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Air intake tube e Throttle body intake collector e Fuel lines e Fuel pressure regulator vacuum line e Fuel injector harness connectors

e Fuel supply manifold connect pipe e Fuel supply manifolds e Fuel injectors To install: 4. Install or connect the following: e Fuel injectors with new O-ring seals ¢ Fuel supply manifolds. Tighten the bolts to 17 ft. Ibs. (23 Nm). e Fuel supply manifold connect pipe.

Tighten the bolts to 22 ft. Ibs. (30 Nm).

=

Fuel injector harness connectors Fuel pressure regulator vacuum line Fuel lines Throttle body intake collector Air intake tube Negative battery cable 5. Start the engine and check for leaks.

DRIVE TRAIN e Starter motor

Foci

e Front driveshaft, if equipped

Transmission Assambly Bi

REMOVAL & INSTALLATION

k

Manual Transmission

‘i

e Rear driveshaft e Gear select cable and bracket

© Throttle Valve (TV) cable, if equipped

Exhaust front pipe

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Drain the transfer case fluid, if

equipped. 4. Remove or disconnect the following: Negative battery cable Shift lever boots Gear shift lever Transfer case shift lever, if

equipped

: saiastipled i

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° Rear driveshaft

GUIPP

© Front driveshaft. if equioped

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* Speedometer cable. if equipped Ulett if eal sensor, eee (VSS) Baad Speed e Vehicle equipped Clutch slave cylinder or cable Flywheel access cover Transmission flange bolts and nuts Transmission braces, if equipped 5. Support the transmission with a jack and remove the transmission mount and crossmember. 6. Place a wooden block at the rear of the cylinder head as shown to support the engine when the transmission is removed.

7. Lower the transmission away from

To install: 8. Install or connect the following: e Transmission. Tighten the flange fasteners to 62-72 ft. Ibs. (85-98 Nm). e Transmission mount and crossmember. Tighten the fasteners to 29-43 ft. Ibs. (40-60 Nm). e Transmission braces, if equipped. Tighten the bolts to 62—72 ft. Ibs. (85-98 Nm).

W 100-150 mm (4.0-8.0") 7017 DISTRIBUTOR CAP 7018 BULKHEAD 7924HG37

Support the engine with a wooden block between the cylinder head and the firewall—All models

Flywheel access cover

Transmission oil cooler lines Transmission brace Flywheel access cover Torque converter Speedometer cable, if equipped Vehicle Speed (VSS) sensor connector, if equipped Transmission flange bolts and nuts e Transmission braces, if equipped 4. Support the transmission with a jack and remove the transmission mount and crossmember.

a wooden block at the rear of 5. Place

* Clutch slave cylinder or cable

the cylinder head as shown to support

° Speedometer cable, if equipped

removed.

e Rear driveshaft if equipped Front driveshaft, Mae 5¢ tartar

6. Lower the transmission away from the vehicle. 7 ele

Reverse light switch connector AWD switch connector, if equipped Transfer case shift lever, if equipped Gear shift lever e Shift lever boots e Negative battery cable 9. Fill the transmission to the correct level. : :

7. Install or connect the following: Transmission. Tighten the flange fasteners to 62-72 ft. Ibs. (85-98

+ VSS sensor, if equipped —

10. Fill the transfer case, if equipped.

Automatic T

gel

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transfer case oil,ifequipped. 3. Remove or disconnect the following: Negative battery cable Center console and transfer case shift lever, if equipped Transmission dipstick tube Transmission wiring harness connectors

the engine when the transmission is

Nm). Transmission mount and crossmember. Tighten the fasteners to 29-43 ft. Ibs. (40-60 Nm). Transmission braces, if equipped. Tighten the bolts to 62-72 ft. Ibs. eeie

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Speedometer cable, if equipped Torque converter. Tighten the bolts to 47 ft. Ibs. (65 Nm). Flywheel access cover Transmission brace Transmission oil cooler lines Exhaust front pipe TV cable, if equipped Gear select cable and bracket Rear driveshaft Front driveshaft, if equipped

_————

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TRACKER @ SIDEKICK © SIDEKICK SPORT ¢ me SANTARA SURAT VEER 1 2-21 ¢ Starter motor Transmission wiring harness connectors

e Transmission dipstick tube ¢ Center console and transfer case shift lever, if equipped Negative battery cable 8. Fill the transmission to the correct level. 9. Fill the transfer case, if equipped.

end of the clutch cable in or out, as necessary to achieve the proper play. 3. Once the correct pedal free-play is obtained, check the free-play on the release arm (Cc), it should be 0.02—0.06 in. (0.5—-1.5mm).

1999-01 Models These vehicles are equipped with a hydraulic clutch system. No adjustment is

necessary.

REMOVAL & INSTALLATION

ADJUSTMENTS 1998 Models

CLUTCH PEDAL HEIGHT The clutch pedal height should not be a periodic adjustment but may be checked after components of the mechanical clutch system have been replaced. _ The proper clutch pedal height should be 0.2 in. (6mm) above the brake pedal

height If adjustment is necessary, loosen the locknut and turn the adjusting bolt until the appropriate height is reached. Once set, keep the bolt from turning and tighten the locknut to secure the adjustment.

CLUTCH PEDAL FREE-PLAY

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the transmission. 3. Loosen the pressure plate mounting

bolts in a 2-step crisscross sequence until the spring tensfon is relieved. 4. Remove the pressure plate and the clutch disc. To install: 5. Using a clutch alignment tool, assemble the clutch disc and pressure plate onto the flywheel. 6. Tighten the pressure plate bolts in multiple passes to 17 ft. Ibs. (23 Nm). 7. Install the transmission. 8. Check for proper clutch operation.

Hydraulic Clutch System

The clutch pedal free-play should be checked from time-to-time in order to assure proper clutch operation. The proper clutch free-play should be 0.6—-1.1 in. (15-25mm). 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If the free-play must be adjusted, turn the joint nut (2) located at the transmission

@® Joint pin (Apply grease)

7924HG30

Pedal free-play is adjusted at the joint nut (2), while keeping the outer cable nuts (3) tightened around the center cable thread

BLEEDING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Fill the master cylinder reservoir to

the MAX line with clean brake fluid and keep it at least half full throughout the bleeding procedure. 3. From beneath the vehicle, remove the bleeder plug cap, then attach a clear vinyl tube to the slave cylinder bleeder plug. Insert the open end of the hose into a container. 4. Have an assistant depress the clutch pedal. Open the bleeder after the pedal is depressed. 5. Close the bleeder before releasing the clutch pedal. 6. Repeat until all air bubbles are gone from the hydraulic fluid. 7. Install the bleeder plug cap. 8. Fill the clutch master cylinder fluid reservoir to the specified full level.

Transfer Case Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the transfer case oil. 3. Remove or disconnect the following: Negative battery cable Distributor or Camshaft Position (CMP) sensor, if equipped Center console Transmission shift lever and case, if equipped with a manual transmission Transfer case shift lever Front and rear driveshafts Exhaust center pipe Speedometer cable or Vehicle Speed (VSS) sensor, as equipped Vent hose e AWD switch connector 4. Support the transmission with a jack and remove the transmission mount and crossmember. 5. Place a wooden block at the rear of the cylinder head as shown to support the engine when the transfer case is removed. 6. Lower the transfer case away from the vehicle. To install: 7. Install or connect the following: Transfer case. Tighten the bolts to 30 ft. Ibs. (41 Nm). AWD switch connector Vent hose Speedometer cable or VSS sensor, as equipped Exhaust center pipe Front and rear driveshafts. Tighten the bolts to 36 ft. Ibs. (50 Nm). Transfer case shift lever Transmission shift lever and case, if equipped with a manual transmission Center console Distributor or CMP sensor, if equipped Negative battery cable 8. Fill the transfer case.

REMOVAL & INSTALLATION Left

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

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4. DOS boot 5. Ball joint boot

SPORT ¢ X-90° VITARA ¢ GRAND VITARA 2. Remove or disconnect the following: e Halfshaft from the vehicle e Grease boot clamps e Outer race snapring e Outer race e Shaft snapring e Inner race, cage and balls To install: 3. Install or connect the following: e Inner race, cage and balls e Shaft snapring e Outer race e Outer race snapring 4. Fill the outer race and the grease boot with CV-joint grease and tighten the boot clamps. 5. Install the axle halfshatt.

6. Bali joint assembly (RH side)

7, Drive shaft assembly (LH side)

8. Left drive shatt 9. Drive shaft bearing circlip 10. Drive shaft beering

7924HG31

Exploded view of the left- and right-hand halfshaft assemblies

2. Remove or disconnect the following: ° Front wheel Hub drive flange or locking hub, as equipped Snapring Thrust washer Halfshaft flange fasteners Halfshatt To install: 3. Install or connect the following: Halfshaft. Tighten the flange bolts to 37 ft. Ibs. (50 Nm). Thrust washer Snapring Locking hub, if equipped. Tighten the bolts to 24 ft. Ibs. (33 Nm). Hub drive flange, if equipped. Tighten the bolts to 35 ft. Ibs. (48 Nm). Front wheel

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

2. Remove or disconnect the following: Front wheel Hub drive flange or locking hub, as equipped Snapring Thrust washer Brake caliper Wheel speed sensor, if equipped Brake rotor Stabilizer bar link Outer tie rod end Lower ball joint Strut bracket bolts Steering knuckle and wheel hub 3. Pry the inboard joint out of the differential and remove the halfshaft.

To 4. ential 5.

install: Insert the inboard joint into the differuntil the circlip is felt to seat. Install or connect the following: Steering knuckle and wheel hub Strut bracket bolts. Tighten them to 70 ft. Ibs. (95 Nm). Lower ball joint. Tighten the nut to 40 ft. Ibs. (65 Nm). - Outer tie rod end. Tighten the nut to 35 ft. Ibs. (48 Nm). Stabilizer bar link. Tighten the nut to 21 ft. Ibs. (29 Nm). Brake rotor Wheel speed sensor, if equipped Brake caliper Thrust washer Snapring Locking hub, if equipped. Tighten the bolts to 24 ft. Ibs. (33 Nm). Hub drive flange, ifequipped. Tighten the bolts to 35 ft. Ibs. (48 Nm). Front wheel 6. Check the wheel alignment and adjust as necessary.

Manual Locking Hubs

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Set the selector knob to the FREE position. 3. Remove or disconnect the following: e Hub cover assembly e Hub body assembly To install: 4. Install the hub body. Tighten the bolts to 18 ft. lbs. (25 Nm). 5. Align the hub cover stopper nail with the groove in the hub body and install the hub cover. Tighten the bolts to 90 inch Ibs. (10 Nm), 6. Check for proper hub operation.

OVERHAUL

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Outer CV-Joint

The outer CV-joint is serviced with the axle shaft as an assembly. The outer CVjoint boot can be serviced by removing the inner CV-joint. Inner CV-Joint

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

1, 2.

Stopper nail Groove 9308HG06

Manual hub alignment—All models

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assembly and install the sub assembly. Tighten the hub bolts to 24 ft. Ibs. (33 Nm). 6. Check for proper hub operation.

Automatic Locking Hubs

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Unlock the hub by setting the transfer case in the 2H position and driving backwards at least 6.5 feet (2 meters). 3. Remove or disconnect the following: e Hub sub assembly e Hub brake assembly To install: 4. Align the brake assembly key with the slot in the spindle and install the brake assembly. 5. Align the matchmark on the sub assembly with the mark on the brake

1. Free wheeling hub sub assembly 2. Free wheeling hub brake assembly 9308HG04

Automatic hub—All models

Spindle Bearings

|

REMOVAL, PACKING & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the control arm with a stand or floor jack. 3. Remove or disconnect the following: Front wheel Locking hub or drive flange, as equipped Brake caliper and rotor Wheel hub and bearing assembly Outer tie rod end Lower ball joint Strut bracket bolts Wheel spindle and steering knuckle assembly Inner oil seal Spindle bearing To install: 4. Fill the recess in the wheel spindle with lithium grease. 5. Coat the spindle bearing and wheel spindle mating surfaces with sealant.

1. Match marks 2. Wire brake 3. Release plate 9308HG05

Automatic hub matchmarks—All models

6. Press or drive the spindle bearing into the wheel spindle. 7. Install or connect the following: Inner oil seal Wheel spindle and steering knuckle assembly Strut bracket bolts Lower ball joint Outer tie rod end Wheel hub and bearing assembly Brake caliper and rotor Locking hub or drive flange, as equipped Front wheel

Axle Shaft, Bearing and Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the parking brake cable for clearance. 3. Remove or disconnect the following: e Rear wheel e Brake drum e Wheel speed sensor, if equipped e Bearing retainer nuts e Axle shaft and bearing e Axle shaft inner oil seal 4. \f equipped with ABS, grind a flat spot on the wheel speed sensor tone ring, then split the ring with a chisel. 5. Grind flat spots on the bearing retainer and split it with a chisel. 6. Press the wheel bearing off the axle shaft. 7. Remove the bearing retainer and the outer oil seal. To install: 8. Install or connect the following: Outer oil seal to the bearing retainer Bearing retainer to the axle shaft Bearing and retainer ring pressed onto the axle shaft Wheel speed sensor tone ring pressed onto the axle shaft, if equipped Axle shaft inner oil seal Axle shaft and bearing Bearing retainer nuts. Tighten them to 17 ft. Ibs. (23 Nm). Wheel speed sensor, if equipped Brake drum Rear wheel 9. Fill the rear differential to the correct level.

Timing belt service is covered in Section 3 of this manual

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the preload torque readings originally recorded.

REMOVAL & INSTALLATION ae Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Driveshaft e Wheels e Brake calipers and pads or brake drum >The brake calipers and pads or brake drum must be removed so that there is no additional drag when measuring pinion bearing preload.

3. Use an inch Ib. torque wrench and measure and record the amount of torque required to maintain pinion rotation through several revolutions. 4. Remove or disconnect the following: e Pinion flange e Pinion seal e Pinion bearing

¢ Collapsible spacer To install: >Use a new collapsible spacer and flange nut for assembly.

5. Install or connect the following: e Collapsible spacer e Pinion bearing e Pinion seal e Pinion flange 6. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly. 7. Take frequent bearing preload torque readings. Tighten the flange nut to achieve

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« CAUTION Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new

collapsible spacer and pinion nut. 8. Install or connect the following: e Driveshaft e Brake calipers and pads or brake drum e Wheels 9. Fill the differential with gear lubricant and check for leaks.

Axle Housing Assembly

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the gear oil. 3. Support the vehicle at the frame with a hoist or jackstands. 4. Support the rear axle with a floor jack. 5. Remove or disconnect the following: Rear wheels Rear brake drums Rear axle shafts Load sensing proportioning valve linkage, if equipped Brake fluid hose Brake backing plates Wheel speed sensor connector, if equipped

CAUTION

Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

° Axle vent tube Rear driveshaft Differential carrier assembly Shock absorber lower bolts Coil springs » Upper rods Lower rods Lateral rod Axle housing To install: 6. Install or connect the following: Axle housing Upper rods Lower rods Coil springs Lateral rod Shock absorber lower bolts Differential carrier assembly. Tighten the nuts to 40 ft. Ibs. (55 Nm). Rear driveshaft Axle vent tube Wheel speed sensor connector, if equipped Brake backing plates Brake fluid hose Load sensing proportioning valve linkage, if equipped Rear axle shafts Rear brake drums e Rear wheels i “Fil the rear axle to the correct level. 8. Lower the vehicle so that the rear Suspension is at curb height.

9. Tighten the upper, lower and lateral rod fasteners to 65 ft. Ibs. (90 Nm). 10. Tighten the lower shock absorber fasteners to 62 ft. Ibs. (85 Nm).

|

STEERING AND SUSPENSION PRECAUTIONS

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Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module, e When carrying a live inflator module, hold securely with both hands and ensure that the bag/trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. ¢ With the inflator module on the bench, never place anything on or close to the

module which may be thrown in the event of an accidental deployment. e Never use air bag component parts from another vehicle. e lf there is a chance of electrical shock to any of the air bag components, remove the air bag module before pl the vehicle.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e AIR BAG fuse e Driver air bag connector

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Recirculating Ball Steering Gear REMOVAL & INSTALLATION Manual Steering 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Skidplate, if equipped e Intermediate shaft pinch bolt e Pitman arm center link joint e Steering gearbox e Pitman arm To install: 3. Install or connect the following: Pitman arm. Tighten the nut to 116 ft. Ibs. (160 Nm). Steering gearbox. Tighten the bolts to 62 ft. Ibs. (85 Nm). Pitman arm center link joint. Tighten the nut to 37 ft. Ibs. (50 Nm). Intermediate shaft pinch bolt. Tighten it to 18 ft. Ibs. (25 Nm). Skidplate, if equipped 4. Check the wheel alignment and adjust as necessary.

> : Release locking of lock lever. : After unlocked, disconnect connector.

Power Steering

Yeliow connector of driver air bag (inflator) module Connector stay Air bag fuse box od a St Yellow connector of passenger air bag (inflator) module oO Glove box 7924HG36

Air bag component location and identification—All models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Skidplate, if equipped e Coolant overflow tank e Intermediate shaft pinch bolt e Power steering hoses e Pitman arm center link joint e Steering gearbox e Pitman arm To install: 3. Install or connect the following:

e Glove box e Passenger air bag connector

ARMING When repairs are complete, install or connect the following: e Passenger air bag connector

e Glove box e Driver air bag connector e AIR BAG fuse e Negative battery cable

1. Flat part 2. Shaft joint 7924HG72

Remove the lower steering shaft mounting bolt and disconnect the shaft from the gearbox—

1998 models

Heater Core replacement is covered in Section 2 of this manual

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1. Pitman arm 2. Center link 3. Tie rod end remover (09913-65210) 7924HG73

Separating the center link from the Pitman arm—1998 models

2. Gear case 3. Pinion shaft 9302HG14

Steering gear centering marks

1. Guide bolt

7924HG75

When installing the steering gear box, note the position of the longer guide bolt—1998 models

Pitman arm. Tighten the nut to 102

ft. Ibs. (140 Nm). Steering gearbox. Tighten the bolts to 62 ft. Ibs. (85 Nm). Pitman arm center link joint. Tighten the nut to 37 ft. Ibs. (50 Nm). Power steering hoses Intermediate shaft pinch bolt. Tighten it to 18 ft. Ibs. (25 Nm). Coolant overflow tank Skidplate, if equipped 4. Fill the power steering system. 5. Start the engine and check for leaks. 6. Check the wheel alignment and adjust as necessary.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ 2. Remove or disconnect the following: e Power steering hoses e Intermediate shaft pinch bolt

To 3.

e Front wheels e Outer tie rod ends ¢ Steering gear install: Install or connect the following: Steering gear. Tighten the bolts to AO ft. Ibs. (55 Nm). Outer tie rod ends. Tighten the nuts to 32 ft. Ibs. (43 Nm). Front wheels Intermediate shaft pinch bolt. Tighten it to 18 ft. Ibs. (25 Nm). Power steering hoses Fill the power steering system. Start the engine and check for

4. 5. leaks. 6. Check the wheel alignment and adjust as necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the control arm with a stand or floor jack. 3. Remove or disconnect the following: e Front wheel e Brake hose bracket e Strut bracket bolts e Upper strut mount nuts e Strut To install: 4. Install or connect the following:

e Strut. Tighten the upper mount nuts to 40 ft. Ibs. (55 Nm) and the bracket bolts to 70 ft. Ibs. (95 Nm). e Brake hose bracket e Front wheel 5. Check the wheel alignment and adjust as necessary.

Shock Absorber

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the rear axle housing with a hydraulic jack or stand. ; 3. Remove or disconnect the following: e Shock absorber upper locknut and retaining nut e Lower shock absorber mounting nut and bolt e Rear shock absorber : To install: 4. Install or connect the following: e Rear shock absorber ¢ Lower mounting nut and bolt e Upper retaining nut and locknut 5. Torque the upper mounting nuts to 21 ft. Ibs. (22-35 Nm) and the lower mounting nut/bolt to 62 ft. Ibs. (85 Nm) 6. Remove the jack or stand from the rear axle assembly.

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e Front wheel

8. Check the wheel alignment and adjust as necessary. Rear

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Rear axle housing Coil spring Axle shaft Shock absorber Upper arm Trailing rod

Brake drum Wheel bearing retainer

Rear wheel bearing Brake back plate Oil drain plug 7924HG32

Rear suspension component identification

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle at the frame with a hoist or jackstand. 3. Support the control arm with a floor jack. 4. Remove or disconnect the following: e Front wheel e Brake caliper and rotor ¢ Locking hub or drive flange, if equipped e Axle shaft snapring and thrust washer, if equipped

e Wheel speed sensor, if equipped e Stabilizer bar link e Lower ball joint e Strut bracket bolts 5. Lower the floor jack and remove the coil spring. To install:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle at the frame with a hoist or jackstand. 3. Support the rear axle housing with a floor jack. 4. Remove or disconnect the following: Rear wheels Parking brake cable hanger Shock absorber lower mounting bolts Wheel speed sensor harness clamps, if equipped Brake pipe E-ring e Axle vent hose 5. Lower the floor jack and remove the coil springs. To install: 6. Install the coil springs onto the axle spring seats and raise the floor jack. 7. Install or connect the following: Axle vent hose Brake pipe E-ring Wheel speed sensor harness clamps, if equipped Shock absorber lower mounting bolts. Tighten them to 62 ft. Ibs. (85 Nm). Parking brake cable hanger Rear wheels

Lower Ball Joint

REMOVAL & INSTALLATION 1998 Models

The bottom of the spring has a larger diameter than the top.

2 WHEEL DRIVE

6. Install the coil spring onto the control arm and raise the floor jack. 7. Install or connect the following: e Strut bracket bolts. Tighten them to 70 ft. Ibs. (95 Nm). e Lower ball joint. Tighten the nut to AO ft. Ibs. (65 Nm). e Stabilizer bar link. Tighten the nut to 21 ft. Ibs. (29 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the control arm with a floor jack. 3. Remove or disconnect the following: e Front wheel e Lower ball joint To install: 4. Install or connect the following:

Brake service is covered in Section 4 of this manual

42-34

ia GEO/CHEYROLETSUZUKL

e Lower ball joint. Tighten the control arm bolts to 62 ft. Ibs. (85 Nm) and the nut to 40 ft. Ibs. (65 Nm) e Front wheel 5. Check the wheel alignment and adjust as Necessary.

4 WHEEL DRIVE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the control arm with a floor jack. 3. Remove or disconnect the following: Front wheel Brake caliper and rotor Locking hub or drive flange Axle shaft snapring and thrust washer Wheel speed sensor, if equipped Stabilizer bar link Lower ball joint nut Strut bracket bolts Steering knuckle Lower ball joint To install: 4. Install or connect the following: Lower ball joint. Tighten the control arm bolts to 62 ft. Ibs. (85 Nm). Steering knuckle. Tighten the ball joint nut to 40 ft. Ibs. (55 Nm). Strut bracket bolts. Tighten them to 70 ft. Ibs. (95 Nm). Stabilizer bar link Wheel speed sensor, if equipped Axle shaft snapring and thrust washer Locking hub or drive flange Brake caliper and rotor e Front wheel 5. Check the wheel alignment and adjust as necessary.

1999-01 Models The lower ball joint is serviced with the. lower control arm as an assembly.

Lower Control Arm

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

2. a hoist 3. jack. 4.

SPORT ¢ X-90 »VITARA e GRAND VITARA

Support the vehicle at the frame with or jackstand. Support the control arm with a floor

Remove or disconnect the following: Front wheel Brake caliper and rotor Locking hub or drive flange, if equipped Axle shaft snapring and thrust washer, if equipped Wheel speed sensor, if equipped Stabilizer bar link Lower ball joint Strut bracket bolts 5. Lower the floor jack and remove the coil spring. 6. Remove the inner control arm bolts and remove the control arm. To install: 7. Install the inner control arm bolts. 8. Install the coil spring onto the control arm and raise the floor jack. 9. Install or connect the following: Strut bracket bolts. Tighten them to 70 ft. Ibs. (95 Nm). Lower ball joint. Tighten the nut to AO ft. Ibs. (655 Nm). Stabilizer bar link. Tighten the nut to 21 ft. Ibs. (29 Nm). Wheel speed sensor, if equipped Axle shaft snapring and thrust washer, if equipped Locking hub or drive flange, if

equipped

Brake caliper and rotor Front wheel 10. Lower the vehicle so that the front suspension is at curb height. 11. Tighten the front inner bolt to 62 ft. lbs. (85 Nm) and the rear inner bolt to 92 ft. lbs. (127 Nm). 12. Check the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the control arm from the vehicle. 3. Remove the control arm bushings with a hydraulic press. To install: 4. Lubricate the control arm bushings with liquid soap.

5. Press the bushings into the control arm until the bushing flange contacts the housing edge of the control arm.

6. Install the control arm to the

vehicle. 7. Check the wheel alignment and adjust as Necessary.

Wheel Bearings

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~ ADJUSTMENT The wheel bearings are not adjustable.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Brake caliper and rotor Locking hub or hub drive flange, if equipped Hub grease cap, if equipped Wheel speed sensor, if equipped Wheel bearing lockwasher Wheel bearing locknut and inner washer Wheel hub and bearing assembly Wheel hub oil seal Wheel bearing oil seal

Snapring 3. Press the wheel bearing and race out of the hub. To install: 4. Press the wheel bearing and race into the hub so that the race is fully seated in the hub bore. 5. Install or connect the NONE e Snapring Wheel bearing oil seal Wheel hub oil seal Wheel hub and bearing assembly Wheel bearing locknut and inner washer. Tighten the nut to 157 ft. lbs. (216 Nm). Wheel bearing lockwasher. Tighten the retaining screws to 13 inch Ibs. (1.5 Nm). Wheel speed sensor, if equipped Hub grease cap, if equipped Locking hub or hub drive flange, if equipped Brake caliper and rotor Front wheel

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GENERAL MOTORS CORP. 1998-02

Chevrolet-Blazer * Xtreme * Trailblazer * Oldsmobile-Bravada * GMC-Envoy * Jimmy DRIVE TRAIN.................. 13-27 ENGINE REPAIR ................ 13-2 FUEL SYSTEM ................ 13-25 PRECAUTIONS.................. 13-2 STEERING AND SUSPENSION ai 13-37

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Assembly... Re Oe Te 13-28 Removal & Instatlation............ 13-28

RIG TIOUSIT vertccteesticwrrt stscscers,13-36 Removal & Installation............ 13-36

Axle Shaft, Bearing and Seal........13-34 Removal & Daa of

Re 13-34

Camshaft and Valve Lifters .......... 13-13 Removal & Installation............ 13-13 GLUE) Ah Sates wine Asia atoils. 13-29

Removal & Installation............ 13-29 TOTES

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Removal & Installation............ 13-40 Be OIG dart Mes Ahntoslin cal.13-32 Overall | UAE ee are er 13-32

Bylinder ead eat. ise reecaese 13-6 . Removal & ett De arti, 13-6 DON tare 2.8 oat eth a! 13-2 TST allLeal, beds ate tcoh a hesnate 13-2 Removal............ ga seh 13-2

Engine ASSEMDIY .........eeeeseeeen 13-3 Removal & Installation............. 13-3 Exhaust Manifold... 13-12 Removal & Installation............ 13-12

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FuelRiter Wir76. Wile, Ne PET Wao 13-25 Removal & Installation............ 13-25 FieIMRIECIOF. 2 2;, 20 SUNS Deets13-26 Removal & Installation............ 13-26 FUG! PONDS eccrtaUete eaca 13-26 Removal & Installation............ 13-26

Fuel System Pressure ............-.+-. 13-25 ROLOVINIGHI sha labadess feantettes 13-20

Fuel System Service

Removal & Installation Piston and Ringis.ahe, ees Positioning eine ese eee Power Steering Gear... Removal & Ware i

Rocker Arms/Shafts ......ccccccceeeee 3 Removal & ies

Precautions........... jpeeramiay 13-25

Halfshatittece. sxmaasupeutan bem vette 13-31 Removal & Installation............ 13-31 Hydraulic Clutch System ............. 13-30 Bleedingy....02..0 OE, PWR 13-30 Igniter? Tmthig? ys a Sa aaa 13-3 ARSE ert ely Dees i GT:13-3 Intake Manifold... cece 13-10 Removal & Raa hice 13-10

SEIN US Installing the distributor 180° out of alignment, or locating the rotor in the wrong holes, may cause a no start condition or can cause premature engine damage and wear.

3. Make sure the rotor is pointing to the cap hold-down mount nearest the flat side of the housing. 4. Using a long screwdriver, align the oil pump driveshaft in the engine in the mating drive tab in the distributor. 5. Install the distributor in the engine. Make sure the spark plug towers are perpendicular to the centerline of the engine. 6. When the distributor is fully seated, the rotor segment should be aligned with the pointer cast in the distributor base. The pointer will have a “6” cast into it indicating a 6 cylinder engine. If the rotor segment is not within a few degrees of the pointer, the distributor gear may be off a tooth or more. If this is the case repeat the process until the rotor aligns with the pointer. 7. Install the cap and fasten the mounting screws. 8. Tighten the distributor mounting bolt to 18 ft. Ibs. (25 Nm). 9. Engage the electrical connections and the spark plug wires.

1. Before Servicing the vehicle, refer to iiprecautions in the beginning of this secion, 2. Remove or disconnect the following: e Negative battery cable Accessory belt Positive battery cable nut from the generator

A/C line mounting bracket bolt at the engine lift hook Right engine lift hook bolts Engine lift hook Mounting bolts Alternator

13-3

Tighten the top alternator bolt to 22 ft. Ibs. (30 Nm) and the bottom bolt to 32 ft. Ibs. (43 Nm) on 1998 models : Tighten the rear bolt to 37 ft. Ibs.

(50 Nm) and the front bolt to 18 ft. bs. (25 Nm) on 1999-01 models

Alternator brace, then tighten the

retaining nut(s) and bolts to 22 ft

lbs..(30.Nm) on 1998 models Tighten the brace-to-alternator and brace-to-intake retainers to 18 ft. Ibs. (25 Nm). Tighten the brace-to-

engine stud nut to 37 ft. Ibs. (50 Nm)on 1999-01 models. Wires and the battery feed wire nut Heater hose bracket Accessory belt Negative battery cable

Ignition Timing

4.3L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable

e Air inlet duct, if necessary e e e e e

Accessory belt Heater hose brace Wires Mounting bolts Alternator

INSTALLATION 4.2L Engine Install or connect the following: Alternator and loosely install the mounting blots Tighten the alternator mounting

bolts to 37 ft. Ibs. (60 Nm) Positive battery cable and secure with the nut; tighten the nut to 80

inch Ibs. (9 Nm) Engine lift hook and bolts; tighten the bolts to 37 ft. Ibs. (60 Nm) A/C line bracket to the lift hook, then tighten the retaining bolt to 89 inch Ibs. (10 Nm) Accessory belt Negative battery cable 4.3L Engine Install or connect the following: e Alternator and loosely install the mounting bolts

ADJUSTMENT The ignition timing is preset and cannot be adjusted.

Engine Assembly REMOVAL& INSTALLATION 4.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine cooling system ->Keep the oil drain plug removed during the engine removal and installation.

3. Drain the engine oil. Install a suitable plug into the oil pan to prevent oil leakage during the remainder of the procedure. 4. Using the proper equipment, discharge and recover the refrigerant from the A/C system, if equipped. 5. Remove or disconnect the following: Hood Negative battery cable Fuel system pressure Air cleaner assembly Throttle body Manifold Absolute Pressure (MAP) sensor ' Windshield washer solvent container Air intake baffle

For complete service labor times, order the Chilton Labor Guide

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Grille Headlight housing Radiator support brace Hood A/C lines from the condenser Transmission cooler lines from the engine, not the radiator

6. Remove the cooling fan and shroud, tilting the radiator forward, and the cooling

fan and shroud rearward for clearance. 7. Remove or disconnect the following: e Accessory belt e Power steering pump bolts; position the pump aside e Heater hoses from the heater core e Transmission filler tube bracket nut from the Air Injector Reactor (AIR) adapter AIR adapter 8. Install a suitable lift hook to the AIR adapter 9. Remove or disconnect the following: Oxygen (02) sensor connector A/C line from the accumulator Front axle actuator electrical connector Camshaft phaser actuator valve electrical connector Transmission cooler lines from the clips on the right side of the engine block

Ignition coil harness connectors Harness retainer from the clips Power brake hose from the booster Powertrain Control Module (PCM) ee eee ®e Fuel lines from the fuel pressure regulator. Cap the lines to avoid excessive fuel leakage All harnesses from the engine harness bracket Engine harness bracket bolt and bracket Starter electrical connections A/C pressure sensor and clutch electrical connector Alternator electrical connector and battery lead Knock Sensor (KS), Crankshaft

Position (CKP) and Camshaft Position (CMP) sensor electrical connectors 4 ground on the left side of the block 10. Raise and safely support the vehicle. 11. Remove or disconnect the following: Left and right side driveshafts Propeller shaft from the front axle pinion yoke Engine protection shield Exhaust pipe from the exhaust manifold. Slide the exhaust pipe backward slightly

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e Fuel tank shield, if equipped e Torque converter access cover and bolts 12. Place a jack on the transmission fluid pan for support. 13. Remove the transmission support. 14. Lower the transmission enough to reach the top bell housing bolts. 15. Remove the top 4 bell housing bolts, there may be 2 harness clips that will need to be removed in order to have access to 2 of the top bolts. 16. Raise the transmission. 17. Reinstall the transmission support using only 2 through bolts 18. Remove or disconnect the following: Remaining bell housing bolts (11 total) Left and right engine lower mount nuts Oil level sensor electrical connector Oil pressure switch electrical connector 19. Carefully lower the vehicle. 20. Remove the left, then the right upper engine mount nut. 21. Install a suitable engine hoist. 22. Raise the engine out of the compartment slowly, keeping the transmission supported. 23. Remove both engine mounts for clearance. 24. Continue raising the engine out of the vehicle. 25. Place the-engine on a suitable engine stand. To install: 26. Remove the engine from the engine stand. 2/7. Slowly install the engine into the engine compartment, aligning the engine mounts with the brackets. 28. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets. 29. Lower the engine onto the mounts and install the upper engine mounting nuts. Tighten the nuts to 51 ft. Ibs. (71 Nm). 30. Remove the engine hoist. 31. Lay the radiator into the radiator support, but do not install the radiator completely. 32. Raise and safely support the vehicle. 33. Install the lower bell housing bolts, except the top four. 34. Remove the 2 through bolts secure the transmission support, then lower the transmission. 35. Install the top 4 bell housing bolts and tighten all 11 bolts to 37 ft. Ibs. (50 Nm). 36. Raise the transmission.

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37. Install or connect the following: e Transmission support e 3 torque converter bolts and renee to 44 ft. Ibs. (60 Nm) Torque converter bolt cover Fuel tank shield, ifequipped Engine protection shield Propeller shaft to the front axle pinion yoke Exhaust pipe to the manifold and tighten the bolts to 37 ft. Ibs. (50 Nm) Oil level switch and oil pressure sender electrical connectors Oil pan drain plug and tighten to 19 ft. Ibs. (26 Nm) Lower radiator hose Left and right wheel driveshafts. 38. Lower the vehicle. 39. Install or connect the following: e 4 grounds on the left side of the block CMP. CKP and knock sensor electrical connectors Alteranator and starter electrical connectors and battery leads. Torque the nuts to 80'inch Ibs. (9 Nm) Fuel lines at the fuel pressure regulator Engine harness bracket and bolt. Torque the bolt to 37 ft. Ibs. (50 Nm) Front differential vent hose, to the engine harness bracket PCM Power brake hose to the booster Harness retainer to its original location Ignition coil harness connectors Transmission cooler lines to clips on right side of engine block Camshaft phaser actuator valve electrical connector Front axle actuator electrical connector

A/C line at the accumulator 40. Remove the lift hook. ; 41. Install or connect the following: e AIR adapter and secure with the Studs. Tighten to 18 ft. Ibs. (25 Nm) e Transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut. Torque the nut to 89 inch Ibs. (10 Nm) ¢ Heater hoses to the heater core * Power steering pump and tighten the bolts to 18 ft: Ibs. (25 Nm). 42. The remainder of installation is the reverse of removal, but please note the following important steps:

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BLAZER e XTREME ¢ TRAILBLAZER © BRAVADA ¢ ENVOY ¢ JIMMY 43. Connect the negative battery cable 44. Check all powertrain fluid levels and add, as necessary. 45. Refill the engine crankcase. 46. Refill the engine cooling system.

47. Perform the CKP System Variation

Learn Procedure, as follows: a. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). lf any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure. b. With the scan tool, select the lh position variation learn proceure c. Observe the fuel cut-off for the 4.2L engine. d. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly. e. Enable the crankshaft position system variation learn procedure. e> While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to

the operator and the engine responds to throttle position after the learn procedure is complete.

f. Sloiwly increase the engine speed to the RPM that you observed. g. Immediately release the throttle when fuel cut-out is reached. h. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting. i. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully. _ 48. Start and run the engine, then check for leaks.

4.3L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the engine cooling system 3. Drain the engine oil. 4. Remove or disconnect the following: e Negative battery cable e Fuel system pressure e Vacuum reservoir and/or the underhoad light from the hood, as

equipped

¢ Outer cowl vent grilles

Hood

Oxygen (02S) sensor and/or wiring Exhaust pipes at the manifolds and

5. Support the transmission. 6. Install a lifting device and lift the engine.

loosen the hanger at the catalytic

To install:

converter. This is necessary to remove the rear catalytic converter

cushion mounts for removal of the exhaust assembly, Skid plate, if equipped Engine-to-transmission pencil braces Slave cylinder and position aside, if equipped Line clamp at the bell housing Wiring from the starter Starter Transfer case on 1998-01 models, if equipped Oil filter Engine mount through bolts Rear engine mount crossbar, nut and washer Bell housing bolts, except the upper left. Battery ground (negative) cable from the engine Front drive axle bolts and roll the axle downward, on 4WD vehicles Air cleaner assembly Upper radiator shroud Fan assembly Drive belt assembly Water pump pulley Upper radiator hose Air conditioning compressor, if equipped, and position aside with the lines intact Lower radiator hose Oil cooler and overflow lines from the radiator, plug the openings to prevent system contamination or excessive fluid loss. Radiator and lower radiator shroud Power steering hoses from the steering gear, then cap the openings to prevent system contamination or excessive fluid loss. Heater hoses from the intake manifold and the water pump Wiring harness and vacuum lines from the engine Throttle cables Distributor cap Remaining bell housing bolt Fuel lines and the bracket Ground strap(s) from the rear of the cylinder head Front body mount bolts, on 4WD vehicles

13-9

7. Install or connect the following: Engine into the vehicle Front body mount bolts, on 4WD vehicles

Ground strap(s) to the rear of the cylinder head Fuel lines and the bracket Upper left bell-housing bolt Distributor, cap and wires Throttle cables Vacuum lines and wiring harness connectors Heater hoses Power steering hoses Lower shroud and radiator Oil cooler lines to the radiator and overflow hose Lower radiator hose Air conditioning compressor to the engine, if equipped Upper radiator hose Water pump pulley Drive belt assembly Fan assembly Upper radiator shroud Air cleaner assembly Front drive axle, for 4WD vehicles Battery ground strap to the engine block Remaining bell housing bolts Engine mount through-bolts. Torque them to 49 ft. Ibs. (66 Nm). Rear engine mount crossbar nut

and washer. Tighten the nut to 33 ft. Ibs. (45 Nm). Oil filter Starter motor Flywheel cover Clutch slave cylinder, if equipped Pencil brace and the skid plate, as equipped Catalytic converter Y-pipe assembly and hangers Hood Outer cow! vent grilles Vacuum reservoir and/or the underhood light to the hood, as equipped Negative battery cable 8. Check all powertrain fluid levels and add, as necessary. 9. Refill the engine crankcase. 10. Refill the engine cooling system. 11. Start and run the engine, then check for leaks.

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

Fan or fan and clutch assembly Serpentine drive belt (ifequipped) by positioning the belt over the pulleys and carefully allow the tensioner back into contact with the belt.

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REMOVAL &INSTALLATION

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4. Relieve the belt tension and remove

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5. Remove or disconnect the following: e Upper fan shroud e Fan or fan and clutch assembly, as applicable e Water pump pulley; use a suitable tool to hold the pulley while remov-

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ing the bolts ¢ Coolant hose(s) from the water pump >For the hoses on some engines, removal may be easier if the hose is left attached until the pump is free from the block. Once the pump is removed from the engine, the pump may be pulled (giving a better grip and greater leverage) from the tight hose connection.

e Water pump retainers e Water pump from the engine

Note the positions of all retainers as some engines will utilize different length fasteners in different locations and/or bolts and studs in different locations.

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To install: 6. Clean the gasket mounting surfaces. >The water pumps on some of the engines covered may have been installed using sealer only, no gasket, at the factory. If a gasket is supplied with the replacement part, it should be used. Otherwise, a % in. (3mm) bead of RTV sealer should be used around the sealing surface of the pump.

7. Apply sealant to the water pump retainer threads. 8. Install or connect the following: e Water pump using a new gasket. Tighten the water pump retainers to 89 inch Ibs. (10 Nm) for 4.2L engines, or to 30 ft. Ibs. (41 Nm) for 4.3L engines e Coolant hose(s)

7924JG06 Exploded view of the water pump assembly mounting—4.3L engine

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Exhaust manifold Front cover Cylinder head access hole plugs Timing chain tensioner shoe bolt and shoe Timing chain tensioner guide bolts and guide e Timing chain and sprockets 5. Unfasten the cylinder head bolts by loosening them in the reverse of the torque sequence, then carefully remove the cylinder head. 6. Remove the cylinder head gasket. To install: 7. Carefully clean and inspect the cylinder head and the gasket mounting surfaces.

8. If using a steel only gasket, apply a thin and even coat of sealer to both sides of the gaskets. 9. Place a new gasket over the dowel pins with the bead or the words “This Side Up” facing upwards (as applicable), then carefully lower the cylinder head into position over the gasket and dowels. 10. Apply a coating of 12345493 or equivalent sealer to the threads of the cylinder head bolts, then thread the bolts into position until finger-tight. 11. Tighten the cylinder head bolts in

sequence as follows:

a. Tighten the long bolts (1-14), in sequence, to 30 ft. Ibs. (40 Nm). b. Tighten the long bolts, in sequence, an additional 90 degrees. c. Tighten the long bolts, in sequence, an additional 60 degrees.

>The gasket surfaces on both the head and block must be clean of any foreign matter and free of nicks or heavy scratches. The cylinder bolt threads in the block and thread on the bolts must be cleaned (dirt will affect the bolt torque).

d. Tightén the 2 long end bolts to 15 ft. Ibs. (20 Nm). e. Tighten the1 short end bolt to 13 ft. Ibs. (18 Nm). 12. Install or connect the following: e Cylinder head access hole plugs and tighten to 44 inch Ibs. (5 Nm) e Timing chain and sprockets e Front cover e Camshaft cover

->DO NOT apply sealer to composition steel-asbestos gaskets.

kk WARNING Make sure the number 1 cylinder is at Top Dead Center (TDC).

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e Exhaust manifold e Negative battery cable 13. Properly refill the engine cooling system. 14. Run the engine to check for leaks. 4.3L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure, then disconnect the negative battery cable. 3. Drain the engine cooling system. 4. Remove or disconnect the following: Intake manifold Exhaust manifold Alternator and bracket, if removing the right cylinder head Cooling fan assembly, on 1998-01 models Air conditioning compressor (position it aside with the refrigerant lines attached), on 1999-01 models equipped Air pipe bracket and nut from the rear of the power steering pump if removing the left cylinder head on equipped 1999-01 models Engine accessory bracket with power steering pump (position the pump aside with the lines attached) and brackets, if removing the left cylinder head Wiring harness and clip from the rear of the cylinder head Coolant sensor wire Wiring from the spark plugs Spark plugs, if necessary Ground wires and if necessary, the fuel line bracket from the rear of the cylinder head, on 1999-01 models Rocker arm cover 5. Loosen the rocker arms and remove the pushrods.

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9355MG02

Cylinder head bolt tightening sequence—4.2L engine

6. Unfasten the cylinder head bolts by loosening them in the reverse of the torque sequence, then carefully remove the cylinder head. To install: 7. Carefully clean and inspect the cylinder head and the gasket mounting surfaces.

Timing belt service is covered in Section 3 of this manual

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Cylinder head and related components— 4.3L engine

->The gasket surfaces on both the head and block must be clean of any foreign matter and free of nicks or heavy scratches. The cylinder bolt threads in the block and thread on the bolts must be cleaned (dirt will affect the boit torque). ->DO NOT apply sealer to composition steel-asbestos gaskets.

8. If using a steel only gasket, apply a thin and even coat of sealer to both sides of the gaskets. 9. Place a new gasket over the dowel pins with the bead or the words “This Side Up” facing upwards (as applicable), then

carefully lower the cylinder head into position over the gasket and dowels. 10. Apply a coating of 12346004 or equivalent sealer to the threads of the cylinder head bolts, then thread the bolts into position until finger-tight. 11. Install the bolts in sequence to 22 ft. lbs. (30 Nm). The bolts must then be tightened again in sequence in the following order: a. Short length bolts: (11, 7, 3, 2, 6, 10) 55 degrees. b. Medium length bolts: (12, 13) 65 degrees. c. Long length bolts: (1, 4, 8, 5, 9) 75 degrees.

12. Install or connect the following: Pushrods, secure the rocker arms and adjust the valves Rocker arm cover Spark plugs, if removed Spark plug wires Attach the fuel line bracket (if removed) and ground wires to the rear of the head and tighten the bolts to 22 ft. lbs. (30 Nm) on 1999-01 models Air conditioning compressor and bracket, if the left cylinder head was removed Alternator and bracket, if the right cylinder head was removed

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adjusters and the rocker arm roller with engine oil. 4. Install or connect the following e Valve lash adjusters, in their original locations ¢ Rocker arm rollers in their original positions e Camshafts e Camshaft cap bolts e Camshaft cover 4.3L Engine

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Cylinder head bolt torque sequence—4.3L engine

Engine accessory bracket with power steering pump. if the left cylinder head was removed Air pipe bracket and nut to the rear of the power steering pump (if equipped), ifthe left cylinder head was removed.on 1999-01 models. Tighten the nut to 30 ft. Ibs. (41 Nm).

A/C compressor, if the left cylinder head was removed Cooling fan assembly, if the left cylinder head was removed on 1999-01 models Wiring harness and clip to the rear of the cylinder head Coolant sensor wire Exhaust manifold Intake manifold Negative battery cable 13. Properly refill the engine cooling system. 14. Run the engine to check for leaks.

e>if valve train components, such as the rocker arms or lash adjusters, are

to be reused,*they must be tagged or

arranged to insure installation in their original locations.

e Rocker arms e Valve lash adjusters To install: 3. Lubricate and fill the valve lash

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rocker arm cover(s) e Rocker arm nut, rocker arm and ball washer elf only the pushrod is to be removed, loosen the rocker arm nut, swing the rocker arm to the side and remove the pushrod.

e Pushrod(s) To install: 3. Inspect and replace components if worn or damaged.

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REMOVAL & INSTALLATION 4.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Camshaft cover ->Make sure to place the camshaft caps in a rack to keep them in order, so they may be installed in their original locations.

¢ Camshaft cap bolts and caps e Camshafts

7924JG46

Exploded view of the rocker arm assembly

Heater Core replacement is covered in Section 2 of this manual

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4. Coat the bearing surfaces of the rocker arms and the rocker arm ball washers with Molykote® or equivalent pre-lube. 5. Install or connect the following:

e Pushrods making sure they seat properly in the lifter e Rocker arms, ball washers and the nuts >The 4.3L engines are equipped with screw-in rocker arm studs with positive stop shoulders.

e Rocker arm adjusting nuts. Tighten them against the stop shoulders to 18 ft. Ibs. (24 Nm). No further adjustment is necessary or possible. 6. Install the rocker arm cover(s). 7. Start and run the engine, then check

for leaks arid for proper ignition timing adjustment.

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Intake Manifold

REMOVAL & INSTALLATION 4.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Disconnect the negative battery cable. 4. Drain the engine cooling system. 5. Remove or disconnect the following: e Throttle body ¢ Powertrain Control Module

e All electrical harnesses from the engine harness bracket Front differential vent hose from the

bracket clip

Engine harness bracket bolt and bracket . Manifold Absolute Pressure (MAP) sensor connector

Crankcase ventilation hose Brake hose from the booster Alternator Intake manifold bolts and manifold. Install manifold gasket. To install: 6. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.

7. Properly position a new intake manifold gasket.

Throttle Cable Bracket Distributor

Water Outlet

Intake Manifold

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Intake Manifold Gasket

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Intake manifold and related components

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Distributor or High Voltage Switch (HVS) assembly Upper radiator hose at the thermostat housing Heater hose at the lower intake manifold Wiring harnesses and brackets,

Automatic transmission dipstick tube

9355MG12

Intake manifold bolt tightening sequence—4.3L engine

8. Install or connect the following: Intake manifold and bolts. Torque the bolts to 16 ft. Ibs. (22 Nm). Alternator Brake hose to.the booster Crankcase ventilation hose, lubricating the inner diameter first with 12345884, or equivalent lubricant MAP sensor electrical connector Engine harness bracket. Tighten the retaining bolt to 37 ft. Ibs. (50 Nm) Front differential vent hose to the engine harness bracket clip All harnesses to their original locations onto the engine harness bracket e PCM e Throttle body Negative battery cable 9. Refill the engine cooling system

4.3L Engine elf only the upper intake manifold is being removed, the fuel system pressure does not need to be released. ALWAYS release the pressure before disconnecting any fuel lines.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the engine cover, if

equipped 3. Properly relieve the fuel system pressure.

4. Disconnect the negative battery cable. 5. Drain the engine cooling system. 6. Remove or disconnect the following: Air cleaner and air inlet duct Wiring harness connectors and brackets e Throttle linkage from the upper intake manifold Ignition coil Fuel lines and bracket from the rear of the lower intake manifold Brake booster vacuum hose at the upper intake manifold Positive Crankcase Ventilation (PCV) hose at the rear of the upper intake manifold Vacuum hoses from both the front and rear of the upper intake Purge solenoid and bracket Upper intake manifold

Exhaust Gas Recirculation (EGR) tube, clamp and tube Air conditioning compressor bracket-to-lower intake manifold pencil brace — Alternator bracket bolts near the thermostat housing Lower intake manifold 7. Insert clean rags into the openings in the cylinder head to prevent dirt and debris from entering the engine. 8. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it. To install: 9. Remove the rags from the cylinder heads. 10. Position the gaskets on thecylinder head with the port blocking plates to the rear and the This Side Up stamps facing upward. Then apply a %e in. (5mm) bead of RTV sealant on the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead % in. (13mm) up each cylinder head to seal and retain the gaskets. 11. Install the lower intake manifold. Tighten the bolts in sequence and in 3 Steps, as follows: a. Step 1: 26 inch Ibs. (3 Nm). b. Step 2: 106 inch Ibs. (12 Nm). c. Step 3: 11 ft. Ibs. (15 Nm). 12. Install or connect the following: Alternator bracket bolt near the thermostat housing EGR tube, clamp and bolt Wiring harness to the lower manifold components, including the injector, EGR valve and ECT sensor Air conditioning compressor bracket-to-the lower intake manifold pencil braces Transmission oil dipstick tube, if necessary Fuel supply and return lines to the rear of the lower intake 13. Temporarily reattach the negative battery cable, then pressurize the fuel system (by cycling the ignition without starting the engine) and check for leaks. 14. Disconnect the negative battery cable.

Brake service is covered in Section 4 of this manual

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15. Install or connect the following: Heater hose to the lower intake Upper radiator hose to the thermostat housing Distributor assembly and engage the wiring Vacuum hoses to the upper and lower intake manifold New upper intake manifold gasket, making sure the green sealing lines are facing upward Upper intake manifold being careful not to pinch the fuel injector wires between the manifolds Manifold retainers. Tighten them to 88 inch Ibs. (10 Nm) using two passes. Purge solenoid and bracket Brake booster vacuum hose at the upper intake manifold. PCV hose to the rear of the upper intake manifold Vacuum hoses to both the front and rear of the manifold assembly Throttle linkage to the upper intake Ignition coil Wiring to the upper intake components including the TP sensor, IAC motor, MAP sensor and the IMTV. Plastic cover Air cleaner and air inlet duct Negative battery cable 16. Refill the engine cooling system. Exhaust Manifold

REMOVAL & INSTALLATION 4.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable eit will be easier if the vehicle is only supported to a height where underhood access is still possible, the vehicle may be left in position for the entire procedure. If the vehicle is raised too high for underhood access, it will have to lowered, raised and lowered again during the procedure. Air cleaner resonator outlet duct Transmission filler tube stud nut

from the Air Injector Reactor (AIR) adapter and move the tube aside Oil level indicator tube Oxygen (O02) sensor from the exhaust manifold.

9355MG03

Exhaust manifold bolt tightening sequence—4.2L engine

e 4 manifold heat shield nuts and shield e Exhaust pipe bolts from the exhaust manifold e Exhaust manifold bolts, and manifold e Old gaskets and discard To install: 3. Using a putty knife, clean the gasket mounting surfaces. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary. 4. Apply a threadlock such as GM 12345493 to the threads of the manifold retainers prior to installation. 5. Install or connect the following: e Exhaust manifold to the cylinder using a new gasket, then tighten the bolts, in 3 passes, in Sequence, to 18 ft. Ibs. (25 Nm) e Heat shield studs, if necessary, and tighten to 89 inch Ibs. (10 Nm) e Oo sensor e Exhaust manifold heat shield Apply a suitable anti-seize compound to the exhaust manifold heat shield nuts prior to installation.

e Heat shield nuts and tighten to 44 inch Ibs. (5 Nm). e Exhaust pipe to the manifold with seal and retaining nuts. Tighten the nuts to 37 ft. Ibs. (50 Nm) e Qil level indicator tube e Transmission filler tube back onto the AIR adapter block stud and

secure with the nut. Tighten the bracket nut to 89 inch Ibs. (10 Nm) e Air cleaner resonator outlet duct. e Negative battery cable. 4.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable elt will be easier if the vehicle is only supported to a height where underhood access is still possible, the vehicle may be left in position for the entire procedure. If the vehicle is raised too high for underhood access, it will have to lowered, raised and lowered again during the procedure.

Exhaust pipe from the exhaust manifold. It may be necessary to remove the tires to gain access to the rear manifold bolts. Engine oil dipstick tube bolt, if removing the right side manifold on 1999-01 models

Exhaust Gas Recirculation (EGR) inlet pipe from the left side manifold, if necessary. Engine Coolant Temperature (ECT) sensor electrical connection, on 1998-01 models Upper radiator support hose and nut, on 1998-01 models

¢ Steering intermediate shaft, if removing the left side manifold on 1999-01 models Wheel house extension, if removing the right side manifold on 1999-01 models Spark plugs wires from the plugs Nuts attaching the secondary air injection pipe to the manifold, on 1999-01 models Air injection pipe and gasket, on 1999-01 models Locktangs (unbend), the exhaust manifold retaining bolts, washers and tab washers Heat shields Exhaust manifold Old gaskets and discard To install: 3. Using a putty knife, clean the gasket mounting surfaces. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary. 4. On 1998-01 models, apply a thread- | lock such as GM 12345493 to the threads of the manifold retainers prior to installation. 5. Install or connect the following: Exhaust mdnifold to the cylinder using a new gasket, then tighten the center bolts to 11 ft. Ibs. (15 Nm) and the front and rear manifold bolts to 22 ft. Ibs. (30 Nm). Once the bolts are tightened, bend the tabs on the washers back over the heads of all bolts in order to lock them in position. Spark plug wires to the plugs Fender wheelhouse extension and the tire assembly, if removed on

1999-01 models Secondary air injection pipe with a NEW gasket to the manifold and tighten the nuts to 18 ft. Ibs. (25 Nm), if removed on 1999-01 models EGR inlet pipe, if removed ECT sensor electrical connection, if removed Upper radiator hose support and nut, if removed Steering intermediate shaft., if removed on 1999-01 models (left side manifold only) Engine oil dipstick tube bolt to 106 inch Ibs. (12 Nm), if removed Exhaust pipe to the manifold Negative battery cable

—

and Valve Lifters

REMOVAL & INSTALLATION 4.2L Engine

1. Before servicing the vehicle, refer to a precautions in the beginning of this secion. 2. Disconnect the negative battery cable. 3. Discharge and recover the refrigerant from the air conditioning system, using the proper equipment. 4. Remove or disconnect the following: Intake manifold

A/C line from the oil level indicator tube A/C line from the accumulator A/C bracket bolt from the engine lift hook” Engine lift bracket Ignition contro! module electrical connectors Ignition control module bolts and module

Be careful not to damage the clips that hold the harness housing in place. e Engine electrical harness housing from the camshaft cover e Fuel injection harness electrical connector e Camshaft cover bolts and cover e Exhaust and intake sprocket bolts 5. Install a suitable sprocket holding tool onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets to maintain timing chain tension and avoid disturbing the timing chain components. 6. Carefully move the sprockets with the timing chain off of the camshafts. 7. Remove or disconnect the following: ->Make sure to place the camshaft caps in a rack to keep them in order, so they may be installed in their original locations.

¢ Camshaft cap bolts and caps e Camshafts To install: 8. Coat the camshaft journals with engine oil. 9. Install or connect the following

e Camshafts, in their original position

¢ Camshaft caps, in their original locations. Tighten the bolts to 106 inch Ibs. (12 Nm) 10. Carefully place the camshaft sprockets back onto the camshafts and remove the holding tool. 11. Install or connect the following: Intake camshaft sprocket washer and bolt and the exhaust camshaft actuator bolt. Tighten the intake camshaft sprocket bolt to 22 ft. Ibs. (30 Nm), plus an additional 135 degrees and the exhaust camshaft actuator bolt to 18 ft. Ibs. (25 Nm), plus an additional 135 degrees. New camshaft cover seal New rubber ignition control module seals Camshaft cover and bolts. Tighten the bolts to 89 inch Ibs. (10 Nm) Ignition control module. Tighten the bolts to 89 inch Ibs. (10 Nm) Ignition control module electrical connectors Fuel injector electrical connectors Engine electrical harness housing A/C line bracket to the oil level indicator tube stud and secure with ~ the nut. Tighten the nut to 62 inch lbs. (7 Nm) Engine lift bracket and secure the lift hook with the bolts. tighten the bolts to 37 ft. Ibs. (50 Nm). A/C line bracket to the engine lift bracket. Tighten the bolt to 89 inch lbs. (10 Nm) Intake manifold Using the proper equipment, recharge the A/C system. 4.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Disconnect the negative battery cable. 4. Drain the engine cooling system. 5. Discharge and recover the refrigerant from the air conditioning system. 6. Remove or disconnect the following: Radiator Air conditioning condenser Rocker arm covers Intake manifold assembly Rocker arms, pushrods and lifters Crankshaft pulley and hub Engine front (timing) cover

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

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solenoid.

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6. Remove or disconnect the following: e Starter mount bolt and nut

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e Starter motor To install: 7. Install or connect the following: e Starter motor ¢ Starter mounting bolt and nut. Tighten to 37 ft. bs. (50 Nm) Positive battery cable to the starter. Tighten the nut to 80 inch Ibs. (9 Nm) ¢ Left front tire and wheel assembly 8. Carefully lower the vehicle, then con-

nect the negative battery cable. 4.3L Engine

2WD MODELS 7924JG50

Thread 3 long bolts into the camshaft to use as a handle, then withdraw it from the engine

7. Align the timing marks on the crankshaft and camshaft sprockets. 8. Remove or disconnect the following: Camshaft sprocket and timing chain Balance shaft drive gear, if equipped Camshaft thrust plate Camshaft by installing the sprocket bolts or longer bolts the camshaft end to act as a handle; then, remove the camshaft while turning Slightly from side to side, as necessary. Take care not to damage the camshaft bearings when removing the camshaft.

To install: 9. Lubricate the camshaft journals with clean engine oil or a suitable pre-lube. 10. Install or connect the following: Camshaft being extremely careful not to contact the bearings with the cam lobes Thrust plate. Torque the bolts to 106 inch Ibs. (12 Nm). Balance shaft drive gear, if equipped Timing chain and camshaft sprocket Engine front (timing) cover Crankshaft pulley and hub Valve lifters, pushrods and rocker arms. Adjust the valve clearance. Intake manifold assembly

e Rocker arm covers e Radiator e Negative battery cable 11. Refill the engine cooling system. Valve Lash

ADJUSTMENT “TRtUp fern ge CAR pie guns eo The 4.2L engines do not require a periodic valve lash adjustment.

The 4.3L engines are equipped with screw-in rocker arm studs with positive stop

shoulders. Because the shoulders that allow the rocker arms to be tightened into proper position, no adjustments are necessary or possible. If a valvetrain problem is suspected, check that the rocker arm nuts are tightened to 18 ft. Ibs. (24 Nm). When valve lash falls out of specification (valve tap is

heard), replace the rocker arm, pushrod and hydraulic lifter on the offending cylinder.

Starter Motor REMOVAL & INSTALLATION 4.2L Engine

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

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Wires from the starter solenoid e Starter motor mounting bolts e Starter motor and if equipped, the shims To install: 3. Install or connect the following: e Starter motor into position

e Starter motor inboard bolt but do not tighten it at this time e Starter motor shims, if equipped ¢ Outboard starter motor bolt. Tighten the bolts to 32 ft. Ibs. (43 Nm). Wires to the solenoid Negative battery cable 4WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: ¢ Negative battery cable e Brush end mounting bracket, if

removed ¢ Wiring from the starter solenoid Transfer case shield, if equipped e Bolts that attach the brake pipe-totransmission bracket to the transmission crossmember and the brackets Transmission crossmember bolts, (usually three on each side)

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Front steering gear crossmember Left and right driveshafts Front drive axle clutch fork assembly

Prop shaft from the front axle pinion yoke Unclip the transmission cooler lines from the engine block Front differential bolts and position the differential aside 4 transmission bell housing-to-oil pan bolts Remaining oil pan bolts Oil pan, by placing 2 oil pan bolts in the jack screws on the oil pan and tighten evenly to release the oil pan from the engine. To install: ; 7. Clean the gasket mounting surfaces. >The alignment between the rear of the oil pan and the rear of the block is critical. When the oil pan is installed it could be inadvertently shifted front or back a small amount which could cause a transmission alignment problem. The back to the oil pan needs to be flush with the engine block. 88452G09

Starter mounting—4.3L

Transmission mount bolts. Support the transmission assembly with a transmission jack and slide the transmission crossmember out of the way. Bracket that attaches the transmission cooler lines to the flywheel housing, brace rod to the flywheel housing, and/or the lower flywheel housing as necessary Starter motor mounting bolts Starter and if equipped, the starter shims To install: 3. Install or connect the following: Shims in their original locations (if equipped), then place the starter motor into position Starter motor bolts and tighten them to 33 ft. Ibs. (45 Nm) Lower flywheel cover, if removed Transmission line bracket to the housing and the brace rod to the housing, if equipped Crossmember and tighten the retaining bolts. Transfer case shield, if equipped Solenoid wiring

e Brush end bracket and tighten the nuts to 97 inch Ibs. (11 Nm), if equipped e Negative battery cable 4. Start the vehicle to check for proper operation.

REMOVAL & INSTALLATION 4.2L Engine

1. Before servicing the vehicle, refer to the precautions in the-beginning of this section. 2. Disconnect the negative battery cable. 3. Remove or disconnect the following: e A/C compressor bottom bolts and

loosen the top bolts e Oil dipstick and tube 4. Raise and safely support the vehic 92 5. Drain the engine crankcase oil. 6. Remove or disconnect the following: Left and right front tire and whee assemblies e Engine protection shield mounting bolts and shield

8. Apply a 0.12 in. (3mm) bead of sealant to engine block, rather than the oil pan. >The oil pan MUST be installed within 10 minutes of applying the sealant to the engine block.

9. Install or connect the following: e Oil pan, maneuvering it to clear the oil pump and screen assembly e»After the bolts are installed, before tightening them to specifications, check the oil pan alignment. Use a straight edge on the back to the block and the oil pan transmission mounting surface.

Oil pan bolts; tighten the side bolts to 18 ft. Ibs. (25 Nm) and the end bolts to 89 inch Ibs. (10 Nm) Transmission bell housing-to-oil pan bolts and tighten to 35 ft. Ibs. (47 Nm) A./C compressor bottom bolts. Tighten to 37 ft. Ibs. (60 Nm) Front differential bolts and tighten to 63 ft. Ibs. (85 Nm) Front drive axle and clutch fork assembly Transmission cooler lines to block Prop shaft to front differential Steering gear crossmember

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

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e Left and right driveshaft ¢ Oil pan drain plug. Tighten to 19 ft. lbs. (26 Nm) e Engine protection shield. Tighten the bolts to 18 ft. Ibs. (25 Nm) e Left and right front wheel and tire assemblies 10. Carefully lower the vehicle. 11. Refill the crankcase with fresh oil. Start the engine, establish normal operating temperatures and check for leaks. 4.3L Engine

2WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Engine e Qil pan retainers (nuts, studs and/or bolts) and rail reinforcements, if equipped e Oil pan e Rubber bell housing plugs and gasket To install: 3. Clean the gasket mounting surfaces. >The alignment between the rear of the oil pan and the rear of the block is critical. The oil pan must be flush or slightly forward of the rear of the block to allow for proper alignment with the transmission housing. Use a feeler gauge to measure the clearance between the 3 oil pan-to-transmission contact points. If the clearance exceeds 0.011 in. (0.3mm) at any of the 3 points, realign the oil pan.

7924JG52

Oil pan mounting—4.3L engines

{0.3 mm™ (0.011")

4. Apply sealant to the oil pan rail where it contacts the timing cover-to-block joint (front) and the crankshaft rear seal retainerto-block joint (rear). Continue the bead of sealant about 1 in. (25mm) in both directions from each of the 4 corners. 5. Install or connect the following: e Rubber bell housing plugs, if equipped e Oil pan using.a new gasket The alignment between the rear of the pan and rear of the block is critical. The two surfaces must be flush to allow for proper alignment with the transmission housing.

6. Use a feeler gauge to check the clearance between the oil pan-to-transmission contacts. If clearance exceeds 0.011 inch (0.3mm) at any of the three contact points, readjust the pan until the clearance is within specification.

7924JG16

If the clearance between the 3 oil pan-to-transmission contact points exceeds 0.011 in. (0.3mm) at any of the 3 points, realign the oil pan

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gauge to measure the clearance between the 3 oil pan-to-transmission contact points. If the clearance exceeds 0.011 in. (0.3mm) at any of the 3 points, realign the oil pan.

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Tighten the bolts in sequence to prevent warping the sealing surface of the oil pan

7. Once the pan is in its correct position tighten the retainers to 18 ft. Ibs. (25 Nm) using the proper sequence. 8. Install the engine into the vehicle. Refill the crankcase with fresh oil. Start the engine, establish normal operating temperatures and check for leaks.

>Use extreme caution when blocking the engine in position. Get out from under the vehicle and rock the engine slightly once the blocks are in place to be sure the engine is properly supported.

4WD MODELS

ing:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine crankcase oil. 4. Remove or disconnect the following: e Dipstick e Drivebelt splash shield, the front axle shield and the transfer case shield e Front skid plate and the flywheel cover e Left and right engine mount through-bolts 5. Raise the engine using a lifting device and block in position. This may be accomplished using large wooden blocks between the motor mounts and brackets.

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6. Remove or disconnect the follow-

Oil cooler line Pitman arm bolt and pitman arm Idler arm bolts and idler arm Front differential through-bolts Front driveshaft, if necessary Differential assembly by rolling it forward for clearance Starter motor Oil pan bolts, nuts and reinforcements Oil pan and discard the gasket To install: 7. Clean the gasket mounting surfaces. >The alignment between the rear of the oil pan and the rear of the block is critical. The oil pan must be flush or slightly forward of the rear of the block to allow for proper alignment with the transmission housing. Use a feeler

8. Apply sealant to the oil pan rail where it contacts the timing cover-to-block joint (front) and the crankshaft rear seal retainer-to-block joint (rear). Continue the bead of sealant about 1 in. (25mm) in both directions from each of the 4 corners. 9. Install or connect the following: Oil pan, using a new gasket. Tighten the retainers, in sequence, to 18 ft. Ibs. (25 Nm). Starter motor Differential by rolling it back into position Front driveshaft Front differential through-bolts Idler arm and secure using the retaining bolts Pitman arm and secure using the bolts Transfer case shield Flywheel cover Front skid plate Front axle shield Drive belt splash shield Dipstick Negative battery cable 10. Refill the engine crankcase. 11. Start the engine and check for leaks.

REMOVAL & INSTALLATION 4.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Engine front cover e (il pump cover bolts e Oil pump cover. Mark the inner and outer gears in relation to the pump housing Inner and outer pump gears Oil pump pressure relief valve plug Oil pump pressure relief valve and spring To install: 3. Install or connect the following: e (Gil pump pressure relief valve and spring

For Tire, Wheel and Ball Joint specifications, see Section 7 of this manual

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e Oil pump pressure relief valve plug. Tighten to 10 ft. Ibs. (14 Nm). e Oil pump outer and inner gears, as marked during removal ¢ Qil pump cover and bolts. Tighten the bolts to 89 inch Ibs. (10 Nm) -e Front cover. = ee ee a Se

4.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Oil pan e Oil pump and the pickup tube/shaft, if equipped Be careful not to crack the retainer.

To install: 3. Ensure that the pump pickup tube is tight in the pump body. If the tube should come loose, oil pressure will be lost and oil starvation will occur. If the pickup tube is loose it should be replaced. 4. If the pump has been disassembled and is being replaced or for any reason oil has been removed, it must be primed. It can either be filled with oil before installing the cover plate and oil kept within the pump during handling or the entire pump cavity can be filled with petroleum jelly.

Rear Main Seal

;

REMOVAL & INSTALLATION 4.2L Engine

Please note that the transmission assembly must be removed to perform this procedure. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Transmission Flywheel Crankshaft rear main seal housing bolts. Install 2 bolts into the jackscrew holes to release the

cover from the block Crankshaft and rear main seal housing Rear main seal from the crankshaft

snout To install: 3. Install or connect the following: e Rear main seal, using a suitable seal installation tool, then remove the tool

e Apply a 0.12 in. (8mm) bead of 12378521, or equivalent sealant to the rear mail seal housing

* Suitable cover alignment pins into the block e>When you install a new seal, make sure to use the plastic installation sleeve supplies with the new seal. The sleeve should come off and be discarded after the seal is installed.

4. Slide the crankshaft rear main seal housing over the alignment pins and crankshaft. 5. Install the crankshaft rear main seal housing bolts, except the 2 in place of the guide pins. 6. Remove the guide pins. 7. Install or connect the following: e Remaining 2 crankshaft rear main seal housing bolts and tighten to 89 inch Ibs. (10 Nm). Wipe off any excess sealant e Flywheel and secure with the mounting bolts. Tighten, in sequence, to 18 ft. Ibs. (25 Nm), plus an additional 50 degrees e Transmission 4.3L-Engine Please note that the transmission assembly and transfer case, if equipped, must be removed to perform this procedure.

“i WARNING If the pump is not primed, the engine could be damaged upon start up. 5. Install or connect the following: e Oil pump by aligning the pump shaft with the distributor drive gear as necessary. Tighten oil pump/pickup tube retainer(s) to 65 ft. Ibs. (90 Nm). e>lf the oil pump does not build up oil pressure almost immediately, remove the pan and check for a loose oil pumpto-pickup tube attachment. If necessary dismantle the pump and pack the pump cavity with petroleum jelly.

e Oil pan 6. Refill the crankcase. 7. Disable the ignition system; crank engine for approximately 10 seconds to aid in priming the oil pump and reducing the risk of engine damage.

Running the engine without measurable oil pressure will cause extensive damage.

9355MG04

Install 2 bolts into the jackscrew holes (1) to push the cover off of the block

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Transfer case, if equipped e Transmission ¢ Clutch assembly/flywheel or flexplate 3. Remove the crankshaft rear oil seal by inserting a suitable prying tool into the notches provided in the seal retainer and prying the seal out. Take care not to damage the crankshaft sealing surface. To install: 4. Inspect the crankshaft for grit, rust or burrs and correct as necessary. 5. Clean the running surface of the crankshaft with a non-abrasive cleaner. 6. Install or connect the following: e New rear seal lubricated with engine oil and a seal installer Flywheel and clutch or flexplate Transmission Transfer case, if equipped Negative battery cable 7. Start the engine and verify no oil leaks. 9355MG05

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION Front Cover and Seal

4.2L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Drain the engine cooling system. e Cooling fan and shroud e Accessory belt e Water pump e Crankshaft balancer

When removing the seal, be careful not to damage the front cover or crankshaft.

7924JG20

Carefully pry the rear main seal out of the retainer

e Seal from the front cover, using a suitable prytool in the slots provided e Power steering pump 3. Raise and safely support the vehicle.

For Wheel Alignment specifications, see Section 1 of this manual

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with rubber. The damper must be removed with a puller which acts on the inner hub only. Pulling on the outer portion of the damper will break the rubber bond or destroy the tuning of the unit.

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Anytime the front cover is removed, the cover must be replaced upon reassembly. If you reuse the old cover, oil leaks may develop.

9355MG06

Place 2 front cover bolts in the jackscrew holes on the cover and tighten to push the cover off of the engine

e Oil pan, then carefully lower the vehicle e 7mm center bolt e Remaining front cover bolts. Place two of the front cover bolts in the jackscrew holes on the front cover and tighten the bolts evenly to release the front cover from the engine e 2 bolts from the front cover e Oil pump To install: 4. Clean the gasket mating surfaces of the engine and cover of all remaining gasket or sealer material. Be careful not to score or damage the surfaces. 5. Install or connect the following: e Suitable cover alignment pins, onto the engine >The front cover MUST be installed

within 10 minutes of applying the sealant.

e Apply a 0.12 in. (3mm) beat of 12378521 or equivalent sealant to the trace grooves on the back side of the engine front cover. Apply sealant on the inside 3 bolt hole bosses on the cover also e Qil pump to the crankshaft splines

e Front cover and bolts, tighten the center bolt last. Tighten to 89 inch

lbs. (10 Nm). 6. Remove the alignment pins and raise and safely support the vehicle. Install the oil pan, then lower the vehicle. e Power steering pump e Crankshaft balancer e Water pump e Accessory belt e Cooling fan and shroud e Negative battery cable 7. Properly refill the engine cooling system. 8. Run the engine until normal operating temperature has been reached, then check for leaks.

4.3L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Drain the engine cooling system. e Crankshaft pulley and damper.

The outer ring (weight) of the torsional damper is bonded to the hub

4. Clean the gasket mating surfaces of the engine and cover of all remaining gasket or sealer material. Be careful not to score or damage the surfaces. >The manufacturer suggests you wait until the front cover is mounted to the engine before you install the replacement crankshaft oil seal. This assures the cover is properly supported.

5. Install or connect the following: e New front cover gasket to the engine or cover using gasket cement to hold it in position. Lubricate the front of the oil pan seal with engine oil to aid in reassembly. Front cover to the engine. Take care while engaging the front of the oil pan seal with the bottom of the cover. On 1998-01 models, apply sealer 12346141 to the oil pan rail where it contacts the timing coverto-block joint (front) and the crankshaft rear seal retainer-to-block joint (rear). Continue the bead of sealant about 1 in. (25mm) in both directions from each of the four corners. Front cover retaining bolts and tighten to 106 inch. Ibs. (12 Nm) 6. Lightly coat the lips of the replacement crankshaft seal with clean engine oil, then position the seal with the open end facing inward the engine. Use a suitable seal installation driver to position the seal in the front cover. ¢ CKP sensor O-ring and the sensor, if equipped

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113-21

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Exhaust camshaft position actuator bolt and actuator Intake camshaft sprocket bolt and sprocket Timing chain Crankshaft sprocket Cylinder head access hole plugs Timing chain tensioner shoe bolt and shoe Timing chain tensioner guide bolts and guide Timing chain tensioner bolts and tensioner To install: e>Every seventh link of the timing chain is darkened to help in aligning the timing marks.

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88453GAU

Installing the crankshaft front oil seal

3. Install or connect the following: Timing chain tensioner and bolts. Tighten to 18 ft. Ibs. (25 Nm) Timing chain guide and bolts. Tighten to 89 inch Ibs. (10 Nm) Timing chain tensioner shoe and bolt. Tighten to 19 ft. Ibs. (26 Nm) Cylinder head access hole plugs and tighten to 44 inch Ibs. (5 Nm) Crankshaft Holding tool No. J44221, or equivalent with the

e Tighten the Oil pan bolts e Water pump e Crankshaft damper and pulley e Negative battery cable 7. Properly refill the engine cooling system. 8. Run the engine until normal operating temperature has been reached, then check for leaks.

J 44221

Timing Chain and Sprockets

4.2L ENGINE ‘The following procedure requires the use of the Crankshaft Holding tool No. J-44221 and a suitable torque angle meter. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Camshaft cover ¢ Timing chain (front) cover ¢ Tension on the timing chain by moving the tensioner shoe in. Place a tee into the tension to hold the shoe in place ¢ Top chain guide bolts and guide

9355MG07

Proper installation of the crankshaft holding tool with the No. 1 cylinder at TDC

For Maintenance Interval recommendations, see Section 1 of this manual

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timing chain

MANUAL SEE

4. Align the dark link of the timing chain with the timing mark on the intake camshaft sprocket. Feed the timing chain down through the opening in the head. e Timing chain onto the crankshaft

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sprocket. Align the dark link of the timing chain with the timing mark on the crankshaft sprocket e>|t may be necessary to remove the crankshaft holding tool to rotate and hold the camshaft hex to align the pin to the camshaft sprocket

e Intake camshaft sprocket onto the

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intake camshaft e Intake camshaft washer and bolt e Exhaust camshaft actuator into the timing chain. Align the dark link of

the timing chain with the timing mark on the exhaust camshaft actuator

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hold the camshaft hex to align the pin

to the camshaft sprocket

Rotate the camshaft actuator clockwise

e Exhaust camshaft actuator onto the exhaust camshaft

e>Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt.

5. Rotate the camshaft actuator clock-

wise (as seen from the front. of the vehicle). The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced.

6. Install the exhaust camshaft actuator bolt and tighten to 18 ft. Ibs. (25 Nm), plus an additional 135 degrees, using a torque angle meter.

9355MG09

The dark lines on the timing chain should be aligned with the marks on the sprockets

7. Tighten the intake camshaft sprocket bolt to 22 ft. Ibs. (30 Nm), plus an additional 135 degrees, using a torque angle meter. 8. Remove the tee from the timing chain tensioner to regain tension on the timing chain. 9. Remove the crankshaft holding tool. The dark lines on the timing chain should be aligned with the marks on the sprockets. 10. Install or connect the following: e Top chain guide e Suitable threadlock to the top chain

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4.3L ENGINE =>The following procedure requires the use of the Crankshaft Sprocket Removal tool No. J-5825-A and the Crankshaft Sprocket Installation tool No. J-5590.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the timing cover from the engine. 3. Rotate the crankshaft until the No. 4 cylinder is on the Top Dead Center (TDC) of its compression stroke and the camshaft sprocket mark aligns with the mark on the crankshaft sprocket (facing each other at a point closest together in their travel) and in line with the shaft centers. 4, Remove or disconnect the following: e Crankshaft Position (CKP) sensor reluctor ring,-if equipped

A. Align Marks as Shown 85383292

Timing mark alignment

e Camshaft sprocket-to-camshaft nut and/or bolts e Camshaft sprocket (along with the timing chain). If the sprocket is difficult to remove, use a plastic mallet to bump the sprocket from the camshaft. >The camshaft sprocket (located by a dowel) is lightly pressed onto the

camshaft and should come off easily. The chain comes off with the camshaft sprocket.

85383299 Removal (top) and installation of the crankshaft timing gear

5. If necessary use J-5825-A crankshaft sprocket removal tool to free the timing sprocket from the crankshaft. 6. If necessary, remove the crankshaft sprocket key. To install: 7. Inspect the timing chain and the timing sprockets for wear or damage, replace the damaged parts as necessary. 8. Using a putty knife, clean the gasket mounting surfaces. Using solvent, clean the oil and grease from the gasket mounting Surfaces. 9. Install or connect the following: e Crankshaft sprocket key, if removed e Crankshaft sprocket onto the crankshaft using J-5590 crankshaft sprocket installation tool and a

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

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marks are in correct alignment between the shaft centers. ¢ CKP sensor reluctor ring, if equipped _ © Timing cover

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Piston ring end-gap spacing—4.3L engine

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Piston ring positioning—4.2L engine

Piston and connecting rod assembly positioning—4.3L engine

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Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but also any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a‘shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

Fuel System Pressure

|

1998-01 Vehicles A Schrader valve is provided on these fuel systems to conveniently test or release the system pressure. A fuel pressure gauge and adapter will be necessary to connect the gauge to the fitting. Most of the MFI sys-

tems utilize a service valve on one end of the fuel rail assembly. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable to assure the prevention of fuel spillage if the ignition switch is accidentally turned ON while a fitting is still detached. 3. Loosen the fuel filler cap to release the fuel tank gressure. 4. Be sure the release valve on the fuel gauge is closed, then connect the fuel gauge to the pressure fitting located on the inlet fuel pipe fitting.

i CAUTION When connecting the gauge to the fitting, be sure to wrap a rag around the fitting to avoid spillage. After repairs, place the rag in an approved container. 5. Install the bleed hose portion of the fuel gauge assembly into an approved container, then open the gauge release valve and bleed the fuel pressure from the system. 6. When the gauge Is removed, be sure to open the bleed valve and drain all fuel from the gauge assembly. 7. When fuel service is finished, tighten the fuel filler cap and connect the negative battery cable. 2002 Vehicles

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

RELIEVING

Do not perform this procedure for more than 2 minutes to avoid damaging the catalytic converter.

The fuel systems operateteunder high fuel pressures. Itis very important that the pressure be properly relieved prior to servicing the system or any of its components.

2. Loosen the fuel filler cap to release the fuel tank pressure. 3. Remove the fuel pump relay from the junction block.

1 3- 25

4. Crank the engine, allowing it to start and stall. 5. Crank the engine for an additional 3 seconds to relieve any remaining fuel pressure. 6. Disconnect the negative battery cable to avoid repressurizing the fuel system. 7. Install the fuel pump relay in the junction block 8. Tighten the fuel filler cap. 9. After you are finished working on the fuel system, connect the negative battery cable.

Fuel Filter REMOVAL & INSTALLATION 1998 Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel filler cap e Fuel lines from the filter using a back-up wrench Fuel filter from the retainer or mounting bolt. For most filters which are retained by band clamps, loosen the fastener(s) and remove the filter. For some filters it may be necessary to completely remove the clamp and filter assembly. To install: 4. Install or connect the following: e Ffilter and retaining bracket with the directional arrow facing away from the fuel tank, towards the throttle body >The filter has an arrow (fuel flow direction) on the side of the case, be sure to install it correctly in the system, the with arrow facing away from the fuel tank.

e Tighten the filter/bracket retainer(s), as applicable e Fuel lines to the filter and tighten using a backup wrench e Negative battery cable e Fuel filler cap 5. Start the engine and check for leaks.

For complete service labor times, order the Chilton Labor Guide

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1999-02 Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pres-

sure. 3. Remove or disconnect the following:

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e Negative battery cable and fuel filler cap, if not already done 4. Raise and support the vehicle. e Fuel tank shield, if equipped e Quick connect fittings from the filter e Filter feed nut and the clamp bolt e Filter and the clamp from the vehicle To install: 5. Install or connect the following: e Filter and clamp with the directional arrow facing away from the

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fuel tank, towards the throttle body e>The filter has an arrow (fuel flow direction) on the side of the case, be sure to install it correctly in the sys-

tem, the with arrow facing away from the fuel tank. ¢ Tighten the fuel feed nut

° Tighten the filter clamp assembly bolt

e Fuel quick disconnect fittings to the

filter

© Fuel tank shield, if equipped ° Fuel filler cap * Negative battery cable

6. Start the engine and check for leaks.

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Fuel Pump

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REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the fuel tank. 4. Support the fuel tank. 5. Remove or disconnect the following: e Negative battery cable e Filler neck from the tank e Shield from tank and tank straps ¢ Fuel lines and vapor hose from pump e Flectrical connection from fuel

pump e Fuel tank

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e Fuel pump/sending unit assembly

by turning the locking ring (located

on top of the fuel tank) counterclockwise using a spanner wrench

* Fuel pump from the fuel lever To eh st 6. Install or connect the following:

° Fuel pump in tank with new seal around opening

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The fuel pump strainer must be in a horizontal position when the fuel

sender is installed in the tank. When installing the sender assembly, make

sure that the fuel pump strainer does not block full travel of the float arm.

View of the in-tank fuel pump assembly

e Tank and connect fuel lines and

i Aro zeframe. Torque the fasteners to 33 ft. Ibs. (45 nm). * Shield

° Fuel filler neck and clamp + Negative battery cable

7. Refill the tank.

8. Run the engine and check for leaks. Fuel Injector

REMOVAL & INSTALLATION 4.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section. 3. Remove or disconnect the following: ¢ Negative battery cable, if not done already ‘ ¢ Intake manifold e>Clean the fuel rail assembly with a suitable spray cleaner before proceeding. Never soak the fuel rail in a cleaning solvent.

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Typical fuel filter location along frame rail

7924)G43

e Fuel pressure regulator vacuum line Fuel feed and return pipes Fuel injector in-line electrical connector Fuel rail attaching bolts and fuel rail

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¢ Fuel injector harness connector from the fuel injectors « © Injector retaining clip e Injector from the fuel rail. e Retainer clip and O-ring seals from each end of the injector and discard To install:

e>Each injector is calibrated. When replacing the fuel injectors, be sure to

replace it with the correct injector. 4. Lubricate the new injector O-ring seats with engine oil. 5. Install or connect the following: e (-rings on the injector e New retainer clip on the injector

6. Push the fuel injector into the fuel rail socket, making sure the connector faces outward. The retainer clip locks to a flange on the fuel rail injector socket.

Fuel rail assembly. Tighten the bolts to 89 inch Ibs. (10 Nm) e Fuel feed and return lines to the rail Fuel injector electrical connectors e Fuel pressure regulator vacuum line e Intake manifold Negative battery cable 7. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.

4.3L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section. 3. Remove or disconnect the following;

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e Negative battery cable ¢ Fuel meter body electrical connection and the fuel feed and return hoses from the engine fuel pipes Upper manifold assembly ¢ Poppet nozzle out of the casting socket Fuel meter body by releasing the locktabs e>Each injector is calibrated. When replacing the fuel injectors, be sure to replace it with the correct injector.

e Lower hold-down plate and nuts 4. While pulling the poppet nozzle tube downward, push with a small prytool down between the injector terminals and remove the injectors. To install: 5. Lubricate the new injector O-ring seats with engine oil. 6. Install or connect the following: e 0Q-rings on the injector

e Fuel injector into the fuel meter body injector socket. e Lower hold-down plate and nuts. Torque the nuts to 27 inch Ibs. (3 Nm). ¢ Fuel meter body assembly into the intake manifold. Torque the fuel meter bracket retainer bolts to 88 inch. Ibs. (10 Nm).

* CAUTION To reduce the risk of fire or injury ensure that the poppet nozzles are properly seated and locked in their casting sockets

Fuel meter body into the bracket and lock all the tabs in place Poppet nozzles into the casting sockets Electrical connections New O-ring seals on the fuel return and feed hoses. Fuel feed and return hoses and tighten the fuel pipe nuts to 22 ft. lbs. (30 Nm). Negative battery cable 7. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks. 8. Install the manifold plenum.

DRIVE TRAIN Manual Transmission Assembly

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Shift the transmission into 3rd or 4th gear position. 3. Remove or disconnect the following: Negative battery cable Shift lever and the if necessary, the shift housing Parking brake cable for clearance Propeller shaft Sid plate, if equipped Transfer case and shift lever, on A4WD models e All wiring harness that would interfere with transmission removal Fuel line retainers from the rear crossmember Muffler from the catalytic converter

Exhaust pipes from the exhaust manifold Catalytic converter hanger, if necesSary Exhaust section Bolts and nuts attaching any transmission braces to the engine and transmission Hydraulic clutch quick-connect from the concentric slave cylinder following 1 of the 2 steps: a. Use 2 small prytools at 180 degrees from each other to depress the white plastic sleeve on the quick connect to separate the clutch line from the concentric slave cylinder quick connect. b. Use special tool J-36221 to depress the white plastic sleeve on the quick connect to separate the clutch line end from the concentric slave cylinder quick connect. 4. Remove or disconnect the following: e Bolts securing the clutch housing cover to the transmission, if equipped

e Clutch plate and clutch cover, if necessary 5. Support the transmission with a suitable jack. e Rear crossmember from the frame rail Wiring harness from the front crossmember, if equipped. Move the wiring harness away from the transmission oil pan. Lower the transmission enough to gain access to the top of the transmission. Fuel line retainers or wiring harness’s from the top of the transmission Bolt, washer, and nut securing the wiring harness ground wires to the engine block Bolts retaining the transmission to the engine. Pull the transmission Straight back on the clutch hub splines. 6. Lower the transmission using the transmission jack.

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To install: Installation is the reverse of removal, but please note the following important steps. 7. Place a THIN coat of high-temperature grease on the main drive gear (input shaft) splines. 8. Secure the transmission to the floor jack and raise the transmission into position. -

>On some models, it may be necesary to rotate the transmission clockwise while inserting it into the clutch hub.

9. Slowly insert the input shaft through the clutch. Rotate the output shaft slowly to engage the splines of the input shaft into the clutch while pushing the transmission forward into place. Do not force the transmission into position, the transmission should easily fall into place once everything is properly aligned. 10. Tighten the transmission mounting bolts to 35 ft. Ibs. (47 Nm). 11. Do not remove the transmission jack until the crossmembers have been installed. 12. Check the transmission fluid level and replenish as necessary. Automatic Transmission

Assembly REMOVAL & INSTALLATION 1998-01 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable 3. Drain the transmission fluid. e Driveshaft from the transmission (2WD) and transfer case, if equipped (4WD) 4. Support the transmission with a suitable transmission jack. Shift cable from the transmission control lever and bracket Nut and washer securing the transmission mount to the crossmember Bolts and washers securing the mount to the transmission Exhaust pipe from the exhaust manifold(s) Bolts securing the converter pan cover to the transmission, if equipped 3 bolts securing the torque converter to the flywheel Bolt, clip, and strap securing the

88457634

Transmission mounting on 4.3L engines

three fuel lines and transmission vent hose to the transmission case Bolts and nut securing the transmission to the engine Oil filler tube and seal from the transmission Transmission cooler lines from the transmission. Plug the lines and the ports in the transmission. Wiring harness connectors from the transmission. 5. Inspect for any other wiring, brackets etc. which may interfere with the removal of the transmission. 6. Since the transmission acts as a rear engine mount, properly support the rear of the engine with an underbody support or other suitable support before attempting to remove the transmission. Otherwise the rear of the engine may pitch downward and components on the rear of the engine and on the firewall may be damaged. 7. Remove the transmission from the engine by pulling the transmission rearward to disengage it from the locator dowel pins on the back of the block. Carefully lower the transmission from the vehicle. Use care that the torque converter does not fall out of the front of the transmission. e>Use converter holding strap tool No. J-21366, to secure the torque converter to the transmission during removal and installation procedures.

To install: Installation is the reverse of removal, but please note the following important steps. 8. Make sure the torque converter is fully seated in the pump drive. If not, the transmission will not fit tightly to the rear of the engine block. 9. Raise the transmission into position and remove the torque converter holding strap. Carefully slide the.transmission forward until the dowel pins are engaged. 10. The torque converter should be flush with the flywheel and turn freely by hand. 11. Install the transmission—to—engine bolts. Tighten the bolts to 34 ft. Ibs. (47 Nm). 12. Tighten the torque converter-to-flywheel bolts to 46 ft. Ibs. (63 Nm). 13. If equipped, tighten the converter

pan cover to the transmission bolts to 37 ft. lbs. (50 Nm) 14. Tighten the bolts and washers securing the transmission mount to 35 ft. Ibs. (47 Nm). 15. Tighten the nut and washer securing the transmission mount to the crossmember to 38 ft. Ibs. (52 Nm). 16. Refill the transmission with the proper amount and type of fluid. 17. Connect the negative battery cable. Start the vehicle and allow to warm while checking for leaks. Road test the vehicle to check for shift quality.

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2002 Vehicles e>This procedure requires the use of a Cofiverter Holding Strap tool No. J 21366 to secure the torque converter to the transmission during removal and installation.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative, then the positive battery cables e Fill tube nut, located on the right side of the engine 3. Drain the transmission fluid. ¢ Rear propeller shaft 4. Support the transmission with a transmission jack e Nuts securing the transmission mount to the transmission support Evaporative emission (EVAP) canister from its mounting bracket on the left inside of the frame to get access to the transmission support

bolts. Do not disconnect the canis_ ter lines Fuel tank shield Transmission support Transmission mount bolts and mount Front exhaust pipe assembly 5. Lower the transmission for access to the top and sides of the transmission. e Transfer case, if equipped e Range selector cable end from the transmission range selector lever ball stud and bracket Transmision heat shield, transmission vent hose park/neutral position switch connector, and main connector from the transmission Bolt that secures the fuel line bracket to the left side of the transmission e Torque converter access plug 6. Matchmark the flywheel and torque converter orientation for reassembly. e Flywheel-to-torque converter bolts. Be careful not to drop the bolts into the bell housing! e Disconnect the transmission oil cooler lines from the transmission. Plug the transmission oil cooler lines connectors in the transmission case 7. Install a safety chain around the transmission. e Bolt that secures the fuel line bracket to the bell housing

e Bolts that secure the coolant pipe to the bell housing

e Remaining nuts, studs and/or bolts

that secure the transmission to the engine 8. Install Converter Holding Strap too! No. J 21366 onto the transmission bell housing to hold the torque converter. 9. Pull the transmission straight back and remove it from the vehicle. To install: Installation is the reverse of removal, but please note the following important steps. 10. Make sure the torque converter is fully seated in the pump drive. If not, the transmission will not fit tightly to the rear of the engine block. 11. Raise the transmission into position and remove the torque converter holding strap. Carefully slide the transmission forward until the ddwel pins are engaged while lining up the marks on the flywheel made during removal. 12. The torque converter should be flush with the flywheel and turn freely by hand. 13. Install the transmission-to-engine nuts, studs and or bolts. Tighten the studs and/or bolts to 37 ft. Ibs. (60 Nm). 14. Tighten the bolts securing the heat shield to the transmission to 13 ft. Ibs. (17 Nm). 15. Tighten the bolts and washers securing the transmission mount to 18 ft. Ibs. (25 Nm). 16. Tighten the nut and washer securing the transmission mount to the transmission support to 35 ft. Ibs. (46 Nm).

17. Refill the transmission with the proper amount and type of fluid. 18. Connect the negative battery cable. Start the vehicle and allow to warm while checking for leaks. Road test the vehicle to check for shift quality. Clutch

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transmission 3. Install a clutch alignment tool or a used transmission input shaft to support the clutch. 4. If the clutch assembly is going to be reused, mark the flywheel, clutch cover and a pressure plate lug for alignment when installing. 5. Remove or disconnect the following: e Clutch cover bolts and washers e Clutch cover assembly and the clutch plate e Clutch alignment tool 6. Clean all parts and inspect for damage. To install: 7. Install or connect the following: e Clutch alignment tool, to support the clutch. e Clutch cover by aligning the

7924JG53

Exploded view of the clutch disc and related components

Timing belt service is covered in Section 3 of this manual

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6. Ifthe previous steps do not result in satisfactory pedal feel, remove the reservoir cap and pump the clutch pedal very fast for 30 seconds. Stop to let the air escape, then repeat the procedure as necessary to purge all remaining air. 7. Test the clutch for proper operation.

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Transfer Case Assembly 7924JG22

Use the clutch alignment tool to center and support the clutch disc during installation

matchmarks or, if new, align the lightest part of the cover, identified by a yellow dot, with the heaviest part identified by an X. Clutch plate/clutch cover assembly to the flywheel. Tighten the bolts to 33 ft. Ibs. (45 Nm) for 2.2L engines or to 29 ft. Ibs. (40 Nm) for 4.3L engines.

4. Close the bleeder screw and have your assistant release the clutch pedal. 5. Repeat the procedure until all of the air is evacuated from the system. Check and refill master cylinder reservoir as required to prevent air from being drawn through the master cylinder.

REMOVAL & INSTALLATION 1998-01 Vehicles 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable.

Tighten each screw 1 turn at a time to avoid warping the clutch cover.

8. Remove the clutch alignment tool. 9. Install or connect the following: e Transmission e Negative battery cable

Hydraulic Clutch System Bleeding air from the hydraulic clutch system is necessary whenever any part of the system has been disconnected or the fluid level (in the reservoir) has been allowed to fall so low, that air has been drawn into the master cylinder. 7924JG27

BLEEDING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Fill master cylinder reservoir with new brake fluid conforming to DOT 3 specifications.

*«-¢ CAUTION Always use new fluid from a sealed container. Never, under any circumstances, use fluid that has been bled from a system to fill the reservoir as it may be aerated, have too much moisture content and possibly be contaminated.

3. Have an assistant fully depress and hold the clutch pedal, then open the bleeder SCreW.

7924JG28

Transfer case-to-automatic transmission mounting

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3. Shift the transfer case into the 4HI range.

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«4. Drain the transfer case fluid. 5. Support the transfer case. 6. Remove or disconnect the following:

+ Sid plat

e Front and rear driveshafts from the transfer case. Matchmark the shafts prior to removal Vacuum lines and/or the electrical connectors, as equipped Transfer case shift rod/cable from the case, if applicable e eS ues case

7. Remove all traces of old gasket material from the mating surfaces. To install: 8. Install or connect the following: New gasket using sealer to hold it in position Transfer case. Torque the bolts to 41 ft. Ibs. (65 Nm) on 1998 models or 33-35 ft. Ibs. (45-47 Nm) on 1999-01 models. Support brace bolts. Torque the bolts to 35-37 ft. Ibs. (47-50 Nm), if equipped Shift rod to the case, if equipped Vacuum lines and/or electrical connections, as necessary Front and rear driveshafts by aligning the matchmarks 9. Refill the transfer case. 10. Install or connect the following: e Skid plate, if equipped e Negative battery cable

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GENERAL MOTORS CORP. 43-31 :

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e Transfer case mounting bolts e Transfer case from the vehicle e Transfer case gasket and discard if

damage

To install: 6. Install or connect the following:

7, Remove the transmission jack. 8. The remainder of installation is the

reverse of removal. 9. Refill the transfer case.

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REMOVAL & INSTALLATION

>You must replace the transfer case

gasket if it is damaged. Never use sili-

1998-01 Vehicles

cone sealant in place of, or with the

transfer case gasket. ° aan

using a new gasket if

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Unlock the steering column so the

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2002 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. . 3. Raise and support the vehicle. Drain the transfer case. 4. Remove or disconnect the following: Fuel tank shield mounting bolts and shield Front and rear propeller shaft. Matchmark the shafts prior to removal Fuel lines from the retainer Electrical harness from the retainers on the right and left sides Speed sensor electrical connectors Motor/encoder electrical connector

Transfer case wiring harness

9:

7924629

Tap the halfshaft out of the hub without damaging the threads

Vent hose

Heater Core replacement is covered in Section 2 of this manual

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Place a drift through the caliper into the edge of the rotor to keep the rotor from turning when the nut is removed

e Cotter pin, retainer, nut and washer. e Brake caliper and support it with a piece of wire to avoid damaging the brake hose e Brake rotor e Brake line support bracket and Anti-lock Brake System (ABS) wire bracket from the upper control arm 4. Place a jackstand or jack under the lower control arm. e Axle shaft from the hub by placing a block of wood against the outer edge of the axle (to protect the threads), then strike the block of wood sharply with a hammer. Do not remove the axle at this time. Tie rods from the steering knuckles Lower shock absorber bolts Upper ball joint from the steering knuckle and suspend the steering knuckle on a wire Skid plate, if equipped Halfshaft-to-axle tube bolts Halfshaft by moving it forward and supporting it away from the frame

e Halfshaft from the hub and bearing assembly e Halfshaft from the differential using a block of wood and a hammer To install: >It is essential that the differential carrier and axle seals are not lubricated or damaged during installation. Prior to shaft installation, cover the shock mounting bracket, lower control arm ball stud and ALL other sharp edges with a cloth or rag to help protect the boot.

5. Install the axle into the carrier. With both hands on the tripot housing, align the splines on the shaft with the carrier. Then center the axle into the carrier seal and push the shaft straight into the carrier until the snapring is properly seated. ->Be careful when supporting the lower control arm that any components are damaged with the supporting device.

6. Raise the lower control arm using a jackstand or jack until the full weight of the arm is Supported. e>It is necessary to slightly start the knuckle onto the axle while at the same time guiding the lower ball joint into position on the knuckle.

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7924JG30

Using a block of wood and a mallet, disengage the halfshaft from the differential assembly

7. Install or connect the following:

e Lower ball joint, the lower shock absorber and the upper ball joint Axle washer and nut. Tighten the nut to 103 ft. Ibs. (140 Nm). ABS and brake line brackets to the top of the upper control arm Caliper and rotor Tire and wheel assembly Differential carrier shield

2002 Vehicles CV-Joints

OVERHAUL Outer CV-Joint 1. Before servicing the vehicle, refer to ‘the precautions in the beginning of this section. ~ 2. Remove or disconnect the following: Front wheel Halfshaft and position it in a vise Large CV-joint boot clamp and discard it Small CV-joint boot clamp and discard it CV-joint boot and slide it back on the shaft Outer race from the halfshaft, by spreading the outer race-to-halfshaft retaining ring, using Snapring Pliers J-8059 Retaining ring from the halfshaft and discard it CV-joint boot from the halfshaft and discard it, if damaged 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the C\V-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. ‘ . : Remove the opposite chrome alloy all. é. Repeat the procedure until all 6 balls are removed. _ 4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands. c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage.

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(2) Tripot Housing Assembly (3) Spacer Ring

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CV Joint Boot Swage Ring

(5) Spacer Ring (6) Tripot Bushing (7) Boot Retaining Clamp (8) Tripot Joint Boot

(15) (16) (17) (18)

Race Retaining Ring Ball CV Joint Inner Race CV Joint Cage

(9) Halfshaft Swage Ring ) Halfshaft Bar

(19) CV Joint Outer Race

(4) Tripot Joint Spider Assembly

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Exploded view of the CV-Joint Assembly

Brake service is covered in Section 4 of this manual

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12. Using the Crimp too! J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 Nm). 13. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is. 14. Install Y2 kit grease into the C\V-joint boot. 15. Measure approximately 0.687 in. (17.5mm) up from the bottom edge of the outer CV-joint assembly. 16. Slide the large end of the CV boot/clamp into place, with the seal lip in place over the outer race. e> lake sure the boot lies flat against the outer race.

17. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the

large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 18. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is. 19. Install the halfshaft and the front wheel.

Inner (Tri-Pot) Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft and place it in a vise Snapring from the stub shaft and discard it Small CV-joint boot clamp, cut and discard it Large CV-joint boot clamp, cut and discard it C\-joint boot by sliding it away from the tri-pot joint 3. Install a Stub Shaft Removal tool J38868-A to the stub shaft snapring groove. 4. Using a slide hammer puller, press the stub shaft from the tri-pot housing. 5. Remove or disconnect the following: Tri-pot housing from the tri-pot spider e Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059 Outboard retaining ring using Snapring Pliers tool J-8059 and discard it Tri-pot joint spider assembly Inboard spacer ring and discard it CV-joint boot Trilobal tri-pot bushing from the housing 6. Thoroughly clean and inspect all parts.

To install: 7. Install or connect the following: e New snapring onto the stub shaft ¢ Small boot clamp e CV-joint boot 8. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 Nm). 9. Install or connect the following: e Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059, past the 2nd groove e Tri-pot joint spider assembly onto

~ the shaft until it passes the 2nd groove Outboard retaining ring into the axle shaft groove using Snapring Pliers tool J-8059 Tri-pot joint spider assembly, slide it against the outboard retaining ring Inboard spacer ring, seat it |inthe groove Vo kit grease into the boot e % kit grease into the tri-pot housing Trilobal tip-pot bushing flush with the tri-pot housing face New large seal clamp onto the CVjoint boot Tri-pot housing, slide it over the tri-pot joint spider assembly CV-joint boot/clamp, slide it into place, over the trilobal tri-pot bushing with the seal lip in the groove e>Make sure the boot lies flat against the trilobal bushing.

10. Position the CV-joint boot so it measures 4.9 in. (125mm). 11. Using the Crimp tool J-35566, latch the large CV-joint boot clamp. 12. Install the halfshaft and the front wheel.

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION For the Axle Shaft, Bearing and Seal, Removal and Installation, please refer to Wheel Bearing procedure Jocated in the section.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e>The following procedure requires the use of the Pinion Holding tool J-861410, the Pinion Flange Removal tool J8614-1, J-8614-2, J-8614-3 and the Pinion Seal Installation tool J-23911 or J-33782.

_ 2. Remove or disconnect the following: ¢ Driveshaft from the pinion flange. Matchmark the driveshaft prior to removal.

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3. Mark the position of the pinion stem, flange and nut for reference. 4. Use an inch Ibs. torque wrench to measure the amount of torque necessary to turn the pinion, then note this measurement as it is the combined pinion bearing, seal, carrier bearing, axle bearing and seal preload. 5. Remove or disconnect the following: ° Pinion flange nut and washer, using a Pinion Holding tool J-8614-10 and a Pinion Flange Removal tool

J-8614-1, J-8614-2, J-8614-3, as

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Removing the pinion nut using a pinion holding fixture tool

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PINION FLANGE

applicable e Pinion flange e Pinion oil seal by driving it out of

the differential with a blunt chisel;

DO NOT damage the carrier To install: 6. Examine the’seal surface of pinion flange for tool marks, nicks or damage, such as a groove worn by the seal. If damaged, replace flange. 7. Examine the carrier bore and remove any burrs that might cause leaks around the 0.D. of the seal. 8. Apply GM seal lubricant 1050169 to the outside diameter of the pinion flange and sealing lip of new seal. 9. Install or connect the following: e New pinion oil seal using a seal installer tool e Pinion flange and tighten nut to the same position as marked earlier. Tighten the nut a little at a time and

turn-the pinion flange several times

after each tightening in order to set the rollers. 10. Measure the torque necessary to turn the pinion and compare this to the reading taken during removal. Tighten the nut additionally, as necessary to achieve the same preload as measured earlier. ->if fluid was lost from the differential

housing during this procedure, be sure

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88457G83

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PINION OIL

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to check and add additional fluid, as necessary.

11. Remove the support then align and secure the driveshaft assembly to the pinion flange.

88457G84

Use the appropriately sized installation tool to drive the new seal into position.

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

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The original matchmarks MUST be aligned to assure proper shaft balance and prevent vibration.

Axle Housing REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the rear axle housing. If a floor jack is being used, take care when removing the U-bolts to keep the axle from suddenly dislodging. 3. Remove or disconnect the following: e Rear wheels and drums for cleareeae eS a See Te ance and to remove some weight from the axle housing

e Axle vibration dampener, if equipped © Rear driveshaft from the pinion flange. Either remove the shaft completely from the vehicle or support it aside from the undercarriage using safety wire, but DO NOT allow the shaft to hang from the Slip joint. Shock absorber-to-axle housing retainers, then swing the shock absorbers away from the axle housin Brake lines from the axle housing clips and the backing plates (wheel cylinders) When disconnecting the brake lines from the wheel cylinders, immediately plug or cap the lines to prevent sys-

tem contamination or excessive fluid loss.

Speed sensor connectors at the junction block, if applicable Parking brake cable(s) Axle housing-to-spring U-bolt nuts, washers, U-bolts and the anchor plates Vent hose from the top of the axle housing Axle with the help of an assistant by moving itto clear the leaf spring To install: 4. With the help of an assistant, carefully position the rear axle into the vehicle. 5. Install or connect the following:

e Vent hose to the axle housing 6. Be sure the housing is properly posi-

Nut

Shock absorber Bolt Retainer Pinion flange U-bolts

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88457G85

Exploded view of the rear axle mounting

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and nuts.

¢ Tighten the U-bolt nuts in a Cross pattern to 18 ft. Ibs. (25 Nm) to made sure everything is evenly seated. Then tighten the nuts in steps to 74 ft. Ibs. (100 Nm)

;

Some vehicles are equipped with an air bag system, also known as the

Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or argund system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. . e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module, that may be thrown in the event of an accidental deployment.

DISARMING 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to LOCK, remove the key, then disconnect the negative battery cable. 3. Remove the AIR BAG or SIR fuse from the fuse block.

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13:37

e Axle vibration dampener, if equipped e Brake drums and the tire/wheel assemblies 7. Bleed the hydraulic brake system. 8. Check the fluid level in the rear axle assembly and add, as necessary. Make sure the vehicle is level when checking and adding fluid.

STEERING AND SUSPENSION 4. Remove the steering column filler panel or knee bolster. 5. Unplug the Connector Position Assurance (CPA) and yellow two way connector at the base of the steering column. 6. Open the glove compartment door, lift the stop and let the door fully open. 7. Remove the Connector Position Assurance (CPA) from the passenger yellow two way connector located behind the glove Dox. 8. Unplug the yellow two way connector located behind the glove box. 9. Connect the negative battery cable. e>With the AIR BAG fuse removed, the battery cable connected and the ignition in the ON position, the AIR BAG warning lamp will be ON. This is normal and does not indicate a system malfunction.

ARMING 1. Disconnect the negative battery cable. 2. Attach the yellow two way connector located behind the glove box. 3. Install the Connector Position Assurance (CPA) to the passenger yellow two way connector located behind the glove Dox. 4. Close the glove compartment door. 5. Turn the ignition switch to LOCK, then remove the key. 6. Attach the two way connector at the base of the steering column and the Connector Position Assurance (CPA). 7. Install the steering column filler panel or knee bolster. 8. Install the AIR BAG fuse to the fuse block. 9. Connect the negative battery cable. 10. From the passenger seat, turn the ignition switch to RUN and make sure that the AIR BAG warning lamp flashes seven times and then shuts off. If the warning lamp does not shut off, make sure that the

wiring is properly connected. If the light remains on, take the vehicle to a reputable repair facility for service.

Power Steering Gear REMOVAL & INSTALLATION 1998-2001 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position a fluid catch pan under the power steering gear. 3. Remove or disconnect the following: Feed and return fluid hoses from the steering gear. Immediately cap or plug all openings to prevent system contamination or excessive fluid loss. Intermediate shaft lower coupling shield, if equipped Intermediate shaft-to-steering gear bolt. Matchmark the intermediate shaft-to-power steering gear and separate the shaft from the gear. Pitman arm from the gear pitman shaft Power steering gear-to-frame bolts and washers, then carefully remove the steering gear from the vehicle. To install: 4, Install or connect the following: e Steering gear to the vehicle and secure by finger-tightening the fasteners. For some vehicles, the pitman arm must be connected to the gear while it is still removed from the vehicle or while it is partially installed and lowered for access. If necessary, align and install the pitman arm to the shaft at this time. Tighten the power steering gear-toframe bolts to 56 ft. Ibs. (75 Nm) Intermediate shaft to the power steering, then secure using the pinch bolt

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and support the vehicle. 3. Position a fluid catch pan under the power steering gear. 4. Remove or disconnect the following: e Front tire and wheel assemblies e Outer tie rod retaining nuts

Do not try to separate a steering linkage joint by driving a wedge between the joint and the attached part. Doing this can cause seal damage and pre-

mature failure of the part. e Outer tie rods from the steering knuckles using a Suitable steering linkage and tie rod puller e Lower intermediate shaft retaining bolt and shaft from the power steering gear e Steering gear crossmember e Feed and return fluid hoses from the steering gear. Immediately cap or plug all openings to prevent system contamination or excessive fluid loss. 5. Support the power steering gear. ¢ Power steering gear mounting bolts, then remove the gear from the vehicle 6. Loosen the outer tie rod jam nuts, then remove the outer tie rods from the inner tie rods and discard the jam nut. To install: 7. Lubricate the inner tie rod threads with a suitable lubricant before installing the outer tie rod. 8. Install or connect the following: ¢ New jam nuts to the outer tie rods ¢ Outer tie rods to the inner tie rods ¢ Power steering gear to the vehicle. Tighten the retaining bolts to 81 ft. lbs. (110 Nm) 9. Remove the support from the power steering gear. ¢ Power steering hose(s) to the gear. Tighten the retaining bolt to 9 ft. lbs. (12 Nm) e Steering gear crossmember ¢ Lower intermediate shaft to the

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power steering gear. Tighten the retaining bolt to 30 ft. Ibs. (40 Nm) ¢ Outer tie rod ends to the steering knuckles. Tighten the retaining nuts to 33 ft. Ibs. (45 Nm) e Front tire and wheel assemblies 10. Remove the drain pan, then lower the vehicle. 11. Bleed the power steering system and adjust the front toe as necessary. Strut/Shock Module

REMOVAL & INSTALLATION Front—2002 Vehicles >In 2002, a “shock module”, similar to a strut was used on these vehicles. This procedure requires the use of a suitable steering linkage and tie rod

puller.

To install: . 3. Install or connect the following: e Shock module to the shock tower and lower control arm e Shock module yoke to the lower control arm ~ e Shock module upper retaining nuts and tighten to 33 ft. Ibs. (45 Nm) e Shock module-to-lower control arm retaining nut and tighten to 81 ft. Ibs. (110 Nm) e Tire and wheel

Shock Absorbers

REMOVAL & INSTALLATION Front—1998-01 Vehicles

2WD MODELS

me 1. Before servicing the vehicle, refer to

1. Before servicing the vehicle, refer to the precautions in the beginning of this secri i NY

the precautions in the beginning of this sec-

2. Remove or disconnect the following:

tion.

2. Remove or disconnect the following: e Shock module upper retaining nuts e Tire and wheel e Shock module-to-lower control arm retaining nut e Shock module yoke from the lower control arm using a Suitable puller e Shock module from the shock tower and lower control arm

e

Wheel

e Mounting nut Hold the shock absorber stem with a

wrench while backing the nut off.

e Retaining nut and grommet e Shock absorber-to-lower control arm bolts e Shock absorber ¢ Replace the parts, as necessary.

9355MG11

View of the shock module used on the front suspension of 2002 vehicles

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly support the rear axle assem-

3. Remove or disconnect the following: ¢ Automatic level control air lines from the shock absorber, if equipped e Shock absorber-to-frame retainer(s) at the top of the shock e Shock-to-axle retainer(s) at the bottom of the shock e Shock absorber To install: 4. Install the shock in the vehicle and loosely install the upper mounting fasteners to retain it 5. Align the lower-end of the shock absorber with the axle mounting, then loosely install the retainers. 6. On 1998 models, tighten the upper

.

7924JG33

Front shock absorber mounting—2WD

shock absorber retainers 22 ft. Ibs. (30

Nm). Then tighten the lower shock absorber

fastener to 62 ft. Ibs. (84 Nm).

To install: 3. Fully extend the shock absorber stem, then push it up through the lower control arm and spring so that the upper stem - passes through the mounting hole in the upper control arm frame bracket. 4. Install or connect the following: e Retaining nut and grommet on the stem. Tighten the nut to 106 inch lbs. (12 Nm). e Shock absorber-to-lower control arm bolts and tighten to 22 ft. Ibs. (30 Nm). e Wheel

4WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel ¢ Lower nut/bolt and collapse the shock absorber e Shock absorber upper nut and bolt e Shock absorber To install: 3. Install or connect the following:

* Shock absorber to the bracket.

7924JG34

Front shock absorber mounting—4WD

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2. Remove or disconnect the following: e Wheel e Shock module e Shock module yoke-to-shock absorber pinch bolt and nut 3. Spread the shock module yoke at the pinch bolt using a suitable flat-bladed tool. e Shock module yoke from the shock absorber 4. Install pieces of heater hose or _ equivalent material to the shock module spring where the spring compressor contacts the lower part of the spring. 5. Install the shock module into the spring compressor. >The spring is compressed when the shock absorber moves freely.

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Rear shock absorber mounting

7. On 1999-01 models, tighten the upper shock retainers to 18 ft. Ibs. (25 Nm). Tighten the lower shock retainers to 62 ft. lbs. (84 Nm) on two door models and 74 ft. lbs. (100 Nm) on four door models. 8. On 2002 models, tighten the upper and lower shock retainers to 59 ft. Ibs. (80 Nm). 9. If equipped, attach the automatic level control air lines to the shock absorber.

Coil Springs REMOVAL & INSTALLATION Front—1998-01 2WD Vehicles 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Shock absorber lower bolts 3. Push the shock absorber through the control arm and into the spring. 4. With the vehicle supported so the control arms hang free, install tool J-23028, onto a support and into the lower control arm bushings. 5. Remove or disconnect the following: ¢ Stabilizer bar from the control arm

e Stabilizer from the lower control arm 6. Raise and remove the tension on the lower control arm bolts. 7. Install a safety chain around the

spring and through the lower control arm. 8. Remove or disconnect the following: e Lower control arm pivot bolts, the rear first e Lower control arm and allow it to

hang free e Spring assembly To install: e>When positioning the spring in the lower control arm, be sure the spring insulator is in the proper position before lifting the control arm in place.

9. Install or connect the following: e Spring assembly e Lower control arm e Lower control arm pivot bolts © Stabilizer to the lower control arm Front—2002 Vehicles

>This procedure requires the use of a suitable spring compressor.

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

6. Turn the spring compressor forcing screw until the coil spring is compressed. 7. Remove or disconnect the folloing: e Shock absorber upper retaining nut e Shock absorber from the shock module 8. Loosen the compressor forcing screw until the upper mounting plate and coil spring can be removed. e Upper mounting plate and coil spring from the spring compressor. To install: 9. Install or connect the following: e Coil spring and upper mounting plate to the spring compresSOr 10. Turn the compressor forcing screw until the coil spring is compressed. e Shock absorber to the shock module. Tighten the retaining nut to 33 ft. Ibs. (45 Nm) 11. Remove the shock module from the spring compressor. Remove the pieces of heater hose from the spring. e Shock module yoke to the shock absorber ¢ Shock module yoke-to-shock pinch bolt and nut and tighten to 52 ft. lbs. (70 Nm) 4 e Shock module to the vehicle e Tire and wheel 12. Lower the vehicle Rear—2002 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and support the vehicle. 3. Support the rear axle. 4. Remove the shock absorber lower mounting bolts.

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5. Lower the rear axle, then remove the

Rear exhaust hangers and lower the rear exhaust, if necessary Shackle-to-frame bolt, washers and

coil springs. To install: «6. Install the coil springs, then raise the rear axle. 7. Install the shock absorber lower

ia bolts and tighten to 59 ft. Ibs. (80 m). 8. Remove the rear axle support. 9. Lower the vehicle.

Leaf Springs REMOVAL & INSTALLATION Rear—1998-01 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ~The following procedure requires the use of two sets of jackstands.

2. Support the rear axle with jackstands, support the axle and the body separately in order to relieve the load on the rear spring. 3. Remove or disconnect the following: e Wheel e Shock absorber e U-bolt nuts, washers, anchor plate and bolts

e Spare tire, if equipped

nut

Fuel tank, if necessary Front bracket nut, washers and bolt Spring Shackle from the spring, if necessary To install: 4. Install or connect the following: Shackle to the rearward spring eye using the bolt, washers and nut, but do not fully tighten at this time. Spring assembly Spring to the front bracket using the bolt, washers and nut, but do not fully tighten at this time. Fuel tank, if removed Shackle-to-frame bolt, washers and

nut, gut do not fully tighten at this time. If used, remove the spring support. U-bolts, anchor plate, washers and U-bolt nuts. Torque the nuts using 2 passes of a diagonal sequence: a. Step 1: Torque to 18 ft. Ibs. (25 Nm). b. Step 2: Torque to 73 ft. Ibs. (100 Nm) in the sequence. 5. Position the axle to achieve an approximate gap of 6.46-6.94 in.

(164—176mm) between the axle housing tube and the metal surface of the rubber © frame bumper bracket. Measure from the housing between the U-bolts to the metal part of the rubber bump stop on the frame. 6. While supporting the axle in this position, tighten the front and rear spring mounting fasteners to 89 ft. Ibs. (122 Nm). 7. Install or connect the following: e Rear exhaust in position and tighten the hangers e Spare tire e Shock absorber Torsion Bar

Instead of the coil spring used on the front suspension of 1998-01 2WD vehicles, the 4WD vehicles are equipped with a torsion bar.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. >The following procedure requires the use of the Torsion Bar Unloader tool J36202.

2. Remove or disconnect the following: e Transmission shield, if equipped e Torsion bar unloader too! to relax the tension on the torsion bar adjusting arm screw; record the number of turns necessary to properly install the tool. Remove the adjusting screw and the unloader tool. e Lower link mount nut from one side e Torsion bars by disengaging them and side of the torsion bar being removed

2. AXLE STOP BRACKET 3. REAR AXLE (END VIEW) 4. BUMPER 5. TRIM HEIGHT 135 — 145MM

(5.35.7 INCHES)

88268GB5

Typical rear suspension trim height measurement

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REMOVAL & INSTALLATION

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1. FRAME

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e Lower link nut from the opposite side e Lower link mount, upper link mount nut e Upper link mount e Torsion bar from the frame To install: 3. Install or connect the following: e Torsion bar and support e Upper link mount. Torque the nut to 48 ft. Ibs. (68 Nm). 4. Place a jack under the torsion bar to release tension. 5. Install or connect the following:

For Wheel Alignment specifications, see Section 1 of this manual

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Upper Ball Joints

REMOVAL & INSTALLATION 1998-2001 2WD Vehicles 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. «>The following procedure requires the use of a ball joint separator tool such as J-23742 and J-9519-E ball joint remover and installer set.

2. Raise and support the front of the vehicle safely by placing stands securely under the lower control arms. Because the vehicle's weight is used to relieve spring tension on the upper control arm, the stands must be positioned between the spring

a Use a ball joint separator tool to drive the upper ball joint from the steering knuckle

seats and the lower control arm ball joints for maximum leverage.

“kk CAUTION With components unbolted, the stand is holding the lower control arm in place against the coil spring. Make sure the stand is firmly positioned and cannot move, or personal injury could result. 3. Remove or disconnect the follow-

ing:

° Tire and wheel assembly —

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knuckle using tool J-23742 and

pull the steering knuckle free of the ball joint

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RIVETS APPROXIMATELY

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ball joint.

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85388024

Service ball joints are bolted to the control arm

61 ft. Ibs. (83 Nm). Insert a new cotter pin. e>When installing the cotter pin, never loosen the castle nut to expose the cotter pin hole.

e Thread the grease fitting into the ball joint. Use a grease gun to lubricate the upper ball joint until grease appears at the seal. e Brake caliper e Tire and wheel assembly 7. Check and adjust the front end alignment, as necessary.

1998-2001 4WD Vehicles 85388023

Punch the rivets out and remove the ball joint

5. Clean and inspect the steering knuckle hole. Replace the steering knuckle if the hole is out of round. To install: 6. Install or connect the following: e Ball joint in the upper control arm ¢ Ball joint retaining nuts and bolts. Position the bolts threaded upward

from under the control arm. Tighten the ball joint retainers to 17 ft. Ibs. (23 Nm). e Anti-lock brake sensor wire bracket, if removed e Ball joint to the knuckle. Make Sure the joint is seated, then install the stud nut and tighten to

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. On 4WD vehicles both the upper and lower ball joints are removed in the same manner. Once the joint is separated from the steering knuckle the rivets are drilled and punched to free the joint from the control arm. Service joints are bolted into position with the retaining bolts threaded upward from beneath the control arm. In this manner, the joint is replaced in an almost identical fashion to the upper joints on 2WD vehicles.

For Maintenance Interval recommendations, see Section 7 of this manual

13-AA GENERAL MOTORSe TRAILBLAZER CORP. BLAZER © XTREME

2. Remove or disconnect the following: e Tire and wheel assembly e Wheel speed sensor wiring connector from the upper control arm, if removing the upper ball joint e Cotter pin from the ball joint, then loosen the retaining nut 3. Position a suitable ball joint separator tool such as J-36607, then carefully loosen the joint in the steering knuckle. Remove the tool and the retaining nut, then separate the joint from the knuckle. ->After separating the steering knuckle from the upper ball joint, be sure to support the steering knuckle/hub assembly to prevent damaging the brake hose.

4. Remove the riveted ball joint from the control arm: a. Drill a¥% in. (3mm) hole, about % in. (6mm) deep into each rivet. b. Then use a % in. (13mm) drill bit, to drill off the rivet heads. c. Using a pin punch and the hammer, drive out the rivets in order to free the ball joint from the control arm assembly, then remove the ball joint. To install: 5. Install or connect the following:

e Ball joint in the control arm e Ball joint retaining nuts and bolts. Position the bolts threaded upward from under the control arm. Tighten the ball joint retainers to 17 ft. Ibs. (23 Nm). Ball joint to the knuckle. Make sure the joint is seated, tighten the lower nut to 79 ft. Ibs. (108 Nm) and the upper nut to 61 ft. Ibs. (83 Nm). Install a new cotter pin. s

e>When installing the cotter pin, never loosen the castle nut to expose the cotter pin hole, but DO NOT tighten more than an additional % turn.

6. Use a grease gun to lubricate the upper ball joint. e Wheel speed sensor wiring connector to the upper control arm, if the upper ball joint was removed e Tire and wheel assembly 7. Check and adjust the front end alignment, as necessary. 2002 Vehicles >This procedure requires the use of the following special tools: J 9519-E Lower Ball Joint Remover and Installer, J 21474-01 Control Arm Bushing Set and J 45117 Ball Joint Installation Spacer.

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The replacement ball joint comes with nuts and bolts for installation

@ BRAVADA e ENVOY e JIMMY

On 4WD vehicles, remove the wheel cap and drive axle nut. Raise and support the vehicle. Remove or disconnect the following: Tire and wheel Wheel hub and bearing, if necessary Outer tie rod retaining nut Out tie rod from the steering knuckle using a suitable puller Brake hose bracket retaining bolts and bracket Upper control arm-to-steering knuckle pinch bolt and nut Upper control arm from the steering knuckle Lower ball joint retaining nut Steering knuckle from the lower control arm using a suitable ball joint removal tool Steering knuckle from the vehicle Upper ball joint retaining clip Upper ball joint from the steering knuckle using Lower Ball Joint Removal and Installer tool No. J 9519-E To install: 4. Install or connect the following: e¢ Upper ball joint to the steering knuckle using J 9519-E, J 2147401 and J 45117

e Upper ball joint retaining clip Steering knuckle to the lower control arm Lower ball joint retaining nut and tighten to 81 ft. Ibs. (110 Nm) Upper control arm to the steering knuckle Upper control arm pinch bolt and nut and tighten to 30 ft. Ibs. (41 Nm) Brake hose bracket to the steering knuckle Brake hose bracket retaining nuts and tighten to 7 ft. Ibs. (10 Nm) Outer tie rod to the steering knuckle Outer tie rod retaining nut and tighten to 33 ft. Ibs. (45 Nm) Wheel hub and bearing, if removed Tire and wheel 5. Lower the vehicle e Drive axle nut, if 4WD, and tighten to 103 ft. Ibs. (140 Nm) e Wheel enter cap, if removed 6. Check the front wheel alignment. Lower Ball Joints

|

REMOVAL & INSTALLATION

1998-01 2WD Vehicles 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. >The following procedure requires the use of a ball joint remover/installer set (the particular set may vary upon application but must include a clampingtype tool with the appropriately sized adapters) and a ball joint separator tool, such as J-23742.

e Tire and wheel assembly 2. Position a jack under the spring seat of the lower control arm, then raise the jack to support the arm.

*:< CAUTION The jack MUST remain under the lower control arm, during the | removal and installation procedures, to retain the arm and spring positions. Make sure the jack is securely positioned and will not slip or release during the procedure or personal injury may result. 3. Remove or disconnect the following: e Brake caliper and support it aside using a hanger or wire. Make sure the brake line is not stressed or damaged.

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Lower ball joint cotter pin and discard e Ball joint stud nut e Lower ball joint from the steering knuckle using tool J-23742 4. Carefully guide the lower control arm out of the opening in the splash shield using a putty knife. Position a block of wood between the frame and upper control arm to keep the knuckle out of the way. e Grease fitting e Ball joint from the control arm using the ball joint remover set along with the appropriate adapters To install: 5. Clean the tapered hole in the steering knuckle of any dirt or foreign matter, then check the hole to see if it is out of round, deformed or otherwise damaged. If a problem is found, then knuckle must be replaced. 6. Install or connect the ewe e Press the new ball joint (with grease fitting pointing inward) until it bottoms in the control arm using a Suitable installation set. Make sure the grease seal is facing inboard. Ball joint stud into the steering knuckle e Ball joint retaining nut and tighten to 79 ft. Ibs. (108 Nm) When installing the cotter pin, never loosen the castle nut to expose the cot-

J 951 9-30

ter pin hole.

e Grease fitting into the ball joint, if not already installed 7. Use a grease gun to lubricate the joint until grease appears at the seal. e Brake caliper e Tire and wheel assembly 8. Check and adjust the front end alignment, as necessary.

1998-2001 4WD Vehicles On these vehicles both the upper and lower ball joints are removed in the same manner. Please refer to the procedure for the 2WD vehicles.

2002 Vehicles

5968007 Driving the lower joint from the control arm

>This procedure requires the use of the following special tools: J 9519-E Lower Ball Joint Remover and Installer, J 34874 Booster Seal Remover/ Installer, J 41435 Ball Joint Installer, J 45105-1 Ball Joint Flaring Adapter and J 45105-2 Receiver.

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

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REMOVAL & INSTALLATION 1998-01 Vehicles

2WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable e Wheel Wheel speed sensor harness bracket retaining bolt and nut, if equipped Steering knuckle from upper control arm ball joint Mounting nuts/bolts and shims

J 9519-30

->Make sure to note the location of the ‘control arm shims prior to removal so that they may be installed in their original positions.

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e Upper control arm To install: 3. Install or connect the following: e Upper control arm 85388029

Installing a new ball joint

1. center 2. 3.

On 4WD vehicles, remove the wheel cap and drive axle nut. Raise and support the vehicle. Remove or disconnect the following: Tire and wheel Wheel hub and bearing, if necessary Outer tie rod retaining nut Out tie rod from the steering knuckle using a Suitable puller Brake hose bracket retaining bolts and bracket Upper control arm-to-steering knuckle pinch bolt and nut Upper control arm from the steering knuckle Lower ball joint retaining nut Steering knuckle from the lower control arm using a suitable ball joint removal tool Steering knuckle from the vehicle e Lower ball joint flange with a chisel 4. Install tools J 9519-E and J 34874 to the lower ball joint, then use those tools to remove the lower ball joint from the lower control arm. To install: 5. Install or connect the following: ¢ Lower ball joint to the lower control arm, using tools J 9519-E, J 41435 and J 45105-2

6. Remove the tools from the lower control arm. e Tools J 9519-E and J 45105-1 to the lower ball joint. 7. Flare the lower ball joint flange with J 9519-E and J 45105-1, then remove the tools from the lower ball joint. Steering knuckle to the lower control arm Lower ball joint retaining nut and tighten to 81 ft. Ibs. (110 Nm) Upper control arm to the steering knuckle Upper control arm pinch bolt and nut and tighten to 30 ft. Ibs. (41 Nm) Brake hose bracket to the steering knuckle Brake hose bracket retaining nuts and tighten to 7 ft. Ibs. (10 Nm) Outer tie rod to the steering knuckle Outer tie rod retaining nut and tighten to 33 ft. Ibs. (45 Nm) Wheel hub and bearing, if removed Tire and wheel 8. Lower the vehicle ¢ Drive axle nut, if 4WD, and tighten to 103 ft. Ibs. (140 Nm) ¢ Wheel enter cap, if removed 9. Check the front wheel alignment.

> Always tighten nut on the thinner shim pack first.

e Mounting nuts/bolts and shims. Torque the nuts to 81-85 ft. Ibs.

(110-115 Nm). e Steering knuckle to upper control arm ball joint e New cotter pin Tighten the nut to align the hole never loosen.

e Wheel speed sensor harness bracket retaining bolt and nut, if equipped e Wheel

4WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Tire and wheel assembly ¢ Cotter pin from the ball joint, then loosen the retaining nut Steering knuckle from the upper ball joint. Be sure to support the Steering knuckle/hub assembly to prevent damaging the brake hose. >The 4WD vehicles do not use shims to adjust the front wheel alignment. Instead, the upper control arm bolts are equipped with cams, which are rotated to achieve caster and camber adjustments. In order to preserve

ree BLAZER - adjustment and ease installation, matchmark the cams to the control arm before removal. If the control arm is being replaced, transfer the alignment marks to the new component before installation.

e Front and rear nuts retaining the control arm retaining bolts to the frame ¢ Outer cams from the bolts e Bolts and inner cams ¢ Control arm from the vehicle e Retaining nut and the bumper from the control arm, if necessary 3. If the bushings are being replaced, use a Suitable bushing service set to remove the bushings from the arm. To install: 4. Install or connect the following: e Bushing service set to drive the new bushings into the control arm, if removed Bumper and retaining nut to the control arm, if removed. Tighten the bumper retaining nut to 20 ft. Ibs.

(27 Nm). Control arm, retaining bolts (from the inside ofthe frame brackets facing outward) and the inner cams. The inner cams must be positioned on the bolts before they are inserted through the control arm and frame brackets. Outer cams over the retaining bolts, then the nuts to the ends of the bolts at the front and rear of the control arm 5. Align the cams to the reference marks made earlier, then tighten the end nuts to 85 ft. lbs. (115 Nm). e Ball joint to the knuckle e Tire and wheel assembly 6. Check and adjust the front end align-

ment, as necessary. 2002 Vehicles

CONTROL ARM BUSHING REPLACEMENT 2WD Vehicles

1. Before servicing the vehicle, refertothe precautions in the beginning of this section. 2, Remove or disconnect the following: ¢ Upper control arm and place it in a vice e Upper control arm shaft nuts and retainers . ¢ Upper control arm bushings using

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tool J 29969-1, a Slotted washer and a short piece ifpipe that is slightly larger than the bushing e Upper control arm shaft To install: 3. Install or connect the following: ¢ Upper control arm shaft ¢ Upper control arm bushings using tool J 22269-1, a slotted washer and a short piece if pipe that is slightly larger than the bushing 4. Tighten J 22269-1 until the bushing is positioned on the shaft and the control arm as shown in the accompanying illustration. The measurement should be 0.48-0.52 inch (12.8-13.8mm) at both sides when the properly installed. e Upper control arm shaft nuts and retainers. Tighten to 85 ft. Ibs. (115 Nm). e Upper control arm If the bushings require replacement, refer to the contro! arm removal and installation procedure for bushing replacement.

Lower Control Arm

REMOVAL & INSTALLATION 1998-01 Vehicles 2WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Coil Spring e Lower ball joint from the steering knuckle e Lower control arm from the vehicle To install: 3. Install or connect the following: Lower control arm Lower ball joint stud into the steering knuckle Ball joint-to-steering knuckle nut and tighten to specification New cotter pin to the lower ball joint stud e Coil spring 4. Align the vehicle.

4WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ->Tools Needed: universal tie rod separator J-24319-01, torsion bar unloader

J-36202, lower control arm bushing

service kit J-36618 (if the control arm bushing are being replaced) and ball joint C-clamp J-9519-23. Parts Needed: whether or not the contro! arm or bushing are being replaced, NEW control arm retaining nut should be used once the old ones have been loosened and removed.

2. Remove or disconnect the following: Front wheels 2 bolts from the front splash shield and pivot it in order to gain access to the tie rod Stabilizer bar from the control arm (keeping all of the link hardware sorted for proper installation). If necessary, completely remove the bar from the vehicle for access. Shock absorber Inner tie rod from the relay rod using a tie rod separator Outer halfshaft nut and washer Bolts from the hub and bearing kit 3, Unload the torsion bar using the unloading tool J-36202. First, mark the adjuster for installation. e Adjustment arm. Slide the bar for- _ ward and the adapter out of the rear to remove the adjusting arm. Lower ball joint cotter pin, nut and ball joint from the control arm ° using a ball joint separator Nuts and bolts and lower control arm with the torsion bar assembly. Note the direction which the control arm retaining bolts are facing for installation purposes. To install: 4. Install or connect the following: e Torsion bar to the lower control arm and place the assembly into the vehicle. Position the front leg of : the lower control arm into the crossmember before installing the rear leg into the frame bracket. Control arm bolts (facing in the direction as noted during removal or shown in the accompanying illustration) with NEW nuts. >The control arm retainers MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nuts now, then installing the remaining components along with the wheels and

For complete service labor times, order the Chilton Labor Guide

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Exploded view of the lower control arm assembly mounting

lowering the vehicle, or by moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure front suspension is at actual ride height compression. If you are unsure, it is best to start the nuts now and tighten them to specification once the vehicle is lowered.

e Ball joint stud in the knuckle 5. With the suspension at the correct height, tighten the control arm retaining nuts to 98 ft. Ibs. (133 Nm). >The lower ball joint retaining nut

- MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nut now, then installing the remaining components along with the wheels and lowering the vehicle, or by

moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure the FULL WEIGHT of the vehicle front end is on the suspension.

6. Install or connect the following: e Joint-to-control arm nut, then tighten the nut to 92 ft. Ibs. (125 Nm) with the suspension at normal ride height and compression. New cotter pin to the castellated nut. Tighten the nut (but no more than an additional Ye turn) in order to align the cotter pin. DO NOT loosen the nut from the specified torque.

Adjuster arm by sliding the adapter forward, over the torsion bar to

install the sides of the nut. Load the torsion bar and install the adjuster bolt aligning the installation mark. Drive axle through the hub and bearing assembly Tighten the hub and bearing assembly retaining bolts Drive axle shaft nut and washer Inner tie rod end to the relay rod Shock absorber Stabilizer bar, if removed Stabilizer link(s) to the control arm(s) Splash shield Front wheels 7. Recheck all fasteners for proper torque and installation before road testing. 8. Refill the differential if any fluid was lost.

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2002 Vehicles 1. Before servicing the vehicle, refer to Eeprecautions in the beginning of this secion. 2. Raise the vehicle. 3. Remove or disconnect the following: e Tire and wheel ¢ Upper ball joint-to-upper contro! arm pinch bolt and nut ¢ Upper control arm from the steering knuckle e Anti-lock Brake System (ABS) wheel speed sensor harness ¢ Upper control arm bolt and control

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To install: 4. Install or connect the following:

¢ Upper control arm and bolts.

J 21474-12

Tighten to 111 ft. Ibs. (150 Nm) e Connect the ABS wheel speed sensor wiring harness e Upper control arm to steering knuckle. Tighten the pinch bolt to 30 ft. Ibs. (40 Nm)

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Removing the lower control arm rear bushing—all 2 wheel drive

e Tire and wheel 5. Lower the vehicle and check the front end alignment.

CONTROL ARM BUSHING REPLACEMENT

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1998-01 Vehicles 2WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

tion.

J 21474-13

2. Remove lower control arm and place it in vise.

3. Install tools J 22269-01, 21474-8, 12 and 13 on the rear bushing and tighten until the bushing is removed. 4. Using a blunt chisel, drive the front bushing flare flush with the rubber part of the bushing. 5. Place a wedge or a spacer between the bushing housing to keep the housing from bending while removing or installing the bushing. 6. Install tools J 21474-3, 4, 5 ae on the front bushing and tighten until the bushing is removed. To install: 7. Install the front bushing into the control arm. 8. Install tools J 21474-4, 5 and 13. Tighten until the bushing is fully seated.

J 21474-5

Installing the lower control arm front bushing—all 2 wheel drive

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Installing the lower control arm rear bushing—all 2 wheel drive

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10. Install tools J 22269-01, J 21474-2 and 13. Tighten until the bushing is fully seated. 11. Install the lower control arm.

Installing the lower control arm front bushing—all 4 wheel drive

J21474-4

4WD MODELS J21474-12

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove lower control arm and place it in vise. 3. Using bushing service set J21474, remove the front and rear bushings. To install: 4. Using bushing service set J21474, install the front and rear bushings. 5. Install the lower control arm.

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2002 Vehicles This procedure requires the use of Steering Linkage and Tie Rod Puller Boone: Soot Naot Egeaee Joint

93081613 Installing the lower control arm rear bushing—all 4 wheel drive

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

J 21474-5

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e Tire and wheel e Outer tie rod retaining nut ¢ Quter tie rod from the steering knuckle using Ball Joint Removal tool No. J 43631 e Stabilizer shaft link lower nut, link and washer e Shock module yoke lower nut and shock module using Steering Linkage and Tie Rod Puller tool No. J 24319-B Lower control arm-to-lower control arm bracket mounting bolts

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Removing the lower control arm front bushing—all 4 wheel drive

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¢ Lower control arm-to-lower control arm bracket mounting bolts © Lower ball joint retaining nut ¢ Lower ball joint from the steering knuckle using Ball Joint Removal tool No. J 43631

2. If equipped, remove the wheel/hub cover for access, then remove the dust cap from the hub. 3. Remove the cotter pin and loosen the spindle nut. 4. Spin the wheel forward by hand and

>On 4WD vehicles, make sure not to disengage the axle shaft from the transmission.

torque the nut to 12 ft. Ibs. (16 Nm) in order

.

4. Pivot the lower control arm out and down to disengage the lower control arm from the bracket, then remove the lower control arm from the knuckle. To install: 5. Install or connect the following: ¢ Lower control arm to the steering knuckle ¢ Lower control to the bracket by pivoting it out and up During installation and tightening of the bolts and nuts, make sure that the lower control arm is parallel to the bracket. This is to maintain proper alignment of the lower control arm bushings.

e Lower control arm-to-bracket mounting bolts and tighten to 81 ft. lbs. (111 Nm) e Shock module yoke to the lower control arm

e Shock module yoke lower mounting nut elf it becomes necessary to replace the washer, use only an identical hardened steel, felt lined washer. Standard washers must not be used.

e Stabilizer shaft link and washer to the lower control arm e Stabilizer shaft link retaining bolt

and tighten to 74 ft. Ibs. (100 Nm) e Outer tie rod to the steering knuckle. Tighten the nuts to 33 ft. lbs. (45 Nm) e Tire and wheel 6. Lower the vehicle and check the front end alignment.

to fully seat the bearings and remove any burrs from the threads. 5. Back off the nut until it is just loose, then finger-tighten the nut. 6. Loosen the nut %4—-¥ turn until either hole in the spindle lines up with a slot in the nut, then install a new cotter pin. This may appear to be too loose, but it is the proper adjustment. 7. Proper adjustment creates a0 ee in. (0.025—0.127mm) endplay.

4WD MODELS The front wheel bearings on the 4-wheel drive vehicles are not adjustable. If the bearings become loose or make noise, they must be replaced.

2001-02 Vehicles The wheel bearings on these vehicles are not adjustable. If the bearings become loose or make noise, they must be replaced.

REMOVAL & INSTALLATION Front

1998-00 2WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Brake caliper with the pads without disconnecting the brake line

e Grease cap ¢ Cotter pin, spindle nut and washer e Hub

Be careful not to drop the outer wheel bearing. As the hub is pulled forward, the outer wheel bearings will often fall forward and they may easily be removed at this time.

Wheel Bearings

ADJUSTMENT 1998-2000 Vehicles 2WD MODELS 1. Before servicing the vehicle, refer tothe precautions in the beginning of this section.

e Outer roller bearing assembly e Inner seal by prying it out of the hub and discard it e Inner bearing assembly

To install: 3. Clean all parts in solvent and allow to air dry, then check for excessive wear or damage. Inspect all of the parts for scoring, pitting or cracking and replace if necessary. ->DO NOT remove the bearing races from the hub, unless they show signs of damage.

4. If it is necessary to remove the wheel bearing races, use the GM front bearing race removal tool J-29117 to drive the races from the hub/disc assembly. A hammer and brass drift may also be used to drive the races from the hub, but the race removal tool is quicker. 5. If the bearing races were removed, position the replacement races in the freezer for a few minutes and then install them to the hub: a. Lightly lubricate the inside of the hub/disc assembly using wheel bearing grease. b. Using the GM seal installation tools J-8092 and J-8850, drive the inner bearing race into the hub/disc assembly until it seats. Be sure the race is properly seated against the hub shoulder and is not cocked. ->When installing the bearing races, be sure to support the hub/disc assembly with GM tool J-9746-02.

c. Using the GM seal installation tools J-8092 and J-8457, drive the outer race into the hub/disc assembly until it seats. 6. Using a high melting point wheel bearing grease, lubricate the bearings, races and spindle; be sure to place a gob of

grease (inside the hub/disc assembly) between the races to provide an ample supply of lubricant. >To lubricate each bearing, place a gob of grease in the palm of the hand, then scoop the bearing through the grease until it is well lubricated.

7. Place the inner bearing in the hub, then apply a thin coating of grease to the sealing lip and install a new inner seal, making sure the seal flange faces the bearing cup. e>Although a seal installation tool is preferable, a section of pipe with a smooth edge or a suitably sized socket may be used to drive the seal into position. Be sure the seal is flush with the outer surface of the hub assembly.

Timing belt service is covered in Section 3 of this manual

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i Wheel bearings, races and related components—2WD vehicles

e Halfshaft from the hub/bearing assembly, using a Spindle Remover tool J-28733-A to prevent damage to the shaft or hub/bearing assembly ¢ Hub/bearing assembly from the knuckle 6. Clean and inspect the parts for nicks, scores and/or damage, then replace them as necessary. To install: 7. Install or connect the following: Hub and bearing assembly by aligning the threaded holes. Torque the bolts to 77 ft. Ibs. (105 Nm). Tie rod end to the steering knuckle using the retaining nut New cotter pin Brake assembly Halfshaft nut. Tighten the nut to 180 ft. Ibs. (245 Nm). Retainer and a new cotter pin but DO NOT back off specification in order to insert the cotter pin. 8. Remove the torsion bar unloader too! and the drive axle boot protector. 9. Install the wheel. 10. Check and/or adjust the vehicle trim ) height, as necessary.

8. Install or connect the following: e Wheel hub over the spindle e Outer bearing into the hub by hand e Spindle washer and nut e Brake caliper e Wheel 9. Properly adjust the wheel bearings 10. Install or connect the following: e New cotter pin e Dust cap e Wheel cover

1998-00 4WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install Torsion Bar Unloading tool J 36202 on the torsion bar adjusting bolt and remove the bolt. To aid during installation, count the number of turns required to remove the bolt. 3. Remove the wheel. 4. Install an axle shaft boot seal protector to the Tri-pot axle joint. 5. Remove or disconnect the following: ¢ Cotter pin and retainer e Castle nut and the thrust washer ¢ Brake caliper and support it aside

using wire or a coat hanger ->Be sure the brake line is not Stretched or damaged.

e Brake disc from the wheel hub

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Use Torsion Bar Unloading tool J 36202 to remove the adjusting bolt and unload the torsion bar

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Hub and bearing assembly—4WD vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. On 4WD vehicles, remove wheel center cap, if equipped, and the drive axle nut and washer 3. Raise and support the vehicle. 4. Remove or disconnect the following: e Tire and wheel e Caliper, leaving the fluid lines connected Brake rotor Halfshaft from the hub and bearing on 4WD vehicles. Place a brass drift against the outer edge of the halfshaft to protect the shaft threads. Use a hammer to sharply strike the brass drift, but to do not remove the halfshaft at this time e Wheel speed sensor

e Wheel hub and bearing-to-steering knuckle bolts and hub and bearing Lay the hub and bearing on the wheel studs on the outboard side. This will avoid damaging the bearing seal.

e Splash shield from the steering knuckle e Seal from the hub and bearing To install: 5. Install or connect the following: Wheel hub and bearing seal Splash shield to the steering knuckle, making sure it's properly aligned Hub and bearing to the steering knuckle, aligning the threaded holes Hub and bearing bolts and tighten

to 77 ft. Ibs. (105 Nm) Wheel speed sensor. Tighten the

bolt to 13 ft. Ibs. (18 Nm)

¢ Rotor and brake caliper e Tire and wheel 6. Lower the vehicle 7. On 4WD vehicles, install the drive axle nut and tighten to 103 ft. Ibs. (140 Nm), then install the center cap. Rear

A new pinion shaft lockbolt should be installed whenever either of the axle shafts is removed. The axle shaft and seal may be removed and replaced without disturbing the bearing or seal but it is highly recommended to replace the seals when removing the axle shaft. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheels

Heater Core replacement is covered in Section 2 of this manual

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7924JG15

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AXLE SHAFT

DO NOT damage the housing oil seal surface. e Wheel bearing using the GM Slide Hammer tool J-2619, the GM Adapter tool J-2619-4 and the GM Axle Bearing Puller tool J-2281301 To install: 7. Clean and inspect the components for excessive wear or damage and replace them, if necessary. 8. Install or connect the following: e New or reused bearing, coated with gear lubricant, using the Axle Shaft Bearing Installer tool J-34974 to drive the bearing in until it bottoms against the seat

BACKING PLATE 7924JG55

Cross-sectional view of the rear axle, bearing and seal assembly

Be sure the bearing installer does not contact and damage the speed sensor on ABS equipped vehicles.

e New seal lubricated with gear oil using the GM Axle Shaft Seal Installer tool J-33782 to seat it in the housing until it is flush with the axle tube ->Be sure the seal installer does not contact and damage the speed sensor on ABS equipped vehicles.

e Axle shaft into the housing by engaging the splines e C-lock retainer on the axle shaft button end 20. Lock bolt 21. “C* lock 7924JG56

Pinion shaft lockbolt and axle C-lock locations, inside the differential

e Brake drums 3. Using a wire brush, clean the dirt/rust from around the rear axle cover. 4. Drain the fluid. 5. Remove or disconnect the following: ¢ Rear pinion shaft lockbolt and the pinion shaft e C-lock from the button end of the axle shaft by pushing the axle shaft inward e Axle shaft from the axle housing

->Be careful not to damage the oil seal.

If equipped with an Anti-Lock Brake System (ABS), be careful not to damage the reflector ring on the axle shaft or the speed sensor bolted to the backing plate, immediately adjacent to the shaft. (oa SE A

BE CAREFUL not to damage the wheel bearing seal. e Axle shaft by pulling it outward to seat the C-lock retainer in the counterbore of the side gears Pinion shaft through the case and the pinions. Tighten the new lockbolt to 27 ft. Ibs. (36 Nm). New rear axle cover gasket Housing cover Brake drums Wheels 9. Refill the housing.

~ GENERAL MOTORS CORP. 1998-01 Escalade * Denali * Denali XL * Suburban * Yukon « Yukon XL DIESEL ENGINE REPAIR.....14-45 DIESEL FUEL SYSTEM....... 14-62 DRIVE TRAIN.................. 14-64 GASOLINE ENGINE GG Leersrceereneeeeer 14-3 GASOLINE FUEL SYSTEM ...14-5 PRECAUTIONG.................. 14-2 STEERING AND SUSPENSION opal 14-86 Tigerwpter. 2 a nw PikaAaa 14-86 DST i)(ee ee 14-87 lecauuOlicn cette nt cons! 14-86 Alternator ................ Pacedeee14-6 OURAN ele ce Ns faites hecnigs 14-6

Automatic Locking Hubs.............. 14-73 Removal & ptenaop Snares! 14-73 Camshaft and Valve Lifters (Diesel Sut ie WetSTHe1 8 Ae oe 14-52 Removal & Installation............ 14-52 Camshaft and Valve Lifters (Gasoline Engine Repair)............ 14-29 Removal & Installation............ 14-29 COlSDEMOSic, acts bamsiiaG acenclicane: 14-92 Removal & Installation............ 14-92 CV -Joinisa: a6 xayon.iia Ane. pad 14-69 Overhaubia. nee .vood wuoy, aK14-69 Cylinder Head (Diesel Engine Repaitt) a8 vst een ni Sie G80, 14-48 Removal & Installation............ 14-48 Cylinder Head (Gasoline Engine ISTE:Gi: ee het ts a a ll 14-12 Removal & Installation............ 14-12

Diesel Injection Pump...........5..... 14-63 Removal & Pesan AD) lla 14-63 Engine Assembly (Diesel Engine Repalii) sales neal tudeote,14-45 Removal & Installation............ 14-45 Engine Assembly (Gasoline Engine Repair iii Nl Wiwventi i.Wile,Wnt, 14-7 Removal & Installation.............. 14-7 Exhaust Manifold (Diesel Engine UI Patek Cm OMe eae sos 14-51

Removal & Installation............ 14-51 Exhaust Manifold(Gasoline Engine Repair)... ogee ee oe14-24 Removal & Hct fl id 14-24 AOU UL AL: DISIHDUIO mck cuteeee 14-3 MDSIGNAUOM sccrcocatecreneptemceneek14-3 POO Valve Skt Seas Her ieee14-3 4.8L, 5.3L and 6.0L Distributor .....14-3 Installation, Engine DIStNDE te wee 14-4 Installation, Engine Not DIStUDEC inc cepccetrs temas 14-4 REMOVAL sacs cere. ee estrea ate 14-3 Front Axle Shaft, Bediing andl Oral... rticnces., 14-74 Removal & Installation............ 14-74 Front Drive Axle Differential Carrier... 14-85 Removal & Installation............ 14-85 Front Drive Axle Pinion SGA aria... oor nda haeeetae 14-82 Removal & Installation............ 14-82 Fuel Filter (Diesel Fuel System) adi 2has.unvatlewn bas 14-62 Removal & Installation............ 14-62 Fuel Filter (Gasoline Fuel SY SICHA a een eae Tei 14-56 Removal & Installation............ 14-56 Fuel Injector (Gasoline Fuel SV SIEU eaten de eee oentrer cs14-58

Removal & Installation............ 14-58 Fuel Injectors (Diesel Fuel SYStBIM) t. aterne(oeene ie: 14-64 Ruel BannpasS.sticiven site beatae, |ss14-57 Removal & Installation............ 14-57 FuebSystem Aire 14-62 Bleeding 2 ey sees ee 14-62 Fuel System Pressure (Diesel os ef Repeat tteae a 14-62 Ste abe aeons 14-62 Fuel System Pressure (Gasoline BS USICKN wai A nuibhied aauasthidys 14-56 RE OVING sruracciaissterereetierineu sate14-56 Fuel System Service

Precautions........... Para (c 14-55

Glow Plugs ...veaveren 2 are 14-47 Removal & ASHEN Pash Adds 14-47 Halfshalt..i..129% ROU S SP Say 14-68 Removal & Installation............ 14-68

[Ble Speed ih tkcuctesk deen tak!14-62 Adjusimenticicii: aio 14-62 Ignitionstimingtiiese.. see hah 14-7 PGIUSUMSMIS ncaa sactnndvpecttut 14-7 Intake Manifold (Diesel Engine Repalr):..c:..0,.¢80 =2am nee 14-51 Removal & Installation............ 14-51 Intake Manifold (Gasoline Engine ROGAG Sab telyineeetenc a eee 14-20 Removal & arg Ned 14-20 Leal SPNINGS st feces .cscdPoca 14-95 Removal & Installation............ 14-95 LOWES Ball JOU ce. tose eee 14-99 Removal & Installation............ 14-99 Lower Control Arm and BUSIIDG iste en ete ae eee 14-102 Control Arm Bushing Repfalementicics sues. eovtoa 14-103 Removal & stanation att Sic 14-102 Manual Locking Hubs.................. 14-73 Removal & oa Seo howe 14-73

Oil Pan (Diesel Engine ROMAIN Ave Gl Vilzus Hau) AON ey 14-53 Removal & Installation............ 14-53 Oil Pan (Gasoline Engine Rep att eh aren Se ae ee een 14-33 Removal & Installation............ 14-33 Oil Pump (Diesel Engine He tral|B etpebanas eta Recs #s BK 14-53 Removal & Installation............ 14-53 Oil Pump (Gasoline Engine Repail): Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

9308KG75

Bellhousing bolt removal—4.8L, 5.3L, 6.0L

The eight injector connectors The idle air control (IAC) motor The throttle position (TP) sensor The evaporative emissions (EVAP) canister purge solenoid The manifold absolute pressure (MAP) sensor The camshaft position (CMP) senSor The ground splice at the rear of the right side of the block The ground splice and the ground strap at the rear of the left side of the block The coolant temperature (CTS) sensor The oil pressure sensor/switch The electrical connector from intake and disconnect from harness Junction block bracket from alternator bracket 6. Set the electrical harness aside. 7. Remove or disconnect the following:

EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid Battery negative cable from the engine block Drive belt Bolts holding the alternator mount-

ing bracket to the cylinder head and block e Bolt behind the power steering pump to engine block e Alternator mounting bracket. Position the bracket aside. e Fuel pipes from the engine 8. Raise the vehicle. 9. Remove or disconnect the follow-

ing: e Steering linkage under body shield, if equipped e Engine oil pan under body shield, if equipped e Engine oil

e Starter motor 10. Disconnect the engine wiring harness from the following components: e The crankshaft position (CKP) sen-

sor The engine oil level sensor The block heater, if equipped The wiring harness to oil pan Reposition wiring from lower engine area 11. Remove or disconnect the following: e Exhaust pipes from the exhaust manifolds e Transmission cooler pipe retainer from the right side of the engine block, if equipped e e e e

17. Remove the engine from the vehicle. To install: 18. Install or connect the following: e Engine to the vehicle ¢ Engine mount bolts e Upper bellhousing bolts 19. Remove transmission support apparatus. 20. Remove the lifting device. 21. Remove the lift brackets from both cylinder heads. 22. Install the ignition coil(s) and the spark plug wire(s). 23. Route the engine wiring harness to the lower right hand side of the engine. 24. Raise the vehicle. 20. Install or connect the following: Remaining bellhousing bolts Torque converter bolts Torque converter shield Transmission oil level indicator tube and nut to bellhousing stud A/C compressor Transmission cooler pipe retainer to right side of engine block Engine exhaust pipes to the exhaust manifolds 26. Reroute wiring to lower engine area and install bolt to oil pan. 27. Connect electrical connectors to the crankshaft position (CKP) sensor, the engine oil level sensor and the block heater, if equipped. 28. Install or connect the following: e Starter motor

Heater Core replacement is covered in Section 2 of this manual

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Engine oil pan under body shield, if equipped e Steering linkage under body shield 29. Lower the vehicle. 30. Install or connect the following: e Fuel pipes to the engine e Alternator mounting bracket to the cylinder head using the nuts and the bolts. Tighten the bolts to 50 Nm (37 ft. Ibs.). e Bolt at the rear of the power steering pump to the engine block. Tighten the bolt to 50 Nm (37 ft. Ibs.). e Alternator to the engine

© Drive belt e Battery negative cable to the engine

: block : e EVAP canister purge solenoid to the intake manifold 31. Route the engine harness over the top of the engine. Connect the following components: e The eight injector connectors

e e e e

The idle air control (IAC) motor The throttle position (TP) sensor The EVAP canister purge solenoid. The manifold absolute pressure (MAP) sensor The camshaft position (CMP) sensor The ground splice at the rear of the right side of engine block The ground splice and the ground strap at the rear of the left side of engine block The coolant temperature (CTS) sensor The oil pressure sensor/switch 32. Install or connect the following: e Nut to the engine wiring harness bracket. Tighten the nut to 10 Nm (89 inch Ibs.).

e Engine sight shield to the intake manifold e Heater hoses to the cowl and the engine ¢ Coolant hose to the throttle body e Radiator support in the vehicle e A/C condenser mounting bolts e Air cleaner duct e Lower radiator hoses to the engine 33. Lower the hood. 34. Fill the engine with oil. 35. Fill the engine with coolant. 36. Connect the negative battery cable.

ae et module es 6. Install Engine Lift Brackets part No.

8.1L Engine At 1S “Belong Servinigg tHe Merial gtETEi 0 the precautions in the beginning of this section. 2. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position. 3. Release the fuel system pressure. 4. Remove or disconnect the following: e Negative, then positive battery cables e Coolant e A/C refrigerant Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

Engine oil cooler lines from the engine block Transmission-to-engine bolts Clutch pressure plate bolts, if equipped Torque converter bolts, if equipped

+ CAUTION In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. e NEW accelerator control cable e Cruise control cable, if equipped, to the throttle shaft e Bolts for the accelerator control

cable mounting bracket. Tighten the bolts to 10 Nm (89 inch Ibs.).

e Catalytic converter e Exhaust manifold pipe e Hoses from power Steering pump, then plug the lines and ports e Starter motor 5. Raise the vehicle. e Engine electrical harness and tie aside e Alternator e Ground cable bolt from engine block e Exhaust Gas Recirculation (EGR) valve adapter e Vacuum lines (tag before removal) e Throttle Actuator Control (TAC)

J 36857

9348NGO01

Install suitable lift brackets to the rear of the right head and the front of the left head

36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head. 7. Install the attaching bolt and washer.

Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. Ibs. (40 Nm). 8. Remove or disconnect the following: e Engine mount heat shield bolt and shields e Engine mount-to-engine mount bracket bolts e Engine from the vehicle, using a Suitable lifting device. Place on a suitable stand e A/C compressor/power steering pump bracket from the cylinder head. e Lift brackets from the cylinder head. To install: 9. Install Engine Lift Brackets part No. J 3685/7, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head. 10. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. Ibs. (40 Nm). 11. Install or connect the following: A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. Ibs. (60 Nm) ¢ Alternator bracket ‘ e Engine into the vehicle ¢ Engine mount-to-engine mount bracket bolts ¢ Engine mount heat shield and bolts 12. Remove the lift hooks from the cylinder heads, then raise the vehicle. e Engine oil cooler lines e Transmission-to-engine bolts ¢ Clutch pressure plate bolts, if equipped e Torque converter bolts, if equipped ¢ Catalytic converter e Exhaust manifold pipe

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ESCALADE ¢ DENALI ¢ DENALI XL ¢ SUBURBAN © YUKON © YUKON XL e Hoses to the power steering pump e Starter motor 13. Lower the vehicle. e Engine electrical harness. Make

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sure the harness is properly routed Alternator Ground cable bolt to engine block. Tighten to 12 ft. Ibs. (16 Nm) EGR valve adapter Vacuum lines, as tagged during removal TAC module electrical connector Radiator

e A/C compressor e e e e

Fuel feed and return lines Ignition coils Positive, then negative battery cables Air cleaner outlet duct and secure

with the clamp 14. Lower the hood from the service

position. 15. Properly recharge the A/C system. 16. Fill the engine with oil. 17. Fill the engine with coolant. 18. Perform the Crankshaft Position (CKP) sensor variation learn procedure: a. Install a suitable scan tool and

i. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully. 19. Start and run the engine, then check for leaks.

e Fan, fan clutch and pulley e Accessory brackets that might interfere with water pump removal e Lower radiator hose from the water pump inlet e Heater hose from the nipple on the pump

Water Pump

REMOVAL & INSTALLATION 4.3L, 5.0L, 5.7L and 7.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the radiator. 3. Remove or disconnect the following: e Fan shroud e Negative battery cable e Drive belt(s) e Alternator and other accessories; if necessary

>On the 7.4L engine, remove the bypass hose.

e Water pump assembly away from the timing cover To install: 4. Clean all old gasket material from the timing chain cover. 5. Install or connect the following: e Pump assembly with a new gasket. Torque the bolts to 30 ft. Ibs. (41 Nm) e Hose between the water pump inlet and the pump e Heater hose and the bypass hose (7.4L only)

check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure. b. With the scan tool, select the crankshaft position variation learn procedure. c. Observe the fuel cut-off for the 8.1L engine. d. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly. e. Enable the crankshaft position system variation learn procedure. e>While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

7924KG02

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f. Sloiwly increase the engine speed to the RPM that you observed. g. Immediately release the throttle when fuel cut-out is reached.

h. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.

ENGINE 7924KG03

Exploded view of the water pump mounting—5.OL and 5.7L engines

Brake service is covered in Section 4 of this manual

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pulley bolts first pass to 10 Nm (89 inch Ibs.); tighten the bolts final pass to 25 Nm (18 ft. Ibs.). Surge tank hose Heater hose Outlet radiator hose to the coolant pump Drive belt Cooling fan and clutch assembly Upper fan shroud Inlet radiator hose to the water pump Air inlet duct e Coolant 8.1L Engines 7924KG04

Exploded view of the water pump mounting—7.4L engine

e Fan, fan clutch and pulley e Alternator and other accessories, if

necessary e Drive belt(s) e Upper radiator shroud 6. Refill the cooling system. 7. Connect the battery. 4.8L, 5.3L and 6.0L Engines 1. Remove or disconnect the following: Air inlet duct e Coolant Inlet radiator hose from the water

pump Upper fan shroud Cooling fan and clutch assembly

e

Drive belt Radiator outlet hose from the coolant pump Surge tank hose Heater hose

e Water pump To install: ->DO NOT use cooling system seal tabs (or similar compounds) unless otherwise instructed. The use of cooling system seal tabs (or similar compounds) may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly. 2. Install or connect the following:

e Water pump. Install the water pump bolis. Tighten the water pump bolts first pass to 15 Nm (11 ft. Ibs.); tighten the bolts final pass to 30 Nm (22 ft. Ibs.). e Water pump drive belt pulley and bolts (if applicable). Tighten the

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Coolant Drive belt Fan clutch Outlet hose clamp and hose 3. Reposition the bypass hose clamps at the water pump and water crossover e Bypass hose

e Water pump bolt and pump. Discard the water pump gaskets To install: ; 4. Install or connect the following: New water pump gaskets. Water pump and bolts. Tighten the water pump bolts 37 ft. Ibs. (50 Nm) Bypass hose and clamps Outlet hose and clamp Fan clutch Drive belt Surge tank hose Heater hose Outlet radiator hose to the coolant pump Drive belt Cooling fan and clutch assembly Upper fan shroud Inlet radiator hose to the water pump Air inlet duct Coolant

Cylinder Head REMOVAL & INSTALLATION rr

4.3L Engine 9302KG01

Exploded view of the water pump assembly—4.8L, 5.3L and 6.0L engines

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

ESCALADE ¢ DENALI ¢ DENALI XL e sySGNERAL MOTORS CORP.1443 2. Drain the coolant. _ 3. Remove or disconnect the following: Negative battery cable Engine cover, if equipped Intake manifold Exhaust manifold Air pipe at the rear of the right cylinder head, if applicable Alternator mounting bolt at the right cylinder head Alternator, if necessary Power steering pump and brackets from the left cylinder head and lay aside Air conditioner compressor, and lay aside Spark plug wires at their brackets Ground strap from the right side and the coolant sensor wire from the left head Cylinder cover Spark plugs Pushrods. Identify the pushrods so that they can be installed in their

6. Clean the cylinder head bolts, apply sealer to the threads, and hand-tighten. 7. Install the cylinder head bolts in sequence to 22 ft. Ibs. (30 Nm) The bolts must, then be tightened again in sequence in the following order: a. Step 1: Short length bolt: (11, 7, 3, 2, 6, 10) 55 degrees b. Step 2: Medium length bolt: (12, 13) 65 degrees c. Step 3: Long length bolts: (1, 4, 8, 5, 9) 75 degrees e Pushrods 8. Adjust the rocker arms, if necessary Spark plugs Rocker arm cover Air conditioner compressor Power steering pump and brackets Alternator or the alternator mounting bolt at the cylinder head. Air pipe at the rear of the head if

order of the tightening sequence Cylinder head and gasket To install: 4. Clean all gasket mating surfaces. 5, Install or connect the following: e New gasket ->Be sure the gasket has the word HEAD up.

e Cylinder head e>Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.

Exhaust manifold(s) Alternator Three bolts holding the alternator mounting bracket to the cylinder head The bolt behind the power steering pump Alternator mounting bracket and set it aside Bolt holding the oil level indicator tube to the right side cylinder head Oil level indicator tube Cylinder head (s) from the engine Spark plugs from the cylinder head >The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.

2. Remove the cylinder head bolts.

removed Exhaust manifold Intake manifold Engine cover, if removed 9. Refill the engine with coolant. 10. Connect the negative battery cable.

original positions. Cylinder head bolts in the reverse

Negative battery cable Intake manifold Push rods

4.8L, 5.3L and 6.0L Engines

RIGHT SIDE

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. a

1. Remove or disconnect the following:

e>After removal, place the cylinder head on two wood blocks to prevent damage.

3. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts. To install: ->Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

4. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material. 5. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole. 6. Clean the cylinder head bolt holes with compressed air. 7. Check the cylinder head locating pins for proper installation. ->When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine.

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Cylinder head bolt tightening sequence—4.3L engine

8. Install or connect the following: e NEW right cylinder head gasket onto the locating pins Cylinder head onto the locating pins and the gasket. NEW M11 cylinder head bolts. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.

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

1 4-1 4 GENERAL MOTORS CORP ESCALADE ¢ DENALI ¢ DENALI "XL ¢ SUBURBAN © YUKON © YUKON XL LEFT SIDE

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

9308KG57

1. Remove or disconnect the following: Negative battery cable Intake manifold Push rods Exhaust manifold(s) Alternator Three bolts holding the alternator mounting bracket to the cylinder head The bolt behind the power steering pump Alternator mounting bracket and set it aside Bolt holding the oil level indicator tube to the right side cylinder head Oil level indicator tube Cylinder head (s) from the engine Spark plugs from the cylinder head The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.

Locating tab—4.8L, 5.3L, 6.0L

2. Remove the cylinder head bolts. > After removal, place the cylinder head on two wood blocks to prevent damage.

3. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts. To install: 9302KG02

Cylinder head bolt tightening sequence—4.8L, 5.3L and 6.0L engines

e M8 cylinder head bolts. 9. Tighten the cylinder head bolts: a. M11 cylinder head bolts first pass in sequence to 30 Nm (22 ft. IDs.). b. M11 cylinder head bolts second pass in sequence + 90 degrees. c. M11 cylinder head bolts

(1,2,3,4,5,6,7,8) + 90 degrees d. M11 cylinder head bolts (9 and 10) +50 degrees e. M8 cylinder head bolts (11,12,13,14,15) to 30 Nm (22 ft. Ibs.). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

~The cylinder head gasket displacement can be verified by markings visible on the underside of the right gasket

locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab. 10. Install the alternator to the engine. 11. Install the exhaust manifold (s) to the engine. 12. Install the pushrods to the engine. 13. Install the intake manifold to the engine. 14. Connect the negative battery cable.

->Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

4. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material. 5. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole. 6. Clean the cylinder head bolt holes with compressed air. 7. Check the cylinder head locating pins for proper installation. e>WWhen properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.

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8. Install or connect the following; e NEW left cylinder head gasket onto the locating pins e Cylinder head onto the locating pins and the gasket. e NEW M11 cylinder head bolts. Apply a5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts. ¢ M8 cylinder head bolts. 9. Tighten the cylinder head bolts. a. M11 cylinder head bolts first pass in sequence to 30 Nm (22 ft. Ibs.). b. M11 cylinder head bolts second pass + 90 degrees c. M11 cylinder head bolts (1,2,3,4,5,6,7,8) + 90 degrees d. M11 cylinder head bolts (9 and 10) +50 degrees e. M8 cylinder head bolts (11,12,13,14,15) to 30 Nm (22 ft. Ibs.). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts. ~The cylinder head gasket displacement can be verified by markings visi-

ble on the top side of the left gasket locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.

10. Install the alternator mounting bracket using the four bolts. Tighten the mounting bracket to the cylinder head bolts to 50 Nm (37 ft. Ibs.). 11. Tighten the bolt at the rear of the power steering pump. Tighten the bolt to 50 Nm (37 ft. Ibs.). 12. Install the exhaust manifold (s) to the engine. 13. Install the pushrods to the engine. 14. Install the intake manifold to the engine. 15. Connect the negative battery cable.

e Exhaust manifolds and position them out of the way ¢ Ground strap at the rear of the right AIR pipe, if equipped 4. If the van is equipped with air conditioning, remove the air conditioning compressor and the forward mounting bracket and lay the compressor aside. Do not disconnect any of the refrigerant lines. e Exhaust Gas Recirculation (EGR) inlet tube 5. On the right side cylinder head, disconnect the fuel pipe, spark plug wires and wiring harness bracket. e Nut and stud attaching the main accessory bracket to the cylinder head. >You may have to loosen the remaining bolts and studs in order to remove the head.

Coolant sensor wire Spark plug wire bracket Cylinder head covers Spark plugs Pushrods, Identify the pushrods so that they can be installed in their Original positions. e Cylinder head bolts in the reverse order of the tightening sequence e Heads To install: 6. Inspect the cylinder head and block mating surfaces. Clean all old gasket material. 7. Install or connect the following: e Cylinder heads using new gaskets. Install the gaskets with the word HEAD up. ->Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.

8. Clean the bolts, apply sealer to the threads, and hand-tighten. 9. Install the cylinder head bolts in sequence to 22 ft. Ibs. (30 Nm) The bolts must be tightened once, then be tightened again in sequence in the following order: a. Step 1: Short length bolt: (3, 4, 7, 8, 11, 12, 15, 16) 55 degrees b. Step 2: Medium length bolt: (14, 17) 65 degrees c. Step 3: Long length bolts: (1, 2, 5, 6, 9, 10, 13) 75 degrees Pushrods so that they are in their original positions Cylinder head covers Spark plugs Coolant sensor wire Spark plug wire bracket Main accessory bracket to the cylinder head EGR vent tube Fuel pipe Spark plug wires Wiring harness bracket Air conditioning compressor and forward mounting bracket Ground strap to the rear of the right AIR pipe Exhaust manifolds Intake manifold Coolant recovery reservoir, if removed Engine cover. 10. Connect the negative battery cable. 11. Refill the engine with coolant. 7.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

5.0L and 5.7L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the coolant. 3. Remove or disconnect the following: ¢ Negative battery cable e Engine cover ¢ Coolant recovery reservoir, if applicable e Intake manifold

7924KG07

Cylinder head bolt tightening sequence—5.OL and 5.7L engines

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

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e Rocker arms and pushrods, keeping them in order for installation e Engine harness ground bolts 4. Reposition the engine harness grounds and ground straps from the cylinder head. e Water crossover e Exhaust manifold e Cylinder head bolts, then discard e>The cylinder head bolts must be ~ replaced for installation.

e Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed. To install:

7924KG09

Cylinder head bolt tightening sequence—7.4L engines

3. Remove or disconnect the following: Negative battery cable _Engine cover

Intake manifold Exhaust manifolds Alternator and bracket Air pump, if equipped Air conditioning compressor and the forward mounting bracket. Do not disconnect any of the refrigerant lines, Rocker arm cover Spark plugs Air pipes at the rear of the head, if equipped Ground strap at the rear of the head Temperature sensor wire Pushrods. Identify the pushrods so that they can be installed in their Original positions. Cylinder head bolts and the heads To install: >The cylinder head should be cleaned and inspected for warpage or damage before installation.

4. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly. e»Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.

New gaskets, with the word HEAD

up Cylinder heads Intake and exhaust manifolds Pushrods Rocker arms Temperature sensor wire Ground strap at the rear of the head AIR pipes at the rear of the head Spark plugs Rocker arm cover Air conditioning compressor and the forward mounting bracket AIR pump Alternator e Engine cover 8. Connect the battery cable and refill the cooling system. 8.1L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. _ 3. Remove or disconnect the following: e Negative battery cable e Intake manifold e Valve cover

->The cylinder head should be cleaned and inspected for warpage or damage before installation.

5. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly. e>lf a composition gasket is used, do not use sealer.

6. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation. 7. Install or connect the following: e New cylinder head gasket e Cylinder head e Sealer to the threads of new cylinder head bolts, if not pre-applied 8. Tighten the head bolts a little at a ’ time in the sequence in 3 stages, a. Step 1: Torque the bolts to 30 ft. lbs. (40 Nm) b. Step 2: Then tighten the bolts, in sequence, an additional 120 degrees using a torque angle meter. c. Step 3: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and

5. Install or connect the following: ¢ Bolts, apply sealer to the threads, and hand-tighten. 6. Tighten the head bolts a little at a time in the sequence in 3 stages, a. Step 1: Torque the bolts to 30 ft.

lbs. (40 Nm) b. Step 2: Then torque the bolts to 60 ft. Ibs. (80 Nm) c. Step 3: Torque the bolts to 85 ft. lbs. (115 Nm) 7. Install or connect the following:

9348NG02

Cylinder head bolt tightening sequence—8.1L engine

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e Exhaust manifold e Water crossover

e Engine harness grounds and ground strap e Rocker arms and pushrods e Valve cover e Intake manifold 10. Connect the battery cable and refill the cooling system.

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable Intake manifold Valve cover Rocker arms and pushrods, keeping them in order for installation Engine Coolant Temperature (ECT) sensor clip from the bracket ECT sensor * ECT sensor bracket bolt and bracket Heater inlet and outlet hoses from the hose bracket Water crossover Exhaust manifold Cylinder head bolts, then discard

7. Tighten the head bolts a little at a time in the sequence in 3 stages, a. Step 1: Torque the bolts to 30 ft.

Ibs. (40 Nm)

b. Step 2: Then tighten the bolts, in sequence, an additional 120 degrees using a torque angle meter. C. Step 3: Torque bolt numbers. 1, 2,

3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees. 8. Install or connect the following: Exhaust manifold Water crossover Heater hose bracket and bolts. Tighten the bolts to 37 ft. Ibs. (50

Nm) ECT sensor bracket and bolt. Tighten to 37 ft. Ibs. (60 Nm) ECT sensor ECT sensor clip Rocker arms and pushrods Valve cover Intake manifold 9. Connect the battery cable and refill the cooling system.

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REMOVAL & INSTALLATION 4.3L, 5.0L and 5.7L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Engine cover Cylinder head cover. Rocker arm nut. If you are only replacing the pushrod, back the nut off until you can swing the rocker out of the way. Rocker arms and balls as a unit -» Always remove each set of rocker arms (1 set per cylinder) as a unit. e Pushrods and pushrod guides To install: 3. Install or connect the following: e Pushrods and their guides. Be sure that they seat properly in each lifter. 4. Position a set of rocker arms (for 1 cylinder) in the proper location.

>The cylinder head bolts must be replaced for installation.

e Cylinder head. Place the head on 2 wood blocks to protect the sealing Surfaces while it is removed. To install: >The cylinder head should be cleaned and inspected for warpage or damage before installation.

4. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly. ->If a composition gasket is used, do not use sealer.

5. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation. 6. Install or connect the following: e New cylinder head gasket e Cylinder head . ¢ Sealer to the threads of new cylinder head bolts, if not pre-applied

7924KG10

Exploded view to the rocker arm and related components—4.3L, 5.0L and 5.7L engines

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

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GENERAL MOTORS CORP.

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Install the rocker arms for each cylinder only when the lifters are off the cam lobe and both valves are closed.

5, Coat the replacement rocker arm with Molykote® or its equivalent, and the rocker arm and pivot with SAE 90 gear oil, and install the pivots. e Nuts and tighten alternately _ e Engine cover 4.8L, 5.3L and 6.0L Engines ->Do not remove the ignition coils from the valve rocker arm cover unless required. Do not remove the oil fill tube from the cover unless service is required. If the oil fill tube has been removed from the cover, install a NEW tube during assembly.

On the right side: 1. Remove or disconnect the follow-

ing:

Ignition coil bracket bolts from the rocker arm cover (if required) Ignition coil and bracket assembly from the cover Valve rocker arm cover bolts Valve rocker arm cover Gasket from the cover. Discard the gasket. The bolt grommets may be reused if not damaged. Oil fill cap from the oil fill tube

© Oil fill tube (if required). Discard the oil fill tube. On the left side: Do not remove the Positive Crankcase Ventilation (PCV) valve grommet from the cover unless service is required.

2. Remove or disconnect the following: Ignition coil bracket bolts from the rocker arm cover (if required) Ignition coil and bracket assembly from the cover Valve rocker arm cover bolts Valve rocker arm cover Gasket from the cover. Discard the gasket. The bolt grommets may be reused if not damaged. Valve rocker arm bolts Valve rocker arms Valve rocker arm pivot support Pushrods To install: e>Valve lash is built in. No valve

adjustment is required.

3. Lubricate the valve rocker arms and pushrods with clean engine oil. 4. Lubricate the flange of the valve rocker arm bolts with clean engine oil. 5. Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm.

6. Install or connect the following: e Valve rocker arm pivot support e>Make sure that the pushrods seat properly to the valve lifter sockets. e Pushrods e>WViake sure that the pushrods seat properly to the ends of the rocker arms.

¢ Rocker arms and bolts. DO NOT tighten the rocker arm bolts at this time 7. Rotate the crankshaft until number one piston is at top dead center of compression stroke. In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. If viewing from the rear of the engine, the additional crankshaft pilot hole (non-threaded) will be in the 10:30 position. The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are left bank. Cylinders 2, 4, 6, and 8 are right bank. e>Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubri-

cants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. With the engine in the number one firing position, tighten the following valve rocker arm bolts: a. Tighten exhaust valve rocker arm bolts 1, 2, 7, and 8 to 30 Nm (22 ft. Ibs.). b. Tighten intake valve rocker arm bolts 1, 3, 4, and 5 to 30 Nm (22 ft. Ibs.). 9. Rotate the crankshaft 360 degrees. Tighten the following valve rocker arm bolts: a. Tighten exhaust valve rocker arm bolts 3, 4, 5, and 6 to 30 Nm (22 ft. Ibs.). b. Tighten intake valve rocker arm bolts 2, 6, 7, and 8 to 30 Nm (22 ft. Ibs.). On the right side:

9308KG68

Rocker arm removal—4.8L, 5.3L, 6.0L

>The valve rocker arm cover bolt grommets may be reused. If the oil fill tube has been removed from the valve rocker arm cover, install a NEW oil fill tube during assembly.

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ESCALADE 10. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. .11. Install or connect the following: ¢ NEW oil fill tube into the rocker arm cover and rotate the tube clockwise until locked in the proper position Oil fill cap into the tube and rotate clockwise until locked in the proper position NEW cover gasket into the valve rocker arm cover Valve rocker arm cover onto the cylinder head e>Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force

and may damage the fastener. Use the

GENERAL MOTORS CORP. DENALI ¢ DENALI XL ¢ SUBURBAN ¢ YUKON © YUKON XL

replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

15. Install the cover bolts with grommets. Tighten the valve rocker arm cover bolts to 12 Nm (106 inch Ibs.). 16. Apply threadlock GM P/N 12345382 or equivalent to the threads of the bracket bolts. Install the ignition coils and bracket assembly and bolts. Tighten the ignition coil and bracket assembly bolts to 12 Nm (106 inch Ibs.). 7.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

14-19

2. Remove or disconnect the following: Engine cover Cylinder head cover Rocker arm bolt. If you are only replacing the pushrod, back the nut off until you can swing the rocker out of the way. Rocker arms and balls as a unit e» Always remove each set of rocker arms (1 set per cylinder) as a unit.

e Pushrods and pushrod guides To install: 3. Install or connect the following: e Pushrods and their guides, Be sure that they seat properly in each lifter. 4. Position a set of rocker arms (for 1 cylinder) in the proper location. ->Install the rocker arms for each cylinder only when the lifters are off the cam lobe and both valves are closed.

5. Coat the replacement rocker arm with Molykote® or its equivalent, and the rocker arm and pivot with SAE 90 gear oil, and install the pivots.

correct tightening-sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

12. Install the cover bolts with grommets. Tighten the valve rocker arm cover bolts to 12 Nm (106 inch Ibs.). 13. Apply threadlock GM P/N 12345382 or equivalent to the threads of the bracket bolts. Install the ignition coil and bracket assembly and bolts. Tighten the ignition coil and bracket assembly studs to 12 Nm (106 inch Ibs.). On the left side: ->DO NOT reuse the valve rocker arm cover gasket. The valve rocker arm cover bolt grommets may be reused. If the vapor vent grommet has been removed from the valve rocker arm cover, install a NEW vapor vent gourmet during assembly.

14. Install or connect the following: e NEW cover gasket (1) into the valve rocker arm cover e Valve rocker arm cover onto the cylinder head e>Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring

7924KG11

Exploded view of the rocker arms and related components—/.4L engines

For Wheel Alignment specifications, see Section 1 of this manual

MoTORS CORP. 3 14-20) SENERAL ESCALADE ¢ DENALI ¢ DENALI XL e SUBURBAN e Rocker arm bolts. Torque the bolts to 45 ft. Ibs. (61 Nm) e Engine cover

8.1L Engine Always make sure to keep all removed valve train components in order for reassembly. They must be installed in the same position from which they were removed.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Valve (rocker arm) cover e Rocker arm nuts, balls and rocker arms >The intake pushrods are shorter than the exhaust pushrods.

e Pushrods e Rocker arm guides and pushrod guides 3. Clean and inspect all components for damage. To install: 4. Apply a suitable sealer to the rocker arm stud-to-cylinder head threads. 5. Install or connect the following: e Pushrod guides and rocker arm studs. Tighten to 37 ft. Ibs. (50 Nm) e Pushrods 6. Coat the rocker arm and ball bearing surfaces with a suitable prelube. e Rocker arms, balls and nuts. Tighten the nuts slowly to 18 ft. lbs. (25 Nm) while guiding the tips of the rocker arms over the tips of the valves e Valve (rocker arm) cover Intake Manifold

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Brake booster vacuum hose from the upper intake manifold Ignition coil and bracket Purge solenoid and bracket Studs and intake manifold attaching bolts, mark for reassembly Upper intake manifold Distributor housing and rotor, mark for reassembly Upper radiator hose from the thermostat housing Heater hoses and the bypass hose from the lower intake manifold Exhaust Gas Recirculation (EGR) valve Transmission dipstick tube, if equipped Positive Crankcase Ventilation (PCV) valve and hoses Air conditioning compressor and bracket. Without disconnecting position out of the way Alternator bracket and bolt next to the thermostat housing. If needed Lower intake manifold mounting bolts and the lower manifold To install: 4, Clean all gasket mating surfaces thoroughly. 5. Position the new gaskets on the cylinder heads with the port blocking plates at the rear and the words THIS SIDE UP facing up. 6. Apply a %e inch (5mm) bead of RTV to the front and rear sealing surfaces on the engine block. Extend the bead 1 inch (13mm) up each cylinder head to retain the gasket.

7. Carefully position the lower intake manifold onto the engine. 8. Apply GM 1052080 or equivalent sealer to the lower intake manifold bolts 9. Torque the bolts using 3 steps in the sequence shown, a. Step 1: Torque the bolt to 24 inch lbs. (3 Nm) b. Step 2: Then torque to 108 inch lbs. (12 Nm) c. Step 3: And finally torque to 11 ft. lbs. (15 Nm) 10. Install or connect the following: Alternator bracket and bolts near the thermostat housing, if removed Air conditioning compressor PCV valve and hose Transmission dipstick tube, if equipped EGR valve Upper radiator and bypass hose to the thermostat housing. Distributor. 11. Position the upper intake manifold gasket on the lower manifold.

Be careful not to pinch the injector tubes between the upper and lower manifolds.

e Upper intake manifold. Torque the bolts and studs to 88 inch Ibs. (10 Nm) e Purge control bracket and valve e Ignition coil e Brake booster vacuum e Fuel lines

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REMOVAL & INSTALLATION 4.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure 3. Remove or disconnect the following: Negative battery cable Air intake duct Wiring harness connectors and brackets from the manifold Throttle linkage and bracket from the upper manifold Cruise control cable, if equipped Fuel lines at the rear of the lower intake manifold

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INTAKE SEQUENCE 7924KG14

Lower intake manifold bolt tightening sequence—4.3L engines

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e Accelerator cable e Cruise control cable, if equipped e Wiring harness brackets and connections e Air intake duct e Negative battery cable 12. Refill and bleed the cooling system. 13. Pressurize the fuel system and check for leaks. 4.8L, 5.3L and 6.0L Engines e>The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

1. Remove or disconnect the following: PCV hose and valve MAP sensor, if required Engine coolant air bleed clamp and hose from the throttle body Accelerator control cable bracket and bolts, if required EVAP solenoid, bolt, and isolator Intake manifold bolts

9308KG63

9308KG69

EVAP solenoid removal—4.8L, 5.3L, 6.0L

Intake manifold with gaskets Intake manifold-to-cylinder head gaskets from the manifold. Discard the intake manifold gaskets. Fuel rail with injectors Throttle body and gasket 2. Clean the intake manifold in solvent. 3. Dry the intake manifold with compressed air. 4. Inspect the throttle body studs and stud inserts for looseness or damaged threads. 5. Inspect the wire harness stud and stud insert for looseness or damaged threads. 6. Inspect the fuel rail bolt inserts for looseness or damaged threads. 7. Inspect the intake manifold vacuum passages for debris or restrictions. 8. Inspect for damaged or broken vacuum fittings, damaged MAP sensor mounting bore, or broken MAP sensor retaining tabs. 9. Inspect the composite intake manifold assembly for cracks or other damage. 10. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage. 11. Inspect the fuel injector bores for excessive scoring or damage. Inspect the intake manifold cylinder head deck for warpage.

For Maintenance Interval recommendations, see Section 7 of this manual

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12. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across a minimum of two runner port openings. 13. Insert a feeler gauge between the

intake manifold and the straight edge. A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. To install: ->Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

14. Install or connect the following: e MAP sensor e EVAP solenoid, bolt, and isolator. Tighten the EVAP solenoid bolt to

10 Nm (89 inch Ibs.). e NEW intake manifold-to-cylinder head gaskets e Intake manifold. Apply a5 mm (0.20 in) band of threadlock GM

P/N 12345382 or equivalent to the threads of the intake manifold bolts. Intake manifold bolts. Tighten intake manifold bolts first pass in sequence to 5 Nm (44 inch Ibs.). Tighten intake manifold bolts final pass in sequence to 10 Nm (89 inch Ibs.). PCV valve and hose. Install the engine coolant air bleed hose and clamp onto the throttle body. Accelerator control cable bracket and bolts, if applicable. Tighten the accelerator control cable bracket bolts to 10 Nm (89 inch Ibs.). 5.0L, 5.7L and 7.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Engine cover Air cleaner intake duct Coolant reservoir Wiring harness connectors and brackets Throttle linkage and bracket from the upper intake manifold Cruise control cable, if equipped Fuel lines and the bracket from the rear of the intake manifold Positive Crankcase Ventilation (PCV) valve and hoses Ignition coil and bracket Purge solenoid and bracket

9302KG03

Lower intake manifold bolt tightening sequence—4.8L, 5.3L and 6.0L engines

->Note the location of the manifold bolts and studs before removal for reassembly in their original positions.

e Intake manifold bolts and studs

->Do not disassemble the Central Sequential Fuel Injection (CSFI) unit.

e Upper intake manifold 3. Clean the old gasket residue from both mating surfaces. Distributor Upper radiator hose from the thermostat housing Heater hose from the lower intake manifold Coolant bypass hose Exhaust Gas Recirculation (EGR) valve Fuel pressure and return lines from the lower intake manifold Wiring harnesses and brackets from the lower manifold Left side valve cover Transmission oil level indicator and tube, if equipped EGR tube, clamp and bolt Positive Crankcase Ventilation (PCV) valve and hoses Air conditioning compressor and bracket, but do not disconnect the lines 4. Loosen the compressor mounting bracket and slide it forward, but do not remove it. e Power brake vacuum tube e Lower intake manifold bolts and lower intake manifold To install: 5. Clean all gasket surfaces completely. 6. Install the intake manifold gaskets with the port blocking plates facing the rear. Factory gaskets should have the words This Side Up visible. 7. Apply gasket sealer to the front and rear sealing surfaces of the engine block. Extend the sealer approximately % inch (13mm) onto the heads. 8. Install the lower intake manifold. 9. Apply sealer to the lower intake’ manifold bolts prior to installation. 10. On the 5.0L and 5.7L engines, install the bolts and torque in sequence as follows: a. Step 1: Torque the bolts to 71 inch lbs. (8 Nm) b. Step 2: Torque the bolts to 106 inch lbs. (12 Nm) c. Step 3: Torque the bolts to 11 ft, lbs. (15 Nm) 11. On the 7.4L engine, torque the bolts to 30 ft. Ibs. (40 Nm) in the sequence shown.

ESCALADE

GENERAL MOTORS CORP. 14-23

DENALI * DENALI XL ¢ SUBURBAN © YUKON © YUKON XL

12. Install or connect the following: Power brake vacuum tube PCV valve and hose EGR tube, clamp and bolt Transmission oil level indicator and tube, if equipped Left side valve cover Wiring harnesses and brackets to the lower manifold Fuel pressure and return lines to the lower intake manifold EGR valve Coolant bypass hose Heater hose to the lower intake manifold Upper radiator hose to the thermostat housing Air conditioning compressor and bracket Distributor Upper intake manifold gasket Upper intake manifold

i WARNING When installing the upper intake manifold be careful not to pinch the injector wires between the upper and lower intake manifolds.

7924KG17

Lower intake manifold bolt tightening sequence—5.OL and 5.7L engines

e Upper intake manifold mounting bolts/studs, torque in a crisscross pattern as follows:

a. Step 1: Torque the bolts/studs to 44 inch Ibs. (6 Nm) b. Step 2: Torque the bolts/studs to 83 inch Ibs. (10 Nm) Purge solenoid and bracket PCV hose Fuel lines and the bracket at the rear of the intake manifold Ignition coil and bracket Throttle linkage and bracket to the upper intake manifold Throttle linkage cable Cruise contro! cable, if equipped Wiring harness connectors and brackets Air cleaner intake duct e Coolant recovery reservoir and the engine cover Negative battery cable 13. Start the vehicle and verify that there are no leaks. 8.1L Engine 7924KG18

Upper and lower intake manifold bolt tightening sequence—7.4L engines

>The intake manifold, throttle body, fuel rail and injectors can be removed as an assembly. If you do not need to service these components individually,

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

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1 4- ? 4 GENERAL MOTORS CORP. ESCALADE DENALI e DENALI XL * SUBURBAN ¢ YUKON * YUKON XL remove the manifold as a complete

assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure and drain the cooling system. 3. Remove or disconnect the following: Air cleaner outlet duct Intake manifold sight shield Fuel feed and return pipes Engine harness clips from the studs on the front of the dash Engine harness clip from the wheelhouse splash shield Pressure cycling switch, surge tank switch and Mass Air Flow (MAF) electrical connectors 4. Reposition the engine harness to the top of the engine e Connector Position Assurance (CPA) retainer from the ignition Coil harness Manifold Absolute Pressure (MAP) sensor, ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors Engine harness bolt and studs

e AIR pump pipe e Fuel pressure regulator vacuum hose e Fuel rail studs and fuel rail, ONLY if replacing the manifold e Intake manifold bolts

head e>Make sure the manifold gasket tabs align with the hole in the head gasket.

e New intake manifold end seals e New intake manifold side gaskets onto the heads. Make sure the Do NOT try to remove the intake stamped THIS SIDE UP is showing. manifold by prying under the sealing = _ e Intake manifold to the block surfaces. e Apply a suitable thread locking material to at least 8 threads of the e Intake manifold intake manifold bolts e Intake manifold side gaskets and 9. Install the intake manifold bolts and end seals and discard tighten, in the sequence shown, in 4 passes: >The splash shield is reusable and a. 1st pass: 44 inch Ibs. (6 Nm) secured using a snap-in fit. Do not disb. 2nd pass: 44 inch Ibs. (5 Nm). tort the shield during removal. Check the manifold joints for shifting and

* WARNING

e Splash shield To install: 7. Clean all gasket surfaces completely. 8. Install or connect the following:

fix as necessary. c. 3rd pass: 89 inch Ibs. (10 Nm) d. 4th pass: 106 inch Ibs. (12 Nm) 10. Install the remaining components

in the reverse order of the removal procedure. 11. Fill the cooling system, then connect the negative battery cable 12. Start the vehicle and verify that there are no leaks.

F

CPA retainer from the ignition coil

harness Alternator, injector harness and ignition coil harness connectors Throttle Position (TP) sensor, Electronic Throttle Control (ETC) and purge valve solenoid connectors 5. Reposition the engine harness to the drivers side of the engine compartment. Bypass valve vacuum hose from the intake manifold Exhaust Gas Recirculation (EGR) valve electrical connector EGR pipe bolts from the EGR adapter. Reposition the EGR pipe EGR valve pipe gasket and discard Secondary Air Injection (AIR) pipe nut from the fuel rail stud, if equipped AIR pipe bolts from the exhaust manifold AIR pipe from the AIR pump pipe AIR pipe gasket and discard AIR pipe nut from the fuel rail stud AIR pipe bolts from the exhaust manifold AIR pipe from the AIR pump pipe AIR pipe gasket 6. Reposition the AIR pump hose clamp, then remove the air pump hose from the pump pipe. e AIR pump pipe bolt from the cylinder head

e Splash shield. Make sure the shield fits properly between the cylinder

2

Exhaust Manifold REMOVAL & INSTALLATION 4.3L Engines

9348NG03

Make sure that the splash shield snap fits

between the cylinder heads

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Engine cover, if equipped e Exhaust Gas Recirculation (EGR) valve, inlet pipe (left side manifold), if necessary

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Intake manifold bolt tightening sequence—8.1L engine

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ESCALADE ¢ DENALI ¢ DENALI XLe RORUFRR CLUE e Exhaust pipe from the exhaust manifold . © Spark plug wires from the plugs and the retaining clips e Heat shields 3. If removing the left side manifold: a. Step 1: Remove the power steering/alternator rear bracket, if needed. b. Step 2: Check for sufficient clearance between the manifold and the intermediate steering shaft. On some models it will be necessary to disconnect the intermediate shaft from the steering gear in order to reposition the shaft for clear-

Air cleaner along with the heat stove pipe and cold air intake pipe Spark plug wires to the retainer clips and plugs Exhaust pipe to the manifold Engine cover, on van models Negative battery cable

4.8L, 5.3L and 6.0L Engines

RIGHT SIDE ->Do not remove the Exhaust Gas Recirculation (EGR) valve from the pipe assembly unless service is required.

ance. 4. \f removing the right side manifold: a. Step 1: Remove air conditioning compressor and bracket, then position the assembly aside, if necessary. Do not disconnect the lines or allow them to become kinked or otherwise damaged. b. Step 2: Remove the spark plugs, dipstick tube and wiring, if necessary 5. Unbend the lock tangs. 6. Remove or disconnect the following: e Exhaust manifold retaining bolts, washers and tab washers e Exhaust manifold e Old gaskets and discard To install: 7. Clean the gasket mounting surfaces. 8. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary. 9. Install or connect the following: e Exhaust manifold to the cylinder using a new gasket. Torque the exhaust manifold-to-cylinder head bolts to 26 ft. Ibs. (36 Nm) on the center exhaust tube and to 20 ft. lbs. (28 Nm) on the front and rear exhaust tubes.

1. Remove or disconnect the following: 2. EGR valve, gasket, and bolts 3. EGR pipe bolt from the intake mani-

fold 4. EGR pipe bolts and gasket from the exhaust manifold 5. EGR pipe bolts from the cylinder head 6. EGR pipe assembly. With mild force, pull the EGR pipe from the intake manifold. 7. O-ring seal from the EGR pipe assembly. Discard the exhaust manifold gasket and O-ring seal.

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e>in order to properly remove the , exhaust manifold, remove the AIR components when applicable.

Do not remove the check valve from the Air Injection Reaction (AIR) pipe unless service is required.

8. AIR pipe (with check valve), nuts and gasket from the right exhaust manifold. e AIR pipe studs from the manifold (if required) 9. Spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required. 10. Exhaust manifold, bolts, and gasket. Discard the gasket. 11. Heat shield and bolts from the manifold, if required To install: ‘Do not reuse the exhaust manifoldto-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

e>Once the bolts are tightened, bend the tabs on the washers back over the heads of all bolts in order to lock them in position.

10. On the right side install: e Spark plugs e Dipstick tube e Wiring e Air conditioning compressor and bracket assembly, if unbolted 11. If the left manifold was removed | install: e Intermediate shaft to the steering gear, if unbolted e Power steering/alternator rear bracket

9308KG72

EGR valve removal—4.8L, 5.3L, 6.0L

For complete service labor times, order the Chilton Labor Guide

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14-26 GENERAL MOTORS CORP.

ESCALADE ¢ DENALI ¢ DENALI XL e SUBURBAN ¢ YUKON ¢ YUKON XL

9308KG71

12. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air. Inspect the exhaust manifold Air Injection Reaction (AIR) passages for restrictions (if applicable). Inspect the AIR flange studs and threaded bolt holes for damage. Inspect the AIR flange gasket surface for excessive scratches or gouging. Inspect the exhaust manifold-to-cylinder head gasket surface for excessive scratches ~ or gouging. Inspect the right side manifold Exhaust Gas Recirculation (EGR) flange sealing surface for excessive scratches or gouging. Inspect the right side manifold EGR flange bolt hole threads for damage. Inspect for a loose or damaged heat shield (2). Inspect the take down studs for damaged threads. 13. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in) within the two front or two rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced. ->Do not reuse Exhaust Gas Recirculation (EGR) valve and pipe gaskets or seals during assembly. Install NEW gaskets and O-ring seal.

14. Install or connect the following: 15. A5 mm (0.2 in) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts. e Exhaust manifold gasket and exhaust manifold e>Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 9308KG70

Right exhaust manifold removal—4.8L, 5.3L, 6.0L

16. Install the exhaust manifold bolts: a. Tighten the exhaust manifold bolts first pass to 15 Nm (11 ft. Ibs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from

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ESCALADE ¢ DENALI ¢ DENALI XL * SUBURBAN © YUKON side-to-side, and work toward the outside bolts. . . Tighten the exhaust manifold bolts final pass to 30 Nm (22 ft. Ibs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from sideto-side, and work toward the outside bolts. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head. 17. Install or connect the following: 18. Heat shield and bolts. Tighten the heat shield bolts to 9 Nm (80 inch Ibs.). 19. AIR pipe studs (if required). Tighten the studs to 5 Nm (45 inch Ibs.). 20. AIR pipe (with check valve), NEW gasket and nuts (if required). Tighten the AIR pipe to exhaust manifold nuts to 25 Nm (18 ft. Ibs.). 21. AIR hose assembly and clamps. 22. AIR pipe bracket-to-cylinder head bolt. Tighten the AIR pipe bracket bolt to 50 Nm (37 ft. Ibs.). 23. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR pipe. Insert the EGR pipe into the intake manifold. | 24. Start the EGR pipe to intake manifold bolt (1). Do not tighten the bolt at this time. Install the EGR pipe to cylinder head bolts. Do not tighten the bolts at this time. 25. Install a NEW EGR pipe exhaust manifold gasket and bolts: a. Tighten the EGR pipe to intake manifold bolt to 10 Nm (89 inch Ibs.). b. Tighten the EGR pipe to cylinder head bolts to 50 Nm (37 ft. Ibs.). c. Tighten the EGR pipe to exhaust manifold bolts to 30 Nm (22 ft. Ibs.). 26. Install the EGR valve, a NEW gasket, and bolts. Tighten the EGR valve bolts a first pass to 10 Nm (89 inch Ibs.). Tighten the EGR valve bolts a second pass to 25 Nm (18 ft. Ibs.).

LEFT SIDE e>in order to properly remove the exhaust manifold, remove the AIR components when applicable.

1. Remove or disconnect the following: 2. AIR center pipe bolt 3. AIR hose clamps and remove the hose assembly =>Do not remove the check valve from the AIR pipe unless service is required.

4. AIR pipe (with check valve), nuts and gasket from the left exhaust manifold

5. AIR pipe studs from the manifold (if required) 6. Spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required. 7. Exhaust manifold, bolts, and gasket. Discard the gasket. 8. Heat shield and bolts from the manifold, if required ->Do not reuse the exhaust manifoldto-cylinder head gaskets. Upon installation of the exhaust manifold, install a

NEW gasket. An improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) Il system performance.

9. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air. Inspect the exhaust manifold Air Intection Reaction (AIR) passages for restrictions (if applicable). Inspect the AIR flange studs and threaded bolt holes for damage. Inspect the AIR flange gasket surface for excessive scratches or gouging. Inspect the exhaust manifold-to-cylinder head gasket surface for excessive scratches or gouging. Inspect the right side manifold Exhaust Gas Recirculation (EGR) flange Sealing surface for excessive scratches or gouging. Inspect the right side manifold EGR flange bolt hole threads for damage. Inspect for a loose or damaged heat shield. Inspect the take down studs for damaged threads. 10. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in) within the two front or two rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced. To install: ->Do not apply sealant to the first three threads of the bolt.

11. Apply a5 mm (0.2 in) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts. Install the exhaust manifold and NEW exhaust manifold gasket. >Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the

YUKON 1 XL 42 7

use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless . specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

12. Install the exhaust manifold bolts: a. Tighten the exhaust manifold bolts a first pass to 15 Nm (11 ff. Ibs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. b. Tighten the exhaust manifold bolts a final pass to 25 Nm (18 ft. Ibs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 13. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head. 14. Install the heat shield (2) and bolts (3). Tighten the heat shield bolts to 9 Nm (80 inch Ibs.). 15. Install the Air Injection Reaction (AIR) pipe studs (if required). Tighten the Studs to 5 Nm (45 inch Ibs.). 16. Install the AIR pipe (with check valve), NEW gasket and nuts (if required). Tighten the AIR pipe to exhaust manifold nuts to 25 Nm (18 ft. Ibs.). 5.0L and 5.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Engine cover Air cleaner, if needed Exhaust pipe at the manifold Oxygen (02S) sensor wiring, if equipped AIR hose at the check valve Exhaust Gas Recirculation (EGR) valve, inlet pipe Heat stove pipe and the dipstick tube bracket, if working on the right side of the engine Power steering pump rear bracket at the manifold, if removing the left side manifold

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© YUKON © YUKON XL e AIR hose at check valve, if removed e Oxygen sensor connector, if equipped e EGR pipe and dipstick tube ¢ Negative battery cable 5. Run engine and check for leaks. 8.1L Engines

7924KG19

Exploded view of the left exhaust manifold, the right side is similar—5.0L and 5.7L engines

e Loosen the alternator and remove the lower bracket, if necessary e Air conditioner compressor rear bracket and the diverter valve and bracket. if needed >On models with air conditioning, it may be necessary to remove the compressor, do not disconnect the compressor lines.

e Manifold bolts and the manifold(s)

Some models have lock tabs on the front and rear manifold bolts which must be removed before removing the bolts. To install: 3. Clean gasket surfaces, and inspect manifold for cracks replace as necessary. 4. Install manifold and torque it in 2 steps. a. Step 1: Torque the bolts to 15 ft. lbs. (20 Nm) b. Step 2: Torque the bolts to 22 ft. lbs. (30 Nm) 5. Install or connect the following: Alternator, if removed Air conditioning compressor, if removed Diverter, if removed Power steering brackets, if removed Dipstick tube on right side EGR inlet pipe Oxygen sensor connector, if equipped Exhaust pipes Negative battery cable 7.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable Engine cover, on van models Heat stove pipe and the dipstick tube. If removing the right side manifold Exhaust Gas Recirculation (EGR) valve inlet pipe Oxygen-(O2S) sensor wiring, if equipped AIR hose at the check valve, if applicable Spark plugs and wires Exhaust manifold bolts and the spark plug heat shields e>Leave the front nut (left manifold) or rear nut (right manifold) in place for support.

e Heat shield bolts from the engine mount and bell housing e Heat shield, if equipped e Exhaust pipe at the manifold e Exhaust manifold To install: 3. Clean the mating surfaces and the retainer threads. 4. Install or connect the following: e Manifold, spark plug heat shields and nuts. Torque the nuts to 22 ft. lbs. (30 Nm), starting from the center bolts and working towards the outside. e Exhaust pipe e Spark plugs and wires

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheelhouse panel Oil dipstick tube, right side only Secondary Air Injection (AIR) pipe nut from the fuel rail stud, if equipped AIR pipe bolts from the exhaust manifold AIR pipe from the AIR pump pipe AIR pipe gasket and discard Spark plug wires from the spark plugs and ignition coils, by first . twisting the boot % turn in each direction and pulling off using the boot. Do not pull on the wire! e Spark plugs 3. lf removing the right exhaust manifold, perform the following: a. Remove the Exhaust Gas Recirculation (EGR) pipe nuts from the manifold. b. Remove the EGR pipe bracket bolt. c. Remove and discard the EGR pipe gasket. d. Reposition the EGR pipe. 4. Raise and support the vehicle. e Exhaust manifold heat shield bolts and shield 5. Lower the vehicle. e Exhaust manifold bolt and nuts e Exhaust manifold e Exhaust manifold gasket and discard To install: 6. Clean the mating surfaces and the retainer threads. 7. Install or connect the following: e New exhaust manifold gasket e Exhaust manifold ‘ e Exhaust manifold bolt and nuts. Tighten the bolt to 26 ft. Ibs. (35 Nm) and the nuts to 12 ft. Ibs. (16 Nm) 8. Raise the vehicle. e Heat shield. Tighten the retaining bolts and nuts to 18 ft. Ibs. (25 Nm) 9. Lower the vehicle. e EGR pipe, right side only. Tighten the pipe bracket bolt to 37 ft. Ibs. (50 Nm) and the nuts to 22 ft. Ibs. (30 Nm)

GENERAL MOTORS CORP. 14-29

ESCALADE ¢ DENALI ¢ DENALI XL ¢eSUBURBAN ¢ YUKON e YUKON XL e Spark plugs and plug wires e Air pipe, using a new gasket and reversing the removal procedure e Wheel house panel

*

Camshaft and Valve Lifters

REMOVAL & INSTALLATION

4.8L, 5.3L and 6.0L Engines

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

4.3L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the engine cooling system. 4. Remove or disconnect the following: Negative battery cable Radiator Cooling fan Water pump Rocker arm covers from the engine Intake manifold assembly

Rocker arms, pushrods and lifters Crankshaft pulley and hub Engine front cover 9. Align the timing marks on the crankshaft and camshaft sprockets. e Camshaft sprocket and timing chain e Balance shaft drive gear, if equipped e Camshaft thrust plate

1. Raise the hood to the servicing position and secure it. Move the hood hinge bolt to hold the hood in the servicing position. 2. Remove or disconnect the following: Battery negative cable e Coolant Upper and lower radiator hoses from the engine Air cleaner duct from the engine A/C condenser mounting bolts, if equipped Radiator support and radiator form vehicle Engine cooling fan Drive belt A/C drive belt, if equipped

e Engine sight shield e Electrical wiring harness from the thermostat housing e Water pump 3. Raise the vehicle. 4, Remove or disconnect the following: e Starter motor e Right side closeout cover and bolt e Crankshaft balancer e Engine oil pan e Engine front cover e Cylinder heads from the engine e Valve lifters from the engine 5. Align the timing marks on the camshaft and crankshaft sprockets. Make sure that the number 1 piston is in the firing position. 6. Remove or disconnect the following: e Camshaft sprocket e Camshaft sensor bolt and the sensor e Camshaft retainer bolts and the retainer -> All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.

Install the sprocket bolts or longer bolts of the same thread into the end of the camshaft as a handle.

To 6. clean 7.

e Camshaft install: Lubricate the camshaft journals with engine oil or a suitable pre-lube. Install or connect the following: e Camshaft e Camshaft thrust plate Balance shaft drive gear, if equipped Timing chain and camshaft sprocket Engine front cover Crankshaft pulley and hub Valve lifters Pushrods and rocker arms, properly adjust the valve clearance

Intake manifold assembly Rocker arm covers to the engine Radiator to the vehicle Negative battery cable 8. Refill the engine cooling system.

9308KG66

Camshaft sensor removal—4.8L, 5.3L, 6.0L

Timing belt service is covered in Section 3 of this manual

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GENERAL MOTORS CORP.

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1 4-30 ESCALADE © DENALI « DENALI XL ¢ SUBURBAN @ YUKON © YUKON XL 13. Install or connect the following: Camshaft sensor and bolt. Tighten the camshaft sensor bolt to 25 Nm (18 ft. Ibs.). Camshaft sprocket and timing chain Valve lifters Cylinder heads Engine front cover to the engine

Oil pan Right side closeout cover Starter motor

Crankshaft balancer to the crank-

shaft Water pump Electrical wiring harness to the thermostat housing A/C drive belt, if equipped Drive belt Engine sight shield Radiator support and radiator A/C condenser mounting bolts Engine cooling fan Air cleaner duct Battery negative cable to the battery

9308KG65

Camshaft retainer removal—4.8L, 5.3L, 6.0L

7. Install the three M8-1.25 x 100 mm bolts in the camshaft front bolt holes. Using the bolts as a handle, carefully rotate and

pull the camshaft out of the engine block. Remove the bolts from the front of the

camshaft.

8. Clean and inspect all sealing surfaces.

5.0L and 5.7L Engines

11. Install or connect the following: e Camshaft retainer and the bolts. Tighten the camshaft retainer bolts

to 25 Nm (18 ft. Ibs.). 12. Inspect the camshaft sensor O-ring

seal. If the O-ring seal is not cut or dam-

aged, it may be reused. Lubricate the O-ring seal with clean engine oil.

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

2. Drain the cooling system. 3. Properly relieve the fuel system pres-

SUTE.

;

4. Remove or disconnect the following: e Engine cover, on van models

To install: e>|lf camshaft replacement is required, the valve lifters must also be replaced.

9. Lubricate the camshaft journals and the bearings with clean engine oil. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts into the camshaft front bolt holes. e>All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.

10. Using the bolts as a handle, carefully install the camshaft into the engine block. Remove the three bolts from the front of the camshaft. e>Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt or debris.

7

ae Install 2 or 3 long bolts into the camshaft to use as a handle for easy removal or installation— 7.4L engine shown, other engines similar

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GENERAL MOTORS CORP.

ESCALADE © DENALI ¢ DENALI XL ¢ SUBURBAN © YUKON e YUKON XL e Air cleaner e Grille and center support, on van models Air conditioning condenser and swing the condenser forward from its mounting, if equipped. e Fan, the shroud and the radiator e Valve covers e Water pump assembly 5. Align the timing marks and remove the torsional damper. e Timing chain cover Electrical and vacuum connections at the intake manifold Distributor assembly, mark the distributor rotor-to-housing location Intake manifold, pushrods and hydraulic lifters Camshaft sprocket bolts Camshaft sprocket and timing chain Crankshaft sprocket, as required Front engine mount through-bolts and raise the engine to gain sufficient clearance for camshaft removal, as required 6. Install 2 or 3 Ae—-18 bolts 4—5 in. (102—127mm) long into the camshaft threaded holes. . e Camshaft ->Inspect the shaft for signs of excessive wear or damage.

To install: Liberally coat camshaft and bearing with heavy engine oil cr engine assembly lubricant.

7. Install or connect the following: Camshaft, align the timing marks on the camshaft and crankshaft gears Engine mount through-bolts Camshaft sprocket and chain. Torque the bolts to 18 ft. Ibs. (25 Nm). Hydraulic lifters and pushrods Distributor assembly Timing chain cover Torsional damper Water pump Valve covers Fan, the shroud ana radiator Air conditioning condenser, if equipped e Grille and center support, on van models Air cleaner Engine cover, on van models

¢ Negative battery cable 8. Refill the cooling system. 7.4L Engines 1. Before servicing the vehicle, refer to iheprecautions in the beginning of this secion. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Properly discharge the air conditioning system. 5. Remove or disconnect the following: Negative battery cable Engine cover, on van models Air cleaner assembly Grille and center support section, as required Air conditioning compressor, condenser and auxiliary fan, if

equipped Fan, the shroud Radiator Accessory belt, as required Alternator, as required Valve covers Hoses from the water pump Water pump 6. Align the timing marks at TDC. e Harmonic balancer and pulley e Engine front cover 7. Mark the distributor rotor-to-housing location. e Distributor assembly e Intake manifold assembly e Lifters, pushrods, and rocker arms 8. Rotate the camshaft so the timing marks align. e Camshaft sprocket bolts e Camshaft sprocket and timing e Engine mount through-bolts 9. Install 2 or 3 %6—-18 bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block. To install: 10. Liberally coat camshaft and bearing with heavy engine oil or engine assembly lubricant 11. Align the timing marks on the camshaft sprocket and crankshaft gears. 12. Install or connect the following: e Camshaft e Camshaft sprocket and chain. Torque the bolts to 25 ft. Ibs. (34 Nm) e Engine mount bolts e Lifters and pushrods and adjust the valves

14-31

Intake manifold Distributor using the locating marks made during removal Engine front cover Harmonic balancer and pulley Water pump Hoses at the water pump Valve covers Alternator, if removed Accessory belt, if removed Fan shroud and radiator Air conditioning condenser and compressor Grille and center support, if removed Air cleaner assembly e Negative battery cable 13. Fill the cooling system with the proper type and quantity of antifreeze. 8.1L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly discharge the air conditioning system. e->Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

3. Remove or disconnect the following: Grille

A/C condenser Intake manifold Rocker arms and pushrods Valve lifter guide retainer bolts and retainer Valve lifter guides, keeping them in proper order for reassembly Valve lifters e>lf any lifters are stuck in their bores, use a Suitable valve lifter to remove them.

e Timing chain and sprocket e Camshaft retaining bolts e Camshaft retainer

All of the cam journals are the same size so be very careful when removing and installing the camshaft that you do not damage the bearings. A. |nstall three 8-1.25 x 100mm bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

Heater Core replacement is covered in Section 2 of this manual

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SCHR TES DENALIEMAL XL ¢ SUBURBAN © YUKON ¢ YUKON XL e Bracket and shield. Torque the nuts to 53 inch Ibs. (6 Nm). e Negative battery cable 5.7L and 7.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Mounting bolts and shims e Wires e Heat shield e Starter To install: 3. Install or connect the following: e Starter ¢ Wires. Torque battery wire nut to 89 inch lbs. (10 Nm), and ignition nut to 18 inch Ibs. (2 Nm) e Heat shield. Torque the bolts to 53 inch lbs. (6 Nm) and the nuts to 35 inch lbs. (3 Nm) e Mounting bolts and shim. Torque the bolts to 33 ft Ibs. (45 Nm) e Negative battery cable 9348NG05

4.8L, 5.3L and 6.0L Engines

Use the 3 bolts as a handle to carefully remove and install the camshaft

5. Remove the bolts from the front of the camshaft. 6. Clean and inspect the camshaft for damage. To install: 7. Liberally coat camshaft and bearings with heavy engine oil or engine assembly lubricant. 8. Install the camshaft, using the 3 bolts threaded into the camshaft bolt holes as a handle, then remove the bolts. 9. Install or connect the following: Camshaft retainer and bolts. Tighten to 106 inch Ibs. (12 Nm) e>if a new camshaft is installed, you MUST install new valve lifters.

Timing chain and sprocket Valve lifters Valve lifter guides over the flats on the lifters. Make sure the rollers of the lifters are properly aligned with the cam lobes e Valve lifter guide retainer.

Tighten the bolts to 18 ft. Ibs. (25 Nm) Rocker arms and pushrods Intake manifold A/C condenser Grille 10. Recharge the A/C system.

Valve Lash

ADJUSTMENT All engines use hydraulic lifters, which require no periodic adjustment.

Starter Motor

REMOVAL & INSTALLATION 4.3L and 5.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Bracket and shield e Wires ¢ Mounting bolts and shims e Starter To install:

3. Install or connect the following: e Starter e Mounting bolts and shim. Torque the bolts to 33 ft Ibs. (45 Nm). e Wires. Torque battery wire nut to 89 inch Ibs. (10 Nm) and Ignition nut to 18 inch Ibs. (2 Nm).

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the protective shields as necessary. 4, Remove the starter solenoid shield. 5. Remove the starter to transmission close out cover bolt. 6. Disconnect the engine oil level sensor connection. , 7. Remove the front axle mounting bracket through bolt nut. 8. Reposition the front axle mounting bracket through bolt until the bolt tip is flush with the support bushing. Do not remove the bolt. 9. Remove the mounting bolts from the

engine block. Slide the starter forward until the starter clears the transmission. Remove the starter transmission close out cover. 10. Disconnect the positive battery cable and wiring harness from the starter. Remove the starter from the vehicle. To install:

ESCALADE ¢ DENALI ¢ DENALI XL ¢ SHRUTI

Vole rUKOnA 1 4 -33 2. Remove or disconnect the following: Negative battery cable Positive battery cable nut

Positive cable from the solenoid Engine harness ground nut and ground from the solenoid Mounting bolts and starter Heat shield bolts, nut and shield, if necessary To install: 3. Install or connect the following: Heat shield, bolts and nut if removed. Tighten the bolts to 35 inch Ibs. (3 Nm) and the nut to 44 inch Ibs. (6 Nm) Starter and bolts. Tighten to 37 ft. lbs. (50 Nm) Ground wire and nut. Tighten to 30 inch lbs. (3.4 Nm) ¢ Positive cable and nut. Tighten to 80 inch Ibs. (9 Nm) Negative battery cable

REMOVAL & INSTALLATION 9308KG03

Exploded view of the starter motor.

11. Install the starter. 12. Connect the positive battery cable to the starter. Tighten the nut to 16 Nm (12 inch lbs.). 13. Install the starter transmission close out cover. Install the mounting bolts to the engine block. Tighten the bolts to 50 Nm (37 ft. Ibs.). 14. Reposition the front axle mounting bracket through bolt until the bolt is fully seated Install the front axle mounting bracket through bolt nut. Tighten the nut to 90 Nm (67 ft. Ibs.). 15. Connect the engine oil level sensor connection. 16. Install the startertotransmission close out cover bolt. 17. Install the starter solenoid shield. 18. Install the protective shields as necessary. 19. Remove the safety stands. 20. Lower the vehicle. 21. Connect the negative battery cable. Tighten the bolts to 17 Nm (13 ft. Ibs.). 9308KG00

Starter removal—4.8L, 5.3L and 6.0L

4.3L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Exhaust crossover pipe Torque converter cover, if equipped with automatic transmission Cooler lines from guides and the oil filter adapter

8.1L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Brake service is covered in Section 4 of this manual

Strut rods at the flywheel/flexplate cover, if equipped Strut rod at the front engine mounts, if equipped Starter assembly Front drive axle tube nuts and lower axle bushing bolts Oil pan bolts/nuts and reinforcements Oil pan and gaskets To install: 4. Thoroughly clean all gasket surfaces 5. Install or connect the following: e New gasket e (Oil pan and new gaskets e Oil pan bolts, nuts and reinforcements. Torque bolts to 18 ft. Ibs. (25 Nm)

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Engine oil and filter Transmission to oil pan bolts Oil level sensor electrical connector Two front wiring harness retainer bolts Engine wiring harness retainer bolts from the engine oil pan Engine oil cooler pipe to oil pan bolt Transmission oil cooler pipe retainer and the bolt from the oil pan Closeout covers and bolts (one each side of engine) e Engine mount bolts each side e Oil pan To install: >The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting ‘points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane.

2. Apply

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sealant GM P/N 12378190 or equivalent 20

Front drive axle tube nuts and lower axle bushing bolts Starter Strut rod brackets at the front engine mounts Strut rods at the flywheel/flexplate cover Cooler lines into guides and oil filter adapter with new filter Torque converter cover, if equipped with automatic transmission Exhaust crossover pipe e Negative battery cable 6. Refill the engine with oil.

4.8L, 5.3L and 6.0L >The original oil pan gasket is retained and aligned to the oil pan by rivets. When installing a new gasket, it is not necessary to install new rivets. DO NOT reuse the oil pan gasket. When installing the oil pan, install a NEW oil pan gasket.

1. Remove or disconnect the following: ¢ Negative battery cable e Front differential if equipped with four wheel drive

° Under body shield from the vehicle

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Install the engine oil cooler pipe to oil pan bolt. Tighten the nut to 10 Nm (89 ft. Ibs.). 9. Install the engine wiring harness retainer bolts to the engine oil pan. 10. Connect the oil level sensor electrical connector. 11. Install the transmission to oil pan bolts. Tighten the bolts to 55 Nm (41 ft. Ibs.). 12. Install the front differential if equipped with four wheel drive. 13. Install the under body shield on the vehicle. Lower the vehicle. Fill the engine with oil and install the engine oil filter. 14. Connect the negative battery cable. 5.0L and 5.7L Engines

9308KG79

Apply sealant at these points at the front of the block—4.8L, 5.3L, 6.0L

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Under body protector shields e Transmission and engine oil lines from guides e Front driveshaft, if needed

mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. 3. Apply a5 mm (0.20 in) bead of sealant GM P/N 12378190 or equivalent 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. ->Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket.

4, Pre-assemble the oil pan gasket to the pan. Install the oil pan bolts to the pan through the gasket. 5. Install the oil pan, gasket and bolts to the engine block. Snug the oil pan bolts finger tight. Do not overtighten. 6. Install the two lower bellhousing bolts to position the oil pan correctly. 7. Snug the lower bellhousing bolt finger tight. Do not overtighten. Tighten the oil pan-to-block and oil pan-to-oil pan front cover bolts to 25 Nm (18 ft. Ibs.). Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch Ibs.). Tighten the bellhousing bolts to 50 Nm (37 ft. Ibs.). 8. Install the transmission oil cooler pipe retainer and the bolt to the oil pan.

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Apply sealant at these points at the rear of the block—4.8L, 5.3L, 6.0L

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

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Front drive axles, if needed Exhaust crossover pipe Flywheel/flexplate or torque converter cover. e Oil filter and adapter e Strut rods at the front engine mounting, if equipped e Oil pan bolts, nuts and reinforcements e Oil pan and gaskets To install: 4. Thoroughly clean all gasket surfaces, 5. Install or connect the following: New gasket e Qil pan and new gaskets e Oil pan bolts, nuts and reinforcements. Torque bolts to 18 ft. Ibs. (25 Nm) e Strut rods at the front engine mounting e Oil filter and adapter e Torque converter or flywheel/flexplate cover e Exhaust crossover pipe e Front drive axles and driveshaft, if removed e Transmission and engine oil lines to guides e Under body protectors e Negative battery cable 6. Fill the crankcase with oil. 7.4L Engines ->Removal of the transmission may be necessary on van vehicles.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Fan shroud Air cleaner Distributor cap Underbody protectors, if needed Front driveshaft and front drive axles, if needed Starter, if equipped with manual transmission Torque converter or clutch housing cover Oil filter and adapter Oil pressure line from the side of the block 4. Support the engine e Engine mount through-bolts e Oil pan bolts e Qi! pan and discard the gaskets To install: 5. Clean all sealing surfaces. 6. Apply RTV gasket material to the front and rear corners of the gaskets.

9348NG06

Oil pan bolt tightening sequence—8.1L engine

7. Install or connect the following: New gaskets, coat the gaskets with adhesive sealer and position them on the block Rear pan seal in the pan with the seal ends mating with the gaskets. Front seal on the bottom of the front cover, pressing the locating tabs into the holes in the cover. Oil pan. Pan bolts, clips and reinforcements. Torque the bolts to 18 ft. lbs. (25 Nm) fee). Lower the engine onto the mounts. e Engine mount through-bolts Oil pressure line Oil filter Starter, if removed Torque converter or clutch housing cover e eee Front drive axles and driveshaft, if removed Underbody protectors, if removed Distributor cap Air cleaner Fan shroud Negative battery cable 9. Fill the crankcase with oil. 8.1L Engine Removal of the transmission may be necessary on van vehicles.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable and drain the engine oil. 3. Remove or disconnect the following: e Front differential, if equipped with 4WD Starter motor Oil pan skid plate bolts and plate Crossbar bolt(s) and crossbar Oil level dipstick Oil level sensor electrical connector Engine harness clip from the oil pan Battery cable channel bolt

e Battery cable channel and reposition e Oil pan bolts, oil pan and gasket >You can reuse the oil pan gasket, if it is not damaged

To install: >You must install the oil pan within 5 minutes of applying the sealer.

4. Apply sealant to the sides of the front and rear crankshaft bearing caps on the left and right sides. 5. Install or connect the following: e Oil pan gasket into the oil pan groove e Oil pan and bolts 6. Tighten the oil pan bolts, in sequence, as follows: a. 1st pass: 89 inch Ibs. (10 Nm) b. 2nd pass: 18 ft. lbs. (25 Nm) 7. Install or connect the following: e Battery cable channel and bolt. Tighten to 80 inch Ibs. (9 Nm) Oil level sensor and tighten to 15 ft. Ibs. (20 Nm) Engine harness clip Oil level sensor connector Oil level dipstick Crossbar and bolt(s). Tighten to 74 ft. Ibs. (100 Nm) Skid plate. Tighten the bolts to 15 ft. Ibs. (20 Nm) Starter motor ‘ Front differential Negative battery cable 8. Fill the crankcase with oil.

REMOVAL & INSTALLATION 4.8L, 5.3L and 6.0L Engines 1. Remove or disconnect the following: e Engine front cover

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3. Install or connect the following: e Oil pump bolts. Tighten the oil pump bolts to 25 Nm (18 ft. Ibs.). e Crankshaft oil deflector. e>Lubricate a NEW oil pump screen Oring seal with clean engine oil.

e NEW O-ring seal onto the oil pump screen. ->Push the oil pump screen tube completely into the oil pump prior to tight-

ening the bolt. Do not allow the bolt to pull the tube into the pump.

9308KG77

Oil pump removal—4.8L, 5.3L, 6.0L

Oil pan Oil pump screen bolt and nuts Oil pump screen with O-ring seal. O-ring seal from the pump screen. Discard the O-ring seal. Remaining crankshaft oil deflector nuts. Crankshaft oil deflector

Oil pump bolts Do not allow dirt or debris to enter the oil pump assembly, cap ends as necessary.

e Oil pump The internal parts of the oil pump assembly are not serviced separately (excluding the spring). If the oil pump

4. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs. 5. Install the oil pump screen. Install the oil pump screen bolt and the deflector nuts. Tighten the oil pump screen bolt (4) to 12 Nm (106 inch Ibs.). Tighten the crankshaft oil deflector nuts (2) to 25 Nm (18 ft. Ibs.). 6. Install the engine oil pan. 7. Install the engine front cover. 4.3L, 5.0L, 5.7L and 7.4L Engines

components are worn or damaged, replace the oil pump as an assembly. Do not attempt to repair the wire mesh portion of the pump and screen assembly. To install:

->Inspect the oil pump and engine block oil gallery passages. These surfaces must be clear and free of debris or restrictions.

2. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Oil pan. e Qil pump attaching bolt, if equipped e Pick-up tube nut/bolt e Pump along with the pick-up tube and shaft, as necessary 3. Clean all sealing surfaces To install: 4. Ensure that the pump pick-up tube is tight in the pump body. If the tube should come loose, oil pressure will be lost and oil starvation will occur. If the pick-up tube is loose it should be replaced. 5. Ifthe pump has been disassembled and is being replaced or for any reason oil has been removed, it must be primed. It can either be filled with oil before installing the cover plate and oil kept within the pump during handling or the entire pump cavity can be filled with petroleum jelly. e>if the pump is not primed, the engine could be damaged before it receives adequate lubrication when the engine is started.

9308KG64

Oil pump disassembly—4.8L, 5.3L, 6.0L

6. Install or connect the following: e Pump, aligning the pump shaft with the oil pump drive gear as necessary. Torque oil pump/pick-up tube

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

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the oil pump and the shaft, when installing the oil pump. During assembly, install a new oil pump driveshaft retainer. To ease installation, slightly

heat the retainer to above room temperature. 5. Assemble the oil pump, driveshaft and a new retainer.

6. Install or connect the following: ~

9302KG04 Exploded view of the oil pump mounting—4.8L, 5.3L and 6.0L engines

e Oil pump, positioning it on the locating pins ¢ Oil pump bolt and tighten to 56 ft. lbs. (75 Nm) e Oilpan © 7. Refill the engine crankcase 8. Disable the ignition system; crank engine for approximately 10 seconds to aid in priming the oil pump and reducing the . risk of engine damage. ‘sIfthe oil pump does not build up oil pressure almost immediately, remove the pan and check for a loose oil pump-to-pick-up tube attachment. If necessary dismantle the pump and

pack the pump cavity with petroleum

retainer(s) to 65 ft. Ibs. (90 Nm) on all 4.3L and all V8 Engines. e Oil pan 7. Refill the engine crankcase 8. Disable the ignition system; crank engine for approximately 10 seconds to aid in priming the oil pump and reducing the risk of engine damage. e>lf the oil pump does not build up oil pressure almost immediately, remove the pan and check for a loose oil pumpto-pick-up tube attachment. If necessary dismantle the pump and pack the pump cavity with petroleum jelly. Running the engine without measurable oil pressure will cause extensive damage.

8.1L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Qil pan e Oil pump screen bolt e Qil pump, retainer and driveshaft. Discard the driveshaft retainer e Crankshaft oil deflector nuts e Crankshaft oil deflector e Oil pump bolts e Oil pump 3. Clean and inspect the oil pump

To install:

4. Install the crankshaft oil deflector. Tighten the nuts to 37 ft. Ibs. (50 Nm)

eC Oil pump removal—8.1L engine

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jelly. Running the engine without measurable oil pressure will cause extensive damage.

Rear Main Seal

thoroughly before instalation of the new Seal. ~ 3. Inspect the crankshaft for grit, rust or burrs and correct as necessary. Also inspect

the portion of the crankshaft where the oil

. REMOVAL & INSTALLATION

‘

Except 8.1L Engine

seal makes contact, for wear due to the rub-

removed to perform thisnoose This procedure requires the use of the following tools: Crankshaft Rear Seal Puller tool No. J 43320 and Crankshaft Rear Seal Installer

tool No, J 42849,

bing action of the oil seal.

e Negative battery cable

‘ ai i seal running surface of the crankshaft with a non-abrasive cleaner.

e Transfer case, if equipped e Transmission assembl

5. Lubricate the inner diameter of the

Please note that the entire transmission assembly and flywheel/flexplate must be removed to perform this procedure. 1. Remove or disconnect the following: ¢ Negative battery cable

new seal and the outer diameter of the crankshaft with engine oil. 6. Install or connect the following: ¢ Rear main oil seal, using installation tool J 38841, until the tool bottoms against the block and

e Transfer case, if equipped

crankshaft rear main bearing cap.

° Transmission assembly

* Clutch assembly and flywheel, if

equipped with manual transmission ° Flexplate, if equipped with automatic transmission ° Crankshaft rear main oil seal by inserting a suitable prying tool and

* Flywheel and clutch

e Flexplate, as required e Transmission assembly e Transfet case, if equipped ¢ Negative battery cable 7. Start the engine and verify no oil

prying the seal out. Take care not to

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, Reuven To install: 2. Clean the oil seal bore in the block

.

1. Remove or disconnect the following:

¢ Clutch assembly and ivi if

equipped with manual transmission e Flexplate, if equipped with automatic transmission 2. Install the guide pins from the Crankshaft Rear Sear Puller into the crankshaft.

3. Install the Rear Seal Puller over the

guide pins.

4. Using a drill, insert 8 of the selfdrilling sheet metal screws into the rear crankshaft seal, using a crisscross pattern as shown. The self tapping screws are included with the Crankshaft Rear Seal

Puller. 5. Thread the center bolt of the Crank=

Please note that the entire transmission assembly and flywheel/flexplate must be

shaft Rear Seal Puller into the crankshaft to remove the seal. 6. Remove the guide pins from the crankshaft. To install: 7. Make sure there is no dirt, rust or loose burrs on the crankshaft. 8. Apply a light coating of engine oil to the crankshaft sealing surface. Do NOT get oil on the sealing surface of the engine block. 9. Install the new rear main seal onto « the Crankshaft Rear Seal Installation ~~~ “a Tool.

10. Position the Rear Seal Installation ~~

Tool against the crankshaft. Thread the *

934aNG08 You must drill the screws into the rear main seal using a crisscross pattern—8.1L engine

attaching screws into the tapped holes in’ the crankshaft. 11. Use a screwdriver to tighten the > = screws securely to make sure the seal is squarely installed against the crankshaft. 12. Rotate the center nut until the installation tool bottoms, then remove the seal installation tool. 13. Install or connect the following: e Flexplate, if equipped with automatic transmission ¢ Clutch assembly and flywheel, if equipped with manual transmission e Transmission assembly e Transfer case, if equipped e Negative battery cable

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

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coRP. SENERAL ¢ MoToRs E 44-4) ESCALADE DENALI © DENALI XL ‘“U Timing Chain, Sprockets, Front Cover and Seal The manufacturer recommends that the

front cover oil seal be replaced whenever the cover is removed.

REMOVAL & INSTALLATION 4.3L, 5.0L, 5.7L and 7.4L Engines

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e Screws holding the timing chain cover to the block. e Cover and gaskets.

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4. Use a suitable tool to pry the old seal out of the front face of the cover. 5. Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in proper alignment. ¢ Camshaft sprocket-to-camshaft nut and/or bolts e Camshaft sprocket (along with the timing chain), if the sprocket is difficult to remove, use a plastic mallet to bump the sprocket from the camshaft. >The camshaft sprocket (located by a dowel) is lightly pressed onto the camshaft and should come off easily. The chain comes off with the camshaft sprocket.

6. If necessary use J-5825-A, or equivalent, crankshaft sprocket removal tool to free the timing sprocket from the crankshaft. To install: 7. Inspect the timing chain and the timing sprockets for wear or damage, replace the damaged parts as necessary. 8. Clean the gasket mounting surfaces of all remaining traces of old gasket. ->During installation, coat the thrust surfaces lightly with Molykote® or equivalent pre-lube.

9. Install or connect the following:

e Crankshaft sprocket onto the crankshaft, use tool J-5590, or equivalent, crankshaft sprocket installation tool, and a hammer, without disturbing the position of the engine. Timing chain, arrange the camshaft sprocket in such a way that the timing marks will align between the shaft centers and the camshaft locating dowel will enter the dowel hole in the cam sprocket. Cam sprocket, with the chain mounted under it in position on the front of the camshaft. Torque the camshaft sprocket-to-camshaft retainer bolts to 106 inch Ibs. (12 Nm). 10. With the timing chain installed, turn the crankshaft 2 complete revolutions, then check to make certain that the timing marks are in correct alignment between the shaft centers.

->Coat the lip of the new seal with oil prior to installation.

e New seal so that the open end is toward the inside of the cover, Using seal driver J-22102, or equivalent. ¢ New front pan seal, cutting the tabs off. 11. Coat a new cover gasket with adhesive sealer and position it on the block. 12. Apply a % in. (8mm) bead of RTV gasket material to the front cover. Cover carefully onto the locating dowels and tighten the attaching Screws Oil pan, if removed Cover-to-pan bolts, Torque to 106 inch Ibs. (12 Nm). Torsional damper Water pump assembly Negative battery cable 13. Fill the cooling system with the proper type and quantity of antifreeze. 4.8L, 5.3L and 6.0L Engine

7924KG21

Timing mark alignment for timing chain removal and installation—gasoline engines

1. Before servicing the vehicle, refer to Hsprecautions in the beginning of this secion. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable ¢ Water pump e¢ Crankshaft balancer from the crankshaft e Front cover bolts ¢ Front cover and gasket. Discard the front cover gasket.

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¢ Camshaft sprocket bolts. Tighten the camshaft sprocket bolts to 26 ft. lbs. (35 Nm). ->Do not lubricate the oil seal sealing surface.

7. Lubricate the outer edge of the oil seal with clean engine oil. Lubricate the front cover oil seal bore with clean engine oil. 8. Install the crankshaft front oil seal with an installer. e>Do not apply any type sealant to the front cover gasket (unless specified). Special tools are used to properly align the engine front cover at the oil pan surface and to center the crankshaft front oil seal.

9. Install the front cover gasket, cover, and bolts onto the engine. Tighten the cover bolts finger tight. Do not overtighten. 10. Start the J41480 tool-to-front cover bolts. Don't tighten the bolts yet. oa0eK6es Front cover and gasket—4.8L, 5.3L, 6.0L

->Align the tapered legs of the tool with the machined alignment surfaces on the front cover.

° Crankshaft front oil seal from the cover

|

¢ Oil pump

4. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. ->Do not turn the crankshaft assembly after the timing chain has been

removed in order to prevent damage to the piston assemblies or the valves.

5. Remove or disconnect the following: e Camshaft sprocket bolts e Camshaft sprocket and timing chain e Crankshaft sprocket e Crankshaft sprocket key To install: 6. Install or connect the following: e Key into the crankshaft keyway e Crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. Camshaft sprocket and timing chain. Locate the camshaft sprocket alignment mark in the 6 o’clock position.

9308KG76

Sprocket and chain removal—4.8L, 5.3L, 6.0L

For Maintenance Interval recommendations, see Section 1 of this manual

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Water pump Crankshaft balancer from the crankshaft Camshaft Position (CMP) sensor

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J 41665 —1

Engine harness clips from the battery cable channel CMP sensor bolt and sensor Battery cable channel bolt e Battery cable channel and reposition Front cover bolts, front cover and gasket >The front cover gasket can be reused if it is not damaged.

9a0eK662 Crankshaft sprocket installation—4.8L, 5.3L, 6.0L

e Crankshaft front oil seal from the front cover

11. Install tool J41476 . Install the crankshaft balancer bolt. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten. Tighten the J41480 bolts and front cover bolts to 25 Nm (18 ft. Ibs.). 12. Remove the tools. 13. Place a straight edge across the engine block and front cover oil pan sealing surfaces. Avoid contact with the portion of the gasket that protrudes into the oil pan surface. Insert a feeler gauge between the front cover and the straight edge tool. The cover must be flush with the oil pan surface or no more than 0.5 mm (0.02 in) below flush. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover. 14. Install the crankshaft balancer bolt. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten the bolt. 15. Snug the oil pan-to-cover bolts in order to position the cover at the pan rail. 16. Tighten the oil pan-to-front cover bolts to 25 Nm (18 ft. Ibs.). 17. Tighten the front cover bolts to 25 Nm (18 ft. Ibs.). 18. Install the water pump.

9308K861 Timing mark alignment—4.8L, 5.3L, 6.0L

GENERAL MOTORS

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the timing chain to avoid damaging the camshaft retainer. c. Never use a hammer to install the sprocket onto the camshaft. 11. Make sure the crankshaft sprocket is alignment at the 12 o'clock position and the cam sprocket is at the 6 o’clock position. 12. Install the camshaft sprocket bolts and tighten, in two passes, to 22 ft. Ibs. (30 Nm) 13. Use clean engine oil to lubricate the sealing surfaces of the front oil seal. 14. Install or connect the following: ¢ New seal into the front cover, using a Suitable seal installation tool >The front cover must be installed while the sealant is still wet to the touch.

¢ Sealant to the 2 places on the engine block where the front cover meets the oil pan e Front cover gasket into the

cover 15. Install the front cover, referring to the accompanying figure and using the following steps only: a. Hold the front cover (1) up to the crankshaft (2).

J41480 installation—4.8L, 5.3L, 6.0L

4. Align the timing marks on the camshaft and crankshaft sprockets. e Camshaft sprocket bolts e Camshaft sprocket and timing chain 5. Install Crankshaft Protector Button tool No. J 42846 into the end of the crankshaft and remove the crankshaft sprocket using a 3-jawed puller. 6. Clean and inspect the timing chain and sprockets. To install: 7. Use the Crankshaft Sprocket Installer tool No. J 22102 to install the crankshaft sprocket. Align the keyway of the sprocket with the crankshaft pin. 8. Remove the installation tool. 9. Rotate the crankshaft until the crankshaft sprocket alignment mark is in the 12 o'clock position. 10. Install the camshaft sprocket and timing chain, noting the following important points: a. The cam sprocket must be installed with the alignment mark at the 6 o'clock position. b. The sprocket teeth must mesh with

J 41476

9308KG84

Seal alignment tool installation—4.8L, 5.3L, 6.0L

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

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GENERAL MOTORS CORP.

ESCALADE ¢ DENALI ¢ DENALI XL ¢ SUBURBAN ¢ YUKON @ YUKON XL

1

b. Lift the cover (1) while sliding the cover over the crankshaft (2). c. Slide the front cover toward the engine block (5) while keeping the cover raised. ; d. Lower the cover down over the dowel pin (4), allowing the front cover to rest on the sealant (3). 16. Install the front cover bolts and tighten, in sequence, as follows: : a. 1st pass: 53 inch Ibs. (6 Nm). b. 2nd pass: 106 inch Ibs. (12 Nm). 17. Install or connect the following: e Battery cable channel and bolt. Tighten to 80 inch Ibs. (9 Nm) e CMP sensor. Inspect the O-ring

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Proper front cover installation sequence—8.1L engine

with oil before installation — CMP sensor bolt to 106 inch Ibs. (12 Nm) Engine harness clips to the battery cable channel CMP sensor electrical connector Crankshaft balancer Water pump Negative battery cable. 18. Fill the cooling system with the proper type and quantity of antifreeze. Piston and Ring

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POSITIONING

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9348NG10

Engine front cover bolt tightening sequence—8.1L engine

General Motors 4.3L, 4.8L, 5.0L, 5.3L, 5.7L and 6.0L engines—piston and connecting rod assembly positioning

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9348NG11

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General Motors 8.1L engine—piston rings 7924AG10

General Motors 7.4L engine—piston and connecting rod assembly positioning

|

(1), piston (2), connecting rod (3) and related components

DIESEL ENGINE REPAIR

Engine Assembiy

of

REMOVAL & INSTALLATION

6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

tion. 2. Drain the cooling system. 3. Discharge the air conditioning sys-

tem and remove the air conditioning vacuum reservoir. 4. Drain the engine oil. 5. Remove or disconnect the following: e Battery cables e Engine cover, if equipped e Air cleaner e Radiator coolant reservoir bottle e Upper radiator support e Grille and the lower grille valance e Front bumper, if necessary e Air conditioning condenser from in front of the radiator 6. If the van is equipped with an automatic transmission, remove the fluid cooler lines from the radiator. e Radiator hoses at the radiator e Radiator support bracket e Radiator and the shroud e Accélerator and cruise control linkages

Hoses’ and wires at the fuel unit Fuel supply unit and cap the lines Intake manifold Turbocharger assembly, if equipped Lower intake manifold, if equipped Exhaust manifolds, if necessary Engine wiring harness from the firewall connection Power steering pump, it’s not necessary to disconnect the hoses;

just move aside Heater hoses at the engine Thermostat housing, if necessary Oil filler and automatic transmission tubes Cruise control servo, servo bracket and transducer, if equipped e Exhaust pipes at the manifolds Driveshaft and plug the end of the transmission Transmission shift linkage and the speedometer cable Fuel line from the fuel tank and pump Transmission mounting bolts 7. Support the transmission and engine.

8. Install lifting hooks J-41427 as follows: a.Step 1: Remove the 2 right rear lower intake manifold retainers and install lifting

hook J-41427 (the one marked “right”) Tighten the bolts to 11 ft. Ibs. (1 Nm) b. Step 2: Remove the air condition-

ing compressor and the accessory drive bracket. c. Step 3: If equipped, disconnect the

EGR tube and the 2 left lower bolts from the intake manifold. d. Step 4: Install the lifting hook J41427 (the one marked “left”) and tighten the bolts to 11 ft. Ibs. (15 Nm) 9. Remove or disconnect the following: e Engine mount bracket-to-frame bolts ; e Engine mount through-bolts 10. Raise the engine slightly and remove the engine mounts, support the engine with wood between the oil pan and the crossmember. 11. Remove the manual transmission and clutch as follows: a. Step 1: Remove the clutch housing rear bolts. b. Step 2: Remove the bolts attaching the clutch housing to the engine and remove the transmission and clutch as a unit. -> Support the transmission as the last bolt is being removed to prevent damaging the clutch.

c. Step 3: Remove the starter and clutch housing rear cover. d. Step 4: Loosen the clutch mounting bolts a little at a time to prevent dis-

For complete service labor times, order the Chilton Labor Guide

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7924KG01

For engine removal and installation, universal lift brackets should be installed in place of the proper intake manifold bolts

torting the disc until spring pressure is released. Remove all of the bolts, the clutch disc and the pressure plate. 12. Remove the automatic transmission as follows: a. Step 1: Lower the engine and support it on blocks. b. Step 2: Remove the starter and converter housing cover. c. Step 3: Remove the flexplate-toconverter attaching bolts. d. Step 4: Support the transmission on blocks. e. Step 5: Disconnect the detent cable on the Turbo Hydra-Matic. f. Step 6: Remove the transmissionto-engine mounting bolts. 13. Attach an engine crane to the engine. a. Step 7: Remove the blocks from the engine only and glide the engine away from the transmission. To install: 14. Install the manual transmission and clutch as follows: a. Step 1: Install the clutch disc and the pressure plate. Tighten the clutch mounting bolts a little at a time to prevent distorting the disc. b. Step 2: Install the starter and clutch housing rear cover.

c. Step 3: Install the bolts attaching the clutch housing to the engine and install the transmission and clutch as a unit. Tighten the bolts to specification. d. Step 4: Install the clutch housing rear bolts. 15. Install the automatic transmission as follows: a. Step 1: Position the transmission. b. Step 2: Install the transmission-toengine mounting bolts. c. Step 3: Connect the throttle linkage and detent cable. d. Step 4: Install the flexplate-to-converter attaching bolts. Torque the bolts to 65 ft Ibs. (90 Nm). e. Step 5: Install the starter and converter housing cover. 16. Install or connect the following: Engine mount through-bolts. Torque the bolts to 50 ft Ibs. (68 Nm) Engine mount bracket-to-frame bolts. Torque the bolts to 44 ft Ibs. (59 Nm) Clutch cross-shaft Transmission mounting bolts. Torque the bolts to 75 ft Ibs. (100 Nm)

e Transmission shift linkage and the speedometer cable. e Driveshaft 17. Remove the lifting hooks. Compressor EGR valve tube Intake manifold retaining bolts Condenser Hood latch support Lower fan shroud and filler panel Transmission dipstick tube and the accelerator cable at the tube Coolant hose at the intake manifold and the PCV valve Distributor cap Cruise control servo, bracket and transducer Oil filler pipe and automatic transmission filler pipe Engine dipstick tube Thermostat housing, if removed Heater hoses at the engine Engine wiring harness to the firewall connection Radiator and the shroud Radiator support bracket Exhaust manifolds if removed Lower intake manifold if removed Intake manifold Fuel supply unit Lines to the fuel supply unit Accelerator and cruise control linkages Windshield wiper jar and bracket Air conditioning condenser Air conditioning vacuum reservoir, if equipped Fluid cooler lines at the radiator, if equipped with an automatic transmission Radiator coolant reservoir battle Hoses at the radiator Upper radiator support Grille and the lower grille valance Air cleaner Air stove pipe Engine cover Battery cables 18. Refill the cooling system. 19. Recharge the air conditioning system.

Water Pump REMOVAL & INSTALLATION 6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

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14-47

GASKET

7924KG05

Exploded view of the water pump assembly and related components—6.5L diesel engines

2. Drain the engine coolant. 3. Remove or disconnect the following: Negative battery cables Fan and fan shroud Air conditioning hose bracket and/or the oil filler tube, as required Accessory drive belt(s) Vacuum pump mounting bracket

nuts/bolt Vacuum pump and bracket Power Steering pump and bracket Coolant hoses from the pump Water pump plate retaining bolts Pump and plate assembly from the engine Remove the bolt on the rear of the water pump plate.

e Separate the pump and gasket from the plate To install: 4. Install or connect the following: e Water pump and a new gasket to the plate. Torque the retaining bolt (at the rear of the plate) to 20 ft. lbs. (28 Nm) 5. Be sure the block mating surface and the plate flanges are free of oil. Apply an

anaerobic sealer GM part 1052357 or equivalent. ->The sealer must be wet to the touch when the bolts are tightened.

Water pump and plate assembly. Torque the bolts to 20 ft. Ibs. (28 Nm). e Coolant hoses to the pump assembly e Power steering pump and bracket Vacuum pump and bracket, along with the bolt holding the pump and alternator e Fan and pulley Accessory drive belt(s) Oil filler tube and/or air conditioning hose bracket nuts. If removed e Fan shroud e Batteries 6. Refill the radiator.

REMOVAL & INSTALLATION

2. Remove or disconnect the following: Negative battery cables Glow plug lead wires Plugs Right front tire Inner splash shield from the fender well Lead wire from the plug at the No. 2 cylinder and the lead wires from plugs in the Nos. 4 and 6 cylinders at the harness connectors Heat shroud for the plug in the No. 4 and 6 cylinder. Slide the shrouds back just far enough to allow access SO you can unplug the wires. Glow plugs in cylinders No. 2, 4 and 6. 3. Reach up under the vehicle and disconnect the lead wire at No. 8. Remove the glow plug. e>You may find that removing the exhaust pipe down mite make this a bit easier when working on Nos. 6 and 8.

6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Please visit our web site at www.chiltonsonline.com

To install: 4. Install or connect the following: e Glow plugs and tighten to 16 ft. lbs. (22 Nm)

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e Coolant crossover pipe/thermostat assembly ;

e Head bolts and the cylinder heads

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7924KG42

Exploded view of the heat shrouds and glow plug wiring—6.5L diesel engine

e Heat shrouds and electrical connection

Air cleaner resonator and bracket e Transmission and oil dipstick tube;

¢ Exhaust pipe, if removed e Splash shields, if removed e Negative battery cable

remove the oil fill tube from the coolant crossover pipe e Heater, radiator and bypass hoses

Cylinder Head REMOVAL & INSTALLATION

6.5L Engine

1. Before servicing the vehicle, refer to the

precautions in the beginning of this section.

To install: mi 6. Clean the mating surfaces of the heads and block thoroughly. 7. Clean the head bolts thoroughly. Coat the threads of the head bolts with sealing compound GM part 1052080 or equivalent, before installation. 8. Install or connect the following: e New gasket . e Cylinder head and bolts. Torque the bolts in the follows: a. Step 1: Torque the bolts to 20 ft. lbs. (25 Nm). b. Step 2: Torque the bolts to 50 ft. lbs. (65 Nm). c. Step 3: Then an additional 90 degrees (Y% turn). Coolant crossover pipe and thermostat . Fuel valve Bypass hose Upper radiator hose Heater hoses’at the head Transmission and oil dipstick tube Air cleaner resonator and bracket Pushrods, hardened ends facing up Rocker arm assemblies 9. Adjust the valves. e Valve cover e Alternator and upper bracket

° Alternator upper bracket

e Exhaust manifolds. Torque bolts to

* Alternator ° Power steering pump

22 ft. Ibs. (30 Nm) e Upper fan shroud

e Sahat be eb ¢ Fuel bleeder valve at the coolan

crossover pipe

|

* Fuel return crossover line clamp

bolts from both cylinder heads

e Intake manifold ¢ Turbocharger, if equipped. -

¢ Vacuum pump, if equipped

* Air conditioning compressor, if

equipped

2. Relieve the fuel system pressure. 3. Drain the coolant system. 4. Discharge the air conditioning system.

5. Remove or disconnect the following: Negative battery cables Intake manifold Fan upper shroud Compressor assembly, if equipped Turbocharger, if equipped Exhaust manifold Valve cover Rocker arm assemblies and pus hrods

e> Mark all components 1) they may be returned to their original location.

7924KG08

Tighten the cylinder head bolts according to the sequence shown for proper cylinder sealing— 6.5L diesel engines

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GENERAL MOTORS CORP. ESCALADE e DENALI e ena XL

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SUBURBAN e YUKON e YUKON XL

° Wires, Torque battery wire nut to

89 inch Ibs. (10 Nm), and ignition nut to 18 inch Ibs. (2 Nm) on

6.5L engines. On 6.6L engines, tighten the solenoid nut to 30

inch Ibs. (3.4 Nm) and the positive battery cable nut to 80 inch lbs. (9 Nm) e Starter Mounting bolts/nuts and shim, if

Starter Motor

REMOVAL & INSTALLATION 1. Before servicing the vehicle, referto the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cables e Right front wheel and fender splash shield, on 6.6L engines e Mounting bolts/nuts and shim, if used e Starter e Wires e Heat shield and bracket To install: 3. Install or connect the following: e Heat shield and bracket. Torque the bolts to 13 ft.lbs. (17 Nm)

used. Torque the bolts to 33 ft Ibs. (45 Nm) and the nut to 75 inch Ibs. (8.5 Nm) for 6.5L engines. For 6.6L engines tighten the starter bolts to

58 ft. Ibs. (78 Nm) Right front fender splash shield and wheel, on 6.6L engines e Negative battery cables

Rocker Arms/Shaft

REMOVAL & INSTALLATION 6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Engine cover ->Rotate the engine until the mark on the crankshaft balancer is at the 2 o'clock position. Rotate the crankshaft counterclockwise 31 in. (88mm) aligning the crankshaft balancer mark with the first lower water pump bolt, at about the 12:30 position. This will ensure that no valves are close to a piston crown

e Cylinder head cover e Rocker shaft assembly The rocker assemblies are mounted on 2 short rocker shafts per cylinder head, with each shaft operating 4 rockers. 2 bolts secure each rocker shaft assembly, Mark the shafts so they can be installed in their original locations.

e Pushrods. The pushrods MUST be installed in the original direction! A paint stripe usually identifies the upper end of each rod, but if you can’t see it, be sure to mark each rod yourself. 3. Insert a small prybar into the end of the rocker shaft bore and break off the end of the nylon retainers. Pull off the retainers with pliers, then slide off the rockers.

To install: 4. Be sure first that the rocker arms and springs go back on the shafts in the exact order in which they were removed. It’s a good idea to coat them with engine oil.

(1) Nut (2) Decoupling element (3) Intake air manifold

(4) Seal 9308KG04

f. 4

5. Center the rockers on the correspond-

‘

ing holes in the shaft 6. Install or connect the following: e New plastic retainers using a 2 in. (13mm) drift e Pushrods with there marked ends up e Rocker shaft assemblies and be sure that the ball ends of the pushrods seat themselves in the rockers 7. Rotate the engine clockwise until the mark on the torsional damper aligns with the 0 on the timing tab. Rotate the engine counterclockwise 3 ¥ in. (88mm) measured at the damper. You can estimate this by checking that the mark on the damper is now aligned with the FIRST lower water pump bolt. BE CAREFUL! This ensures that the piston is away from the valves. e Rocker shaft bolts. Torque them to AQ ft. Ibs. (65 Nm) e Cylinder head cover e Engine cover

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Exploded view of the starter motor—6.5L engine shown

Timing belt service is covered in Section 3 of this manual

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hand rotate the compressor

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* Oil feed line. Torque the connection to 13 ft. Ibs. (17 Nm). ¢ Exhaust pipe to the turbocharger exhaust elbow V-band clamp. Torque the clamp to 71 inch. Ibs. (8 Nm). 4. Disengage the injection pump fuel shutdown solenoid connector and crank the engine for no more 15 seconds to prime the oil system. Do not let the engine Start. Right front wheel and splash shield Heat shield. Apply Loctite or equiv-

alent to the bolts. Torque to 56 inch. Ibs. (6 Nm) Air cleaner assembly 7924KG22

Rocker shaft assembly and related components—diesel engines

Turbocharger e

REMOVAL & INSTALLATION

Turbocharger compressor outlet CDR valve, tube and bracket Air intake duct

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and the oil drain tube. Torque the bolts to 19 ft. Ibs. (26 Nm)

6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air inlet duct Oil feed line from the top of the turbocharger Crankcase Depression Regulator (CDR) valve vent bracket screw CDR valve and vent tube Air cleaner assembly Heat shield Right front tire assembly and the splash shield Exhaust pipe-to-turbocharger exhaust outlet elbow V-band clamp Oil drain tube-to-turbocharger center bearing bolts Exhaust manifold-to-turbocharger nuts Turbocharger To install: e>Use anti-seize compound on all threaded fasteners connected to the turbocharger

3. Install or connect the following:

e Turbocharger to the exhaust mani-

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Intake Manifold

REMOVAL & INSTALLATION 6.5L Engine _ 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e>Refer to Section 1 of this manual for the intake manifold torque sequence illustration. The illustration is located after the Torque Specification Chart.

2. Recover air conditioning system, and reposition air conditioning lines. 3. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly Fuel lines, and electrical connections e Engine and transmission oil level tubes

« WARNING

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side intakes as an assembly.

Center intak ifold imam

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° Side intake bolts and fuel retaining

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Torque the bolts to 31 ft. Ibs. (42 Nm)

e Side intakes 4. Clean all gaskets surface. To install: 5. Install or connect the following: e Side intakes and new gaskets.

4

trical connection e Center intake with new gaskets. Torque the bolts to 17 ft. Ibs. (23 Nm)

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e Engine oil and transmission oil level tubes Glow plug relay Air conditioning lines Air cleaner assembly Negative battery cable 6. Recharge air conditioning system. Exhaust Manifold

REMOVAL & INSTALLATION 6.5L Engine

7924K640 Exploded view of the side intake manifold mounting—1998-00 6.5L engines

;

e Fuel lines retaining clips and elec-

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Batteries cables e Exhaust pipe from the manifold flange e Engine oil and transmission oil fill tubes e Engine cover and disconnect the glow plug wires

Heater Core replacement is covered in Section 2 of this manual

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14-52

GENERAL MOTORS CORP.

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YUKON ¢ YUKON XL e Glow plugs e Turbocharger assembly, as required e Air conditioner compressor rear bracket, as required e Manifold bolts and the manifold To install: a 3. Install or connect the following: Exhaust manifold. Torque the bolts to 26 ft. Ibs. (35 Nm) Exhaust pipe Glow plugs and electrical connection Engine and transmission oil fill tubes Air conditioning compressor bracket Negative battery cable

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Camshaft and Valve Lifters

REMOVAL & INSTALLATION 6.5L Engine 7924KG44

Exploded view of the left exhaust manifold mounting—6.5L diesel engines

7924KG45

Exploded view of the right exhaust manifold mounting—6.5L diese! engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Discharge the air conditioning system. 4. Relieve the fuel system pressure. 5. Remove or disconnect the following: Battery cables Radiator, condenser, shroud and fan assembly Grille and parking light assembly Hood latch and brace assembly Oil pump drive Power steering pump and position aside Alternator, air conditioner compressor and position aside Rocker arm covers Rocker arm assemblies and pushrods. Mark them so they can be returned to their original position. Cylinder heads Hydraulic lifters and keep them in order so they can be returned to their original bore e Front cover Timing chain and camshaft sprocket Injector pump Front engine mounting throughbolts Air conditioner condenser mounting bolts and lift the condenser out Thrust plate bolts and thrust plate Camshaft from the block Thrust plate spacer, if necessary

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2. Drain the engine oil. 3. Remove or disconnect the following: e Battery cables Oil dipstick Flywheel/flexplate cover Oil cooler line guides Front driveshaft Front axle, if needed Exhaust pipes from the manifolds Front engine mount through-bolts Oil pan bolts and the oil pan Oil pan rear seal To install: 4. Clean all sealing surfaces. 5. Apply a%e in. (5mm) bead of RTV

sealant to the oil pan sealing surface, inboard of the bolt holes. The sealant must be wet to the touch when the oil pan is to be installed. 6. Install or connect the following: Oil pan rear seal Oil pan to the engine. Torque all bolts except the rear 2 bolts to 84 inch Ibs. (9.4 Nm) Tighten the rear

bolts to 17 ft. Ibs. (23 Nm).

7924KG46

Exploded view of the lifter, guide plate and clamp—6.5L diesel engines

To install: 6. Install the spacer with the ID chamfer toward the camshaft. >It is recommended that the engine oil, oil filter and hydraulic lifters be replaced when installing a new camshaft.

7. Coat the camshaft lobes with Molykote® or equivalent. 8. Lubricate the camshaft journals with engine oil. 9. Install or connect the following: Camshaft carefully into the block Thrust plate and bolts. Tighten to 17 ft. Ibs. (23 Nm) Engine mount through-bolts Timing chain and sprockets, Align the timing marks Air conditioner condenser, if equipped Injector pump Front cover Cylinder head Hydraulic lifters in the same bore as they were removed Rocker arm assemblies and pushrods in their original locations

Rocker arm covers Power steering pump, alternator and air conditioner compressor Oil pump drive Hood latch and brace Grille and parking light assembly Radiator, the shroud and fan assembly Negative battery cables 10. Refill the cooling system with the proper type and quantity of antifreeze.

Valve Lash

ADJUSTMENT All engines use hydraulic lifters, which require no periodic adjustment.

REMOVAL & INSTALLATION 6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Engine mounting through-bolt and nut Front axles and front driveshaft, if removed Oil cooler lines in guides Oil dipstick Exhaust pipes to the manifolds Flywheel/flexplate cover Battery cables 7. Refill with the proper grade and quantity of oil. ;

REMOVAL & INSTALLATION 6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil 3. Remove or disconnect the following: e Oil pan e (il pump to crankshaft rear main bearing attaching bolt e (Oil pump and hex drive To install: 4. Inspect the oil pan pick up tube and screen for damage and the hex drive for cracks. 5. Install or connect the following: e Oil pump and extension shaft to the engine. Align the extension shaft

Brake service is covered in Section 4 of this manual

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Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION

out

To install: _ 3. Clean the oil seal bore in the block

6.5L Engine

thoroughly before installation of the new Seal. 4. Inspect the crankshaft for grit, rust or burrs and correct as necessary. Also inspect the portion of the crankshaft where the oil seal makes contact, for wear due to the rubbing action of the oil seal. ->Because of rear crankshaft wear or

grooving, the new oil seal should be seated in a new location. The J 39084 installation tool will control the seal positioning. This will provide a new surface on the crankshaft for the seal to ride on.

5. Clean the running surface of the

7924KG48

Exploded view of the oil pump mounting— 6.5L diesel engines

hex with the drive hex, the oil pump should push easily into place. e Oil pump bolt. Torque the bolt to 65 ft. Ibs. (90 Nm). e Oil pan 6. Refill the crankcase with oil.

crankshaft with a non-abrasive cleaner. 6. Lubricate the inner diameter of the new seal and the outer diameter of the crankshaft with engine oil.

7. Install or connect the following: e Rear main oil seal using a crankshaft rear oil seal installation tool e Flywheel. e Transmission assembly e Transfer case, if equipped e Negative battery cables 8. Start the engine and verify no oil leaks.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cables e Water pump and pulleys 4. Rotate the crankshaft to align the marks on the torsional damper with the 0 mark on the timing tab. 5. Scribe a mark aligning the injection pump flange and the front cover, if not already marked. >The outer ring (weight) of the torsional damper is bonded to the hub with rubber. The damper must be removed with a puller that acts on the inner hub only. Pulling on the outer portion of the damper will break the rubber bond or destroy the tuning of the unit.

6. Remove or disconnect the following: e Crankshaft pulley and torsional damper e Front cover-to-oil pan bolts (4) e 2 fuel return line clips e Injection pump gear e Injection pump retaining nuts from the front cover

Rear Main Seal

REMOVAL & INSTALLATION Please note that the entire transmission assembly must be removed before performing this procedure. Before a new seal is installed, the Crankcase Depression Regulator (CDR) and crankcase ventilation system should be cleaned and inspected. In addition, use care removing the flywheel. Some models use a heavy, dual mass flywheel that must be handled with care. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cables e Transfer case, if equipped e Transmission assembly ¢ Clutch assembly and flywheel, if equipped with manual transmission

FRt TIMING CHAIN CAMSHAFT SPROCKET NJECTOR PUMP GEAR

CRANKSHAFT SPROCKET 7924KG23

Timing chain and related components—6.5L diesel engines

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e Crankshaft sensor ¢ Baffle ¢ Cover bolts remaining and the front cover ¢ Injection pump gear 7. Align the camshaft timing gear marks 8. Remove the bolt and washer attaching the camshaft gear. ¢ Camshaft sprocket with the timing chain. Remove the crankshaft sprocket. To install: 9. Install or connect the following: ¢ Cam sprocket, timing chain and crankshaft sprocket as a unit, aligning the timing marks on the sprockets. 10. Rotate the crankshaft to align the injection pump and camshaft gears. e Injection pump gear 11. If the front cover oil seal is to be replaced, it can now be pried out of the cover with a suitable prying tool. Press the new seal into the cover evenly. 12. Clean both sealing surfaces until all traces of old sealer are gone. Apply a %z in. (2mm) bead of GM sealant 1052357 or equivalent to the seating surface. Apply a %e in. (5mm) bead of RTV type sealer to the bottom portion of the front cover which attaches to the oil pan. Install the front cover. e Baffle e Injection pump. Torque the nuts to 31 ft. Ibs. (42 Nm), making sure the scribe marks on the pump and front cover are aligned. e Injection pump driven gear. Torque

the injection pump gear bolts to 17 ft. Ibs. (23 Nm), making sure the marks on the cam gear and pump are aligned.

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¢ Oil pan bolts. Torque the bolts to 106 inch Ibs. (12 Nm). e Water pump

e Pulley assembly e Negative battery cables 13. Refill the cooling system with the proper type and quantity of antifreeze. 14. Inspect the engine for leaks.

e»Verify that there is a minimum clear-

ance of 0.040 in. (1.0mm) between the injection pump gear and baffle or noise may be result.

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Fuel line clips Front cover-to-oil bolts Torsional damper Crankshaft pulley. Torque the bolts to 80 inch Ibs. (9 Nm).

Piston and Ring

POSITIONING

3 1 Oil control ring expander

gap

2. Second compression

ring gap

3. Centerline of piston pin 4. Oil control ring gap §. Tap compression ring gap 7924AG11

General Motors 6.5L Diesel engines—piston ring end-gap spacing

GASOLINE FUEL SYSTEM Fuel System Service Precautions ’ Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied.

e Always relieve the fuel system presSure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked

cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

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

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14-56 REEL ROESOERALYS DENALI XL Fuel System Pressure

RELIEVING A Schrader valve is provided on these fuel systems, in order to conveniently test or release the system pressure. A fuel pressure gauge and adapter will be necessary to connect the gauge to the fitting. Most of the MFI systems utilize a service valve on one end of the fuel rail assembly. The CMFI system covered here uses a valve located on the inlet pipe fitting, immediately before it enters the CMFI assembly (towards the rear of the engine) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the ignition OFF. 3. Disconnect the negative battery cable. 4. Loosen the fuel filler cap in order to relieve the fuel tank vapor pressure. 5. Connect a fuel pressure gauge to the

fuel pressure valve/fitting.

6. Wrap a shop towel around the fitting

while connecting the gauge in order to

avoid spillage.

7. Install the bleed hose of the gauge

|

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The spin-on fuel filter is serviced in the same manner as a spin-on oil filter

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the filter mounting clamp, then

tem, with the arrow facing away from

remove the clamp and filter assem-

the fuel tank.

into an approved container. 8. Open the valve on the gauge to bleed the system pressure. The fuel connections are now safe for

bly. Separate the filter from the _ clamp. To install: ~The inline filter has an arrow (fuel

servicing. Drain any fuel remaining in the

flow direction) on the side of the case,

gauge into an approved container.

7apaKe24

3. Install or connect the following: e In line filters place filter in clamp ¢ Install filter and clamp e Spin-on filters, lubricate the gasket before installation. Then tighten the

be sure to install it correctly in the sys-

REMOVAL & INSTALLATION

filter an additional 94 of a turn from

1

1998-99 Vehicles

The fuel filter is normally located along the frame rail of the vehicle. On some vehicles however, it may have been relocated to the engine compartment. When in doubt, trace a fuel line from the engine backwards or from the tank forward in order to locate the filter. Some vehicles utilize a spin-on fuel filter located on the frame rail. This filter can be turned counterclockwise after the fuel presSure is relieved. 1. Properly relieve the fuel system pressure. 2. Remove or disconnect the following: e Negative battery cable e Fuel line connections from the filter or unscrew the filter in the case of the spin-on type e Inline filters, remove the bolt from

9302K605 Typical in-line fuel filter mounting location

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15. Turn the ignition OFF for 10 seconds. 16. Turn the ignition ON. 17. Inspect for fuel leaks.

Fuel Pump

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REMOVAL & INSTALLATION 1998-99 Vehicles

9308KG55

Fuel filter-—4.8L, 5.3L, 6.0L engines

the point when the gasket touches the filter adapter. Always check for leaks after a new filter is installed.

1. Before servicing the vehicle, referto the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Drain the fuel from the vehicle. 4. Remove or disconnect the following: e Negative battery cable e Fuel tank from the vehicle ¢ Locking ring (located on top of the fuel tank) counterclockwise ¢ Lift the fuel pump assembly out of the tank To install: 5. Install or connect the following:

2000-01 Vehicles

1. Disconnect the negative battery cable. 2. Relieve the fuel system pressure. 3. Raise the vehicle. 4. Clean all the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. 5. Disconnect the threaded fittings from the fuel filter. 6. Cap the fuel pipes in order to prevent possible fuel system contamination. 7. Slide the fuel filter from the bracket. 8. Inspect the fuel pipe O-rings for cuts, nicks, swelling, or distortion. Replace

the O-rings if necessary. To install: 9. Slide the fuel filter into the bracket. Remove the caps from the fuel pipes. 10. Connect the threaded fittings to the fuel filter. Tighten the fittings to 25 Nm (18 ft. Ibs.). 11. Lower the vehicle. 12. Tighten the fuel filler cap. 13. Connect the negative battery cable. 14. Turn the ignition ON for 2 seconds.

7924KG25

Lift the fuel pump assembly out of the tank after removing the locking ring

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

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horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, _ assure that the fuel pump strainer does

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not block full travel of the float arm.

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e Fuel sender assembly into the fuel tank e Fuel sender assembly retaining ring

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attaching bolts. Tighten the bolts to 40 Nm (30 ft. Ibs.). 8. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable. 9. Turn the ignition ON for 2 seconds. 10. Turn the ignition OFF for 10 sec-

onds. 11. Turn the ignition ON. 12. Inspect for fuel leaks: i

Fuel Injector

REMOVAL & INSTALLATION 9308KG53

Fuel pump/sender assembly—4.8L, 5.3L and 6.0L engines

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e Fuel pump and secure with locking

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¢ Fuel tank to vehicle and refill e Negative battery cable 6. Run engine and check for fuel leaks. 2000-01 Vehicles

1. Remove or disconnect the following: e Negative battery cable 2. Relieve the fuel system pressure. 3. Drain the fuel tank. 4. Remove or disconnect the following: e Fuel tank

Do not handle the fuel sender assembly by the fuel pipes. The amount of

leverage generated by, handling the fuel pipes could damage the joints.

e Fuel sender assembly retaining ring using a fuel tank sénding unit wrench: Remove the fuel Sender assembly and the seal. Discard the seal.

Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off

4.3L, 5.0L, and 5.7L Engines

the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank. Fuel pump electrical connector Electrical connector retaining clip from the fuel level sensor Sensor electrical connector from under the fuel sender cover Fuel level sensor retaining clip 5. Squeeze the locking tangs and remove the fuel level sensor. 6. Remove the fuel pressure sensor. To install: 7. Install or connect the following: Fuel pressure sensor Fuel level sensor Sensor retaining clip Electrical connector to the fuel level sensor Electrical connector retaining clip

to the fuel level sensor Fuel pump electrical connector e> Always install a new fuel strainer when replacing the fuel tank fuel pump module.

New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of

WITH MULTI-PORT FUEL INJECTION (MFI) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. >Use care when removing the injectors to prevent damage to the electrical connector pins on the injector and the nozzle. The fuel injector is serviced as a complete assembly only. Since the injector is an electrical component, it should not be immersed in any type of cleaner.

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: ¢ Negative battery cable e Intake manifold plenum ¢ Fuel rail assembly _ © Wiring harness e Injector clip and discard it ¢ Injector O-ring seals from both ends of the injector. Save the 0ring backups for use on reassembly To install: 4. Install or connect the following: ¢ O-ring backups before installing the O-rings 9. Lubricate the new injector O-rings with clean engine oil

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Electrical connection Fuel feed and return hoses from the engine fuel pipes Upper manifold assembly Poppet nozzle out of the casting socket Fuel meter body by releasing the locktabs

Each injector is calibrated. When replacing the fuel injectors, be sure to replace it with the correct injector.

9308KG05

e Lower hold-down plate and nuts 4, While pulling the poppet nozzle tube downward, push with a small prytool down between the injector terminals and remove the injectors. ; To install: 9. Lubricate the new injector O-ring seats with engine oil. 6. Install or connect the following: e 0-rings on the injector

Exploded view of the fuel rail assembly—MFI systems

e 0Q-ring to injector assembly e Fuel ee ni the fuel rail injector socket with the electrical connectors facing outward e New injector retaining clips on the injector fuel rail assembly by sliding the clip into the injector groove as it snaps onto the fuel rail e Fuel rail assembly e Manifold plenum

e Fuel injector into the fuel meter

body injector socket e Lower hold-down plate and nuts, Torque the nuts to 27 inch Ibs. (3 Nm). e ih meter body assembly into the intake manifold. Torque the fuel meter bracket retainer bolts to 88 inch. Ibs. (10 Nm)

¢ Wiring harness e Negative battery cable WITH CENTRAL SEQUENTIAL FUEL INJECTION (CSFI) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable

“

CAUTION

To reduce the risk of fire or injury ensure that the poppet nozzles are properly seated and locked in their casting sockets e Fuel meter body into the bracket and lock all the tabs in place e Poppet nozzles into the casting sock-

ets e Electrical connections e New o-ring seals on the fuel return and feed hoses e Fuel feed and return hoses. Torque the fuel pipe nuts to 22 ft. Ibs. (30 Nm) e Negative battery cable 7. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks. e Manifold plenum 4.8L, 5.3L and 6.0L Engines

9908K606 Exploded view of the fuel injector assembly—MFI systems

1. Relieve the fuel system pressure. 2. Remove or disconnect the following: e Negative battery cable e Engine sight shield bolts and bracket

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

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GENERAL MOTORS CORP.

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YUKON XL . and to prevent damage to the nozzle. Service the fuel injector as a complete assembly only. The fuel injector is an electrical component. DO NOT immerse _ the fuel injector in any type of cleaner.

e Injector retainer clip. Insert the fork of a fuel injector assembly removal tool behind the injector connector between the fuel rail pod and the 3 protruding retaining clip ledges. Use a prying motion while inserting the tool in order to force the injector out of the fuel rail pod. Injector retainer clip. Injector O-ring seals from both ends of the injector. Discard the Oring seals. To install:

1. 2. 3. 4. 5. 6.

->When ordering new fuel injectors, be sure to order the correct injector for the application being serviced. The fuel injector assembly is stamped with a part number identification.

Regulator Assembly Fuel Meter Body Flexible Fuel Line Injector Assembly Poppet Nozzle Regulator Retainer 9308KG07

Exploded view of the CSFI fuel meter body assembly

7. Lubricate the new injector O-ring seals with clean engine oil. 8. Install or connect the following: e New injector O-ring seals on the injector e New retainer clip on the injector

e Accelerator control and cruise control cables from the cable bracket and throttle body e Upper engine wire harness retainer nut e Evaporative Emission (EVAP) purge valve harness connector 3. Position the upper engine wire harness aside 4. Tag the injector connectors for identification, then pull the top part of the injector connector up. Do not pull the top part of the connector past the top of the white portion. 5. Push the tab on the lower side of the injector connector to release the connect from the injection. Perform these steps on each injector connector. 6. Remove or disconnect the following: ¢ Fuel feed and return pipes from the fuel rail e Fuel pressure regulator vacuum line ¢ Crossover tube-to-right fuel rail retainer screw ¢ Fuel rail attaching bolts and fuel rail e>Use care in removing the fuel injectors in order to prevent damage to the electrical connector pins on the injector

1. 2. 3. 4. 5.

Flexible Fuel Line Seat Armature Flow Control Assembly Nozzle Assembly 9308KG08

Exploded view of the fuel injector assembly-CSFI systems

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e Accelerator control and cruise con- — trol cables to the bracket and

throttle body e Engine sight shield mounting bracket and bolts 13. Tighten the fuel cap. 14. Connect the negative battery cable. 15. Turn the ignition ON for 2 seconds. 16. Turn the ignition OFF for 10 seconds. 17. Turn the ignition ON. 18. Inspect for fuel leaks. 19. Install the engine sight shield. Tighten the engine sight shield bolts to 10 Nm (89 inch Ibs.)

2

3

8.1L Engine 1. Relieve the fuel system pressure.

4

2. Remove or disconnect the following: e Negative battery cable e Engine sight shield nuts and

9308KG52

bracket

Fuel injector—4.8L, 5.3L, 6.0L engines

e Alternator harness connector

9. Push the fuel injector into the fuel rail injector socket with the electrical con-

=

nector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket. 10. Remove the crossover tube-to-right fuel rail retainer, then remove the crossover tube. 11. Replace the crossover tube O-ring with a new, lubricated one. 12. Install or connect the following: Crossover tube and loosely install the retainer Fuel rail to the intake manifold Apply a 0.020 (5mm) band of threadlock to the fuel rail retaining

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bolts, then install and tighten to 89

inch Ibs. (10 Nm). Tighten the crossover pipe retainer to 34 inch lbs. (3.8 Nm) Fuel pressure regulator vacuum line Fuel feed and return pipes Fuel injector electrical connectors, as tagged during removal. Rotate the injectors as necessary to avoid stretching the wire harness Upper engine wire harness EVAP purge solenoid electrical connector

= Fuel rail assembly—4.8L, 5.3L, 6.0L engines

For Wheel Alignment specifications, see Section 1 of this manual

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Evaporative Emission (EVAP) purge valve harness connector ¢ Throttle Position (TP) sensor electrical connector _ Electronic Throttle Control (ETC) electrical connector 3. Upper engine wire harness bracket studs, and position the harness aside 4. Secondary Air Injection (AIR) crossover pipe, if equipped. 5. Tag the injector connectors for iden_ tification, then pull the top part of the injector connector up. Do not pull the top part of the connector past the top of the white portion. 6. Push the tab on the lower side of the injector connector to release the connect from the injection. Perform these steps on each injector connector. 7. Remove or disconnect the following: e Fuel feed and return pipes from the

fuel rail

+ Fuel pressure regulator vacuum

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e Fuel rail attaching bolts and fuel rail >Use care in removing the fuel injectors in order to prevent damage to the electrical connector pins on the injector and to prevent damage to the nozzle. Service the fuel injector as a complete assembly only. The fuel injector is an electrical component. DO

| Fuel System Pressure RELIEVING Fuel system pressure can be released by wrapping a fuel fitting in a heavy shop towel and slightly loosening the fitting. NEVER perform this with any source of ignition nearby!

Fuel System Air BLEEDING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Open the air bleed valve on the fuel manager/filter. 3. Connect a hose to the air bleed valve and place the other of the hose in a suitable container.

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NOT immerse the fuel injector in any type of cleaner.

e Injector retainer clip. Insert the fork of a fuel injector assembly removal tool behind the injector connector between the fuel rail pod and the 3 protruding retaining clip ledges. Use a prying motion while inserting the tool in order to force the injector out of the fuel rail pod. Injector retainer clip Injector from the fuel rail pod Injector O-ring seals from both ends of the injector. Discard the Oring seals. To install: ->When ordering new fuel injectors, be sure to order the correct injector for the application being serviced. The fuel injector assembly is stamped with a part number identification.

8. Lubricate the new injector O-ring

seals with clean engine oil.

9. Install or connect the following:

* New injector O-ring seals on the injector

e New retainer clip on the injector 10. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket. 11. Install or connect the following:

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e Fuel rail to the intake manifold Apply a 0.020 (5mm) band of threadlock to the fuel rail retaining bolts, then install and tighten to 106 inch Ibs. (12 Nm) Fuel pressure regulator vacuum line Fuel feed and return pipes Fuel injector electrical connectors, as tagged during removal. Rotate the injectors as necessary to avoid stretching the wire harness AIR crossover pipe, if equipped e Upper engine wire harness bracket Retainer studs to the upper engine wire harness and tighten the nut to 89 inch Ibs. (10 Nm) Alernator electrical connector EVAP purge solenoid electrical connector

TP and ETC sensor connectors Engine sight shield mounting

bracket and bolts

12. Tighten the fuel cap.

13. Connect the negative battery

cable. 14. Turn the ignition ON for 2 seconds. 15. Turn the ignition OFF for 10 sec16. Turn the ignition ON. 7. Inspect for fuel leaks. 18. Install the engine sight shield. Tighten the engine sight shield bolts to 10 Nm (89 inch Ibs.)

DIESEL FUEL SYSTEM + CAUTION The diesel/water mixture is flammable and may be hot. To avoid personal injury or property damage, do not allow the diesel/water mixture to come in contact with skin, open flame or a hot engine. Do not overfill the container holding the fuel mixture as heat from a warm engine or any another heat source may cause the fuel to expand and leak from the container that may lead to a fire.

vehicle. Allow the vehicle to run at idle for 5 minutes. 8. Check for fuel leaks, and clear any Diagnostic Trouble Code’s (DTC’s)

Idle Speed ADJUSTMENT Idle speed and injection timing is controlled by the PCM. There is no provision

for adjustment.

FST ES Se SE St

4. Remove the F/SOL fuse from the fuse panel. 5. Crank the engine in short intervals of 10-to-15 seconds until clear fuel is observed at the air bleed hose (wait for 1 minute between cranking intervals) 6. Remove the hose and close the air bleed valve. 7. Install the F/SOL fuse and start the

REMOVAL & INSTALLATION 6.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

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7. If not already done, open the air bleed valve on top of the fuel manager/filter

REMOVAL & INSTALLATION

assembly, then connect a length of hose placing the other end in a suitable container.

6.5L Engine

e>Be extremely cautious when handling diesel fuel. Do not expose the fuel to sparks or open flames. Also, be cautious as the fuel coming out of the drain hose could be hot.

FILTER FILTER HOUSING

8. Disconnect the fuel injection pump shutdown solenoid wire. 9. Crank the engine for 10-15 seconds, then wait 1 minute for the starter motor to cool. Repeat until clear fuel is observed coming from the air bleed. 10. Close the air bleed valve, reconnect the injection pump solenoid wire and replace the fuel tank cap. 11. Start the engine, allow it to idle for 5

minutes and check the fuel manager/filter

assembly for leaks.

Diesel Injection Pump 7924KG26

Exploded view of the’fuel filter assembly—6.5L diesel engines

2. Turn the ignition OFF. Remove the fuel tank cap to release any pressure or vacuum in the tank. >It is not necessary to drain all the fuel from the header in order to change the element since the fuel will remain in the header’s cavity.

3. Remove or disconnect the following: e Open the air bleed valve to relieve residual pressure e Element nut, turning it by hand to the left. If necessary, a strap wrench may be used to loosen the nut. ¢ Element by lifting straight up and out of the header assembly To install: 4. Be sure the mating surface between the element assembly and the header assembly is clean. 5. Install or connect the following: e New element by aligning the widest key slot located under the element assembly cap with the widest key in the header assembly. 6. Carefully push the element downward until the mating surfaces make contact. e Flement nut and tighten securely by hand

All vehicles are equipped with an electronically controlled pump. The electronic pump Is driven by gears and rotates at the same speed as the camshaft. An electronic stepper motor used to control injection timing and a fuel solenoid driver used to control the fuel injection solenoid on the electronic model.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Negative battery cables Intake manifold Fuel injection and inlet lines Cables wires, and hoses at the injection pump Fuel return line at the top of the injection pump Fuel feed line at the injection pump, if necessary Oil filler tube grommet ->Do not engage the starter in order to rotate the engine with the injection pump removed. The pump driven gear could jam in the front housing resulting in a sheared crankshaft or camshaft gear key and possible valvetrain damage.

4. Scribe or paint a matchmark on the front cover and the injection pump flange. 5. Rotate the crankshaft by hand and remove the injection pump driven gear bolts, accessing the bolts through the oil filler neck hole.

1

SLOTIN DRIVEN GEAR

2

PUMP HUB 7924KG27

Align the pin on the pump hub with the slot in the driven gear, NOT into the hole in the gear— diesel engines

For Maintenance Interval recommendations, see Section 1 of this manual

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6. Remove the injection pump-to-front cover attaching nuts. Remove the pump. Be sure to cap all open lines and nozzles in order to prevent system contamination and damage. To install: 7. Align the locating pin on the pump hub with the slot in the injection pump driven gear (the SLOT not the hole in the gear) At the same time, align the timing marks. 8. Attach the injection pump to the front cover. Torque the nuts to 30 ft. Ibs. (40 Nm) checking the timing marks before tightening. 9. Install or connect the following: Driven gear-to-injection pump bolts. Torque the bolts to 20 ft. Ibs. (25 Nm). Grommet and oil fill tube Air conditioning bracket. If applicable Fuel feed line. Torque to 20 ft. Ibs. (25 Nm). Fuel return line to the pump, if removed Cables, wires and hoses previously removed Injector lines Intake manifold Negative battery cables 10. Start the engine and check for leaks.

Fuel Injectors 6.5L Engine

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

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e Injection line. Torque the nut to 20 ft. Ibs. (25 Nm). e Fuel return hose e Fuel line clips e Batteries

> Special tool J-29873, or its equivalent, an injection nozzle socket, will be necessary for this procedure.

2. Remove or disconnect the following: e Batteries. e Fuel line clip e Fuel return hose e Fuel injection lines 3. Using GM special tool J-29873, remove the injector. Always remove the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector. Always cap the injector and fuel lines when disconnected, to prevent contamination. To install: 4. Always install the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector.

5. Install or connect the following: e Injector with a new gasket. Torque

9308KGO09

Fuel injector nozzle.

to 50 ft. Ibs. (70 Nm).

DRIVE TRAIN Transmission Assembly REMOVAL & INSTALLATION Automatic Transmission

1998-99 VEHICLES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission. 3. Remove or disconnect the following: Negative battery cable shift cable, control lever and the bracket e Exhaust pipes e Parking brake cables e Driveshaft, matchmark for reassembly e Transfer case, if equipped e Transmission to engine braces (vehicles equipped with diesel engines have only 1 brace) e Wiring harness at the transmis4. Support the transmission with a transmission jack.

e Nut securing the transmission mount to the cross member 5. Position a transmission jack or equivalent, under the transmission for support. e Crossmember. Visually inspect to see if other equipment, brackets or lines, must be removed to permit removal of transmission. e»Mark position of crossmember when removing to prevent incorrect installation. The tapered surface should face the rear.

6. Perform the following: a. Step 1: Remove the torque converter inspection cover. b. Step 2: Mark the alignment of the torque converter to the flexplate. c. Step 3: Remove the torque converter to flexplate bolts. Remove the dipstick tube and seal from the transmission. Plug the opening to avoid contamination. d. Step 4: Disconnect both transmission lines at the transmission and plug them to avoid contamination and leakage.

e. Step 5: Position a J 21366 converter holding strap onto the transmission/torque converter to keep the torque converter from sliding off of the transmission turbine shaft. ->The use of guide pins will not only support the transmission but will prevent damage to the clutch disc. Guide pins can be made by using 2 bolts, the same as those just removed only

longer, and cutting off the heads. Make an adjustment slot.

7. Remove the remaining bolts and slide transmission straight back from engine. Use care to keep the transmission drive gear straight in line with clutch disc hub. 8. Remove or disconnect the following: e Wiring, clips, tubes and brackets etc., which would interfere with the removal of the transmission. ->Ensure that the engine is supported with a jack stand before detaching the transmission from the engine.

e Transmission from the engine 9. Carefully lower the transmission using the transmission jack.

GENERAL MOTI

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ESCALADE © DENALI * DENALI XL * SUBURBAN © WIKRE TURE 14-65 To install: 10. Check the area behind the torque converter for leaks. Replace the front seal, if required. 11. It is good practice to examine the area around the rear crankshaft seal, checking for leaks. If necessary, remove the flexplate and replace the seal. 12. Inspect the flexplate ring gear teeth. -If damaged, replace the flexplate. 13. Perform the following steps: a. Step 1: With tool J 21366 or equivalent, torque converter holding strap in place, raise the transmission into position with a transmission jack. b. Step 2: Remove the torque converter holding strap and slide the transmission into place. Slide the transmission straight onto the locating pins while lining up the marks on the flexplate and the torque converter. Be sure the transmission is fully seated against the rear of the engine block and _ the locating pins are completely engaged. fuck WARNING ==

DO NOT attempt to draw the trans-

mission to the block with the mounting bolts. If the transmission is not

° Shifter cable e Starter ¢ Exhaust pipes e Transmission crossmember. Torque the bolts to 56 ft. Ibs. (77 Nm). e Transmission mount on the transmission. Torque the bolts to 35 ft. lbs. (47 Nm). e Nut and washer that secure the transmission mount to the crossmember. Torque the nut to 38 ft. lbs. (52 Nm). ¢ Transmission to engine brace(s) Torque the bolts to 41 ft. Ibs. (55 Nm) for gasoline engines and to 51 ft. bs. (70 Nm) for diesel engines. e Transfer case, if equipped 17. Remove the transmission jack and engine support stands. e Driveshaft e Shifter, lever and boot, on manual transmissions e Negative battery cable 18. Refill the transmission with fluid. 19. Road test the vehicle and test for proper operation. Check for leaks.

2000-01 VEHICLES—4L60E

1. Remove or disconnect the following: e Transmission fluid

¢ Transmission oil level indicator tube and seal from the transmission . e Plug the oil level indicator tube opening in the transmission. 2. Remove or disconnect the following: e Shift cable end from the transmission shift lever ball stud e lf equipped with a transfer case, remove the front propeller shaft. e Rear propeller shaft. 3. Plug the transmission oil cooler line connectors in the transmission case. 4, Remove or disconnect the following: e Starter motor. 5. Support the transmission with a transmission jack. 6. Remove or disconnect the following: e Torque converter access plug ¢ Flywheel to torque converter bolts e The two bolts and nut securing the transmission rear mount to the transmission e The two bolts securing the heat shield to the transmission The transmission vent hose, fuel lines, and the wiring harness from ee

the transmission

The stud and the bolt securing the transmission to the engine

properly seated, the bolts will break

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the transmission case.

=The torque converter must be flush with the flexplate and rotate freely by hand.

14. When satisfied that the transmission is properly seated, install and tighten the transmission-to-engine bolts and/or studs to 34 ft. Ibs. (47 Nm). 15. Perform the following steps: a. Step 1: Install the dipstick tube and Seal. b. Step 2: Check the alignment marks on the torque converter and flexplate to be sure that they are properly aligned. Install the torque converter bolts. Fingertighten the bolts to ensure proper converter seating. When the converter is properly seated, tighten the bolts to 46 ft. lbs. (63 Nm) c. Step 3: Install the torque, converter cover. Tighten the retaining bolts to 24 ft. lbs. (33 Nm) on the 4.3L engines or 89 inch Ibs. (10 Nm) on the V8 engines.

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16. Install or connect the following:

e Wiring, clips, tubes and brackets etc e Transmission cooling lines

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e The six studs and one bolt securing the transmission to the engine. Install tool J21366 onto the transmission bell housing to retain the torque converter. Pull the transmission straight back. 7. The transmission from the vehicle 8. Flush the transmission oil cooler and cooling lines when you remove the transmission. To install: 9. Install or connect the following: e Tool J21366 onto the transmission bell housing to retain the torque converter. 10. Support the transmission with a transmission jack. 11. Raise the transmission into place and remove the tool from the transmission. 12. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand. 13. Install or connect the following: Six studs and one bolt securing the transmission to the engine. Tighten the studs and the bolt to 50 Nm (37 ft. Ibs.). Stud and bolt securing the transmission to the engine. Tighten the stud and the bolt to 50 Nm (37 ft. lbs.). Flywheel to torque converter bolts. Torque converter access plug. Transmission vent hose, fuel lines, and the wiring harness to the transmission. Two bolts securing the heat shield to the transmission. Tighten the bolt to 17 Nm (13 ft. Ibs.). Two bolts and nut securing the transmission rear mount to the transmission. Tighten the bolts and nut to 25 Nm (18 ft. Ibs.). 14. Remove the transmission jack from the transmission. 15. Unplug the transmission oil cooler line connectors in the transmission case. 16. Install or connect the following: Transmission oil cooler lines to the transmission If equipped with a transfer case, install the front propeller shaft. The rear propeller shaft The shift cable end to the transmission shift lever ball stud Unplug the oil level indicator tube opening in the transmission. 17. Install the transmission oil level indicator tube and seal to the transmission.

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18. Tighten the oil pan bolts and fill the transmission with transmission fluid. 19. Lower the vehicle.

One nut and-one bolt securing the transmission brace to the engine bracket and transmission

2000-01 VEHICLES—4L80E 1. Remove or disconnect the following: e Transmission fluid e Transmission oil level indicator tube and seal from the transmission 2. Plug the oil level indicator tube opening in the transmission. 3. Remove or disconnect the following: e Shift cable from the transmission shift lever ball stud e |f 4WD vehicle, remove the propeller shaft. e If RWD vehicle, remove the propeller shaft. e The transmission oil cooler lines from the transmission 4. Plug the transmission oil cooler line connectors in the transmission case. 5. Remove or disconnect the following: e Starter motor e Support the transmission with a transmission jack. 6. Remove or disconnect the following: e The two bolts securing the heat

The two bolts securing the torque converter cover to the engine The four bolts securing the torque converter cover to the transmission The six flywheel to torque converter bolts The two bolts and nut securing the transmission rear mount to the transmission The stud and the bolt on the right side securing the transmission to the engine The remaining six studs and the one bolt securing the transmission to the engine Tool J21366 onto the transmission bell housing to retain the torque converter 7. Pull the transmission straight . back. Remove the transmission from the vehicle. 8. Flush the transmission oil cooler

and cooling lines when you remove the transmission.

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ESCALADE © DENALI © DENALI XL * SUBURBAN © YUKON © YUKON XL 1 4-67 To install: 9. Install or connect the following: . © 100! J21366 onto the transmission bell housing to retain the torque converter

10. Support the transmission with a transmission jack. 11. Raise the transmission into place and remove the tool from the transmission. 12. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand. 13. Install or connect the following: Six studs and one bolt securing the transmission to the engine. Tighten the studs and the bolt to 50 Nm (37

ft. Ibs.). The stud and bolt on the right side securing the transmission to the engine. Tighten the stud and the bolt to 50 Nm (37 ft. Ibs.). Six flywheel to torque converter bolts. Tighten the bolts to 60 Nm (44 ft. Ibs.). . The two bolts securing the torque converter cover to the engine.

Tighten the bolt to 50 Nm (37 ft.

lDs.). The four bolts securing the torque converter cover to the transmission. Tighten the stud and the bolt to 33 Nr (24 ft. Ibs.). The transmission vent hose, fuel lines, and the wiring harness to the transmission. The two bolts securing the heat shield to the transmission. Tighten the bolt to 17 Nm (13 ft. Ibs.). The two bolts and nut securing the transmission rear mount to the transmission. Tighten the bolts and nut to 25 Nm (18 ft. Ibs.). The flywheel to torque converter bolts. One nut and one bolt securing the transmission brace to the engine bracket and transmission. Tighten the bolts and nut to 50 Nm (37 ft. Ibs.). 14. Remove the transmission jack from the transmission. 15. Install or connect the following: e Starter motor 16. Unplug the transmission oil cooler line connectors in the transmission case. 17. Connect the transmission oil cooler lines to the transmission.

18. Install or connect the following: e The transfer case e The rear propeller shaft e The shift cable end to the transmission shift lever ball stud 19. Unplug the oil level indicator tube opening in the transmission. 20. Install the transmission oil level indicator tube and seal to the transmission. 21. Tighten the oil pan bolts and fill the transmission with transmission fluid. 22. Lower the vehicle.

Transfer Case Assembly

|

REMOVAL & INSTALLATION 1998-99 Vehicles

1. Before servicing the vehicle, refer to the precaution$ in the beginning of this section. 2. Drain transfer case of lubricant. 3. Remove or disconnect the following: Negative battery cable Skid plate, if equipped Vent hose clamp at the transfer case Front driveshaft at the transfer case and support it aside

Rear driveshaft and support it aside Electrical connections at the transfer case Transfer case shift linkage 4. Support the transfer case with a transmission jack. e Transmission to transfer case bolts and spring washers e Transfer case assembly and gasket 5. Carefully lower the transfer case. To install: 6. Carefully raise the transfer case into position. 7. Install or connect the following: ~e New gasket to the transmission using gasket sealer to hold it in place e Transfer case onto the transmission or transmission adapter. Torque the

bolts to 33 ft. Ibs. (45 Nm). e Electrical harness connectors to the transfer case connections e Transfer case shift linkage and make the proper adjustments e Front and rear driveshafts 8. Refill the transfer case with DEXRON®IIE automatic transmission fluid.

Skid plate, if equipped

e Negative battery cable 9. Test drive for proper operation.

2000-01 Vehicles NVG261-NP2 2-SPEED MANUAL TRANSFER CASE 1. Remove or disconnect the following: Transfer case shields Front propeller shaft Rear propeller shaft Shift rod from the transfer case - Vent hose from the transfer case Vehicle speed sensor electrical connectors Any wiring harness from the transfer case Support the transfer case with a transmission jack. 2. If equipped with a NV3500 manual transmission, remove the bolt securing the left side support brace to the transmission. 3. If equipped with a NV3500 manual transmission, remove the bolt and stud securing the left side support brace to the transfer case. 4. If equipped with a NV3500 manual transmission, remove the 2 bolts securing the right side support brace to the transmission and transfer case. 5. For vehicles equipped with a manual transmission, remove the 6 nuts securing the transfer case and bracket to the transmission. Remove the transfer case. 6. For vehicles equipped with a automatic transmission, remove the 6 nuts securing the transfer case and bracket to the transmission adapter. Remove the transfer case. 7. Remove and discard the gasket. To install: 8. Install a new gasket to the transmis-

sion. Use Teflon pipe sealant GM P/N 12346004 in order to hold the gasket in place. 9. Raise and position the transfer case to the vehicle 10. For vehicles equipped with a automatic transmission, install the 6 nuts securing the transfer case and bracket to the transmission adapter. Tighten the nuts to 50 Nm (37 ft. Ibs.). 11. For vehicles equipped with a manual transmission, install the 6 nuts securing the transfer case and bracket to the transmission. Tighten the nuts to 50 Nm (37 ft. IDs.). 12. If equipped with a NVG 261manual transmission, install the bolt securing the

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transmission, Install the bolt and stud securing the left side support brace to the transfer case. Tighten the bolt and stud to 50 Nm (37 ft. Ibs.). - 14. If equipped with a NVG 261manual transmission, install the 2 bolts securing the right side support brace to the transmission and transfer case. Tighten the bolts to 50 Nm (37 ft. Ibs.). 15. Install the vent hose to the transfer case. 16. Check the transfer case oil level. 17. Connect the speed sensor electrical connectors. 18. Connect wiring harness to the trans-

fer case. 19. Install case. ~ 20. Install 21. Install 22. Install 23. Lower

the shift rod to the transfer the the the the

rear propeller shaft. front propeller shaft. transfer case shields. vehicle.

NVG246-NP8 2-SPEED AUTOMATIC TRANSFER CASE 1. Remove or disconnect the following: Transfer case shields Front propeller shaft Rear propeller shaft Vent hose from the transfer case Vehicle speed sensor electrical connectors Electrical connectors from the transfer case motor/encoder Any wiring harness from the transfer case 2. Support the transfer case with a transmission jack. 3. If equipped with a NV3500 manual transmission, remove the bolt securing the left side support brace to the transmission. 4. |f equipped with a NV3500 manual transmission, remove the bolt and stud securing the left side support brace to the transfer case. 5. If equipped with a NV3500 manual transmission, remove the two bolts securing the right side support brace to the transmission and transfer case.

6. For vehicles equipped with a manual transmission, remove the six nuts securing the transfer case and bracket to the transmission. Remove the transfer case. 7. For vehicles equipped with a automatic transmission, remove the six nuts securing the transfer case and bracket to the transmission adapter. Remove the transfer case. 8. Remove and discard the gasket.

cotter pin. Separate the tie rod from

To install: 9. Install a new gasket to the transmission. Use Teflon Pipe Sealant GM P/N 12346004 in order to hold the gasket in place. 10. Raise and position the transfer case to the vehicle : 11. For vehicles equipped with a automatic transmission, install the six nuts securing the transfer case and bracket to the transmission adapter. Tighten the nuts to 50 Nm (37 ft. Ibs.). 12. For vehicles equipped with a manual transmission, install the six nuts securing the transfer case and bracket to the transmission. Tighten the nuts to 50 Nm (37 ft.

Ibs.). 13. If equipped with a NV3500 manual transmission, install the bolt securing the left side support brace to the transmission. Tighten the bolt to 50 Nm (37 ft. Ibs.). 14. If equipped with a NV3500 manual transmission, Install the bolt and stud securing the left side support brace to the transfer case. Tighten the bolt and stud to 50 Nm (37 ft. Ibs.). 15. If equipped with a NV3500 manual transmission, install the two bolts securing the right side support brace to the transmission and transfer case. Tighten the bolts to

50 Nm (37 ft. Ibs.). 16. Install or connect the following: Vent hose to the transfer case Oil Speed sensor electrical connectors Electrical connectors to the transfer case motor/encoder e Any wiring harness to the transfer case e Rear propeller shaft e Front propeller shaft Transfer case shields

REMOVAL & INSTALLATION 1998-99 Vehicles 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel and tire assembly Skid plate, as required. If equipped Drive axle hub nut and washer Brake line and wheel speed sensor support bracket from the upper control arm to allow extra travel of the control arm. Left outer tie rod attaching nut and

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the steering knuckle 3. Position the tie rod aside and push steering linkage to the opposite side of the vehicle. e Lower shock attaching nut and bolt; position the shock aside e Left stabilizer bar bracket and bushing at the frame e Stabilizer bar bolt, spacer and bushings at the lower control arm 4. Taking pressure off the upper control arm by placing a support below the lower’ control arm between the spring seat and the ball joint. e Upper ball joint cotter pin and loosen (do not remove) the upper ball joint attaching nut. Separate the ball joint stud from the steering knuckle. Remove the attaching nut. eCover the shock mounting bracket and lower ball joint stud with a towel to prevent the axle boot from tearing during removal and installation.

5. Separate the axle shaft from the hub and rotor using tool J-28733 or equivalent. e Axle shaft inner flange bolts and shaft To install: 6. Lubricate the axle and hub splines with an approved high temperature wheel bearing grease. 7. Install or connect the following: e Axle shaft in the hub e Inboard CV-joint-to-flange bolts. Torque the bolts to 60 ft. Ibs. (80 Nm). Upper ball joint to steering knuckle. Torque the stud nut to 61 ft. Ibs. (83 Nm). New cotter pin through the upper ball joint stud and nut, lubricate the ball joint as required. Left stabilizer bar bracket and bushing at the frame Stabilizer bar bolt, spacer and bushings at the lower control,arm Lower shock in the mount bracket and the attaching nut and bolt Left tie rod end at the steering knuckle. Torque the nut to 35 ft. lbs. (47 Nm). New cotter pin through the tie rod stud and nut Brake line bracket to the control arm, ensuring the line and/or hose is not twisted or kinked Skid plate, as required Axle hub washer and nut. Insert a drift through the rotor vanes to

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keep the axle from turning. Torque the hub nut to 180 ft. Ibs. (245 Nm) e Wheel and tire assembly

2000-01 Vehicles 1. Remove or disconnect the following: e Wheels 2. Insert a drift or a large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the drive axle wheel drive shaft from turning. 3. Remove or disconnect the following: e Nut and the washer from the hub. Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. e The 6 bolts securing the wheel drive shaft inboard flange to the output shaft flange e The drift from the rotor e The stabilizer shaft link from the lower control arm 4, Wrap shop towels around both the inner and the outer wheel drive shaft boots in order to avoid damage to the boots during removal and installation. 5. Pull the wheel drive shaft through the lower control arm opening.

To install: 6. Wrap shop towels around both the inner and the outer wheel drive shaft boots in order to avoid damage to the boots during removal and installation.

Tighten the hub nut to 210 Nm (155 ft. Ibs.). 10. Remove the drift from the rotor. 11. Install the stabilizer shaft link. 12. Install the wheel and tire assembly.

->Clean the steering knuckle and the wheel drive shaft splines and threads. These areas must be dry and free of grease, dirt, and contamination.

OVERHAUL

7. Insert the wheel drive shaft splined shank into the knuckle hub.

1998-99 Vehicles

e>Use only a genuine GM front wheel drive shaft nut. Installation of anything but an OEM front wheel drive shaft nut could cause damage to the vehicle.

8. Install or connect the following: e Washer and the new hub nut to the wheel drive shaft. Do not tighten. e The wheel drive shaft inboard flange to the output shaft flange using the inboard flange bolts 9. Insert a drift or a large screwdriver through the brake caliper into 1 of the brake rotor vanes in order to prevent the wheel drive shaft from turning. Tighten the inboard flange bolts to 78 Nm (58 ft. Ibs.).

OUTER CV-JOINT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft and position it in a vise Large CV-joint boot clamp and discard it Small CV-joint boot clamp and discard it C\-joint boot and slide it back on the shaft Outer race from the halfshaft by spreading the outer race-to-half-

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shaft retaining ring using Snapring Pliers J-8059 e Retaining ring from the halfshaft and discard it e CV-joint boot from the halfshaft and discard it if damaged 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. d. Remove the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are removed. 4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands. c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. 5. Throughly clean and inspect all parts. To install: 6. Lubricate the parts with a light coat of grease. _ 7. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 8. Assemble the chrome alloy balls into the C\V-joint cage, as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. d. Insert the opposite chrome alloy ball. é. Repeat the procedure until all 6 balls are inserted. 9. Install / of the kit grease into the CV-joint. 10. Install or connect the following: e Small ring clamp on the CV boot e New retaining ring on the halfshaft

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e Large ring clamp on the CV boot e Outer race assembly onto the halfshaft until the ring engages the halfshaft groove 11. Slide the small end of the CV-joint boot/clamp into place, with the seal lip in the halfshaft groove e>Make sure the boot lies flat against the halfshaft.

12. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 Nm). 13. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.

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16. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the . large CV-joint boot clamp to 130 ft. Ibs.

(176 Nm). 17. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is. 18. Install the halfshaft and the front wheel.

Legend

(9) CV Joint Seal (10) Race Retaining Ring

(3) (4) (5) (6) (7)

(12) (13) (14) (15)

(11) Ball CV Joint CV Joint CV Joint Deflector

Inner Race Cage Outer Race Ring

(8) Drive Axle Shaft 9308GK10

Exploded view of the CV-Joint assemble

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CV-joint boot. i 15. Slide the large end of the CV ‘boot/clamp into place, with the seal lip in

(1) Tripot Housing Assembly (2) Spacer Ring

Tripot Joint Spider Assembly Swage Ring Tripot Joint Seal Small Seal Retaining Clamp Drive Axle Seal Cover (Optional)

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INNER (TRI-POT) JOINT 1. Before servicing the vehicle, refer to theprecautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft and place it in a vise Snapring from the stub shaft and discard it Small CV-joint boot clamp, cut and discard it Large CV-joint boot clamp, cut and discard it CV-joint boot by sliding it away from the tri-pot joint 3. Install a Stub Shaft Removal tool J38868-A to the stub shaft snapring groove. 4. Using a slide hammer puller, press the stub shaft from the tri-pot housing. 5. Remove or disconnect the following: Tri-pot housing from the tri-pot spider Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059 Outboard retaining ring using Snapring Pliers tool J-8059 and discard it Tri-pot joint spider assembly Inboard spacer ring and discard it CV-joint boot Trilobal tri-pot bushing from the housing 6. Throughly clean and inspect all

GENERAL MOTORS CORP. 4A-71

SUBURBAN © YUKON © YUKON XL

° Inboard spacer ring, seat itin the groove Ve of the kit grease into the boot V2 of the kit grease into the tri-pot housing Trilobal tip-pot bushing flush with the tri-pot housing face New large seal clamp onto the CVjoint boot Tri-pot housing, slide it over the tri-pot joint spider assembly CV-joint boot/clamp, slide it into place, over the trilobal tri-pot bushing with the seal lip in the groove e> Make sure the boot lies flat against the trilobal bushing.

10. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm) 11. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is. 12. Install the halfshaft and the front wheel.

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To install: 7. Install or connect the following: e New snapring onto the stub shaft e Small boot clamp e CV-joint boot 8. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 Nm). 9. Install or connect the following: e Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059, past the 2nd groove Tri-pot joint spider assembly onto the shaft until it passes the 2nd groove Outboard retaining ring into the axle shaft groove using Snapring Pliers tool J-8059 Tri-pot joint spider assembly, slide it against the outboard retaining ring

2000-01 Vehicles

INNER JOINT e>With removal of the halfshaft for any reason, the transmission sealing surface (the tripot male/female shank of the halfshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the halfshaft reinstalled free of any buildup. 1. Use a hand grinder in order to cut through the swage ring. 2. Remove the tripot housing from the halfshaft. Wipe the grease off of the tripot assembly roller bearings and the tripot housing. Thoroughly degrease the tripot housing. Allow the tripot housing to dry prior to assembly. e> Handle the tripot spider assembly with care. Tripot balls and needle rollers may separate from the spider

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3. Use side cutters to cut away.the small boot clamp. 4. Compress the tripot boot up the halfshaft away from the tripot spider assembly toward the outboard (CV joint assembly)

~ end of the halfshaft. 5. Spread the spider spacer ring with tool J8059, or equivalent. 6. Remove the following items from the halfshaft bar: a. The spacer ring

b. The spider assembly c. The tripot boot 7. Clean the halfshaft bar. Use a wire brush in order to remove any rust in the boot mounting area (grooves). 8. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts. To assemble: 9. Place the new small boot clamp onto the small end of the joint boot. 10. Compress the joint boot and small boot clamp onto the halfshaft bar. 11. Position the small end of the joint boot into the joint boot groove on the halfshaft bar. 12. Secure the small boot clamp with tool J35910, or equivalent, a breaker bar, and a torque wrench. Tighten the small boot clamp (1) to 136 Nm (100 ft. Ibs.). 13. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. e>Assemble the CV joint with the convolute retainer in the correct position, as illustrated.

14. Install the convolute retainer over the inboard joint boot, being sure to capture three convolutions. 15. Install the tripot spider assembly onto the halfshaft bar with the counterbore towards the end of the halfshaft bar. 16. Install the spacer ring in the groove at the end of the halfshaft bar. 17. Push the spider assembly back toward the end of the halfshaft bar until the Spacer ring is covered by the spider assembly counterbore. 18. Pack the tripot boot and the tripot housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 19. Reassemble the tripot housing and the tripot boot using the following procedure: a. Pinch the swage ring slightly by

race 90 degrees to the center line of the outer race. At the same time, align the cage

d. Install the boot onto the tripot

20. Mount tool J36652 ina vise. Install the bottom half of the split-plate swage clamp. For K15 models, use tool J3665298. For K25 models, use tool J36652-1. 21. Check the inboard stroke position. Use measurement A for the K15 models. Use measurement B for the K25 models. 22. Position the inboard end (tripot end) of the halfshaft assembly in tool J36652. Install the top half of the proper size tool on the lower half of the tool. For K15 models, use tool J36652-98. For K25models, use tool J36652-1. 23. Align the swage ring and the swage ring clamp. Insert the bolts. Hand tighten the bolts in tool J36652 until the bolts are snug. 24. Align the following during this procedure: a. The tripot boot b. The housing c. The swage ring. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J36652 touch the bottom half of the tool. 25. Loosen the bolts and remove the halfshaft assembly from J36652. 26. Remove the convolute retainer from the boot.

OUTER JOINT 1. Place protective covers over the vise jaws. Place the halfshaft in the vise. 2. Use a hand grinder to cut through the swage ring. Use side cutters to cut off

the small boot clamp. 3. Slide the boot down the halfshaft bar and away from the CV-joint outer race. Wipe all grease away from the face of the CV joint. 4. Find the halfshaft bar retaining snap ring, which is located in the inner race. 5. Spread the snapring ears apart. 6. Pull the CV joint and the CV joint boot from the halfshaft bar. Discard the old CV joint boot. 7. Place a brass drift against the CV joint cage. Tap gently on the brass drift with a hammer in order to tilt the cage. 8. Remove the first chrome alloy ball

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when the CV intcage tilts. Tilt the CV joint cage (1)in the opposite direction to remove the opposing chrome alloy ball. Repeat this process to remove allsix of the balls. 9. Pivot the CV joint cage and the inner

hand in order to distort it into an oval shape. b. Slide the distorted swage ring over the large diameter of the boot. c. Place the tripot housing over the spider assembly.

housing. e. Align the tripot boot with the swage ring in place, over the flat area on the tripot housing.

oe

windows with the lands of the outer race. /

Lift out the cage and the inner race. 10. Remove the inner race from the cage by rotating the inner race upward. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. a. The inner and outer race assemblies ' b. The CV joint cage c. The chrome alloy balls 11. Dry all the parts. Check the CV joint assembly for unusual wear, cracks, or other damage. Replace any damaged parts. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). To assemble: 12. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. Put a light coat of the recommended grease on the inner and the outer race grooves. 13. Hold the inner race at 90 degrees to the centerline of the cage. Align the lands of the inner race with the windows of the cage. Insert the inner race into the cage by rotating the inner race downward. 14. Insert the cage and inner race into the outer race. 15. Place a brass drift against the CV joint cage. Tap gently on the brass drift with a hammer in order to tilt the cage. Install the first chrome alloy ball when the CV joint cage tilts. Tilt the CV joint cage in the opposite direction to install the opposing chrome alloy ball. Repeat this process in order to install all six of the balls. 16. Pack the CV joint boot and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 17. Place the new small boot clamp onto the CV joint boot. 18. Slide the CV joint boot onto the halfshaft bar. 19. Position the small end of the CV joint boot into the joint boot groove on the halfshaft bar. 20. Secure the small boot clamp, a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 ft. Ibs.). 21. Check the gap dimension on the

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ESCALADE ¢ DENALI ¢ DENALI XL ¢ SUBURBAN ¢ YUKON © YUKON XL clamp ear. Continue tightening until the gap dimension is reached. 22. Pinch the new swage ring slightly by hand to distort it into an oval shape. Slide the distorted swage ring over the large diameter of the boot.

Do not place the transfer case in either 4-wheel mode unless the hubs are in the Lock position!

e>Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation.

Locking hubs should be run in the Lock position periodically for a few miles to assure proper differential lubrication.

23. Slide the CV joint onto the halfshaft bar. The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position. 24. Pull on the CV joint to verify engagement. 25. Slide the large diameter of the CV joint boot with the large swage ring in place, over the outside edge of the CV joint

REMOVAL & INSTALLATION

outer race.

26. Clamp the CV joint boot tightly to the CV joint outer race with the large swage ring, using the following procedure: a. Mount tool J36652 in a vise. b. Install the bottom half of the splitplate swage clamp. For K15 models, use tool J36652-98. « c. For K25 models, use tool J36652lt d. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of tool J36652. 27. Align the following during this procedure: a. The CV joint boot b. The CV joint assembly c. The swage ring 28. Install the top half of tool J36652 onto the lower half of the tool, over the CV

joint boot and the CV joint assembly. 29. Align the swage ring and the swage ring clamp. _ 30. Insert the bolts into J36652. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 31. Loosen the bolts and remove the halfshaft assembly from the tool.

Manual Locking Hubs The engagement and disengagement of the hubs is a manual operation which must be performed at each hub assembly. The hubs should be placed FULLY in either Lock or Free position or damage will result.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels 3. Lock the hubs. Remove the outer retaining plate, Allen head bolts and take off the plate, O-ring, and knob assembly. External snapring from the axle

shaft * Compression spring Clutch cup O-ring and dial screw Clutch nut and seal Large internal snapring from the wheel hub e Inner drive gear e Clutch ring and spring e Smaller internal snapring from the clutch hub body e Hub body 4. Clean all hub parts in a safe, nonflammable solvent and wipe them dry. 5. Inspect each component for wear or damage. Make sure that the springs are functional and stiff. Make sure that all gear teeth are intact, with no chips or burrs. 6. Make sure that the splines on the inside of the wheel hub are clean and free of dirt, chips and burrs. 7. Surface irregularities can be cleaned up with light filing or emery paper. 8. Prior to assembly, coat all parts with the same wheel bearing grease. To install: 9. Install or connect the following: e Hub body e Smaller internal snapring in the clutch hub body e Clutch ring and spring Inner drive gear Large internal snapring in the wheel hub External snapring on the axle shaft. If the snapring groove is not completely visible, reach around, inside the knuckle and push the axle shaft outwards.

e e e e

Clutch nut and seal (Q-ring and dial screw Clutch cup Compression spring 10. Place the hub dial in the Lock position. 11. Coat the hub dial assembly O-ring with wheel bearing grease and position the hub dial and retainer on the hub. e Allen head bolts. Make sure that you used any washers that were there originally. Torque these bolts to 45 inch Ibs. (6 Nm) 12. Rotate the hub dial to the free position and turn the wheel hubs to make sure that the axle is free. e Wheels

Automatic Locking Hubs

REMOVAL & INSTALLATION The following procedure covers removal & installation only, for the hub assembly. The hub should be disassembled ONLY if overhaul is necessary. In that event, an overhaul kit will be required. Follow the instructions in the overhaul kit to rebuild the hub. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Capscrews and washer from the hub cap Hub cap and spring Bearing race, bearing and retainer Keeper from the outer clutch housing Large snapring to release the locking unit Locking unit from the hub. You can make this job easier by threading 2 hub cap screws into the outer clutch housing and hold these to pull out the unit. To install: 3. Wipe clean all parts and check for wear or damage. 4. Coat all parts with the same wheel bearing grease you've used on the bearings. 5. Install or connect the following: e Locking unit in the hub e Large snapring, pull outward on the unit to make sure the snapring is fully seated in its groove e Keepers e Bearing retainer, bearing and race. Make sure that the bearing is fully pack with grease.

Heater Core replacement is covered in Section 2 of this manual

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14-7

RP.

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TEMAI DANA XL ¢ SUBURBAN ¢ YUKON @ YUKON XL

6. Coat the hub cap O-ring with wheel bearing grease and install the hub cap. e Capscrews and washers. Tighten

the screws to 45 inch Ibs. (5 Nm).

Front Axle shaft, Bearing and Seal

REMOVAL & INSTALLATION 1998-99 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the front axle. 3. Remove or disconnect the following: e Electrical connectors, if equipped e Drive axle (halfshaft) e Axle shaft (output shaft) e Axle shaft from case e Deflector and seal e Bearing To install: 4. Install or connect the following: e New Bearing, square shoulder in Lubricate the new seal with grease.

e New seal e Deflactor e Axle shaft (output shaft) e Drive axle (halfshaft) e Electrical connectors, if equipped 5. Refill the front axle.

9308KG19

Front axle shaft exploded view

e Axle shaft (output shaft) tube nuts

2000-01 Vehicles 1. Remove or disconnect the follow-

ing: e Halfshaft assembly e Front axle fluid e Electrical connectors

from the bracket e Bracket bolts from the frame. Do not remove the bracket. The bolts are removed in order to provide clearance.

e Axle shaft (output shaft) bolts from the carrier Keep the open end of the tube up.

e Axle shaft (output shaft) tube from

9308KG21

Front axle shaft removal

the carrier. Ensure the spring is not lost during removal. In a vise, hold the axle shaft (output shaft) tube by the mounting flange. 2. Remove the following components: a. The shift shaft b. The damper spring c. The fork d. The clip assembly ‘ 3. Remove or disconnect the following: Sleeve Gear Thrust washer Axle shaft (output shaft). Tap out the axle shaft (output shaft) with a Soft mallet. Deflector. Pry out the deflector with a screwdriver. Seal. Pry out the seal with a screwdriver. Bearing, using a slide hammer. 4. Clean the parts in suitable solvent.

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Clean the gasket surfaces on the axle shaft (output shaft) tube and carrier housing. To install: 5. Install or connect the following: New bearing into the axle shaft tube using a driver. Apply axle lubricant to the bearing. New seal using a driver. Coat the seal lips with axle lubricant. Deflector e Axle shaft Thrust washer. Use grease in order to hold the thrush washer in place. Ensure the tabs on the thrush washer align with the slot in the

axle shaft tube. Gear Sleeve Shift shaft Damper spring Fork e Clip assembly 6. Apply sealant GM P/N 12345739 or the equivalent to the carrier sealing surfaces. 7. Install or connect the following: Spring into the carrier case Axle shaft tube to the carrier Axle shaft (output shaft) bolts. Tighten the bolts to 40 Nm (30 ft. Ibs.). Bracket bolts to the frame. Tighten the bolts to 90 Nm (67 ft. Ibs.). Axle shaft (output shaft) tube nuts to the bracket. Tighten the nuts to 100 Nm (75 ft. Ibs.). Halfshaft assembly e Electrical connectors 8. Fil the front differential with lubricant until the level is 12mm (0.5 in) below the fill plug.

Rear Axle Shaft, Bearing and | Seal | REMOVAL & INSTALLATION 1998-99 Vehicles SEMI-FLOATING NON-LOCKING DIFFERENTIALS 1. Remove the wheels and brake drums. 2. Remove the differential cover 3. Turn the differential until you can reach the differential pinion shaft lockscrew. Remove the lockscrew and the pinion shaft. 4. Push in on the axle end. Remove the

C-lock from the inner (button) end of the shaft. 5. Remove the shaft, being careful of the oil seal. 6. You can pry the oil seal out of the housing by placing the inner end of the axle shaft behind the steel case of the seal, then prying it out carefully. 7. A puller or a slide hammer is required to remove the bearing from the housing. To install: 8. Pack the new or reused bearing with wheel bearing grease and lubricate the cavity between the seal lips with the same grease. 9. The bearing has to be driven into the housing. Don’t use a drift, you might cock the bearing in its bore. Use a piece of pipe or a large socket instead. Drive only on the outer bearing race. In a similar manner, drive the seal if flush with the end of the tube. 10. Slide the shaft into place, turning it slowly until the splines are engaged with the differential. Be careful of the oil seal. 11. Install the C-lock on the inner axle end. Pull the shaft out so that the C-lock seats in the counterbore of the differential side gear. 12. Position the differential pinion shaft through the case and the pinion gears, aligning the lockscrew hole. Install the lockscrew. 13. Install the cover with a new gasket and tighten the bolts evenly in a criss-cross pattern. 14. Fill the axle with lubricant. 15. Replace the brake drums and wheels.

SEMI-FLOATING LOCKING DIFFERENTIALS This axle uses a thrust block on the differential pinion shaft. 1. Remove the wheels and brake drums. 2. Clean off the differential cover area, loosen the cover to drain the lubricant, and remove the cover. 3. Rotate the differential case so that you can remove the lockscrew and support the pinion shaft so it can’t fall into the housing. Remove the differential pinion shaft lockscrew. 4. Carefully pull the pinion shaft partway out and rotate the differential case until the shaft touches the housing at the top. 5, Use a screwdriver to position the Clock with its open end directly inward. You can’t push in the axle shaft till you do this.

.

6. Push the axle shaft in and remove the C-lock. 7. Remove the shaft, being careful of the oil seal. 8. You can pry the oil seal out of the housing by placing the inner end of the axle shaft behind the steel case of the seal, then prying it out carefully. 9. A puller or a slide hammer is required to remove the bearing from the housing. To install: 10. Pack the new or reused bearing with wheel bearing grease and lubricate the cavity between the seal lips with the same grease. 11. The bearing has to be driven into the housing. Don't use a drift, you might cock the bearing in its bore. Use a piece of pipe or a large socket instead. Drive only on the outer bearing race. In a similar manner, drive the seal in flush with the end of the tube. 12. Slide the shaft into place, turning it slowly until the splines are engaged with the differential. Be careful of the oil seal. 13. Keep the pinion shaft partway out of the differential case while installing the Clock on the axle shaft. Put the C-lock on the axle shaft and carefully pull out on the axle shaft until the C-lock is clear of the thrust block. 14. Position the differential pinion shaft through the case and the pinion gears, aligning the lockscrew hole. Install the lockscrew. 15. Install the cover with a new gasket and tighten the bolts evenly in a criss-cross pattern. 16. Fill the axle with lubricant. 17. Replace the brake drums and wheels.

FULL-FLOATING AXLES The procedures are the same for locking and non-locking axles. The best way to remove the bearings from the wheel hub is with an arbor press. Use of a press reduces the chances of damaging the bearing races, cocking the bearing in its bore, or scoring the hub walls. A local machine shop is probably equipped with the tools to remove and install bearings and seals. However, if one is not available, the hammer and drift method outlined can be used. 1. Support the axles on jackstands. 2. Remove the wheels. 3. Remove the bolts and lock washers that attach the axle shaft flange to the hub.

Brake service is covered in Section 4 of this manual

14-7

GENERAL MOTORS CORP. ESCALADE

DENALI ¢ DENALI XL e SUBURBAN ¢ YUKON ¢ YUKON XL

88797P14

87987P17

87987P15

Remove the pinion shaft

87987P18

Use a puller to remove the oil seal

87987P16

Remove the C-lock from the inner (button) end of the shaft

87987P19

Install the oil seal using a seal installer

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ae

14. Drive the outer bearing fromthe hub with a hammer and drift. “ae To install: 15. Place the outer bearing into the hub. The larger outside diameter of the bearing should face the outer end of the hub. Drive the bearing into the hub using a washer that will cover both the inner and outer races of the bearing. Place a socket on top of this washer, then drive the bearing into place with a series of light taps. If available, an arbor press should be used for this job. 16. Drive the bearing past the snapring groove, and install the snapring. Then, turning the hub assembly over, drive the bearing back against the snapring. Protect the bearing by placing a washer on top of it. You can use the thrust washer that fits between the bearing and the adjusting nut for the

B. Pinion Shaft C. Differential

D.

job.

17. Place the inner bearing into the hub. The thick edge should be toward the shoul-

Case

Housing

der in the hub. Press the bearing into the 84907357

et

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“Vai

‘

Positioning the case for the best clearance—semi-floating axle w/locking differential

4. Rap on the flange with a soft faced hammer to loosen the shaft. Grip the rib on the end of the flange with a pair of locking pliers and twist to start shaft removal. Remove the shaft from the axle tube. 5. The hub and drum assembly must be removed to remove the bearings and oil seals. You will need a large socket to remove and later adjust the bearing adjustment nut. There are also special tools available. 6. Disengage the tang of the locknut retainer from the slot or slat of the locknut, then remove the locknut from the housing tube. 7. Disengage the tang of the retainer from the slot or flat of the adjusting nut and remove the retainer from the housing tube. 8. Remove the adjusting nut from the housing tube. 9. Remove the thrust washer from the housing tube. 10. Pull the hub and drum straight off the axle housing. 11. Remove the oil seal and discard. 12. Use a hammer and a long drift to knock the inner bearing, cup, and oil seal from the hub assembly. 13. Remove the outer bearing snapring with a pair of pliers. It may be necessary to

hub until it seats against the shoulder, using a washer and socket as outlined earlier. Make certain that the bearing is not cocked

and that it is fully seated on the shoulder.

B. Pinion Shaft E. Thrust Block F. Side Gear (Locking Differential) G. Lock (C-Lock) H. Shaft

84907358

Aligning the lock—semi-floating axle w/locking differential

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

|

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14-78 GENERAL MOTORS CORP.

8

i

6. Axle shaft flange 7. Washer

8. Bolt

A. Dana

9. Retaining ring 10. Key

1. Drum

11. Adjusting nut

2. 3. 4. 5.

12. 13. 14. 15.

Hub Stud Gasket Shaft

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YUKON XL

ESCALADE ¢ DENALI ¢ DENALI XL e SUBURBAN ¢ YUKON

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Outer bearing Retaining ring Inner bearing Oil seal 84907359

Exploded view of the axle, hub and drum assembly—full-floating axle, 954 and 10% in.

J-2222-C

84907360

Removing the bearing adjusting nut—full-floating axle, 9% and 1074 in.

18. Pack the cavity between the oil seal lips with wheel bearing grease, and position it in the hub bore. Carefully press it into place on top of the inner bearing. 19. Pack the wheel bearings with grease, and lightly coat the inside diameter of the hub bearing contact surface and the outside diameter of the axle housing tube. 20. Make sure that the inner bearing, oil seal, axle housing oil deflector, and outer bearing are properly positioned. Install the hub and drum assembly on the axle housing, being careful so as not to damage the oil seal or dislocate other internal components, 21. Install the thrust washer so that the tang on the inside diameter of the washer is in the keyway on the axle housing. « 22. Install the adjusting nut. Tighten to 50 ft. Ibs. (68 Nm) while rotating the hub. Back off the nut /% turn and retighten to 35 ft. lbs. (47 Nm) on models with the 11 inch ring gear and 13 ft. Ibs. (17 Nm) on models with the 10 % inch ring gear. 23. Install the tanged retainer against the inner adjusting nut. Align the adjusting nut so that the short tang of the retainer will engage the nearest slot on the adjusting nut. 24. Install the outer locknut and tighten to 65 ft. Ibs. (88 Nm). Bend the long tang of

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the retainer into the slot of the outer nut. This method of adjustment should provide 0.001—-0.010 in. (0.0254-0.254mm) endplay. 25. Place a new gasket over the axle shaft and position the axle shaft in the

J-8092

housing so that the shaft splines enter the differential side gear. Position the gasket so that the holes are in alignment, and install the flange-to-hub attaching bolts. Tighten to 115 ft. Ibs. (156 Nm) on models with the 10 ¥ inch ring gear and tighten the axle cap bolts on models with the 11 inch ring gear to 19 ft. Ibs. (20 Nm). ©

J-24426

e>To prevent lubricant from leaking through the flange holes, apply a nonhardening sealer to the bolt threads. Use the sealer sparingly.

26. Replace the wheels. 2000-01 Vehicles

8.5 INCH AND 9.5 INCH REAR AXLE 84907361 Removing the bearing outer cup—full-floating axle, 954 and 10% in.

J 2222-C

1. Raise and support the vehicle on a hoist. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4, Remove the rear cover and the gasket. 5. Remove the pinion shaft locking SCIeW. 6. On axles without a locking differential, remove the pinion shaft. 7. On axles with a locking differential,

remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 8. On axles with a locking differential,

TORQUE WRENCH

use a screwdriver, or a similar tool, in order to enter the differential case and rotate the

lock until the lock aligns with the thrust block.

9. Push the flange of the axle shaft

a

toward the differential. Remove the lock

Rus

v

from the button end of the axle shaft.

HI

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=>When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult.

10. Remove the axle shaft from the 84907362

housing.

11. Inspect all the parts for damage. Replace the parts as necessary. To install: ;

Tightening the adjusting nut—tull-floating axle, 994 and 1012 in.

e>Carefully insert the axle shaft in the seal. damage order to not

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

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73. 74. 75. 76.

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Gasket Axle Shaft Axle Housing Bracket

77. Wheel Stud

74

73

. Deflector

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80. 81. 82. 83.

84

Oil Seal Inner Bearing Brake Disc Retaining Ring

84. Outer Bearing

85. 86. 87. 88. 89. 90.

Spacer Hub Thrust Washer Adjusting Nut Lock Washer Nut 84907363

Exploded view of the axle and hub assembly—tull-floating axle, 12 in.

J 2919-01

12. Install the axle shaft into the housing. Slide the axle shaft into place allowing the splines to engage the differential side gear. 13. On axles without a locking differential, place the lock on the button end of the axle shaft. 14. On axles with a locking differential, keep the pinion shaft partially withdrawn. 15. On axles with a locking differential, place the lock on the axle shaft so that the ends are flush with the thrust block. Pull the

shaft flange outward in order to seat the lock in the differential gear.

84907364

Removing the axle shaft—full-floating axle, 12 in.

e>Anytime you remove a differential pinion shaft locking screw, coat the screw threads with LOCTITE 242 before reinstalling the screws. The screw has an adhesive coating in order to prevent the screw from loosening in the case. Removing the screw removes the adheSive on the screw.

16. Align the hole in the pinion shaft with the screw hole in the differential case. 17. Install the pinion flange locking screw. Tighten the pinion flange locking screw to 34 Nm (25 ft. Ibs.) 18. Install the rear cover and the gasket. 19. Install the brake caliper. 20. Install the tire and wheel assembly.

E

21. Fill the rear axle. 22. Remove the supports and lower the vehicle.

10.5 INCH REAR AXLE 1. Remove the tire and wheel. 2. Remove the brake caliper. 3. Remove the brake rotor. 4, Remove the flange bolts. 5. Lightly rap the axle shaft with a softfaced hammer in order to loosen the shaft. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. Remove the axle shaft from the tube. 6. Remove the gasket. 7. Clean the axle shaft flange and the outside face of the hub assembly. Inspect all the parts. Replace the parts as necessary. To install: 8. Install the gasket onto the axle shaft. 9. Install the gasket and the axle shaft into the tube. Ensure the shaft splines mesh into the differential side gear. Align the holes in the axle flange and the gasket with

es

the holes in the hub. 10. Install the axle flange bolts. Tighten

the bolts to 150 Nm (110 ft. Ibs.). 11. Install the brake rotor.

Removing the wheel bearing nut—full-floating axle, 12 in.

12. Install the brake caliper.

13. Install the wheel and tire.

9308KG17

Rear axle shaft removal—8.5/9.5 inch 15 Series

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

14-82 GENERAL MOTORS CORP.

ESCALADE ¢ DENALI « DENALI XL » SUBURBAN « YUKON « YUKONXL 13. Tap the deflector onto the flange and stake it in three places. 14. Position the new seal in the carrier bore and drive it into place until flush. Coat the seal lips with wheel bearing grease. 15. Coat the outer edge of the flange neck with wheel bearing grease and slide it onto the pinion shaft. 16. Place a new nut and washer onto the pinion shaft and tighten it to the position originally recorded. That is, the alignment ~ marks are aligned, and the recorded number

of threads are exposed on the pinion shaft.

Never hammer the flange onto the pinion!

17. Measure the rotating torque of the pinion. Compare this to the original torque. Tighten the pinion nut, in small increments, ‘until the rotating torque is 3 inch Ibs. (0.35 Nm) GREATER than the original torque. 18. Install the driveshaft. 19. Install the calipers and install the wheels. 9308KG16

2000-01 Vehicles 1. Raise the vehicle on a hoist. 2. Remove the propeller shaft from the axle.

Rear axle shaft removal—10.5 inch 25 Series

Front Drive Axle Pinion Seal

REMOVAL & INSTALLATION 1998-99 Vehicles 1. Raise and support the front end on jackstands. 2. Matchmark and disconnect the front driveshaft at the carrier. 3. Remove the wheels. 4, Dismount the calipers and wire them up, out of the way. 5. Position an inch pound torque wrench on the pinion nut. Measure the torque needed to rotate the pinion one full revolution. Record the figure. 6. Matchmark the pinion flange, shaft and nut. Count and record the number of exposed threads on the pinion shaft. 7. Hold the flange and remove the nut and washer. 8. Using a puller, remove the flange. 9. Carefully pry the seal from its bore. Be careful to avoid scratching the seal bore. 10. Remove the deflector from the flange. To install: 11. Clean the seal bore thoroughly. 12. Remove any burrs from the deflector staking on the flange.

rae? Measuring the pinion rotating torque

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12. Install and stake the dust deflector on the flange. 13. Position the oil seal in the bore. Then place the a driver over the oil seal. Strike the

driver with a hammer until the seal flange seats on the axle housing surface. Drive the seal in straight, not at an angle, as this will damage the aluminum housing. e>Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

14. Install the flange onto the pinion using tool J8614-01. Place the washer and a new nut on the pinion threads. Tighten the nut to the original scribed position using the scribe marks and the exposed threads as reference. 15. Measure the rotating torque of the pinion. Compare the measurement with the rotating torque recorded earlier. Tighten the

rca

pinion nut by small increments until the torque required in order to rotate the pinion is 0.35 Nm (3 inch Ibs.) greater than the original torque.

Scribed marks

3. Tie the propeller shaft to a frame rail or the crossmember. 4, Measure the torque required in order to rotate the pinion. Record the torque value for reassembly. 5. Scribe a line on the pinion stem, the pinion nut and the companion flange. Record the number of exposed threads on the pinion stem. 6. Remove the nut. 7. Position tool J8614-01 on the flange so that the 4 notches on the tool face the flange. 8. Remove the flange. Use the special nut and the forcing screw. e>Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.

9. Remove the oil seal. 10. Inspect the pinion flange for a smooth oil seal surface. Inspect the pinion flange for worn drive splines. Replace the pinion flange if necessary. 11. Remove the dust deflector. To install: e»Stake the new deflector at 3 new equally spaced positions. You must stake the new deflector in such a way that you do not damage the seal operating surface.

84907308

Removing the pinion nut

For Wheel Alignment specifications, see Section 1 of this manual

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MOTORS CORP. ait ees TERALIXL » SUBURBAN © YUKON +YUKON XL

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FULL-FLOATING AXLES

84907309

Removing the pinion flange

16. Install the propeller shaft. 17. Lower the vehicle. Rear Drive Axle Pinion Seal

REMOVAL & INSTALLATION 1998-99 Vehicles

SEMI-FLOATING AXLES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and support the truck on jackstands. It would help to have the front end slightly higher than the rear to avoid fluid loss. 3. Matchmark and remove the driveshaft. 4. Release the parking brake. 5. Remove the rear wheels. Rotate the rear wheels by hand to make sure that there is absolutely no brake drag. If there is brake drag, remove the drums. 6. Using a torque wrench on the pinion nut, record the force needed to rotate the pinion. 7. Matchmark the pinion shaft, nut and flange. Count the number of exposed threads on the pinion shaft. 8. Install a holding tool on the pinion. A very large adjustable wrench will do, or, if one is not available, put the drums back on and set the parking brake as tightly as possible. 9. Remove the pinion nut.

10. Slide the flange off of the pinion. A puller may be necessary. 11. Centerpunch the oil seal to distort it and pry it out of the bore. Be careful to avoid scratching the bore. To install: 12. Pack the cavity between the lips of the seal with lithium-based chassis lube. 13. Position the seal in the bore and carefully drive it.into place. A seal installer is VERY helpful in doing this. 14. Pack the cavity between the end of the pinion splines and the pinion flange with Permatex No.2 sealer, or equivalent non-hardening sealer. 15. Place the flange on the pinion and push it on as far as itwill go. 16. Install the pinion washer and nut on the shaft and force the pinion into place by turning the nut.

1. Raise and support the truck on jackstands. It would help to have the front end slightly higher than the rear to avoid fluid loss. 2. Matchmark and remove the driveshaft. 3. Matchmark the pinion shaft, nut and flange. Count the number of exposed threads on the pinion shaft. 4. Install a holding tool on the pinion. ~ A very large adjustable wrench will do, or, if one is not available, set the parking brake as tightly as possible. 5. Remove the pinion nut. 6. Slide the flange off of the pinion. A puller may be necessary. 7. Centerpunch the oil seal to distort it and pry it out of the bore. Be careful to avoid scratching the bore. To install: 8. Pack the cavity between the lips of the seal with lithium-based chassis lube. 9. Position the seal in the bore and carefully drive it into place. A seal installer is VERY helpful in doing this. 10. Place the flange on the pinion and push it on as far as it will go.

Never hammer the flange into place! 11. Install the pinion washer and nut on the shaft and force the pinion into place by turning the nut. 12. On models with the 11 inch ring gear, tighten the nut to 440-500 ft. Ibs. (596-678 Nm) 13. On models with the 10 ¥% inch ring gear Tighten the nut until the exact number of threads previously noted appear and the matchmarks align. 14. Install the driveshaft.

2000-01 Vehicles 1. Raise the vehicle on a hoist.

Never hammer the flange into place! 17. Tighten the nut until the’exact number of threads previously noted appear and the matchmarks align. 18. Measure the rotating torque of the pinion under the same circumstances as before. Compare the two readings. As necessary, tighten the pinion nut in VERY small increments until the torque necessary to rotate the pinion is 3 inch Ibs. (0.35 Nm) higher than the originally recorded torque. 19. Install the driveshaft.

=>Observe and accurately mark the positions of all driveline components

relative to the propeller shaft and axles prior to disassembly. These components include the propeller shaft, drive axles, pinion flanges, output shafts, etc. Reassemble all components in the exact relationship the components had to each other during removal. Follow the specifications and the torque values. Follow any measurements made prior to removal.

2. Accurately mark the installed posi-

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ESCALADE ¢ DENALI * DENALI XL ¢ SUBURBAN tion of the rear propeller shaft. Remove the rear propeller shaft. 3. Measure the torque required to turn the-pinion. Record the torque number measurement which gives the combined pinion bearing, seal, carrier bearing, axle bearing and seal preload. 4. Make and accurate alignment mark on the pinion flange. Record the number of exposed threads on the pinion stem. 5. Remove the pinion flange nut and the washer. Use a container in order to catch any lubricant. e>Use care not to damage any of the machined surfaces.

6. Remove the pinion flange. >The pinion flange has an oil seal that is part of the pinion flange assembly. The pinion flange must be inspected to ensure that the seal is not damaged.

7. Pry the oil seal from the bore. 8. Thoroughly clean any foreign material from the contact area. Replace any parts as necessary. To install: ; 9. Lubricate the cavity between the lips of the oil seal with wheel bearing lubricant. 10. Install the oil seal into the bore using a driver.

15. Install the retainers and the bolts.

e Right side inner tie rod end at the relay rod

Tighten the bolts to 20 Nm (15 ft. Ibs.). 16. Fill the rear axle. 17. Lower the vehicle. Front Drive Axle Differential Carrier

REMOVAL & INSTALLATION

1998-99 Vehicles 1.. Remove or disconnect the following: e Wheels e Skid plate e Fluid 2. Matchmark and remove the front driveshaft. 3. Remove or disconnect the following: e Right axle shaft at the tube flange e Left axle shaft at the carrier flange ->Wire both axle shafts out of the way. e Connectors at the indicator switch and actuator e Carrier vent hose e Axle tube-to-frame bolts, washers and nuts

e Lower carrier mounting bolt

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MOTORS CORP. +4- 85 a © YUKON ¢ YUKON XL

GENERAL

->Depending on the model, it may be necessary to remove the engine oil filter.

4. Support the carrier on a floor jack 5. Remove or disconnect the following; e Upper carrier mounting bolt 6. Lower the carrier assembly from the truck,

To install: 7. Raise the carrier into position. 8. Install or connect the following: Upper carrier mounting bolt, washers and nut. Then, install the lower carrier mounting bolt, washers and nut. Tighten the bolts to 80 ft. Ibs. (110 Nm). Oil filter Tie rod end. Tighten the nut to 35

ft. Ibs. (47 Nm). Axle tube-to-frame bolts, washers and nuts. Tighten the nuts to 75 ft. lbs. (100 Nm) for 15 and 25 series; 107 ft. Ibs. (145 Nm) for 35 series. Vent hose Wiring

->Do not hammer the pinion flange onto the pinion stem.

11. Install the pinion flange. Use the alignment marks in the installation of the pinion flange. 12. Install the washer and a new nut. Tighten the nut on the pinion stem as close as possible to the alignment marks without going past the marks. Use the alignment marks and the thread count as a reference. Tighten the nut a little at a time. Turn the pinion flange several times after each tightening in order to seat the rollers. elf the recorded preload torque value was less than 4 Nm (3 ft. Ibs.), reset the torque specification to 3-5 Nm (4-7 ft. Ibs.).

13. Measure the torque required to rotate the pinion flange. Compare the measured torque with the recorded value. Continue tightening the pinion nut and measuring the torque until you achieve the recorded value. 14. Align the propeller shaft with the alignment marks. Connect the propeller shaft.

9308KG18

Front differential carrier removal—15 Series

For Maintenance Interval recommendations, see Section 1 of this manual

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e Axle shafts at the flanges. Tighten the bolts to 59 ft. Ibs. (80 Nm). e Driveshaft. Tighten the bolts to 15

ft. Ibs. (20 Nm). e Gear oil e Wheels 9. Add any engine oil lost oe the filter was removed.

2000-01 Vehicles 1. Remove or disconnect the following: 2. Front axle fluid 3. Front propeller shaft 4. Left and the right drive axle wheel drive shaft 5. Axle tube nuts from the bracket 6. Wiring at the axle 7. Vent hose at the axle 8. Carrier assembly lower mounting bolt and the nut 9. Idler arm from the relay rod 10. Pitman arm from the relay rod 11. Attach a transmission jack to the carrier assembly. 12. Remove the upper carrier assembly mounting bolt and the nut. 13. Remove the carrier assembly from the vehicle. To install: 14. Install or connect the following: 15. Carrier assembly in the vehicle 16. Carrier assembly upper mounting bolt and the nut 17. Lower carrier assembly mounting bolt and the nut. Tighten the bolts to 100 Nm (75 ft. Ibs.). 18. Pitman arm to the relay rod 19. Idler arm to the relay rod 20. Axle tube nuts to the bracket. Tighten the bolts to 100 Nm (75 ft. Ibs.). 21. Vent hose 22. Wiring to the axle 23. Left and the right drive axle wheel drive shaft 24. Front propeller shaft to the pinion flange 25. Fill the front differential with lubricant.

Rear Drive Axle Housing

REMOVAL & INSTALLATION 1998-99 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the lubricant from the axle housing 3. Remove or disconnect the following: e Driveshaft e Wheel, the brake drum or hub and the drum assembly e Parking brake cable from the lever and at the brake flange plate Hydraulic brake lines from the connectors Shock absorbers from the axle brackets Vent hose from the axle vent fitting, if equipped Height sensing and brake proportional valve linkage, if equipped e Stabilizer shaft, if equipped 4. Support the axle assembly with a jack. e U-bolts e Spring plates and spacers e Axle assembly To install: 5. Raise the axle assembly into position. 6. Install or connect the following: e U-bolts Spring plates and spacers Nuts and washers on the U-bolts. Torque the nuts to 81 ft. Ibs. (110 Nm). Stabilizer shaft, if equipped Height sensing and brake proportional valve linkage, if equipped Vent hose at the axle vent fitting, if equipped Shock absorbers at the axle brackets Hydraulic brake lines

STEERING AND SUSPENSION

Kk CAUTION Some vehicles are equipped with an air bag system. The system must be disabled before performing service on or around system components, Steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling

procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. SS

SS

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury.

e Parking brake cable e Wheels e Driveshaft 7. Fill the axle housing.

2000-01 Vehicles 1. Before servicing the vehicle, refer to ‘the precautions in the beginning of this section. 2. Remove or disconnect the following: e Axle lubricant Propeller shaft Wheel assemblies Parking brake cable Brake calipers Shock absorbers from the axle brackets Vent hose from the rear axle vent fitting Nuts and the washers from the Ubolts. U-bolts, the spring plates and the spacers form the axle assembly. 3. Lower the axle assembly. To install: 4. Place the rear axle assembly under the vehicle. Align the rear axle assembly with the springs. Connect the spacers, the spring plates and the U-bolts to the rear axle. Raise the rear axle assembly into position. 5. Install or connect the following: Washers and nuts to the U-bolts. Tighten the nuts to 80 Nm (59 ft. lbs.). first, then to 120 Nm (89 ft. lbs.). Vent hose to the rear axle vent fitting Shock absorbers to the rear axle Brake calipers Parking brake cable Weel assemblies Propeller shaft 6. Fill the rear axle. 7. Bleed the brake system. 8. Remove the supports and lower the vehicle.

; e Never carry the inflator module by the wires or connector on the underside of the module e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away e Place the inflator module on a bench or other surface with the bag and trim cover facing up e With the inflator module on the bench,

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- GENERAL MOTORS CORP.

ESCALADE © DENALI ¢ DENALI XL e SUBURBAN e YUKON ¢ YUKON XL

14-87

never place anything on or close to the module that may be thrown in the event of an accidental deployment

DISARMING 1. Turn the front wheels to the straightahead position. 2. Turn the ignition switch to the LOCK position and remove the key. e>if the key is in the RUN position when the Air Bag fuse is removed or

open (blown), the Air Bag warning lamp in the dash will light up. This is normal operation, not a sign of a malfunction.

7924KG30

3. Remove the Air Bag fuse from the fuse panel. 4. Remove the drivers side knee bolster and unplug the yellow 2-pin connector at the base of the steering column to disarm the driver's side Air Bag. Remove the passenger side knee bolster and unplug the yellow 2-pin connector to disable the passenger’s side Air Bag. 5. Reverse the procedure to arm the Air Bag restraint system.

Power Steering Pump REMOVAL & INSTALLATION 4.3L, 5.0L, 5.7L, 6.5L and 7.4L Engines

7924KG31

Typical air bag connector location—passenger’s side

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the hoses at the pump. When the hoses are disconnected, secure the ends in a raised position to prevent leakage. Cap the ends of the hoses to prevent the entrance of dirt. 3. Cap the pump fittings. 4. Loosen the belt tensioner. 5. Remove the pump drive belt. 6. Remove the pulley with a pulley puller such as J-29785-A. 7. Remove the following fasteners: e 6-4.3L, 8-5.0L, 8-5.7L engines: front mounting bolts e 8~-7.4L engine: rear brace e 8-6.5L diesel: front brace and rear mounting nuts 8. Lift out the pump. To install: 9. Observe the following torques: e 6-4.3L, 8-5.0L, 8-5.7L engines,

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

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9308KG50

Power steering pump—4.8L, 5.3L and 6.0L engines shown

front mounting bolts: 37 ft. Ibs. (50 Nm) e 8-/.4L engine, rear brace nut: 61 ft. Ibs. (82 Nm); rear brace bolt: 24 ft. Ibs. (82 Nm); mounting bolts: 37 ft. Ibs. (50 Nm) e 8-6.5L diesel, front brace: 30 ft. lps. (40 Nm); rear mounting nuts: 17 ft. Ibs. (23 Nm). 10. Install the pulley with J-25033-8. 11. Install the drive belt. 12. Install the hoses. 13. Fill and bleed the system. 4.8L, 5.3L, 6.0L, and 8.1L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Upper radiator fan shroud, if necessary

© Drive belt ° Pulley.

Nut and clamp retaining the filler neck to the power steering pump, if equipped 3. Place a drain pan under the pump. Remove the hoses from the pump. ¢ Bolts from the rear of the pump ¢ Bolts from the front of the pump e Pump from the vehicle To install: 4. Install or connect the following: ¢ Power steering pump ¢ Bolts to the front and the rear of the

pump. Tighten the bolts to 50 Nm (37 ft. Ibs.) e Hoses to the pump. Tighten the nut to 28 Nm (20 ft. Ibs.) e Nut and clamp retaining the filler neck to the power steering pump, if equipped e Pulley. Install the pulley with 0.5 mm (0.020 in) play e Drive belt e Upper radiator shroud. 5. Fill and bleed the power steering system.

Recirculating Ball Power Steering Gear REMOVAL & INSTALLATION 1998-99 Vehicles

These vehicles use a conventional power

steering gear with a recirculating ball system. All tubes, hoses and fittings should be inspected for leakage at regular intervals. Fittings must be tight. Be sure the clips, clamps and supporting tubes and hoses are in place and properly secured. Inspect the hoses with the wheels in the straight-ahead position. Then, turn the wheels fully to the left and right while observing the movement of the hoses. Correct any hose contact with other parts of the vehicle that could cause chafing or wear. Power steering hoses and pipes should not be twisted, kinked or tightly bent. The hoses should have suffi-

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cient natural curvature in the routing to absorb movement and hose shortening during vehicle operation. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Set the front wheels in the straightahead position. 3. Place a drain pan under the steering gear and disconnect the fluid lines. Cap the openings to protect the system from contamination. 4. Remove or disconnect the following: Negative battery cable Adapter and shield from the gear and flexible coupling Flexible coupling clamp and steering box input shaft, matchmark for reassemble Flexible coupling pinch bolt Pitman arm to the Pitman shaft, matchmark for reassemble Pitman shaft nut and lockwasher Pitman arm from the shaft using the proper puller Steering gear to frame bolts Gear assembly To install: 5. Install or connect the following: e Steering gear in position, guiding the input shaft into the flexible coupling. Align the flat in the coupling with the flat on the input shaft. e Steering gear-to-frame bolts. Torque the bolts to 100 ft. Ibs. (135 Nm) e Flexible coupling pinch bolt. Torque the pinch bolt to 22 ft. Ibs. (30 Nm) e>Check that the relationship of the flexible coupling to the flange is %4-%%4 in. (6-19mm) of flat.

e Pitman arm onto the Pitman shaft, lining up the marks made at removal. Torque the nut to 215 ft. lbs. (285 Nm). S Addotér anihshiaht

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with the proper power steering fluid 6. Properly bleed the system and verify no leaks. 7. Road test the vehicle for proper steering system operation.

2000-01 Vehicles 1. 2. 3. gear. 4,

Raise the vehicle. Remove the shield. Place a drain pan below the steering Remove or disconnect the following:

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GENERAL MOTORS CORP. 4 4.9Q —

ESCALADE © DENALI ¢ DENALI XL ¢ SUBURBAN © YUKON ¢ YUKON XL

e Hoses from the steering gear e Intermediate shaft from the steering gear e Pitman arm from the relay rod e Steering gear frame bolts and the steering gear To install: 5. Place the steering gear in position. 6. Install or connect the following: e Steering gear to the frame bolts.

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Tighten the bolts to 135 Nm (100

ft. Ibs.) e Pitman arm e Intermediate shaft 7. Remove the plugs and the caps from the steering gear and the hoses. Connect the hoses to the steering gear. Tighten the hose connection to 28 Nm (20 ft. Ibs.).

8. Install the shield.

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9. Fill and bleed the system.

—=RETURN

10. Lower the vehicle.

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Rack & Pinion Steering Gear REMOVAL & INSTALLATION 2000-01 Vehicles

7924KG32

3 long bolts attach the power steering gear to the driver’s side frame rail

9308KG48

Recirculating ball gear

1. Remove or disconnect the following: Wheel assemblies Engine shield, if equipped Stabilizer shaft Power steering high pressure line from the rack and pinion assembly Power steering low pressure line from the rack and pinion assembly Coupler clamp bolt from the intermediate shaft Intermediate shaft from the rack and pinion assembly Rack and pinion assembly mounting nuts, the washers and the bolts 2. Remove the rack and pinion assembly from the vehicle. To install: 3. Install or connect the following: e Rack and pinion assembly into the vehicle Rack and pinion assembly mounting bolts, the washers and the nuts. Tighten the nuts to 185 Nm (136 ft. Ibs.). Intermediate shaft to the rack and pinion assembly. Install the coupler clamp bolt to the intermediate shaft. Tighten the coupler clamp bolt to 45 Nm (33 ft. Ibs.). Power steering low pressure hose to the rack and pinion assembly.

For complete service labor times, order the Chilton Labor Guide

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SUBURBAN ¢ YUKON © YUKON XL vehicle or component damage could result. 1. The vehicle’s weight should rest on correctly placed safety stands located under the frame. Chock the front wheels to prevent vehicle movement. 2. Support the rear axle with a floor jack. 3. Ifthe vehicle is equipped with air lift type shocks, bleed the air from the lines and disconnect the line from the shock

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4. Remove or disconnect the following: e Shock absorber at the top by removing the 2 mounting bolts/nuts from the frame bracket e Nut, washers and bolt from the bottom mount e Shock To install: 5. Install or connect the following: e Shock e Upper mounting nuts/bolts. Torque the nuts/bolts to 20 ft Ibs. (25 Nm). e Lower mounting bolt/nuts. Torque the nuts/bolts to 60 ft Ibs. (80 Nm). 6. Check that no parts such as exhaust components bind on the shock absorbers.

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e Power steering high pressure hose to the rack and pinion assembly. Tighten the hoses to 27 Nm (28 ft. lbs.). e Engine protection shield, if equipped e Stabilizer shaft e Wheels 4. Lower the vehicle. 5. Fill and bleed the power steering system.

Shock Absorber

REMOVAL & INSTALLATION 1998-99 Vehicles

FRONT

The front shock absorbers are multifunctional. They not only aid ina smooth ride, they serve as the suspension stop when the suspension is fully extended. When replacing front shocks, a shock of equivalent length and strength must be used. Use of a shock that does not comply may result in suspension over travel and component failure.

1. Support the front of the vehicle safely under the lower control arms. 2. Remove or disconnect the following: e Tire and wheel assembly e Upper and lower shock absorber retaining fastener(s) Vehicles equipped with quad shocks have a spacer between them.

e Shock absorber To install: 3. Install or connect the following: e Shock absorber 4. On 2-wheel drive vehicles. Torque the upper bolt to 12 ft. Ibs. (16 Nm) and the lower bolts to 24 ft. Ibs. (33 Nm) 5. On 4-wheel drive vehicles. Torque the nuts to 66 ft. Ibs. (90 Nm) Be sure the bolts are inserted in the proper direction. The upper bolt head should be forward; the bottom bolt head should be rearward.

REAR

Original equipment shock absorbers serve additionally as suspension drop cutoffs. Replacement shock absorbers must have a built in suspension cutoff feature and must not be longer than original shocks when they are fully extended or serious

2000-01 Vehicles

2WD FRONT 1. Raise and support the vehicle. 2. lf equipped with selectable ride, disconnect the Real Time Damping (RTD) link rod from the sensor. Grasp the connector lock tabs. Rotate the connector tabs counter clockwise until the connector is unlocked. Disengage the connector from the tennon by firmly pulling the connector up. Hold the tennon end with a wrench while removing the nut. Remove the nut. 3. Remove the upper insulator. Do not discard the plastic pilot ring. 4. Remove the shock absorber mounting bolts at the lower control arm. Remove the shock absorber through the lower control arm from below. To install: 5. Support the lower control arm, with a suitable jack in order to align the tennon with the mounting hole if equipped with selectable ride. 6. Install the shock absorber through the lower control arm from below. Insert the tennon through the mounting hole in the upper spring pocket. Align the shock absorber with the mounting holes in the lower control arm. 7. Install the shock absorber mounting bolts to the lower control-arm. Tighten the bolts to 25 Nm (18 ft. Ibs.).

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The upper insulators are substantially larger that the lower insulators. The upper insulator must be installed above the shock mounting bracket on the frame. The plastic pilot ring will assist the alignment of the isolators.

8. Install the upper insulator to the shock absorber. Install the nut to the tennon end. Do not tighten the nut.

9. Connect the RTD link rod to the sensor (if equipped). 10. Remove the safety stands. 11. Lower the vehicle. Hold the tennon end with a wrench while torquing the nut. Tighten the nut to 20 Nm (15 ft. Ibs.). 12. Connect the electrical connector using the following procedure: a. Verify that the connector is unlocked. b. Align the connector so that the tabs are perpendicular to the wrench flats on

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9308KG43

RTD connector

the tennon end. c. Engage the connector to the tennon by firmly pushing the connector down. d. Grasp the connector lock tabs. Rotate the connector counter clockwise, 13. The connector is locked into place when you hear an audible snap and the tabs are aligned.

4WD FRONT 1. Raise and support the vehicle. 2. Disconnect the (RTD) link rod from the sensor (if equipped). 3. Disconnect the electrical connector if equipped with selectable ride. Grasp the connector lock tabs. Rotate the connector tabs counter clockwise until the connector is unlocked. Disengage the connector from the tennon by firmly pulling the connector up. Hold the tennon end with a wrench while removing the nut. Remove the nut. 4. Remove the upper insulator. Do not discard the plastic pilot ring. 5. Remove the shock absorber mounting bolt at the lower control arm (15 Series). The lower shock mounting bushing is serviceable by driving the bushing out with the appropriate tool. 6. Remove the shock absorber mounting bolt at the lower control arm (25 Series). 7. Remove the shock absorber. To install: 8. Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame. Align the shock absorber with the mounting holes in the lower control arm (15 Series). Align the shock absorber with the mounting holes in the lower control arm (25 Series). 9. Install the shock absorber through bolt to the lower control arm.

9308KG41

9308KG42

Upper shock insulator

Shock absorber removal—4WD vehicles

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

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GENERAL MOTORS CORP.

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Rabed The upper insulators are substantially larger that the lower insulators. The upper insulator must be installed above the shock mounting bracket on the frame. The plastic pilot ring will assist the alignment of the isolators.

11. Install the upper insulator to the shock absorber. Install the nut to the tennon end. Do not tighten the nut. Connect the RTD link rod to the sensor (if equipped). 12. Remove the safety stands. Lower the vehicle. Hold the tennon end with a wrench while torquing the nut. Tighten the nut to 20 Nm (15 ft. Ibs.). 13. Connect the electrical connector using the following procedure if equipped with selectable ride. a. Verify that the connector is unlocked. b. Align the connector so that the tabs (1) are perpendicular to the wrench flats on the tennon end. c. Engage the connector to the tennon by firmly pushing the connector down. d. Grasp the connector lock tabs (1, 2). Rotate the connector counter clock-

7924KG33

Position the coil spring so the bottom end of the spring covers only one drain hole—the other hole must remain open

GENERAL MOTORS CORP 44-93 a

ESCALADE ¢ DENALI ¢ DENALI XL ¢ SUBURBAN © YUKON e YUKON XL

J 23028 -15 9308KG47

Installing J23028-15 on the 25 Series

e Tire and wheel assembly e Shock absorber assembly 4. Install tool J-23028, or equivalent, under the lower control arm and a jack. Install a safety chain around the spring and through the lower control arm. e Stabilizer shaft from the lower control arm. Remove the tension on the lower control arm bolts. e Lower control arm rear bolt, than the other retaining bolt e Spring assembly To install: 5. Install or connect the following: e Chain and spring. If you used spring compressors, install the spring and compressors. 6. Be sure the insulator is in place and the tape is towards the bottom of the spring. Position the gripper notch on the top coil in the frame bracket. 7. Be sure one drain hole in the lower arm is covered by the bottom coil and the other is open. 8. Slowly raise the lower control arm. Guide the control arm into place with a prybar. 9. Install or connect the following: e Pivot shaft bolts, front one first. The bolts must be installed with the heads towards the front of the vehicle. Remove the safety chain or spring compressors. ->Do not tighten the bolts yet. The bolts must be tightened with the vehicle at its proper ride height.

10. Remove the jack. e Stabilizer bar to the lower control arm. Torque the nuts to 24 ft Ibs. (33 Nm).

e Shock absorber e Wheel 11. Once the weight of the vehicle is on the wheels, bounce the vehicle 2 or 3 times by pushing down on the front bumper a couple of inches. When the vehicle settles, tighten the front nut first,, then the rear nut to 101 ft. Ibs. (137 Nm).

2000-01 Vehicles

FRONT 1. Raise and support the vehicle. 2. Remove or disconnect the following: e Engine protection shield e Frame cross bar (25 series only) e Tire and wheel assembly 9308KG46

Retaining hook installation

e Shock absorber e Front stabilizer shaft link

For Tire, Wheel and Ball Joint specifications, see Section 7 of this manual

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To install:

11. Install the coil spring and the insula-

tor to the lower control arm.

8.

12. Raise the transmission jack in order to compress the front coil spring. It may be necessary to use a pry bar in order to guide the lower control arm into position. 13. Install or connect the following: Front pivot bolt (15 Series) Rear pivot bolt Lower control arm pivot nuts. Tighten the pivot bolt nuts to 145 Nm (107 ft. Ibs.) Front pivot bolt (25 Series) Rear pivot bolt Lower control arm pivot nuts. Tighten the pivot bolt nuts to 145 Nm (107 ft. Ibs.) 14. Lower the jack. Remove the tool from the control arm. ¢ Front stabilizer shaft link e Shock absorber e Tire and wheel assembly e Frame cross bar (25 series only). oe the nuts to 100 Nm (74 ft. 5) 15. Install the engine protection shield. 16. Remove the safety stands. Lower the vehicle. 9308KG44

Lower control arm removal

3. Install tool J23028-15 using the outboard locating tab (15 Series), or, the inboard locating tab (25 Series). 4. Attach the retaining hook to the control arm. Tighten the wing nut until you eliminate any free play. 5. Securely attach tool J23028-01 to a suitable transmission jack. Raise the jack until the yokes of tool J23028-01 line up with the notches in J23028-15. 6. Using the tools and the transmission jack, relieve the spring tension from the lower control arm pivot bolts. 7. Remove the lower control arm pivot bolt nuts (15 Series). Remove the rear pivot bolt. Remove the front pivot bolt. 8. Remove the lower control arm pivot bolt nuts (25 Series). Remove the rear pivot bolt. Remove the front pivot bolt. 9. Slowly lower the transmission jack in order to unload the front coil spring. It ‘may be necessary to use a pry bar in order to guide the lower control arm out of position. 10. Remove the coil spring and the insulator.

REAR 1. 2. (RTD) 3.

Raise and support the vehicle. Disconnect the Real Time Damping sensor, if equipped. Remove the lower shock absorber nuts and bolt from the rear axle.

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e U-bolt nuts, plates, and spacer(s) e Anchor plate e Spring-to-shackle retaining bolts. (Do not remove these bolts) e Bolts which attach the shackle to the rear bracket ¢ Bolt which attaches the spring to the front bracket e Spring from the vehicle 4. Inspect the spring and replace any damaged components. To install: elf the spring bushings are defective, use the following procedures for replacement. On bushings that are staked in place, the stakes must first be straightened. Using a press or vise, remove the bushing and install the new one. When a new, previously staked

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6. Install or connect the following: e Front and rear brackets bolts loosely

4. Lower the rear axle until the springs are fully unloaded. 5. Remove the spring and the upper and lower insulators. To install: 6. Position the spring and the upper and lower insulators. 7. Install the rear spring to the rear axle. 8. Raise the rear axle. Install the lower shock absorber nuts to the rear axle. 9. Connect the RTD sensor, if equipped. _ 10. Remove the rear axle support. Lower the vehicle.

Leaf Springs REMOVAL & INSTALLATION 1998-99 Vehicles

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise the vehicle and support it so that there is no tension on the leaf spring

assembly.

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3. Remove or disconnect the following:

| Rear leaf spring front shackle

For Wheel Alignment specifications, see Section 1 of this manual

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e 16mm U-bolt nuts to 120 Nm (89 ft. Ibs.) e Front hanger bracket nut to 125 Nm (92 ft. Ibs.). e Shackle to the frame nut to 95 Nm (70 ft. Ibs.). e Shackle to the spring nut to 95 Nm (70 ft. Ibs.). 10. Install the fuel tank for left side applications. 11. Install the trailer hitch if equipped. 12. Connect the RTD sensors (25 series utilities if equipped). 13. Remove the rear axle support. 14. Remove the safety stands. Lower the vehicle.

Torsion Bars

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REMOVAL & INSTALLATION

1998-99 Vehicles 9308KG22

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

Rear leaf spring rear shackle

Spacers and spring plate New u-bolts, washers and nuts Anchor plate U-bolt nuts. Torque them in a diagonal sequence, to 17 ft. Ibs. (23 Nm) When the spring is evenly seated, tighten the nuts to 81 ft. lbs. (110 Nm) Hanger and shackle bolts are properly installed. All bolt heads should be inboard. Don't tighten them yet. 7. Using the floor jack, raise the axle until the distance between the bottom of the rebound bumper and its contact point on the axle is 182mm plus or minus 6mm. 8. When the spring is properly positioned, tighten all the hanger and shackle nuts to 70 ft. Ibs. (95 Nm) e Leaf spring-to-shackle nuts 15/25/35 series: 70 ft. Ibs. (95 Nm). e Leaf spring-to-shackle nuts C3HD series: 157 ft. Ibs. (213 Nm). e Shackle-to-bracket nuts C3HD series: 157 ft. Ibs. (213 Nm). 2000-01 Vehicles

1. Raise and support the vehicle. 2. Support the rear axle independently in order to relieve the tension on the leaf Springs. 3. Remove or disconnect the following:

Real Time Damping (RTD) sensors (if equipped) Trailer hitch if equipped Fuel tank for left side applications U-bolt nuts and U-bolts Spring spacer and anchor plate Shackle to the frame bracket nut and the bolt Front spring bracket bolt 4. Leaf spring assembly from the vehicle e Shackle from the spring To install: 5. Loosely assemble the spring shackle bracket to the frame. Install the shackle bolt.

Install the shackle nut. 6. Install the leaf spring assembly to the vehicle. 7. Loosely assemble the spring to the front hanger bracket. 8. Install or connect the following: e Front spring hanger bracket bolt e Front spring hanger bracket nut e Shackle to the spring bolt e Shackle to the spring nut ->Do not reuse the U-bolts.

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Y nae af + U-bol an 9. Observe the following torques: ¢ 14mm U-bolt nuts to 80 Nm (59 ft. Ibs.)

Special tool J-36202, or its equivalent, is necessary for this procedure.

2. Remove or disconnect the following: e Wheels 3. Support the lower control arm with a floor jack. 4. Matchmark both torsion bar adjustment bolt positions. 5. Using tool JH-36202, increase the tension on the adjusting arm. 6. Remove or disconnect the following: e Adjustment bolt and retaining plate 7. Move the tool aside, and slide the torsion bars forward. e Adjusting arms e Torsion bar support crossmember and slide the support crossmember rearwards Torsion bars, matchmark the position. They are not interchangeable Support crossmember Retainer, spacer and bushing,from the support crossmember To install: 8. Install or connect the following: e Retainer, spacer and bushing to the support crossmember ¢ Support assembly on the frame, out of the way

* Torsion bars, sliding them forward until they are supported. Align the

marks made when removed. e Support crossmember into position. Torque the center nut to 18 ft.

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lbs. (24 Nm), the edge nuts to 46 ft. Ibs. (62 Nm). e Adjuster retaining plate and bolt on each torsion bar 9. Using tool J-36202, increase tension on both torsion bars. 10. Set the adjustment bolt to the marked position. 11. Release the tension on the torsion bar until the load is taken up by the adjustment bolt. 12. Install both wheels 2000-01 Vehicles >This procedure requires the removal of both torsion bars.

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1. Raise and support the vehicle. 2. Mark the adjustment bolt setting. Install tool J36202 to the adjustment arm and the crossmember. 3. Increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. 4, Remove or disconnect the following: e Adjustment bolt and the adjuster nut Tool, allowing the torsion bar to unload. Adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. Use your hand to support the adjustment arm as the adjustment arm releases from the torsion bar. 5. Remove the torsion bar crossm ember bolts from the weld nuts (15 Series). 6. Remove the upper link mounting nuts and the bolts (25 Series). 7. Remove the torsion bar crossmember.

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Installing the torsion bar—K-Series

->Note the position of the torsion bars as the left and right bars are different.

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Retainer installation—torsion bar

8. Remove the torsion bars. To install: 9. Install or connect the following: e Torsion bars e Torsion bar crossmember e Torsion bar crossmember bolts to the weld nuts (15 Series). Tighten the bolt to 95 Nm (70 ft. Ibs.) e Upper link mounting nuts and the bolts (25 Series). Tighten the nut to 95 Nm (70 ft. Ibs.) 10. While supporting the adjustment

For Maintenance Interval recommendations, see Section 7 of this manual

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arm 3. Using a Yin. drill bit, drill a pilot hole through each ball joint rivet. 4. Drill out the rivets with a ¥% in. drill bit. Punch out any remaining rivet material, ¢ Cotter pin and nut from the ball: stud 5. Support the lower control arm. e Stud from the knuckle. Using a ball

9308KG26

Adjuster nut removal—15 Series

joint separator

To install: 6. Install or connect the following: ¢ New ball joint on the control arm Service replacement ball joints come with nuts and bolts to replace the rivets.

e Bolts and nuts. Torque the nuts to 17 ft. Ibs. (23 Nm) for 15- and 25Series, 52 ft. Ibs. (70 Nm) for 35Series. >The bolts are inserted from the bottom.

7. Start the ball stud into the knuckle. Ensure it is squarely seated. Install the ball stud nut and pull the ball stud into the knuckle with the nut. Tighten the nut after the vehicle wheels are on the ground and the suspension is loaded. e Wheel 8. Once the weight of the vehicle is on the wheels tighten the nut to 84 ft. Ibs. (115 Nm).

2000-01 Vehicles

9308KG25

Adjuster bolt removal—15 Series

arm, Slide the torsion bar rearward until the torsion bar fully engages the adjustment arm. Install tool J36202 to the adjustment arm and the crossmember. Increase the tension on the adjustment arm in order to load the torsion bar. e Adjustment bolt and the adjuster nut 11. Remove the tool, releasing the tension on the torsion bar until the load is taken up by the adjustment bolt. 12. Remove the safety stands. 13. Lower the vehicle. 14. Measure the ride height.

15. Turn the adjustment bolt clockwise to increase the ride height and counterclockwise to decrease it.

Upper Ball Joint REMOVAL & INSTALLATION 1998-99 Vehicles 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the upper control arm. 4. Using a press, remove the upper ball joint. To install: >The ball joint must be installed with the flat edges or notches in the same position as the replaced ball joint. The ball joint is directional and damage will occur if this procedure is not followed.

5. joint. 6. 7. 8. 9. 10.0.

Using a press, install the upper ball Install the upper control arm. Install the tire and wheel assembly. Remove the safety stands. Lower the vehicle. Verify the wheel alignment.

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REMOVAL & INSTALLATION 1998-99 Vehicles

2-WHEEL DRIVE MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place jack under lower control arm, then raise the jack slightly. 3. Remove or disconnect the following: e Tire and wheel assembly e Brake caliper and position it to the side Cotter pin and the lower ball joint retaining nut. Using the proper tool separate the ball joint from its mounting. Support the knuckle assembly so its weight will not damage the brake hose. Ball joint out of the lower control arm, using tool J-9519-30-D or equivalent. _ To install: 4. Start the new ball joint into the control arm. Position the bleed vent in the rubber boot facing inward. 5. Install or connect the following: e Ball joint into the control arm until fully seated Lower ball joint stud into the steering knuckle Brake caliper, if removed Ball stud nut. Torque the nut to 90 ft. Ibs. (122 Nm) plus the additional tighten necessary to align the cotter pin hole. Do not exceed 130 ft. Ibs. (175 Nm) or back the nut off to align the holes with the pin. New lube fitting and lubricate the new joint. e Tire and wheel

4-WHEEL DRIVE MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel ¢ Splash shield from the knuckle e Inner tie rod end from the relay rod using a ball joint separator

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e Hub nut and washer. Insert a long drift or dowel through the vanes In the brake rotor to hold the rotor in place.

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

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ESCALADE ¢ DENALI e DENALI XL ¢ SUBURBAN ¢ YUKON ¢ YUKON XL 8. Move the tool aside and slide the torsion bars forward. e Ball joint from the knuckle. Using a screw-type forcing tool e Lower control arm ¢ Lower ball joint out of contro! arm with tool J-9519-E or equivalent ball joint press To install: 9. Install or connect the following: e New ball joint into the control arm with tool J-9519-E or equivalent e Lower control arm

e Axle shaft inner flange bolts 3. Using a puller, force the outer end of the axle shaft out of the hub. e Axle shaft. e Cotter pin and nut from the ball stud 4. Support the lower control arm. 5. Matchmark both torsion bar adjustment bolt positions. 6. Using tool J-36202 or equivalent, increase the tension on the adjusting arm.. 7. Remove or disconnect the following: e Adjustment bolt and retaining plate

10

10. Using tool J-36202 or equivalent, increase tension on both torsion bars. ¢ Adjustment retainer plate and bolt on both torsion bars 11. Set the adjustment bolt to the marked position. 12. Release the tension on the torsion bar until the load is take up by the adjustment bolt and remove the tool. e Shaft in the hub and the washer and hub nut. Leave the drift in the rotor vanes and torque the hub nut ~ to 175 ft. !bs. (238 Nm). e Flange bolts. Tighten them to 59 ft.

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Use these specifications and diagrams to determine if the vehicle ride height is correct

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ESCALADE e DENALI e DENALI XL ¢ SUBURBAN ¢ YUKON ¢ YUKON XL Ibs. (80 Nm), remove the drift. e Inner tie rod end at the steering . telay rod. Torque the nut to 35 ft. lbs. (48 Nm). e Splash shield e wheel 13. Once the weight of the vehicle is on the wheels follow these steps: a. Step 1:Lift the front bumper about 1 Ya in. (38mm) and let it drop. b. Step 2: Repeat this procedure 2-3 more times. c. Step 3: Draw a line on the side of the lower control arm from the centerline of the control arm pivot shaft, dead level to the outer end of the control arm. d. Step 4: Measure the distance between the lowest corner of the steering knuckle and the line on the control arm, record the figure. e. Step 5: Push down about 1% in. (38mm) on the front bumper and let it return. Repeat the procedure 2-3 more times. f. Step 6: Re-measure the distance at the control arm. , g. Step 7: Determine the average of

the 2 measurements. This is the “2”

height measurement. The “Z” height should be as specified in the chart. h. Step 8: If the figure is correct, tighten the control arm pivot nuts to 94 ft. Ibs. (128 Nm). i. Step 9: If the figure is not correct, tighten the pivot bolts to 94 ft. Ibs. (128 Nm) and have the front end alignment corrected.

2000-01 Vehicles

e Lower control arm ¢ Coil spring e Tire and wheel tire assembly 8. Remove the safety stands. 9. Lower the vehicle. 10. Verify the wheel alignment.

4WD 1. Raise and support the vehicle. 2. Remove or disconnect the following: e Tire and wheel assembly e Lower control arm 3. Place the lower control arm in a bench vice. 4. Using a chisel, remove the 4 securing crimps from the ball joint body (15 series only). 5. Using a press, remove the ball joint from the lower control arm. To install: Use the outer flange of the ball joint in order to press the ball joint into place.

6. Install the new ball joint using a press. 7. Place the lower control arm ina bench vice. 8. Using a punch, install 4 crimps to the ball joint. Use the replaced ball joint as a reference (15 series only). 9. Install or connect the following: e Lower control arm e Tire and wheel assembly 10. Remove the safety stands. 11. Lower the vehicle. 12. Verify the wheel alignment.

Upper Control Arm

2WD 1. Raise and support the vehicle. 2. Remove or disconnect the following: e Tire and wheel assembly e Front coil spring e Lower control arm 3. Secure the lower control arm ina bench vice or equivalent. 4. Center punch the rivet heads. 5. Drill out the rivets. To install: 6. Install or connect the following: e Ball joint to the lower control arm ¢ Replacement bolts to the lower control arm e Nuts to the bolts. Tighten the nuts to 70 Nm (52 ft. Ibs.) 7. Remove the lower control arm from the bench vice.

REMOVAL & INSTALLATION 1998-99 Vehicles 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm with a floor jack. 3. Remove or disconnect the following: Wheel Brake hose bracket from the control arm Air cleaner extension (if necessary) Brake hose bracket retainer and wire the hose aside Cotter pin from the upper control arm ball stud and loosen the stud nut until the bottom surface of the

nut is slightly below the end of the stud e Ball joint from the knuckle

e Control arm to the frame brackets e Shims and spacers To install: 4. Install or connect the following: ¢ Control arm in position e Shims and spacers, bolts and new nuts. Both bolt heads must be inboard of the control arm brackets. Tighten the nuts finger tight for now. ->Do not tighten the bolts yet. The bolts must be torqued with the truck at its proper ride height. —

e Ball joint to the knuckle. Torque the nut to 84 ft. Ibs. (115 Nm). ¢ Cotter pin. Never back off the nut to install the cotter pin. Always advance it. Never advance it more than Ye turn. 5. Lower the truck. Once the weight of the truck is on the wheels. Torque the control arm pivot nuts to 140 ft. Ibs. (190 Nm) 2000-01 Vehicles

1. Raise and support the vehicle. 2. Remove or disconnect the following: Tire and wheel assembly Real Time Damping (RTD) link rod from the sensor (if equipped) Retaining bolt for the brake hose and the wheel speed sensor brackets Halfshaft Nut at the upper ball joint. Discard the nut Upper control arm from the steering knuckle Upper control arm nuts and the adjustment cams (15 Series RWD, 4WD, and 25 Series RWD) Upper control arm bolts (15 Series RWD, 4WD, and 25 Series RWD) Upper control arm nuts and the adjustment cams (25 Series 4WD) Upper control arm bolts (25 Series AWD) Upper control arm To install: 3. Install or connect the following: e Upper control arm e Upper control arm bolts (25 Series AWD) e Upper control arm nuts and the adjustment cams (25 Series 4WD). Tighten the nuts to 190 Nm (140 ft. lbs.)

For complete service labor times, order the Chilton Labor Guide

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Upper control arm

Upper control arm bolts (15 Series RWD, 4WD, and 25 Series RWD) Upper control arm nuts and the adjustment cams (2) (15 Series RWD, 4WD, and 25 Series RWD). Tighten the nuts to 190 Nm (140 ft. lbs.) Upper control arm to the steering knuckle Halfshaft New nut to the upper ball joint stud. Tighten the nut to 50 Nm (37 ft. Ibs.) Retaining bolts for the brake hose and wheel speed sensor brackets. Tighten the bolts to 9 Nm (80 inch Ibs.) RTD link rod to the sensor (if equipped) Tire and wheel assembly 4. Remove the safety stands. 5. Lower the vehicle. Verify the wheel alignment.

—

4. Using tool J-36202, increase the tension on the adjusting arm. e Adjustment bolt and retaining plate, and move the tool aside 5. Slide the torsion bars forward. e Adjusting arm Splash shield from the knuckle, if equipped Hub nut and washer. Insert a long drift or dowel through the vanes in the brake rotor to hold the rotor in place. Axle shaft out of the hub Brake caliper and wire it aside Rotor Shock absorber from control arm Inner tie rod end from the relay rod 6. Support the lower control arm with a floor jack. e Stabilizer bar from the control arm e Cotter pin from the lower ball stud and loosen the nut Ball joint from control arm ¢ Control arm-to-frame bracket bolts,

nuts and washers J-36618-5, and J-9519-23, or their equivalents, are necessary for this procedure.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel 3. Matchmark the both torsion bar adjustment bolt positions.

e Lower control arm and torsion bar as a unit 7. Separate the control arm and torsion bar. To install: 8. Install or connect the following:

¢ Control arm assembly into position. Insert the front leg of the control arm into the crossmember first, then the rear leg into the frame bracket.

CONTROL ARM BUSHING REPLALEMENT 1. The control arm bushings are removed and installed using a press.

Lower Control Arm and Bushing REMOVAL & INSTALLATION 1998-99 Vehicles e>Special tools J-36202, J-36618-1, J-36618-2, J-36618-3, J-36618—-4,

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washers (25 Series). Tighten the lower control arm nuts to 145 Nm (107 ft. Ibs.) Front stabilizer shaft link. Shock absorber Tire and wheel assembly 4, Remove the safety stands. Lower the vehicle. Verify the wheel alignment.

4WD 1. Raise and support the vehicle. 2. Remove or disconnect the following:

Tire and wheel assembly Real Time Damping (RTD) link rod from the sensor (if equipped)

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Lower control arm bolts Lower control arm nuts and the

2WD lower control arm—25 Series

e Mounting bolts, front one first. The bolts must be installed with the front bolt head heads towards the front of the truck and the rear bolt head towards the rear of the truck!

Do not tighten the bolts yet. The bolts must be torqued with the truck at its proper ride height.

e Ball joint into the knuckle. Torque the nut to 94 ft Ibs. (128 Nm). e Adjuster arm 9. Using tool J-36202, increase tension on both torsion bars. e Adjustment retainer plate and bolt on both torsion bars and set to marked positions. Release the tension on the torsion bar until the load is taken up by the adjustment bolt. e Wheel 10. Lower the truck. Once the weight of the truck is on the wheels. Torque the bolts to 121 ft. Ibs. (165 Nm). 2000-01 Vehicles

2WD 1. Raise and support the vehicle. 2. Remove or disconnect the following: e Tire and wheel assembly

washers (15 Series)

Real Time Damping (RTD) link rod from the sensor (if equipped) Shock absorber Front stabilizer shaft link Front coil spring Lower control arm nuts and the washers (15 Series) e Lower control arm bolts (15 Series) Lower control arm nuts and wash-

‘ers (25 Series) Lower control arm bolts (25 Series) Lower ball joint stud nut Lower ball joint stud from the Steering knuckle Lower control arm To install: 3. Install or connect the following: Lower control arm Ball joint stud to the steering knuckle Lower ball joint stud nut. Tighten the lower ball joint stud nut to 100 Nm (74 ft. Ibs.) Front coil spring Lower control arm bolts (15 Series) Lower control arm nuts and the washers (15 Series). Tighten the lower control arm nuts to 145 Nm (107 ft. Ibs.) Lower control arm bolt (25 Series) Lower control arm nuts and the

washers (25 Series) Lower control arm bolts Lower control arm To install: Lower control arm

Lower control arm bolts (15 Series) Washers with the shoulder facing

the arm

Nuts. Tighten the nuts to 145 Nm (107 ft. Ibs.) Halfshaft Lower ball joint stud to the steering knuckle. Install the nut to the ball joint stud. Tighten the nut to 100 Nm (74 ft. Ibs.) Torsion bars Shock absorber through nut and bolt Stabilizer shaft links to the lower control arm RTD link rod to the sensor (if equipped) Tire and wheel assembly 3. Remove the safety stands. Lower the vehicle. Verify the wheel alignment.

CONTROL ARM BUSHING REPLALEMENT Front Bushing

1. On 15 and 25 Series, the bushings are not replaceable. If they are damaged, the control arm will have to be replaced.

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Be eies DENALI ¢ DENALI XL e SUBURBAN ¢ YUKON @ YUKON XL ¢ Bushing into control arm 7. Press in the bushings with tools J-36618-5, J-9519-23, J-36618-3 and J-36618-2. There are no crimps. e Control arm and mounting bolts. Torque the front nut first then the rear to 140 ft Ibs. (190 Nm) e Wheel Wheel Bearings

~ ADJUSTMENT «>The front wheel bearings on 2-wheel drive vehicles (exc. 2000-01 vehicles) are adjustable.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the dust cap, cotter pin. 3. Loosen the spindle nut.

die, 4WD lower control arm—15 Series 2. Before servicing the vehicle, refer to the precautions in the beginning of this section. 3. Remove or disconnect the following: e Wheel e Lower control arm e Unbend the crimps with a punch on the front bushing 4. Press out the bushings with tools J-36618-2, J-9519-23, J-36618—4 and 36618-1. To install: 5. Lubricate the outer case of the bushing. 6. Install or connect the following: e Bushing into control arm 7. Press in the bushings with tools J-36618-2, J-9519-23, J-36618—4 and 36618-1 until the bushing is seated in. 8. After bushing is installed crimp it in place. e Control arm and mounting bolts. Torque the front nut first then the rear to 140 ft Ibs. (190 Nm) e Wheel

4. Press out the bushings with tools. § J-386618-5, J-9519-23, J-36618-3 and J-36618-2. There are no crimps. To install: 5. Lubricate the outer case of the bushing. 6. Install or connect the following:

4. Spin the wheel hub by hand and tighten the nut until it is just snug—12 ft. lbs. (16 Nm) Back off the nut until it is loose, then tighten it finger-tight. Loosen the nut until either hole in the spindle lines up with a slot in the nut and insert a new cotter pin. There should be 0.001—0.008 in. (0.025—0.200mm) end-play. This can be measured with a dial indicator, if you wish. 5. Replace the dust cap, wheel and tire.

Rear Bushing

1. On 15 and 25 Series, the bushings are not replaceable. If they are damaged, the control arm will have to be replaced. 2. Before servicing the vehicle, refer to

the precautions in the beginning of this section. 3. Remove or disconnect the following: e Wheel

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¢ Lower control arm Use a dial indicator to measure the wheel bearing end-play—2-wheel drive vehicles

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SEAL BALL JOINT, LOWER BOLT JOINT KIT, FRONT AXLE

Exploded view of the front hub and knuckle assembly—4-wheel drive

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and require no lubrication maintenance. Darkened areas on the bearing assembly are caused by a heat treatment process and do not require bearing replacement. 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

(C1 2. Remove or disconnect the follow-

ing:

¢ New seal in the steering knuckle,

Y

© Caliper and wire it out of the way

= Wrap shop towels around the CV-

e Grease ca e Cotter pin,P spindle nut, and washer e Hub.

Joint boots to protect them from damP . age during this procedure.

Do not drop the wheel bearings.

e Outer roller bearing assembly from the hub 3. The inner bearing assembly will remain in the hub and may be removed after prying out the inner seal. Discard the seal. 4. Clean all parts in a non-flammable solvent and let them air dry. Never spin-dry a bearing with compressed air! Check for excessive wear and damage. 5. If necessary for replacement, remove the bearing races from the hub using a hammer and drift. They are driven out from the inside out. To install: 6. Install or connect the following: e New bearing races, if required. When installing new races, ensure that they are not cocked and that they are fully seated against the hub shoulder. 7. Pack both wheel bearings using high melting point wheel bearing grease for disc brakes. e Inner bearing in the hub and a new inner seal, making sure that the seal flange faces the bearing race. ¢ Wheel hub over the spindle e Outer bearing into the hub e Spindle washer and nut 8. Spin the wheel hub by hand and tighten the nut until it is just snug—12 ft. lbs. (16 Nm) Back off the nut until it is loose, then tighten it finger-tight. Loosen the nut until either hole in the spindle lines up with a slot in the nut and insert a new

e Splash shield 4. Support the lower control arm with a jack stand. e Upper and lower ball joints from the steering knuckle e Pea yey “Solent e Seal from the steering knuckle en To aah 5. Install or connect the following:

e Wheel

Fs fs

+2 CAUTION

~f

e Brake caliper and support it aside e Brake rotor e Cotter pin, retainer, castle nut, and thrust washer from the axle shaft e Tie rod end from the knuckle e Hub/bearing assembly retaining bolts 3. Using a J-28733-B hub/bearing puller tool or equivalent, press the hub/bearing assembly from the splined shaft.

After removal, lay the hub and bearing assembly on the outboard side. This will prevent damage and/or contamination of the bearing seal.

: rab ate path

(100 Nm) and the lower ball joint nut to 94 ft. Ibs. (128 Nm) Tighten the nuts to align the holes for cotter pin insertion, but do NOT tighten more than an additional % turn. Splash shield Hub/bearing assembly over the splined shaft, making sure the splines line up correctly. Torque the bolts to 133 ft. Ibs. (180 Nm) Tie rod end at the steering knuckle Thrust washer and axle nut, Torque the nut to 165 ft. Ibs. (225 Nm). Retainer and cotter pin Rotor and caliper 6. Remove the shop towels from the CVJoint boot.

AXLE SHAFT

cotter pin. There should be 0.001—0.008 in.

(0.025—-0.200mm) end-play. This can be measured with a dial indicator, if you wish. 9. Replace the dust cap, wheel and tire.

4-WHEEL DRIVE FRONT "K” Series (4WD) vehicles have sealed front wheel bearings that are pre-adjusted

ek

ae ee and the retaining nuts. Torque the upper ball joint nut to 74 ft. Ibs.

BACKING PLATE 7924KG49

Cutaway view of the rear axle shaft and bearing assembly

—— io.

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GENERAL MOTORS CORP.

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ESCALADE ¢ DENALI ¢ DENALI XL ¢ SUBURBAN ¢ YUKON ¢ YUKON XL 1 4-1 07

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e Tire and wheel assemblies

4

;

7. Check and adjust the front end alignment and road test the vehicle.

;

a

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. A new pinion shaft lockbolt should be installed whenever either of the axle shafts is removed. e>Axle shaft seal removal and installation uses the following special tools: the GM Axle Shaft Seal Installer tool No. J-33782 (seal driver) or equivalent and the Axle Shaft Bearing Installer tool No. J-34974 (bearing driver) or equivalent.

2. Place a catch pan under the differential, then remove the drain plug (if

equipped) or rear axle cover and drain the

20. Lock bolt

fluid (discard the old fluid)

21. “C" lock

3. Remove or disconnect the following: e Rear wheel assemblies e

4 4

Brake drums’

4, Using a wire brush, clean the dirt/rust from around the rear axle cover.

7924KG50

Remove the lockbolt and pinion shaft, then push in the axle shaft and remove the C-lock

f

i

e Rear pinion’shaft lockbolt and the

f

pinion shaft, at the differential

F

¢ C-lock from the button end of the

iM

axle shaft, push the axle shafts

y

inward. e Axle shaft from the axle housing.

Mi i

Be careful not to damage the oil

i

seal.

On vehicles equipped with an AntiLock Brake System (ABS) be careful not to damage the reluctor ring on the axle shaft or the speed sensor bolted to the backing plate, immedi-

ately adjacent to the shaft.

5. Clean the gasket mounting surfaces.

@ IN LD me

e>it is recommended, when the axle shaft is removed, to replace the oil seal.

6. To replace the oil seal use a medium prybar or, better yet, an inexpensive seal removal tool, to pry the oil seal from the end of the rear axle housing. DO NOT damage the housing oil seal surface. And again, on late-model ABS equipped vehicles, STAY CLEAR OF THE SPEED SENSOR. 7. Using the slide hammer and adapter, pull the bearing out of the axle tube.

7924KG51

Using a slide hammer and adapters, remove the axle bearing and seal

Timing belt service is covered in Section 3 of this manual

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GENERAL MOTORS CORP.

ESCALADE ¢ DENALI e DENALI XL ¢ SUBURBAN

YUKON ¢ YUKON XL

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To install: 8. If the wheel bearing was removed: a. Step 1: Using solvent, thoroughly clean the wheel bearing, then blow dry with compressed air. Inspect the wheel bearing for excessive wear or damage, then replace it (if necessary) b. Step 2: With a new or the reused bearing, thoroughly coat the bearing with gear lubricant. c. Step 3: Using the Axle Shaft Bearing Installer tool No. J-34974, or equivalent, drive the bearing into the axle housing until it bottoms against the seat. Be sure the bearing installer does not contact and damage the speed sensor on ABS equipped vehicles. 9. If the axle shaft seal was removed: a. Step 1: Clean and inspect the axle tube housing. : b. Step 2: Using the GM Axle Shaft

Seal Installer tool No. J-33782, or an

equivalent driver, seat the new seal into the housing until it is flush with the axle tube. Be sure the seal installer does not contact and damage the speed sensor on ABS equipped vehicles. c. Step 3: Using gear oil, lubricate the new seal lips. 10. Slide the axle shaft into the rear axle housing and engage the splines of the axle shaft with the splines of the rear axle side gear, then install the C-lock retainer on the axle shaft button end.

6

me

J 8092

J 23690 OR

J 29709

nike

Axle and seal installation using a bearing driver

BE CAREFUL not to damage the wheel bearing seal with the splines on the axle shaft. 11. After the C-lock is installed, pull the axle shaft outward to seat the C-lock retainer in the counterbore of the side gears. 12. Install or connect the following: Pinion shaft through the case and the pinions New pinion shaft lockbolt. Torque the new lockbolt to 25 ft. Ibs. (4 Nm). Housing cover use a new rear axle cover gasket Brake drums Tire and wheel assemblies

13. Refill the housing. REMEMBER that the vehicle must be completely level, meaning that if the rear is still raised and supported, the front should also be raised.

Sire

2000-01 Vehicles

2WD FRONT 1. Raise and support the vehicle. 2. Remove or disconnect the following:

2WD front hub—15 Series

GENERAL MOTORS CORP.

ESCALADE © DENALI» DENALI XL § UBURBAN

e¢ YUKON e YUKON XL

14-109

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9308KG32

2WD front hub—25 Series

9308KG35

AWD front hub—15 Series

Tire and wheel assembly Rotor e Wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle Electrical connection for the wheel speed sensor e Hub and bearing assembly mounting bolts e Hub and bearing assembly e (Q-ring seal from the steering knuckle bore (25 Series) 3. Clean and inspect the O-ring seal (25 Series). To install: 4. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 5. Install the O-ring to the steering knuckle (25 Series). 6. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 7. Install or connect the following: e Hub and bearing assembly e Hub and bearing assembly mounting bolts (15 Series). Install the hub and bearing assembly mounting bolts (25 Series). Tighten the hub to knuckle bolts to 180 Nm (133 ft. Ibs.).

Heater Core replacement is covered in Section 2 of this manual

14-11 ‘

GENERAL MOTORS CORP.

ESCALADE ¢ DENALI ¢ DENALI XL e SUBURBAN e YUKON e YUKON XL

e Wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle e Electrical connection for the wheel speed sensor e Front drive halfshaft assembly. e Hub and bearing assembly mounting bolts 3. Remove the hub and bearing assembly. 4. Remove the O-ring seal from the -steering knuckle bore (25 Series). 5. Clean and inspect the O-ring seal (25 Series). To install: 6. Clean all corrosion or contaminates from the steering knuckle bore and the hub

9308KG34

AWD front hub—25 Series

e Electrical connection for the wheel Speed sensor e Wheel speed sensor and brake

hose mounting bracket bolt to the

steering knuckle. Tighten the bolt to 12 Nm (106 inch Ibs.).

° Rotor

e Tire and wheel assembly

8. Remove the safety stands. Lower the vehicle .

4WD FRONT 1. Raise and support the vehicle. 2. Remove or disconnect the following:

¢ Tire and wheel assembly e Rotor

and bearing assembly. . 7. Install the O-ring to the steering knuckle (25 Series). 8. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 9. Install or connect the following: e Hub and bearing assembly e Hub and bearing assembly mounting bolts Tighten the hub to knuckle bolts to 180 Nm (133 ft. Ibs.) Front drive halfshaft assembly Electrical connection for the wheel speed sensor e Wheel speed sensor and brake hose mounting bracket bolt to the

steering knuckle. Tighten the bolt to

12 Nm (106 inch Ibs.) * Rotor

* Tire and wheel assembly.

|

HONDA 1998-01 CR-V

DRIVE TRAIN.................. 15-16 ENGINE REPAIR................ 15-2 FUEL SYSTEM ................ 15-13 PRECAUTIONS.................. 15-2 STEERING AND SUSPENSION................. 15-19

A

Air Bag he Terese taseree cera15-19 CRSAUTHEOR: Kat ece aha a,15-19 PFAGAULIONS spss. loasasrien. ancus: 15-19

Alterpatonsshansitiesin wisanileua., 15-3 installations pnind.ali. hiloonie 5381. Removahiany tad. inl Aolose jiod :15-3 ;

Camshattl dvinen. ai oalloatuene 15-11 Removal & Installation........... 15-11

Che Mae PBC NO Srl No eneik 15-17 Aditsimenco ence 15-17 Removal & Installation............ W217 COON ee

Removal & Installation............ 15-11 Fuel Filters 2s 2en8 8e Leta 15-15 Removal & Installation............ 15-15 FiePiniectormse 05% aan or15-15 Removal & Installation............ 15-15 Fer PUIG ....acee eters ae 15-15

Piston and RING... POSIMOMHIO .sccsecusacinacc teen. Power Rack and Pinion Steering Gear SUM cece oe aoe See 15-19 Removal & Installation............ 15-19

Removal & Installation............ 15-15

Reat Mai ocdh scnsuanads-tresente 15-13

Fuel System Pressure ....ccccsssseee- 15-13 RAVING scusscus leleerstrecen atte 15-13 Fuel SystemsService

Precautions iisccs, wy), eeaeaonte 15-13

H Halfshaft.:. 2vignar-metevelseeaan 15-17 Removal & Installation............ PHATE

Hydraulic Clutch System ............ 15-17

Bieeditig 20 20" § poinssner15-17 |

Removal & Installation.............. 15-8

CVploint sett ae eoieeren.e 15-18 15-18 er

Lower Ball Joint. esesesenen 15-21 Removal & Installation............ 15-21

Cylinder Head ....cssccssesssesssecsien 15-7

Lower Control Arm ....sccsssssece 15-18

aie 15-2

Removal & Installation........... 15-18

Removal & Installation............. 15-7 D

TST

Removal

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& Installation Se

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Control Arm Bushing Replacement........cssssseeeseseee 15-18

15-2

E EMIQING*ASSOMDIY .Use new self-locking nuts and colorcoded self-locking bolts when installing the engine mounts and suspension

components.

Please visit our web site at www.chiltonsonline.com

P

15-

HONDA CR-V

~e Transaxle fluid cooler lines e Transaxle ground cable and hose clamp e Shift cable e Shift cable cover 20. For all vehicles, install or connect the following: e Axle halfshafts Lower ball joints Right damper fork Exhaust front pipe HO2S connector Heater hoses Radiator hoses Splash shield PSP switch Accelerator cable

@) 12 x 1.25 mm 83 N-m (8.5 kgf-m, 61 Ibf-ft)

Brake booster vacuum line Fuel lines

A/C compressor drive belt Power steering pump and belt Cruise control actuator Left engine wire harness connectors PCM connectors and grommet

3) 12 x 1.25 mm

59 N-m (6.0 kgf-m, 43 Ibf-ft) Replace.

(2) 10 x 1.25 mm 44 N-m (4.5 kgf-m, 33 Ibf-ft) 7924MG07

Air intake assembly Battery and tray Fuse/Relay box battery cables Negative battery cable 21. Fill the engine crankcase to the correct level. 22. Fill the transaxle to the correct level. 23. Fill the cooling system. 24. Start the engine and check for leaks. 25. Check the wheel alignment and adjust as necessary.

Water Pump

Left front mount tightening sequence—CR-V

REMOVAL & INSTALLATION ->Do not tighten the engine or transaxle mount fasteners until instructed to do so.

14. Lower the powertrain into position. 15. Install or connect the following: Transaxle mount and bracket. Tighten the frame mounting bolts to

47 ft. Ibs. (64 Nm). Upper bracket. Tighten the nuts in sequence to 54 ft. Ibs. (74 Nm). Rear mount bracket through bolt Right front mount and bracket Left front mount and bracket 16. Tighten the remaining mount fasteners as follows: a. Transaxle mount fasteners to 47 ft. lbs. (64 Nm) and the through bolt to 54

ft. Ibs. (74 Nm). b. Rear mount bracket through bolt to 43 ft. Ibs. (59 Nm). c. Right front mount 12mm bolts to

47 ft. Ibs. (64 Nm) and the 10mm bolts to 33 ft. Ibs. (44 Nm). d. Left front mount 12mm stud bolt to 61 ft. Ibs. (83 Nm), 10mm bolts to 33 ft. lbs. (44 Nm), and 12mm nut to 43 ft. Ibs. (59 Nm). e. Right front mount 12mm nut to 43 ft. Ibs. (59 Nm). 17. Install or connect the following: e Rear driveshaft, if equipped e A/C compressor e Radiator e A/C hose clamp 18. If equipped with a manual transaxle, install or connect the following: e Shift cables e Transaxle ground cable e Clutch hose bracket e Clutch slave cylinder 19. If equipped with an automatic transaxle, install or connect the following:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Accessory drive belts e Front cover ‘ e Timing belt e Water pump To install: 4. Install or connect the following: e Water pump. Use a new O-ring seal and tighten the bolts to 105 inch lbs. (12 Nm). Timing belt Front cover Accessory drive belts Negative battery cable 5. Fill the cooling system.

eS

rouny 45-7

ee RT

eee

Idle Air Control (IAC) valve connector

—

Spark plug wires Distributor Cruise control actuator Engine side mount bracket Front cover Timing belt. Refer to the Timing Belt unit repair section. Camshaft sprockets

Rear timing belt cover Valve cover 5. Loosen the valve adjuster locknuts and screws so that all valves are closed. e>Keep all valvetrain components in order for assembly. O-RING Replace.

6x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft)

7924MG10

Exploded view of the water pump mounting

6. Start the engine and check for leaks. ;

e Throttle Position (TP) sensor connector

e Manifold Absolute Pressure (MAP)

Cylinder Head ©

sensor connector

.

e Heated Oxygen Sensor (HO2S) connector

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Air intake assembly Accessory drive belts Power steering pump and bracket Accelerator cable Fuel lines Evaporative Emissions (EVAP) control canister hose and vacuum hose e Brake booster vacuum line Intake manifold vacuum line Positive Crankcase Ventilation (PCV) valve and hose Upper radiator hose Heater hose Bypass hoses Fuel injector connectors Engine Coolant Temperature (ECT) sensor connector Radiator fan switch connector ECT gauge sending unit connector

6. Remove or disconnect the following: e Camshafts e Rocker arms e Exhaust front pipe e Exhaust manifold bracket e Intake manifold 7. Loosen the cylinder head bolts in sequence and ¥% turns until all bolts are loose. 8. Remove the cylinder head. To install: 9. Install the cylinder head with a new gasket.

@) 9308MG13

Cylinder head bolt loosening sequence—CR-V

Timing belt service is covered in Section 3 of this manual

15-

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HONDA CR-V

3. Loosen the valve adjuster locknuts and screws so that all valves are closed.

->Keep all valvetrain components in order for assembly.

ae SO

4. Remove or disconnect the following: e Camshaft sprockets e Rear timing belt cover e Camshafts e Rocker arms To install: 5. Install or connect the following: e Rocker arms in their original positions e Camshafts e Rear timing belt cover ¢ Camshaft sprockets. Tighten the bolts to 27 ft. Ibs. (37 Nm). e Timing belt 6. Adjust the valve clearance. 7. Install or connect the following: e Front cover e Accessory drive belts

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oO) 9308MG14

Cylinder head bolt tightening sequence—CR-V

10. Apply clean engine oil to the bolt threads and under the bolt heads. 11. Tighten the cylinder head bolts in sequence as follows: a. Step 1: 22 ft. Ibs. (29 Nm) b. Step 2: 63 ft. Ibs. (85 Nm) 12. Install or connect the following: Intake manifold. Tighten the bolts to 17 ft. Ibs. (24 Nm). Exhaust manifold bracket Exhaust front pipe Rocker arms in their original positions Camshafts Rear timing belt cover Camshaft sprockets. Tighten the bolts to 27 ft. Ibs. (37 Nm). Timing belt 13. Adjust the valve clearance. 14. Install or connect the following: Valve cover Front cover Engine side mount bracket Cruise control actuator Distributor Spark plug wires IAC valve connector HO2S connector MAP sensor connector TP sensor connector ECT gauge sending unit connector Radiator fan switch connector ECT sensor connector Fuel injector connectors

Bypass hoses Heater hose Upper radiator hose PCV valve and hose Intake manifold vacuum line Brake booster vacuum line EVAP control canister hose and vacuum hose Fuel lines Accelerator cable Power steering pump and bracket Accessory drive belts Air intake assembly Negative battery cable 15. Fill the cooling system. 16. Start the engine and check for leaks.

Rocker Arms/Shafts

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Spark plug wires Distributor Valve cover Accessory drive belts Front cover Timing belt. Refer to the Timing Belt unit repair section.

e Valve cover e Distributor e Spark plug wires e Negative battery cable 8. Start the engine and check for leaks.

Intake Manifold

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Air intake assembly Intake manifold resonator chamber and bracket, for 1999-01 models Accelerator cable Fuel lines Evaporative Emissions (EVAP) control canister hose and vacuum hose Brake booster vacuum line Intake manifold vacuum line Positive Crankcase Ventilation

(PCV) valve and hose Bypass hoses Fuel injector connectors

Throttle Position (TP) sensor connector

Manifold Absolute Pressure (MAP) sensor connector

Idle Air Control (IAC) valve connector

Cruise control actuator

-

is. \

wh

HONDA

—

CR-V

INTAKE MANIFOLD

F

Replace if cracked or if mating surfaces are

INTAKE AIR TEMPERATURE

(IAT) SENSOR

22 N-m (2.2 kgf-m, 16 Ibf-ft)

damaged, INTAKE AIR CONTROL (IAC) VALVE

_

=f

8 x 1.25 mm

22Nm (2.2 kgfm, 16 Ibf-ft)

ete

|

Replace.

mS, Use new self-locking nuts and split pins for assembly.

3. Install or connect the following: Lower control arm. Tighten the front flange bolt to 76 ft. Ibs. (103 Nm). Rear bushing bracket. Tighten the bolts to 66 ft. Ibs. (89 Nm). Stabilizer bar link. Tighten the nut

to 22 ft. Ibs. (29 Nm). Damper fork lower bolt. Tighten the nut to 47 ft. Ibs. (64 Nm).

e>Use a new self-locking nut for assembly.

3. Install or connect the following: e Rear bushing. Tighten the nut to 61

ft. Ibs. (83 Nm). e Rear bushing bracket. Tighten the : bolts to 66 ft. Ibs. (89 Nm). e Front wheel 4. Check the wheel alignment and adjust as necessary.

Lower ball joint. Tighten the nut to 36-43 ft. Ibs. (49-59 Nm). Front wheel 4. Check the wheel alignment and adjust

Wheel Bearings

ADJUSTMENT

as NECESSAry.

REMOVAL & INSTALLATION

CONTROL ARM BUSHING REPLACEMENT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm assembly with a floor jack. 3. Remove or disconnect the following: e Upper ball joint e Inner control arm flange bolts. e Upper control arm To install:

The lower control arm front inner bushing and the damper fork bushing are serviced with the control arm as an assembly.

4. Install the upper control arm. Tighten the ball joint nut to 29-35 ft. Ibs, (39-47 Nm) and the inner flange bolts to 40 ft. Ibs. (54 Nm).

CONTROL ARM BUSHING REPLACEMENT The upper control arm bushings are serviced with the upper control arm as an assembly.

:

2. Remove or disconnect the following:

e Rear bushing bracket bolts e Lower control arm To install:

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

>Use new self-locking nuts for assembly.

ie

_

The wheel bearings are sealed units and are not adjustable.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Press

WHEEL BEARING Replace.

4

HUB DIS/ASSEMBLY 07GAF - SE00100

TOOL

HUB DIS/

ASSEMBLY BASE 07GAF - $040700

Lower Control Arm REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ 2. Remove or disconnect the following: e Front wheel ¢ Lower ball joint ¢ Damper fork lower bolt e Stabilizer bar link ¢ Front inner flange bolt

FRONT HUB 7924MG37

Removing the hub from the wheel bearing using the disassembly tools

4

{

:

e Front wheel

HUB DIS/ASSEMBLY TOOL 07GAF - SE00100

e Spindle nut e Brake hose bracket e Brake caliper and rotor Wheel speed sensor, if equipped

Outer tie rod end Upper and lower ball joints

Steering knuckle WHEEL BEARING INNER RACE Replace.

3. Press the hub out of the wheel bear4, Remove the splash guard. 5. Remove the snapring and press the wheel bearing out of the steering knuckle. 6. If necessary, press the inner bearing race off of the hub. To install: >Use new ball joint nuts, split pins, snapring and a new spindle nut for

assembly. 7. Press the bearing into the steering knuckle and install the snapring. 8. Install the splash guard. 9. Press the hub into the bearing. 10. Install or connect the following: Steering knuckle. Tighten the upper ball joint nut to 29-35 ft. Ibs. (39-47 Nm) and the lower ball joint nut to 36-43 ft. Ibs. (49-59 Nm). Outer tie rod end. Tighten the nut to

BEARING = SEPARATOR, 0 to 4 1/2 in.

Commercially,

—

available. Pressing out the wheel bearing inner race

32 ft. Ibs. (43 Nm). Wheel speed sensor, if equipped e Brake caliper and rotor. Tighten the caliper bracket bolts to 80 ft. Ibs. (108 Nm). ° ¢ Brake hose bracket e Spindle nut. Tighten the nut to 181 ft. Ibs. (245 Nm). ¢ Front wheel 11. Check the wheel alignment and adjust as necessary.

DRIVER 07749 - 0010090

WHEEL BEARING

m

07746 - 0010400

Rear

7924MG39

Utilizing the hub support base and driving attachment tools to install the new wheel hearing

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Rear wheel Brake drum Spindle nut Brake shoes and parking brake cable Brake fluid line Wheel sensor, if equipped Wheel bearing flange bolts Hub, backing plate and bearing assembly

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

*

FLANGE BOLT 12x 1.25 mm 103 N-m (10.5 kgf-m, 76 Ibf-ft)

O-RING Replace.

BACKING PLATE SPINDLE NUT 22x 1.5mm

181 N-m (18.5 kgf-m, 134 Ibf-ft) Replace.

NOTE: After tightening, use a drift punch to lock the spindle nut shoulder into the spindle.

BRAKE SHOE TRAILING ARM Check for cracking and damage.

HUB BEARING UNIT Replace. FLANGE BOLT 10 x 1.25 mm 64 N-m (6.5 kgf-m, 47 Ibf-ft)

REAR HUB Check for cracking and damage.

BRAKE DRUM ~ Check for wear and damage.

WHEEL NUT 12 x 1.5 mm

108 N-m (11.0 kgf-m, 80 Ibf-ft) 7924MG43

Exploded view of the rear hub and wheel bearing components—CR-V

3. Press the hub out of the wheel bearing. 4. If necessary, press the inner bearing race off of the hub. 5. Remove the backing plate from the bearing assembly. To install: e>Use a new spindle nut for assembly.

6. Use a new O-ring and install the backing plate to the bearing assem-bly. Tighten the bolts to 47 ft. Ibs. (64 Nm). 7. Press the hub into the bearing assembly. 8. Install or connect the following: e Hub, backing plate and bearing assembly. Tighten the flange bolts to 76 ft. Ibs. (103 Nm).

Brake fluid line Parking brake cable and brake shoes Wheel sensor, if equippedSpindle nut. Tighten the nut to 134 ft. Ibs. (181 Nm). Brake drum Rear wheel 9. Bleed the brake system.

2001 7

Santa Fe DRIVE TRAIN.................. 16-15 ENGINE REPAIR................ 16-2 FUEL SYSTEM ................ 16-14 PRECAUTIONS.................. 16-2

Exhaust Manifold......cccesee 16-8 Removal & Installation.............. 16-8

pines. acireate foyet e 16-14

Power Rack and Pinion Steering Géar..- 0... emer: 16-20 Removal & Installation............ 16-20 . R

STEERING AND SUSPENSION................. 16-20

Removal & Installation............ 16-14 Fefellinfector. (1S)AVe SU. lee 16-15

Rear Main Seal... 16-13 Removal & Installation............ 16-13

A

Removal & Installation............ 16-15 FUCrPORIGs cece eee Um 16-15

Rocker Arms/Shafts «0.0... 16-6 Removal & Installation.............. 16-6

Fuel System RreSSUTe ...........c. 16-14 HN ENING crrtesca teeta kod. 16-14

Shock Absorber-........... bee ee 16-21 Removal & Installation............ 16-211

BAR

sce eet

oe

16-20

DTS ET(61 allen eee 16-20 PROCAHONS | indinie® aateacc tad OF2U

BeAUN ecb nsceaoss 16-2 > Installationsass. Removaltal

ait actiaennovait 16-2

vec. 2atndey. anew T6A2

Ball JOIUAmas. All guunes vac bus16-21 Removal & Instatlation........... 16-21 C CeaViSH lait COMPA SIN QUERLY 16-8

Fuehbitterac

Removal & Installation............ 16-15

Fuel System Service

PreCaUllOns fnacus.cisied akene-avia 16-14 H

$

Starter Motor ........... ugha 16-9 Removal & Installation............. 16-9

STRUT Sct eras seek

ee

ties Se

tea 16-20

Halishall vic sauclanb-nab enone 16-17

Removal & Installation............ 16-20

Removal & Installation............ 16-17 Hydraulic Clutch System............. 16-16 Bleeding ws Miu 4 00. 0ao UA. 16-16

ai Trailing Arm... ivi Gu 16-23 Removal & Installation............ 16-23

I

Trailing Arm Bushing

Removal & Installation.............. 16-8 Cluver! Jel cei Sote Prinigmoyer 16-16 OTOSAGCpa ee 16-16 Removal & Installation............ 16-16

tgnitionimitiga.chy 218) AaaNs Adjustment. 254) 2uom 900 Intake Manifold... Removal & Installation..............

Removal & Installation............ 16-24 PV olautarteLévks ok at 16-18 Quarauls Aalennanaduh ented 16-18

Lower Control ArM.........:s0 16-22 Removal & Installation............ WG-22) 0

ValVeN AST So imscen tas re 16-9 ACJUSTMON I. 5, Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor The Santa Fe is equipped with a Distributorless Ignition System (DIS).

Alternator

REMOVAL 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Negative battery cable e Drive belt e Alternator electrical connections e Alternator mounting bolts e Alternator

2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Drive belt Alternator electrical connections Alternator mounting bolts Alternator

INSTALLATION 2.4L Engine

1. Install or connect the following: e Alternator e Alternator mounting bolts. Tighten the adjuster (upper) bolt to 15-18 ft. Ibs. (20-25 Nm) and the lower bolt and nut to 26-41 ft. Ibs. (34-54 Nm). Alternator electrical connections Drive belt Negative battery cable 2.7L Engine 1. Install or connect the following: e Alternator

a

HYUNDAL

SANTA FE

46.3 Bi

| trol module (PCM). No adjustment is nec-

[2.4 14] 2

essary.

panes

Adjusting bolt 20-25 (200-250, 15-18.6)

(

Engine Assembly

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the battery and air cleaner assembly. 3. Drain the cooling system. 4. Drain the engine oil. 5. Drain the transaxle fluid. 6. Relieve fuel system pressure. 7. Disconnect the following electrical connections: e Starter Alternator Throttle Position Sensor (TPS) Power steering switch connector Oil pressure gauge connector Back-up lamp switch connector A/T solenoid inhibitor switch con-

&

[2.7 V6]

nector

e

Coolant Temperature Sensor (CTS) Ignition coil Idle Speed Control (ISC) vale connector Manifold Absolute Pressure (MAP)

sensor e Oxygen (02S) sensor connector 8. If equipped with an automatic transmission, disconnect the oil cooler lines. Generator

Adjusting bolt

\\ 12-15 (120-150, 9-11.3) Support bolt

’

20-25 (200-250, 15-18.6) TORQUE

: Nm (kg-cm, Ib-ft) 9355LG01

Exploded view of the alternator mounting for both engines used in the Santa Fe

e Alternator mounting bolts. Tighten the adjuster (upper) bolt to 9-11 ft. lbs. (12-15 Nm) and the lower bolt

and nut to 15-18 ft. Ibs. (20-25 Nm). rs A Shae ean

° Negative battery cable

Ignition Timing ADJUSTMENT ; ae, The Santa Fe is equipped with a Distributorless Ignition System (DIS). The ignition

timing is controlled by the Powertrain Con-

9. Remove or disconnect the following: Raditor hoses from the engine Radiator Engine ground Brake vacuum hose Heater hoses at the engine Throttle cable at the engine Cruise control cable at the engine, if equipped Main fuel line at the supply/return pipe

Speedometer cable at the transaxle Clutch or control cable from the transaxle Power steering hoses from the

pump Steering dust cover in the engine compartment Gear box universal joint bolt Front wheel Brake caliper and support with wire

For complete service labor times, order the Chilton Labor Guide

| \ r

.“s

’

4 6-4

Mee

HyuNDal

:

GS

Po ’

eee

ee 2

oe 2 ee

er

ry

SANTA FE

5-

[DOHC ENGINE] © L= 65 (2.56)

Engine coolant pump

=

= a

L= 22 (0.86)

93551602

Attach the special tool to the transmission

jack and support the transmission

z

¢ Strut lower bolt

.

e Transaxle control rod and extension

i

¢ Front muffler bolts ~ rod, if equipped with a manual transmission

10. Support the transmission with a jack

using the special attachment shown in the accompanying illustration. 11. Make sure all cable, harness connectors and hoses are disconnected from

the engine and transmission.

|

L= 22 (0.86) ;

L=Length of bolt mm (in.)

Make sure the water pump bolts are positioned in their original positions as the bolts are dif-

ferent lengths—2.4L engine 2. Drain the cooling system. 3. Remove or disconnect the following:

e Negative battery cable

¢ Engine and transaxle mounting brackets

e Water pump inlet pipe e Drive belt and water pump pulley

e Sub frame bolts e Drive shaft

e Timing belt covers e Timing belt tensioner

12. Lower the engine and transaxle

|

(90-110 Nm) e Tighten the engine mount bracket bolts to 43-58 ft. Ibs. (60-80 Nm) 15. Fill the engine crankcase to the correct level. 16. Fill the transaxle to the correct level. 17. Fill the cooling system. 18. Fill the power steering system.

T : 90-110 (900-1100, 65-80)

bracket bolts to 65~80 ft. Ibs.

20. Check the wheel alignment and adjust as necessary.

e Alternator brace e Water pump and gasket

4. Clean the gasket mating surfaces.

To install: 5. Install or connect the following:

e New O-ring onto the groove on the front end of the coolant pipe and

e Water pump bolts

assembly enough so the front and rear roll stoppers can be removed. 13. Remove the engine assembly 14. Installation is the reverse of removal but please note the following steps: e Tighten the roll stopper bolts to 36—47 ft. Ibs. (60-65 Nm e Tighten the transaxle mounting

19. Start the engine and check for leaks.

re

wet the O-ring with water

al a Auto tensioner

fe

B

eee

B|

@)

aie

F °

Ca

gy

Timing belt ldler bearing

(200-270, 14-20)

Water Pump

REMOVAL & INSTALLATION

Tension bearing

Crank ehat spice?

2.4L Engine

1. Before servicing the vehicle, refer to

TORQUE : Nm (kg-em, Ib-ft)

the precautions in the beginning of this section.

98551606 Exploded view of the water pump mounting and related components—2.7L engine

Via Ay Cee

ila e Water pump and gasket e Bolts and alternator bracket. ; Tighten the bolts to 14-20 ft. Ibs. (20-27 Nm). Timing belt tensioner ¢ Timing belt covers e Water pump pulley and drive belt ¢ Water pump inlet pipe ¢ Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

After adjustment, tighten the bolt until it reaches the pedal stopper and tighten the lock nut.

b. Turn the push rod until the proper Specification is reached and tighten the lock nut.

Bleeding air from the hydraulic clutch, system is necessary whenever any part of the system has been disconnected or the fluid level (in the reservoir) has been: allowed to fall so low that air has been drawn into the master cylinder. nat cok

e>When adjusting the clevis pin play or the pedal height, make sure not to push the push rod towards the master cylinder.

c. After the adjustments are made, check that the clutch pedal free play is 0.2-0.5 inch (6-13mm). The free play is measured at the face of the pedal pad 5. If the adjustments do not bring the pedal into specifications, check the hydraulic system for air or a faulty component.

NEVER use fluid that has been bled from a clutch system to fill the master cylinder reservoir, as it may be aerated, contain excessive moisture and/or be contaminated in some other way. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

aa

~—-HYUNDAL SANTA FE 2. Fill the clutch master cylinder reservoir with new hydraulic clutch fluid. _ 3. Attach a hose to the bleeder on the clutch actuator and submerge the other end of the hose in a container of hydraulic clutch fluid. 4. Have an assistant slowly depress and hold the clutch pedal. 5. Loosen the bleeder to purge air. 6. Tighten the bleeder. 7. Repeat the above 3 steps until all air is completely purged from the system. 8. Refill the clutch master cylinder reservoir.

16-17

Strut assembly

10-12

i= Transaxle assembly

-

200 - 260 (2000 - 2600, 146 - 190)

Hie €@ A

Seg Prveshalt - RH

Hub and knuckle

REMOVAL & INSTALLATION Lower arm assembly Re

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle. 3. Remove or disconnect the following: Negative battery cable Aluminum wheel cover Split pin and halfhaft nut Wheel Speed Sensor (WSS) from the bracket, if equipped Brake hose from the bracket Knuckle from the strut by removing the flange bolts Halfshaft from the hub by tapping the end with a plastic mallet e Halfshaft from the transaxle using a pry bar. 4. \nsert a plug in the transaxle opening. To install:

e>Use new circlips, split pins and selflocking nuts for assembly.

5. Remove the plug from the transaxle opening. 6. Coat the halfshaft splines and sliding surfaces with gear oil. 7. Make sure the gap of the circlip is facing downwards. 8. Install the inner CV-joint to the transaxle until the circlip locks in the retaining groove. Pull on the shaft by hand to make sure it is properly engaged. 9. Install or connect the following: ¢ Halfshaft into the hub e Knuckle to the strut e Flange bolts and tighten to 74-88 ft. Ibs. (100-120 Nm)

Transfer case assembly (4WD)

Driveshaft - LH

TORQUE : Nm (kg-cm, Ib-ft) 9355LG40

Exploded view of the halfshaft mounting and related components

e Halfshaft nut and tighten to 146-190 ft. Ibs. (200-260 Nm) e New split pin e Brake hose to the bracket

e WSS to the bracket, if equipped e Aluminum wheel cover

e Negative battery cable 10. Fill the transaxle to the correct level and check for leaks. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Split pin and nut e Spare tire and support the hanger of the main muffler to avoid interfering with the carrier during right hand shaft removal 3. Matchmark the propeller rubber coupling and differential flange, then remove the bolts and nuts. 4. Support the differential carrier with a

jack and remove the differential carrier mounting nuts and bolts.

e Shaft from the carrier by inserting a prybar between the carrier and the shaft e Differential carrier to the rear after lowering the jack e Shaft from the axle hub using a plastic mallet e Shaft from the vehicle To install: 5. Install or connect the following: Shaft into the axle hub Differential carrier to the rear using a jack Shaft to the carrier Differntial carrier mounting nuts and bolts. Tighten the carrier nuts and bolts to 51-58 ft. Ibs. (70-80 Nm) and the carrier rear bracket bolt to 58-73 ft. Ibs. (80-100 Nm). Propeller shaft Spare tire and remove the support from the main muffler hanger

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

ies

16-1 ) ;

ae HYUNDAI SANTA FE

e New shaft nut and tighten to 146-253 ft. Ibs. (200-260 Nm) e New split pin e Rear wheel

CV-Joint

-

OVERHAUL 9355LG44

DOJ-BJ Type

9355LG42

The DOJ-Bu type joint is used on both the front and rear of the vehicle and the fol-

Remove snap-ring and take out the inner race, cage and balls as an assembly

Remove the boot clamps from the DOJ

e Snap-ring and take out the inner race, cage and balls as an assembly

lowing overhaul procedure is used. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

3. Clean the outer race, cage and balls without disassembling them. e BJ boot clamps e DOJ and BJ boots To install:

->Do not disassemble the BJ assembly.

2. Remove or disconnect the following: e Axle halfshaft from the vehicle and place it in a vise e DOJ boot clamps and push the boot back from the outer race e Circlip with a flat bladed prytool e Driveshaft from the DOJ outer race

.

>Use new circlips and boot clamps for assembly.

93661643 Remove the circlip with a suitable tool

D.O.J. outer race D.O.J. inner race

Circlip

Snap ring Cage Bail

D.O.J. boot

Boot band

Dust cover

D,.O.J. boot band

B.J.-boot band

4. Apply some of the grease supplied with the kit to the halfshaft.. 5. Install the boots. 6. Apply the grease supplied with the kit to the inner race and cage. 7. Install the cage so that it is offset on the race. 8. Apply the grease supplied with the ‘kit to the cage and install the balls 9. Install the chamfered side of the cage as shown in the accompanying illustration, then insert the inner race onto the shaft and install the snap-ring. 10. Apply the grease supplied with the kit to the BU outer race (67-73 grams of grease in the joint and 62-68 grams of grease in the boot); and install the outer race onto the shaft. 11. Apply the grease supplied with the kit to the DOJ outer race (62-68 grams in the joint and 37-43 grams in the boot); and install the circlip. 12. Tighten the DOJ boot clamps. 13. Apply the grease supplied with the kit to the BJ. 14. Install the boots. 15. Tighten the BJ boot clamps.

Inner race

TORQUE : Nm (kg-cm, Ib-ft)

9355LG45

9355LG41

Install the cage so that it is offset on the Exploded view of the DOJ-BJ type CV-joint assembly

race

AAG

‘HYUNDAL 4 SANTA FE Fi ates Ba ; me

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Se v a

| » 1!

Snap ring Spider assembly

il 9355L646

Dynamic dampey~ band

Install the chamfered side of the cage as shown

Dynamic damper

>To control the volume of air in the DOJ boot, make sure the distance

Boot band B.J. boot band

between the boot bands is as shown in — the accompanying illustration. 16. Install the axle halfshaft to the vehicle.

TJ-BJ Type 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Axle halfshaft from the vehicle. e TJ boot clamps

TORQUE : Nm (ka-cm. Ibrft)

e TJ boot from the TJ case e Sanp-ring and spider assembly ¢ BJ boot clamps, then pull out the TJ boot and the BJ boot 3. Clean all the components properly To install: .

93551648

Exploded view of the TJ-BJ type CV assembly

kit to the TJ boot (97-103 grams in the joint and 42-48 grams in the boot), then install the boot. 7. Tighten the TJ boot clamps. 8. Add the grease supplied with the kit

>Use new circlips and boot clamps for assembly.

to the BJ as much as was wiped out during

4. Apply the grease supplied with the kit to the shaft and install the boots. 5. If installing the dynamic damper, keep the BJ shaft in a straight line and attach the damper in the direction shown in the accompanying illustration, then install the boot clamp. 6. Apply the grease supplied with the

a7 id BARRos

cleaning and inspection. 9. Install the boots. 10. Tighten the BU boot clamps. >To control the volume of air in the TJ boot, make sure the distance between the boot bands is as shown in the accompanying illustration

:

a)ual

'

93651650

If installing the dynamic damper, keep the BJ shaft in a straight line and attach the damper in the direction shown

tap

;

ag

A

93551651

H+} 9355LG47

To contro! the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown

To control the volume of air in the TJ boot, make sure the distance

between the boot bands is as shown

For Wheel Alignment specifications, see Section 7 of this manual

2

46-21

HYUNDAI

SANTA FE

STEERING AND SUSPENSION

+ CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service

on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible injury

and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment. Before servicing the vehicle, also make sure to refer to the precautions in the beginning of this section as well.

3. Drain the power steering system. 4. Remove or disconnect the following: e Negative battery cable e Pressure and return hoses e Joint assembly connecting bolt e Tie rod end from the knuckle e Feed tube e Gear box mounting bolts e Gear box assembly with the rubber mounts To install: 5. Install or connect the following: Gear box assembly with the rubber mounts Gear box mounting bolts and tighten to 66-81 ft. Ibs. (90-110 Nm) Feed tube and tighten to 7-11 ft. lbs. (10-16 Nm) Tie rod end from the knuckle and tighten to 18-25 ft. Ibs. (24-34 Nm) Joint assembly connecting bolt and tighten to 11-14 ft. Ibs. (15-20 Nm) Pressure and return hoses. Tighten the fittings to 9-13 ft. Ibs. (12-18 Nm). Negative battery cable 6. Fill the power steering system

7. Check the wheel alignment and adjust as necessary.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Brake hose clip from the strut mounting bracket Wheel Speed Sensor (WSS) from the knuckle Stabilizer bar link Strut-to-knuckle bolts 3 upper mounting nuts e Strut To install: 3. Install or connect the following: Strut. Tighten the upper mount nuts to 30-37 ft. Ibs. (40-50 Nm). e Strut-to-knuckle bolts and tighten to 74-88 ft. lbs. (100-120 Nm) Dust cover

40 - 50 (400 - 500, 30 - 37) »

Upper strut mounting nut

(600 -700, 44 -52)

:

Strut insulator assembly

=

———Gw§

Upper spring seat ——

ea

—

tales =

Upper spring pad

Bumper rubber eg

DISARMING

Dust cover

1. Turn the wheel to the straight ahead position. 2. Disconnect the negative battery cable and wait at least 30 seconds for the air bag energy to deplete. 3. After work has been completed, connect the battery cable.

Strut ee Coil spring

4

Lower spring pad

Power Rack and Pinion Steering

a

; a

Gear

100 - 120

iy

(1000 - 1200, 74 - 88)

_

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Center the steering wheel and lock it in position.

60-70

Self-locking nut i

Bee: Al

TORQUE

: Nm (kg-cm, Ib-ft) 9355LG52

Exploded view of the front strut assembly and mounting

HYU |AL

sion

SANTA FE ¢ Stabilizer bar link and tighten to 30-37 ft. Ibs. (30-50 Nm) e WSS from the knuckle e Brake hose clip to the strut mounting bracket e Front wheel 4. Check the wheel alignment and adjust

as necessary.

To install: | 4. Install or connect the following: e Shock absorber. Tighten the upper nut to 15-22 ft. Ibs. (20-30 Nm) and the lower nut to 104-118 ft. lbs. (140-160 Nm). e Rear wheel

Coil Spring Shock Absorber

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

tion. 2. Support the vehicle under the lower control arm. 3. Remove or disconnect the following: Rear wheel Upper shock absorber upper nut Lower shock absorber nut Shock absorber

=

4

45

;

&

a

To install: ->Use a new self-locking nut. *d

5. Compress the spring and position the strut so that the end of the spring aligns _ with the notch in the spring seat. 6. Install the upper strut mounting com- 4 ponents and tighten the nut to 44-82 ft. Ibs. (60-70 Nm).

as necessary.

Front

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut from the vehicle and install in a strut spring compressor. Compress the spring until the end of the spring comes away from the spring seat. 3. Remove the upper strut mount, spring seat and related components. 4. Remove the coil spring from the strut spring compressor.

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

2. Support the vehicle under the lower control arm. 3. Remove or disconnect the follow-

e Rear wheel e Flange nut and brake caliper assembly e Parking brake assembly

e Wheel Speed Sensor (WSS) and the parking brake cable Rear shock assembly 4. Lower the jack assembly and remove the spring. To install: 5. Install or connect the following: e Spring and raise the jack into position Rear shock assembly Parking brake cable and WSS Parking brake assembly Flange nut and brake caliper assembly Rear wheel

Rear crossmember

20 - 30 (200 - 300, 15 - 22) Rear shock absorber

Ball Joint 160 - 180 (1600 - 1800, 118 - 133)

140 - 160 (1400 - 1600, 104 - 118) 140 -160 (1400- 1600, 104 - 118)

TORQUE : Nm (kg-cm, [b-ft)

7

8. Check the wheel alignment and adjust. 4

REMOVAL & INSTALLATION

Rear

(hy

7. Install the strut to the vehicle.

|

REMOVAL & INSTALLATION

pas 4

a ene aL. — a i =. f

3

9355LG53

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec- ; tion. 2. Remove the control arm. 3. Using tools 09551-3100 and 0921621100, remove the bushing. 4. Using a suitable prytool and remove the dust cover from the ball joint. 5. Remove the snap-ring. 6. Remove the ball joint from the arm using a plastic hammer. To install: 7. Install the ball joint.

Exploded view of the rear suspension assembly

For Maintenance Interval recommendations, see Section 1 of this manual

es e o-F e a ee

16-2

- HYUNDAI SANTA FE

“Lower Control Arm 09551-31000

REMOVAL & INSTALLATION

09545-21100 Lower arm

09216-21100

Ball joint

flange

Front

09545-11000

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

9355LG56

Installing the ball joint dust cover 935555

Removing the bushing from the control arm using the appropriate removal and

installation tools

8. Install the bushings into the arm using the appropriate tools. Make sure that the ball joint flange is supported while pressing down on the bushing until the flange touches the arm surface.

2. Remove or disconnect the follow-

9. Install the ball joint snap-ring. Be careful to keep the snap-ring expansion as small as possible during installation. 10. Apply multi-purpose grease to the dust cover lip and inside of the cover. 11. Using tool 09545-11000, install the dust cover until it is completely seated on the snap ring. 12. Install the control arm.

ing: e Front wheel

e Ball joint-to-knuckle bolt e Sub frame bolts and the frame e Lower arm bolts and the arm 3. Installation is the reverse of removal. Tighten the fasteners as follows: a. Tighten the arm bolt A to 74-88 ft.

lbs. (100-120 Nm) and bolt B to 66-81 ft. Ibs. (90-110 Nm).

Front strut assembly

Sub-frame

45 - 55 (450 - 550, 33 - 41)

100 - 120 (1000 - 1200, 74 - 88)

Stabilizer bar

i We os

4

a“

wee

|

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_

cS

200 - 260 (2000 - 2600, 146 - 190) .

Tongue = Brake drum

| Flange nut

Hub cap

’

.)

Hub assembly

NG. NY: —

200 - 260 (2000 - 2600, 146 - 190)

Tongue washer

Brake disc

Flange nut

TORQUE : Nm (kg-cm, Ib-ft)

Exploded view of the rear hub assembly

For complete service labor times, order the Chilton Labor Guide

Hub cap

;

rr

dle y

|

09216-21100 and 09532-3200

9355LG71 9355LG69

Removing the wheel bearing inner race

from housing

Piameniag the rear hub from housing

09517-21500

¢ Snap-ring ¢ Backing plate, then press the hub onto the housing using tool 0951721500 6. Rotate the bearing several times to seat the bearing. — 7. Measure the wheel bearing torque using an inch Ib. torque wrench. The ~measurement is 16.64 inch lbs. (1.88 Nm). 8. Measure the end-play of the hub using a dial gauge. The specification is

0.003-0.008mm. 9. Install the remaining components in the reverse order of removal. 10. Check the wheel alignment and adjust as necessary. * fy:

_

9355LG70

Removing the wheel bearing snap-ring

9355LG72

Press the hub onto the housing

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| 1998-01 | | lsuzu-Amigo * Rodeo * Rodeo Sport * Trooper * Vehicross * Honda-Passport DRIVE TRAIN.................. 17-22

ENGINE REPAIR................ 17-2

Removal & Installation............ PE=2ie . Rear MainSeale

R

eee Come Ay-19

FUEL SYSTEM ................ 17-20 PRECAUTIONS.................. 17-2 STEERING AND SUSPENSION................. 17-30

Fuelinjector merc..lio onlin jae 17-21 Removal & Installation............ 17-21 FUSE Pennie arn Se eereSy Wot |17-21 Removal & Installation............ 17-21

A

PUI SYSIEN) Piesstie nine auca Tee2U,

Removal & Installation............ 17-19 Recirculating Ball Steering Gear” SARE YN USICNE VOU Bit a 17-30 Removal & Installation............ 17-30 ROCKEP gs idles eee reeeee 17-8

Fuel System Service PReCaIT ORSienuied antlentc omc, 17-20) H

) SNOCR ADS OTE icc cccahaena ames 17-30 Removal & Installation............ 17-30

WHE). s\ Bicalden ipa

raae 17-30

UGE SLILLGN) pose etc da 17-30 cocoevatonca: 17-30 Preted Oli peresncscctins PLCUNOUON etttaet ab nt danctt searhntors 17-2

[stella

(21(vy Dnagsmtnlenetiedinert 17-20

Removal & Installation............. 17-8

DNessrerr ice cats.08ers Aros —~ Halishablotpmatteteas titan aettet eaWeadbs ~~ Starter Moto: cncsnlcteashatchiieness 17-17

eyes 17-2 PROMMOVAN art ich ceistnicliasted Axle Shaft, Bearing,and Seal........17-29

Removal & Installation........... 17-29

Removal & Installation............ 17-26 Hydraulic Clutch System............. 17-26

Bleedinguni2

vines. timiye. vier:17506)

Removal & Installation............ 17-17 T

Torsion Batiatss

ee 17-30 J caiee 17-30 17-26 17-26 17-22 17-22

17-11 17-11 17-26 17-26

i 17-3 Leprarticorie Tiverton aaa ACIOSTMONT A008 BDO s317-3 Intake Manifold... 17-8 Removal & Installation.............. 17-8

Removal & Installation............ Transfer Case Assembly............... Removal & Installation............ Transmission Assembly ............... Removal & Installation............

Coll SOL feea ae, 17-30 Removal & Installation......:..... 17-30 CV OIOINGNE Loe ee ee. 17-29

LOWER Bal SONIte sy wenn eee. 17-31 Removal & Installation............ 17-31 Lower Control ArM............:cre0s 17-33

Upper Ball Joint.......... Rare 17-31 Removal & Installation............ 17-31 Upper Control Arm ou... cece 17-32

C Camshaft and Valve Lifters .......... Removal & Installation............ CALLE Na Le alee hictes. «Maret PIHUSUTIONES returnees:

Removal & Installation............ 17-26

Over Hiilieie Wii Mane 817-29

CylindenHead jade ial sauteas.avise 17-6 Removal & Installation.............. 17-6 D

ete iStHD MONE Se ee E

ens WD 5 ae Tae

Engine ASS@MDIY ...............seseeecee 17-3 *

Fuel piltets cutis vngbaatlieaad dian17-21

Removal & Installation.............. 17-3 Exhaust Manifold......ccccccccccccccsceeees 17-9 Removal & Installation........:.... 17-9

F .............. 17-10 Seal Crankshaft Front Removal & Installation............ 17-10

pene

Control Arm Bushing

cue1f-33 ROD IACOIE NL i2edit cacastyi Removal & nslanalion Pyirisatbigs 17-33

Fer

Control Arm Bushing

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lp Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

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PRECAUTIONS brake fluid internally, seek medical assistance IMMEDIATELY. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to.the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid from a sealed container is essential to the safe and

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e>Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor

REMOVAL These engines are equipped with a Distributorless Ignition System (DIS).

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proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. Ifthe brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; itwill damage the paint. ¢ Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles: may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the A/C system or its components.

ENGINE REPAIR Alternator

REMOVAL 2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Accessory drive belt e Alternator harness connectors e Alternator

3.2L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Accessory drive belt ‘ e Alternator harness connectors e Alternator 3.5L Engine

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

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4. Remove or disconnect the following: Battery Hood Accessory drive belt Accelerator cable Air intake assembly Engine wiring harness connectors at left rear of the engine compartment Brake booster vacuum line

INSTALLATION 2.2L Engine Install or connect the following: e Alternator. Tighten the long bolt to 26 ft. Ibs. (35 Nm) and the short bolt to 15 ft. lbs. (20 Nm). e Alternator harness connectors

e Engine ground cables Clutch fluid line bracket and slave cylinder Fuel lines and bracket Exhaust front pipe Transmission A/C compressor Power steering pump Chassis harness connectors at right rear of the engine compartment Framé ground cable Radiator hoses Heater hoses Cooling fan connector

e Accessory drive belt

¢ Negative battery cable 3.2L Engine Install or connect the following: e Alternator. Tighten the 10mm bolt to 30 ft. Ibs. (41 Nm) and the 8mm bolt to 15 ft. Ibs. 21 Nm). e Alternator harness connectors e Accessory drive. belt e Negative battery cable

Cooling fan and shroud

3.5L Engine 1. Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2. Install or connect the following: e Alternator. Tighten the 10mm bolts to 30 ft. Ibs. (41 Nm) and the 8mm bolts to 15 ft. Ibs. (21 Nm). e Alternator wiring connectors e Accessory drive belt e Negative battery cable

Radiator Left and right engine mounts 5. Lift the engine from the vehicle. To install: 6. Position the engine in the engine compartment.

ADJUSTMENT These engines are equipped with a Dis-

tributorless Ignition System (DIS). No adjustment is possible.

|

REMOVAL & INSTALLATION 2.2L engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure.

7. Install or connect the following: Left and right engine mounts.

Tighten the fasteners to 30 ft. Ibs. (41 Nm). Radiator Cooling fan and shroud Cooling fan connector Heater hoses Radiator hoses Frame ground cable Chassis harness connectors at right rear of the engine compartment Power steering pump

A/C compressor Transmission Exhaust front pipe Fuel lines and bracket Clutch fluid line bracket and slave cylinder Engine ground cables Brake booster vacuum line Engine wiring harness connectors at left rear of the engine compartment Air intake assembly Accelerator cable Accessory drive belts Hood Battery 8. Fill the cooling system. 9. Start the engine and check for leaks. 3.2L Engines

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Engine Assembly

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7924NG01

Left and right motor mounts—2.2L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Battery Hood Accelerator cable Cruise control cable Air intake assembly Canister vacuum hose Brake booster vacuum hose Engine wiring harness connectors Front axle harness connector, if equipped Transmission harness connector and bracket Frame ground cable Firewall ground cable Starter harness connectors Alternator harness connectors Coolant overflow reservoir hose Radiator hoses Cooling fan and shroud Accessory drive belt

For complete service labor times, order the Chilton Labor Guide

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Exhaust front pipes Heater hoses Fuel lines Transmission Left and right engine mounts Lift the engine from the vehicle. install: Lower the engine into the vehicle. Install or connect the following: Left and right engine mounts. Tighten the bolts to 30 ft. Ibs. (41

Nm) and the nuts to 37 ft. Ibs. (50 Nm). Transmission Fuel lines Heater hoses Exhaust front pipes Heated Oxygen (HO2S) sensor connectors A/C compressor Power steering pump Accessory drive belt Cooling fan and shroud Radiator hoses Coolant overflow reservoir hose Alternator harness connectors Starter harness connectors Firewall ground cable Frame ground cable Transmission harness connector and bracket Front axle harness connector, if equipped Engine wiring harness connectors Brake booster vacuum hose Canister vacuum hose Air intake assembly Cruise control cable Accelerator cable Hood Battery 8. Fill the cooling system. 9. Start the engine and check for leaks.

Radiator

Engine wiring harness connectors Transmission harness connectors and bracket

Upper fan shroud Heater hoses Radiator hoses Coolant reservoir tank hose Alternator harness connector Starter harness connector

Engine ground cable Starter harness connector Alternator harness connector Coolant reservoir tank hose Radiator hoses Heater hoses Upper fan shroud Radiator Cooling fan Accessory drive belt

Engine ground cable Transmission harness connectors and bracket Engine wiring harness connectors Brake booster vacuum line Canister vacuum line

Cruise control cable

Power steering pump

A/C compressor Heated Oxygen (HO2S) sensor connectors

Left and right exhaust front pipes. Fuel lines Flywheel dust cover Transmission. Refer to the transmission procedure in this section. e Left and right engine mounts e Engine To install: 4. Install or connect the following: e Engine Left and right engine mounts. Tighten the bolts to 30 ft. Ibs. (41 Nm). Transmission Flywheel dust cover Fuel lines Left and right exhaust front pipes HO2S sensor connectors A/C compressor Power steering pump Accessory drive belt Cooling fan. Tighten the nuts to 16 ft. Ibs. (22 Nm).

Accelerator cable Air cleaner assembly Hood Battery 5. Fill the cooling system. Check all

fluid levels and adjust as necessary. 6. Start the engine and check for leaks.

Water Pump

REMOVAL & INSTALLATION 2.2L Engine

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

2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Radiator hose Accessory drive belt Front cover Timing belt. Refer to the Timing Belt unit repair section. Water pump

3.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Battery e Hood e Air cleaner assembly ¢ Accelerator cable e Cruise contro! cable e Canister vacuum line ¢ Brake booster vacuum line

7924NG03

Exploded view of the water pump mounting, showing the location of the mounting lug—2.2L engine

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e Accessory drive belt e Radiator hose e Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for

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e Timing belt. Refer to the Timing Belt Unit Repair Section. e Idler pulley e Water pump To install:

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3.5L Engine

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the follow-

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e Negative battery cable e Upper radiator hose

3.2L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Radiator hose e Accessory drive belt

4. Install or connect the following: e Water pump. Tighten the bolts in two passes, in sequence, to 13 ft. Ibs. (18 Nm) for 3.2L engines or to 18 ft. Ibs. (25 Nm) for 3.5L engines. 9 Idler pulley . i Timing belt " Upper radiator hose e Negative battery cable

1. Timing belt 2. Idle pulley 3. Water pump assembly

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Timing belt. Refer to the Timing Belt unit repair section. e Timing belt idler pulley e Water pump To install: 4. Install or connect the following: e Water pump. Tighten the bolts in sequence to 18 ft. Ibs. (25 Nm). ¢ Timing belt idler pulley. Tighten the bolt to 38 ft. Ibs. (52 Nm). e Timing belt e Front cover

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7924NG04

Water pump bolt tightening sequence—3.2L engines

Water pump torque sequence. Apply LOCTITE® 262 to bolt number 3

(arrow) —3.5L engine

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Engine wiring harness connectors

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Power steering pump pressure switch connector Front cover Spark plugs and wires Camshaft Position (CMP) sensor Valve cover Timing belt. Refer to the Timing Belt unit repair section. Timing belt idler pulleys Timing belt rear cover Oil pressure switch connector Camshafts Cylinder head. Remove the bolts in reverse of the tightening sequence. To install:

REMOVAL & INSTALLATION 2.2L Engine .

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4, Remove or disconnect the following: e Negative battery cable Intake Air Temperature (IAT) sensor connector e Positive Crankcase Ventilation (PCV) valve and hose Air intake assembly Upper radiator hose Accessory drive belt Exhaust front pipe Alternator and brackets Crankshaft Position (CKP) sensor connector Knock sensor connector Heater hoses Water bypass hose Fuel lines Evaporative Emissions (EVAP) valve connector

e>Use new cylinder head bolts for assembly.

5. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows: a. Step 1: 18 ft. Ibs. (25 Nm) b. Step 2: Plus 90 degrees c. Step 3: Plus 90 degrees d. Step 4: Plus 90 degrees 6. Install or connect the following: ¢ Camshafts e Oil pressure switch connector 5.

e Timing belt rear cover Timing belt idler pulleys. Tighten the bolts to 18 ft. Ibs. (25 Nm). Timing belt Valve cover CMP sensor Spark plugs and wires

Front cover — Power steering pump pressure switch connector Engine wiring harness connectors at left rear of the engine compartment Intake manifold Canister hose EVAP valve connector Fuel lines Water bypass hose Heater hoses Knock sensor connector CKP sensor connector Alternator and brackets Exhaust front pipe Accessory drive belt Upper radiator hose Air intake assembly PCV valve and hose IAT sensor connector Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks. eeeeee e

3.2L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: » Negative battery cable Hood Engine cover Mass Air Flow (MAF) sensor connector Intake Air Temperature (IAT) sensor connector Positive Crankcase Ventilation (PCV) valve and hose Air cleaner assembly ‘ Manifold Absolute Pressure (MAP) sensor connector

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Vacuum Switching Valve (VSV) connector and vacuum line

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Cylinder head torque sequence—2.2L (VIN D) engine

Fuel injector connectors Throttle Position (TP) sensor connector Idle Air Control (IAC) valve connector Ignition coils Brake booster vacuum line Canister purge vacuum line

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Cylinder heads

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Cylinder head torque sequence—3.2L DOHC and 3.5L engines

>The left and right cylinder head gaskets are not interchangeable.

5. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows: a. Step 1: 21 ft. Ibs. (29 Nm) b. Step 2: 47 ft. Ibs. (64 Nm) 6. Install or connect the following: Oil dipstick tube Left and right exhaust front pipes Timing belt Valve covers Timing belt cover Oil cooler hoses Crankshaft pulley. Tighten the pulley bolt to 123 ft. Ibs. (167 Nm).

A/C compressor Power steering pump and bracket. Tighten the bolts to 34 ft. Ibs. (46 Nm).

7924NG11

Right (1) and left (2) head gasket identification mark locations—3.2L DOHC engine

Timing belt service is covered in Section 3 of this manual

Idler pulley Alternator Cooling fan and pulley Accessory drive belt and tensioner Upper fan shroud Engine coolant manifold Radiator hoses Intake manifold Fuel lines Duty solenoid valve Canister purge vacuum line Brake booster vacuum line Ignition coils

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Fuel injector connectors VSV connector and vacuum line MAP sensor connector Air cleaner assembly PCV valve and hose IAT sensor connector MAF sensor connector Engine cover Hood Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks. 3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Hood Engine cover Mass Air Flow (MAF) sensor connector Intake Air Temperature (IAT) sensor connector Positive Crankcase Ventilation (PCV) valve and hose Air cleaner assembly Manifold Absolute Pressure (MAP) sensor connector Vacuum Switching Valve (VSV) connector and vacuum line Fuel injector connectors Throttle Position (TP) sensor connector Idle Air Control (IAC) valve connector Ignition coils Brake booster vacuum line Canister purge vacuum line Duty solenoid valve Fuel lines Intake manifold Radiator hoses Engine coolant manifold Upper fan shroud Accessory drive belt and tensioner Cooling fan and pulley Alternator Idler pulley Power steering pump and bracket A/C compressor Crankshaft pulley Oil cooler hoses Timing belt cover Valve covers Timing belt. Refer to the Timing Belt Unit Repair Section. Left and right exhaust front pipes

7924BG04

Right (1) and left (2) head gasket identification mark locations—3.5L engine

Oil dipstick tube Cylinder heads To install:

e>Use new head bolts when installing the cylinder head. Do not apply oil to the head bolt threads. >The left and right cylinder head gaskets are not interchangeable.

4, Install the cylinder heads with new gaskets. Tighten the bolts to 47 ft. Ibs. (64 Nm) 5. Install or connect the following: Oil dipstick tube Left and right exhaust front pipes Timing belt Valve covers Timing belt cover Oil cooler hoses Crankshaft pulley. Tighten the pulley bolt to 123 ft. Ibs. (167 Nm). A/C compressor Power steering pump and bracket. Tighten the bolts to 34 ft. Ibs. (46 Nm). Idler pulley Alternator Cooling fan and pulley Accessory drive belt and tensioner Upper fan shroud Engine coolant manifold Radiator hoses Intake manifold Fuel lines Duty solenoid valve Canister purge vacuum line Brake booster vacuum line

Ignition coils IAC valve connector TP sensor connector Fuel injector connectors VSV connector and vacuum line MAP sensor connector Air cleaner assembly PCV valve and hose IAT sensor connector MAF sensor connector Engine cover Hood Negative battery cable 6. Fill the cooling system. 7. Start the engine. Check for leaks and proper operation.

Rocker Arms/Shafts

REMOVAL & INSTALLATION These engines are not equipped with rocker arms. The camshaft lobes act directly on the valve shims. ‘

Intake Manifold

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REMOVAL & INSTALLATION 2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: ¢ Negative battery cable

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Positive Crankcase Ventilation (PCV) valve and hose Air intake duct

Idle Air Control (IAC) valve connector Throttle Position (TP) Sensor con-

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nector Canister purge solenoid connector Electronic Vacuum Sensing Valve

nector Idle Air Control (IAC) valve con-

Fuel lines Fuel injector connectors Fuel pressure regulator vacuum line Fuel supply manifold Accelerator cable

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Ignition coil and bracket Brake booster vacuum line Intake manifold

e Fuel lines Fuel injector connectors Intake manifold

Intake manifold. Use a new gasket and tighten the bolts to 16 ft. Ibs. (22 Nm). Brake booster vacuum line Ignition coil and bracket Intake manifold bracket. Tighten the bolts to 16 ft. Ibs. (22 Nm). Water pipe Alternator and brackets. Tighten the short bolts to 14 ft. Ibs. (20 Nm) and the long bolts to 25 ft. Ibs. (35 Nm). Accelerator cable Fuel supply manifold Fuel pressure regulator vacuum line Fuel injector connectors Fuel lines IAC valve connector 7P sensor connector Throttle body water hoses Air intake duct PCV valve and hose

¢ Accessory drive belt

To install:*

3. Install or connect the following: Intake manifold. Tighten the fasteners to 18 ft. Ibs. (25 Nm). Fuel injector connectors Fuel lines Throttle body. Tighten the bolts to 88 inch Ibs. (10 Nm). Ventilation hose Pressure regulator vacuum line PCV valve and hose EGR valve EVSV connector and vacuum line Canister purge solenoid connector TP sensor connector IAC valve connector MAP sensor connector Brake booster vacuum line Cruise control cable

Accelerator cable Air cleaner assembly Engine cover Negative battery cable

4. Start the engine and check for proper operation.

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Engine cover e Air cleaner assemb| e Accelerator cable > e Cruise control cable

(EVSV) connector and vacuum line Exhaust Gas Recirculation (EGR) valve Positive Crankcase Ventilation (PCV) valve and hose — e Pressure regulator vacuum line

e Ventilation hose e Throttle body e Fuel lines

e Fuel injector connectors e Intake manifold To install: 3. Install or connect the following: Intake manifold. Tighten the fasteners to 18 ft. Ibs. (25 Nm). Fuel injector connectors Fuel lines Throttle body. Tighten the bolts to 88 inch Ibs. (10 Nm). Ventilation hose Pressure regulator vacuum line PCV valve and hose EGR valve EVSV connector and vacuum line Canister purge solenoid connector TP sensor connector IAC valve connector MAP sensor connector Brake booster vacuum line Cruise control cable Accelerator cable Air cleaner assembly Engine cover Negative battery cable 4. Start the engine and check for proper operation.

Exhaust Manifold

Sot Engine

REMOVAL & INSTALLATION

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

2.2L Engine

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3.2L Engine

Electronic Vacuum Sensing Valve

(EVSV) connector and vacuum line Exhaust Gas Recirculation (EGR) valve Positive Crankcase Ventilation (PCV) valve and hose Pressure regulator vacuum line Ventilation hose Throttle body

Alternator and brackets Water pipe

To install: 5. Install or connect the following:

Idle Air Control (IAC) valve connector Throttle Position (TP) sensor connector Canister purge solenoid connector

sensor connector

Throttle body water hoses Throttle Position (TP) sensor con-

2. Remove or disconnect the following: Negative battery cable Engine cover Air cleaner assembly Accelerator cable Cruise control cable Brake booster vacuum line

Manifold Absolute Pressure (MAP) sensor connector

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

2. Remove or disconnect the following: Negative battery cable e Air intake duct ¢ Exhaust front pipe

¢ Exhaust manifold heat shield e Exhaust manifold

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EGR pipe and bracket

e Tightening sequence:

Step1:JGHBDCJGBD Step2: ABCDEFGHJK Step3: ABCDEFGHJK e Tightening torque: Step1: 14 N-m (10 Ib ft) Step2: 20 N-m (14 Ib ft) Step3: 20 N-m (14 Ib ft)

Front Crankshaft Seal

REMOVAL & INSTALLATION 2.2L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec7924NG17

Exhaust manifold torque sequence—2.2L engine

To install: 3. Install the exhaust manifold. Tighten the nuts in sequence as follows: a. Step 1: 10 ft. Ibs. (14 Nm) b. Step 2: 14 ft. Ibs. (20 Nm) c. Step 3: 14 ft. Ibs. (20 Nm) 4. Install or connect the following: Exhaust manifold heat shield. Tighten the bolts to 71 inch Ibs. (8 Nm). Exhaust front pipe. Tighten the bolts to 18 ft. Ibs. (25 Nm). Air intake duct Negative battery cable 5. Start the engine and check for leaks. 3.2L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable Air cleaner assembly Heated Oxygen (HO2S) sensor connectors Right torsion bar Exhaust Gas Recirculation (EGR) pipe and bracket Left and right exhaust front pipes Heat shields

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Right torsion bar HO2S sensor connectors Air cleaner assembly Negative battery cable 4. Start the engine and check for leaks.

tion.

2. Remove or disconnect the following:

e Accessory drive belt e A/C compressor and bracket e Exhaust manifolds To install: 3. Install or connect the following: Exhaust manifolds. Tighten the bolts to 42 ft. Ibs. (57 Nm). A/C compressor and bracket Accessory drive belt Heat shields Left and right exhaust front pipes EGR pipe and bracket Right torsion bar HO2S sensor connectors Air cleaner assembly Negative battery cable 4. Start the engine and check for leaks. 3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Air cleaner assembly ¢ Heated Oxygen (HO2S) sensor connectors Right torsion bar Exhaust Gas Recirculation (EGR) pipe and bracket

e Negative battery cable Accessory drive belts Cooling fan A/C belt tensioner, if equipped Water pump pulley Power steering pump Crankshaft pulley Front cover Timing belt. Refer to the Timing Belt unit repair section. Crankshaft timing sprocket Rear timing cover Crankshaft oil seal To install: 3. Install or connect the following: Crankshaft oil seal Rear timing cover Crankshaft timing sprocket. Tighten the bolt to 94 ft. Ibs. (130 Nm) plus 45 degrees. Timing belt. Refer to the Timing Belt unit repair section. Front cover Crankshaft pulley Power steering pump Water pump pulley A/C belt tensioner, if equipped Cooling fan

Accessory drive belts Negative battery cable 4. Start the engine and check for leaks.

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the precautions in the beginning of this section. _ 2. Remove or disconnect the following: Negative battery cable Air cleaner assembly Upper fan shroud

Accessory drive belt and tensioner Cooling fan and pulley Idler pulley Power steering pump

Crankshaft pulley

Timing belt cover Timing belt. Refer to the Timing Belt Unit Repair Section. e Crankshaft timing sprocket e Oil seal To install: 3. Install or connect the following: e Oil seal so that it is flush with the oil pump housing Crankshaft timing sprocket Timing belt

Timing belt cover Crankshaft pulley. Tighten the bolt to 123 ft. Ibs. (167 Nm).

3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner assembly Upper fan shroud Accessory drive belt and tensioner Cooling fan and pulley Idler pulley Power, steering pump and move it aside Crankshaft pulley Timing belt cover Timing belt. Refer to the Timing Belt Unit Repair Section. Crankshaft timing sprocket e Oil seal

- To install: 3. Install or connect the following: Oil seal so that it is flush with the oil pump housing Crankshaft timing sprocket Timing belt Timing belt cover Crankshaft pulley. Tighten the bolt to 123 ft. Ibs. (167 Nm). Power steering pump Idler pulley Cooling fan and pulley Accessory drive belt and tensioner Upper fan shroud Air cleaner assembly Negative battery cable 4. Start the engine and check for leaks.

Camshaft and Valve Lifters

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REMOVAL & INSTALLATION 2.2L Engine

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

BNem(5.9 Ib ft) 25Nem(18 Ib ft)

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L engine Exploded view of the cylinder head and camshaft components—2.2

Brake service is covered in Section 4 of this manual

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2. Remove or disconnect the follow-

Negative battery cable

Positive Crankcase Ventilation (PCV) valve and hose Air intake duct and bracket Ground cables Engine wiring harness connectors at left rear of the engine compartment Cooling fan harness connector Accessory drive belt

Spark plug wire cover Spark plug wires Camshaft Position (CMP) sensor connector Crankshaft Position (CKP) sensor connector

Crankshaft pulley Front cover Camshaft Position (CMP) sensor. Loosen the rear timing cover bolt for access. Valve cover Timing belt. Refer to the Timing Belt unit repair section. Camshaft sprockets Camshaft bearing caps Camshaft seals Camshafts @ eeeeoe Hydraulic tappets

7924NG19

Camshaft bearing cap identification locations—2.2L engine

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Keep all valvetrain components in order for assembly.

To install: 3. Install or connect the following: Hydraulic tappets in their original locations Camshafts Camshaft bearing caps. Tighten the bolts in sequence to 71 inch Ibs: (8 Nm). Camshaft seals Camshaft sprockets 4. Tighten the camshaft sprocket bolts as follows: a. Step 1: 36 ft. Ibs. (50 Nm) b. Step 2: Plus 60 degrees C. Step 3: Plus 15 degrees 5. Install or connect the following: Timing belt Valve cover CMP sensor. Loosen the rear timing cover bolt for access. Front cover

Crankshaft pulley. Tighten the bolts to 14 ft. Ibs. (20 Nm). CKP sensor connector CMP sensor connector Spark plug wires Spark plug wire cover Accessory drive belt

7924NG20

Camshaft bearing cap tightening sequence—2.2L engine

Cooling fan harness connector e Engine wiring harness connectors at left rear of the engine compartment e Ground cables e Air intake duct and bracket e PCV valve and hose ¢ Negative battery cable

:

3.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly e Upper fan shroud ¢ Accessory drive belt and tensioner ¢ Cooling fan and pulley

e Idler pulley

+ Power steering pump and move it aside Crankshaft pulley Timing belt cover

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¢ Timing belt. Refer to the Timing Belt Unit Repair Section. Ignition coils Valve covers Camshafts Valve shims and tappets e>Keep the valve shims and tappets in order for installation.

To install: 3. Install the valve tappets and shims in their original locations. 4. Using Gear Spring Lever J-42686, turn the sub gear clockwise to align the 5mm bolt holes in the sub gear and the camshaft driven gear. Tighten the 5mm bolt. 5. Install or connect the following: Camshafts by aligning the timing marks as shown. Tighten the bolts in sequence to 89 inch Ibs. (10 Nm). Valve covers Ignition coils Timing belt Timing belt cover Crankshaft pulley. Tighten the bolt

to 123 ft. Ibs. (167 Nm). Power steering pump Idler pulley Cooling fan and pulley Accessory drive belt and tensioner Upper fan shroud Air cleaner assembly Negative battery cable

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7924NG21

Guide pin location for the exhaust cam gear—2.2L engine

M5x0.8

3.5L Engine

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

7924NG45

Aligning the sub gear with the Gear Spring Lever J-42686—3.2L DOHC engine

tion.

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2. Remove or disconnect the following: Negative battery cable Air cleaner assembly Upper fan shroud Accessory drive belt and tensioner Cooling fan and pulley Idler pulley Power steering pump and move It aside Crankshaft pulley Timing belt cover Timing belt. Refer to the Timing Belt Unit Repair Section. Ignition coils Valve covers Camshafts Valve shims and tappets

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

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Legend (1) Right Bank (2) Left Bank

7924NG46

Camshaft alignment marks for the left and right cylinder heads—3.2L DOHC engine

->Keep the valve shims and tappets in order for installation.

To install: 3. Install the valve tappets and shims in their original locations. 4. Using Gear Spring Lever J-42686, turn the sub gear clockwise to align the 5mm bolt holes in the sub gear and the camshaft driven gear. Tighten the 5mm bolt. 5. Install the camshafts. Align the timing marks as shown. Tighten the bolts in sequence to 89 inch Ibs. (10 Nm). 6. Install or connect the following: e Valve covers e Ignition coils Timing belt. Refer to the Timing Belt Unit Repair Section. Timing belt cover Crankshaft pulley Power steering pump Idler pulley Cooling fan and pulley Accessory drive belt and tensioner Upper fan shroud Air cleaner assembly Negative battery cable

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7924NG47

Camshaft retaining bracket tightening sequence—3.2L DOHC engine

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Right Bank Left Bank,

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7924BG11

Camshaft alignment marks for the left and right cylinder heads—3.5L engine

M5x0.8

7924BG13

7924BG12

Aligning the sub gear with the Gear Spring

Lever J-42686—3.5L engine

Camshaft retaining bracket tightening sequence—3.5L engine

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

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Valve Lash

ADJUSTMENT 2.2L Engine

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The 2.2L DOHC engine is equipped with hydraulic lash adjusters. No valve adjustment is necessary. 3.2L Engines > Measure valve clearance with the engine cold.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the valve covers. 3. Check the valve clearance with the camshafts positioned as shown. Intake valve clearance should be 0.0091—0.0130 in. (0.2311-0.3302mm). Exhaust valve clearance should be 0.0098—0.0138 in. (0.2489-0.3505mm). 4. |f adjustment is required, replace the shims as follows: a. Step 1: Position special tool J42689 on the edge of the tappet.

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b. Step 2: Rotate the crankshaft until the maximum lift portion of the camshaft lobe contacts the upper edge of the special tool and presses the tappet down to create enough clearance between the adjustment shim and the camshaft for the shim to be removed. c. Step 3: Replace shims as necessary to achieve correct valve clearance. d. Step 4: Repeat for each valve to be adjusted. 5. Replace the valve covers. Tighten the bolts to 80 inch Ibs. (9 Nm).

9302BG02

Cross section of the 3.5L cylinder head. Note the position of the camshaft lobe (1), adjustment shim (2) and the tappet (3)

9302NGO01

Cross section of the 3.2L DOHC cylinder head. Note the position of the camshaft lobe (1), adjustment shim (2) and the tappet (3)

9302BG03

Valve clearance adjusting tool J-42689 (1)

9302NG03 9302NG02

Insert special tool J-42689 (1) and use the camshaft to press the tappet down—3.2L

DOHC engine

Rotate the camshaft to depress the valve with special tool J-42689—3.2L DOHC engine

9302BG04

Using the valve clearance adjusting tool to hold the tappet for shim replacement

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> Measure valve clearance with the engine cold.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the valve covers. 3. Check the valve clearance with the camshafts positioned as shown. Intake valve clearance should be 0.0091-0.0130 inches. Exhaust valve clearance should be 0.0098—0.0138 inches. 4. If adjustment is required, replace the shims as follows: a. Step 1: Position special tool J-42689 on the edge of the tappet. b. Step 2: Rotate the crankshaft until the maximum lift portion of the camshaft lobe contacts the upper edge of the special tool and presses the tappet down to create enough clearance between the adjustment shim and the camshaft for the shim to be removed. c. Step 3: Replace shims as necessary to achieve correct valve clearance. d. Step 4: Repeat for each valve to be adjusted. i 5. Replace the valve covers. Tighten the

bolts to 80 inch Ibs. (9 Nm). Starter Motor

REMOVAL & INSTALLATION 2.2L Engines

e Starter wiring connectors

e Starter motor To install: 3. Install or connect the following: e Starter motor. Tighten the bolts to 30 ft. Ibs. (40 Nm), e Starter wiring connectors e Heat shield e Exhaust front pipe e Heated Oxygen (HO2S) sensor connectors e Negative battery cable

3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable

e Heated"Oxygen (HO2S) sensor con-

nectors e Exhaust front pipe e Heat shield e Starter wiring connectors e Starter motor To install: 3. Install or connect the following: e Starter motor. Tighten the bolts to 30 ft. Ibs. (40 Nm). Starter wiring connectors Heat shield Exhaust front pipe Heated Oxygen (HO2S) sensor connectors e Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Starter harness connections e Starter motor To install: 3. Install or connect the following: e Starter motor. Tighten the fasteners to 18 ft. Ibs. (25 Nm) for the 2.2L engine or to 30 ft. Ibs. (40 Nm) for the 2.6L engine. e Starter harness connections e Negative battery cable

REMOVAL & INSTALLATION — 2.2L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Flywheel dust cover e Left and right engine mounts. Raise the engine for access. e Oil pan e Oil pan support, for 2.2L engine To install: 4. Perform the following: a. Install the oil pan support and tighten the bolts to 14 ft. Ibs. (20 Nm). b. Install the oil pan and tighten the bolts to 70 inch Ibs. (8 Nm) plus 30 degrees. 5. Install or connect the following: e Left and right engine mounts. Tighten the nuts to 41 ft. Ibs. (55 Nm). e Flywheel dust cover 6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks. 3.2L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following:

3.2L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Heated Oxygen (HO2S) sensor connectors e Exhaust front pipe

7924NG24

Oil pan bolt tightening sequence—2.2L engines

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

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VEHICROSS ° PASSPORT 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Front wheels Oil level dipstick Stone guard Radiator under fan shroud Suspension crossmember Flywheel dust cover Pitman arm Idler arm 4. lf equipped with 4 wheel drive, unbolt and lower the front axle housing assembly for clearance. 5, Remove or disconnect the following:

9308BG01

Lower crankcase torque sequence—3.2L DOHC engine

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Negative battery cable Front wheels Oil level dipstick Stone guard Radiator under fan shroud Suspension crossmember Flywheel dust cover

e Pitman arm

e Idler arm 4. ‘I equipped with 4 wheel drive, unbolt and lower the front axle housing assembly for clearance. 5. Remove or disconnect the following: e Oil pan e Lower crankcase To install: 6. Apply a bead of silicone sealant to the crankcase flange and install the crankcase. Tighten the fasteners in sequence to 89 inch Ibs. (10 Nm). 7. Apply a bead of silicone sealant to the oil pan flange and install the oil pan. Tighten the fasteners to 89 inch Ibs. (10 Nm). 8. If equipped, raise the axle housing assembly into position. Tighten the axle case bolts to 61 ft. Ibs. (82 Nm) and the mounting bolts to 112 ft. Ibs. (152 Nm). 9. Install or connect the following: e Pitman arm. Tighten the nut to 159 ft. Ibs. (216 Nm). e Idler arm. Tighten the bolt to 33 ft. lbs. (44 Nm). e Flywheel dust cover e Suspension crossmember. Tighten the bolts to 58 ft. Ibs. (78 Nm). e Radiator under fan shroud

e e e e

Stone guard (il level dipstick Front wheels Negative battery cable 10. Fill the crankcase with engine oil. 11. Start the engine and check for leaks. ’ 3.5L Engine

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

e Oil pan e Lower crankcase To install: 6. Apply a bead of silicone sealant to the crankcase flange and install the crankcase. Tighten the fasteners in sequence to 89 inch Ibs. (10 Nm). 7. Apply a bead of silicone sealant to the oil pan flange and install the oil pan. Tighten the fasteners to 89 inch Ibs. (10 Nm). 8. If equipped, raise the axle housing assembly into position. Tighten the axle case bolts to 61 ft. Ibs. (82 Nm) and the mounting bolts to 112 ft. Ibs. (152 Nm). 9. Install or connect the following: e Pitman arm. Tighten the nut to 159 ft. Ibs. (216 Nm). e Idler arm. Tighten the bolt to 33 ft. lbs. (44 Nm).

9308BG01

Lower crankcase torque sequence—3.5L engine

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REMOVAL & INSTALLATION 2.2L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Accessory drive belts Cooling fan

A/C belt tensioner, if equipped Water pump pulley Power steering pump Crankshaft pulley Front cover

ISUZU/HHONDA

RODEO « RODEO SPORT ¢ TROOPER e VEHICROSS ° PASSPORT Timing belt. Refer to the Timing Belt unit repair section. e Crankshaft timing sprocket e Rear timing cover e Crankshaft oil seal e Oil pan e Oil pump pickup tube e Oil pump To install: 4. Install or connect the following: Oil pump. Use a new gasket and tighten the bolts to 53 inch Ibs. (6 Nm). Oil pump pickup tube. Tighten the bolts to 70 inch Ibs. (8 Nm). Oil pan Crankshaft oil seal Rear timing cover Crankshaft timing sprocket. Tighten the bolt to 94 ft. Ibs. (130 Nm) plus 45 degrees. Timing belt. Refer to the Timing Belt unit repair section. Front cover Crankshaft pulley. Tighten the bolts to 14 ft. Ibs. (20 Nm). Power steering pump Water pump pulley A/C belt tensioner, if equipped Cooling fan

17-19,

e Accessory drive belts. e Negative battery cable 5. Fill the crankcase to the correct level. 6. Start the engine and check for leaks.

3.2L Engine 1. Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Timing belt e Oil pan e (il pickup tube e Oil filter adapter e Oil pump To install: 3. Apply silicone sealant to the oil pump mounting surface and install the oil pump. Tighten the bolts in sequence to 18 ft. Ibs. (25 Nm). 4. Install or connect the following: e Oil filter adapter e Oil pickup tube e Oil pan e Timing belt 5. Fill the crankcase to the correct level. 6. Start the engine and check for leaks. 3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Timing belt e Oil pan e Oil pick-up tube e Oil filter adapter e Oil pump

To install: 3. Apply silicone sealant to the oil pump mounting surface and install the oil pump. Tighten the bolts in sequence to 18 ft. Ibs. (25 Nm). 4. Install or connect the following: e Oil filter adapter e Oil pickup tube e Oil pan e Timing belt Rear Main Seal. Ley)

9308BG02

Oil pump torque sequence

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transmission

For Wheel Alignment specifications, see Section 1 of this manual

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AMIGO ¢ RODEO « RODE 0 SPORT ¢ TROOPER © VEHICROSS © PASSPORT

Do not damage the crankshaft sealing surface.

7924NG48

Installing a one-piece rear crankshaft oil seal

¢ Clutch assembly, if equipped with a manual transmission e Flywheel by loosening the flywheel bolts in a 2-step crisscross sequence e Rear main seal, using a seal puller

To install: 3. Install or connect the following: New rear main seal, by lubricating it with engine oil Flywheel, using new flywheel bolts. Tighten the bolts, in a 2-step crisscross pattern, to 40 ft. Ibs. (54 Nm). Clutch assembly, if removed Transmission Negative battery cable 4. Check the oil and refill as necessary. Piston and Ring

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a 7924AG55

= Piston ring positioning and top mark loca-

POSITIONING

tions—all engines

Upper Compression Ring

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Upper \e Oil Spree

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Rail

(Upper)

Rail

7924AG51

—r»— Lower Compression Ring

7924AG58

7924AG59

Piston ring end-gap spacing—2.2L engine

Piston ring positioning—3.2L and 3.5L

Piston ring end-gap spacing—3.2L and 3.5L engines

FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines: e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system presSure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection.

Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing Skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. ¢ Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a backup wrench when loosening and tightening fuel line connec-

tion fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper tightening specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the fuel filler cap. 3. Remove the fuel pump relay from the underhood relay box. 4. Start the engine and let it run until it

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REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Fuel lines from the fuel filter e Fuel filter To install: 4. Install or connect the following: e Fuel filter and tighten the bracket

Fuel Pump

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Drain the fuel tank. 4, Remove or disconnect the following: e Negative battery cable e Fuel filler and vent hoses e Fuel tank skid plate e Fuel tank wiring connectors

e Fuel tank wiring connectors e Fuel tank skid plate e Fuel filler and vent hoses

e Negative battery cable 6. Start the engine and check for leaks. Fuel Injector

REMOVAL & INSTALLATION 2.2L Engine

bolt. Note the fuel flow directional

arrow, ' e Fuel lines to the fuel filter e Negative battery cable 5, Start the engine’and inspect the fuel filter connections for leaks.

e Fuel supply and return lines e Fuel tank e Fuel pump assembly To install: 5. Install or connect the following: e Fuel pump assembly e Fuel tank. Tighten the bolts to 27 ft. lbs. (36 Nm). e Fuel supply and return lines

7924BG17

Fuel pump assembly mounting

Fuel Hose

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3, Remove or disconnect the following: e Negative battery cable e Fuel injector harness connectors e Pressure regulator vacuum line e Fuel lines e Fuel supply manifold with injectors attached e Fuel injector retaining clips e Fuel injectors To install: 4. Install or connect the following: Fuel injectors. Use new O-ring seals. Fuel injector retaining clips Fuel supply manifold with injectors attached. Tighten the fasteners to 14 ft. Ibs. (19 Nm). Fuel lines Pressure regulator vacuum line Fuel injector harness connectors Negative battery cable 5. Start the engine and check for leaks. 3.2L Engines

Fuel Filter

Filter Mounting Bolt 7924NG25

Fuel filter mounting location under the vehicle

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Engine cover e Fuel injector wiring connectors e Fuel lines e Fuel supply manifold with injectors attached Fuel injector retaining clips Fuel injectors

For Maintenance Interval recommendations, see Section 1 of this manual

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3.5L Engine

To install: 4. Install or connect the following:

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4. Install or connect the following: New O-rings on the fuel injectors ‘evils Fuel injectors Fuel supply manifold with injectors attached. Tighten the bolts to 60

1. Before servicing the vehicle, refer tothe of this section. Boe in rac 4) REEVE TUG) SYSTEM Pressures 3. Remove or disconnect the following: ° Negative battery cable

Fuel injectors. Use new O-ring seals. Fuel injector retaining clips Fuel ae manifold with injectors attached. Tighten the bolts to 60

inch Ibs. (6.5 Nm).

* Engine cover

© Fuel lines

inch Ibs. (6.5 Nm).

e Fuel injector wiring connectors

© Fuel injector wiring connectors

* Fuel lines

¢ Negative battery cable 5. Start the engine and check for leaks.

attached ° Clips

° Engine cover

© Fuel lines

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¢ Fuel injector wiring connectors

e Fuel supply manifold with injectors

* Engine cover

¢ Negative battery cable 5. Start the engine and check for leaks.

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DRIVE TRAIN

.

saei TANS IBISSION ASSEMUIY REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the hood. 3. Install a support fixture to the engine

Grommet assembly e Shift lever Clutch slave cylinder and hose bracket e Driveshaft

Manual Transmissions

lifting eyes. 4. Remove ordisconnect the following: e Negative battery cable

¢ Fuel line heat shield e Vehicle Speed (VSS) sensor connector

2 WHEEL DRIVE

>The transmission flange bolts vary in

e Shift lever knob

e Reverse light switch connector

length. Note their locations for assembly.

e Rear console assembly

¢ Flywheel under cover

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Transmission flange bolt identification and torque—2 wheel drive transmission

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4, Remove or disconnect the following: Negative battery cable Shift lever knob

e Transmission flange bolts * e Transmission To install: 5. Install or connect the following: e Transmission. Tighten the large flange bolts to 52 ft. Ibs. (71 Nm) and the small bolts to 30 ft. Ibs. (41 Nm). Crossmember. Tighten the bolts to 56 ft. Ibs. (76 Nm). Transmission mount. Tighten the fasteners to 30 ft. Ibs. (41 Nm). Flywheel under cover. Tighten the bolts to 69 inch Ibs. (8 Nm). Reverse light switch connector Vehicle Speed (VSS) sensor connector Fuel line heat shield Driveshaft. Tighten the bolts to 37 ft. Ibs. (50 Nm). Clutch slave cylinder and hose bracket Shift lever Grommet assembly Rear console assembly

Shift lever knob Negative battery cable 6. Remove the engine support fixture and install the hood.

Console assembly Grommet assembly Shift lever Transfer case control lever Transfer case skid plate Front and rear driveshafts Reverse lamp switch connector 7924NG26

Insert the Release Bearing Remover tool J-39207 through the bell housing—4 wheel drive manual transmission

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Turn the remover to separate the release hearing

4 WHEEL DRIVE

Indicator switch connectors Vehicle Speed (VSS) sensor connector AWD actuator connector Transmission harness clamps Fuel pipe bracket Clutch slave cylinder and heat shield Transmission mount and crossmember Heated Oxygen (HO2S) sensor connectors Right exhaust front pipe Wiring harness heat shield Flywheel under cover 5. Release the throw out bearing from the pressure plate as shown. 6. Remove the transmission flange bolts and remove the transmission. To install: 7. Install the transmission. Tighten the large bolts to 56 ft. Ibs. (76 Nm) and the

small bolts to 52 inch Ibs. (6 Nm). 8. Apply 13-18 Ibs. (59-78 N) of force to the clutch fork to engage the throw out bearing to the pressure plate. 9. Install or connect the following: Flywheel under cover Wiring harness heat shield Right exhaust front pipe. Tighten the manifold flange fasteners to 49 ft. bs. (67 Nm) and the exhaust flange bolts to 32 ft. Ibs. (43 Nm). HO2S sensor connectors

>The transmission flange bolts vary in length. Note their locations for assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the hood. 3. Install a support fixture to the engine lifting eyes.

Crossmember. Tighten the bolts to

7924NG27

7924NG28

Insert the tool between the wedge collar

Push the release bearing fork toward the transmission to release the bearing from the pressure plate—4 wheel drive manual transmission

37 ft. Ibs. (50 Nm). Transmission mount. Tighten the bolts to 30 ft. Ibs. (41 Nm). Clutch slave cylinder and heat shield Fuel pipe bracket Transmission harness clamps AWD actuator connector VSS sensor connector Indicator switch connectors Reverse lamp switch connector Front and rear driveshafts. Tighten the flange bolts to 46 ft. Ibs. (63 Nm).

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

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Transmission mounting bolt identification and torque specifications—V6 engine with 4 wheel drive transmission shown

Transfer case skid plate. Tighten the bolts to 27 ft. Ibs. (87 Nm). Transfer case control lever Shift lever Grommet assembly Console assembly Shift lever knob Negative battery cable 10. Remove the engine support fixture and install the hood.

Automatic Transmissions

2 WHEEL DRIVE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the hood. 3. Install a support fixture to the engine lifting eyes. 4. Remove or disconnect the following: e Negative battery cable

A/T dowel! Position

M/T dowel position

M/T dowel position

7924BG21

Push the release bearing fork toward the transmission to engage the release bearing with the pressure plate

A/T dowel! position 7924NG02

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9308NG03

Automatic transmission mounting bolt locations and torque specifications

Front console assembly and wiring connectors Shift lock cable

Shift control rod Selector lever assembly Driveshaft Wiring harness heat shield Transmission mount and crossmember Heated Oxygen (HO2S) sensor connectors

Left and right exhaust front pipes Transmission oil cooler lines Starter motor Fuel line bracket Transmission harness connectors

Flywheel under covers Torque converter Transmission flange bolts Transmission To install: e>Use new torque converter bolts.

5. Install or connect the following: Transmission. Tighten the large bolts to 56 ft. Ibs. (76 Nm) and the small bolts to 69 inch Ibs. (8 Nm). Torque converter. Tighten the bolts to 40 ft. Ibs. (64 Nm). Flywheel under covers

Transmission harness connectors Fuel line bracket Starter motor. Tighten the bolts to 30 ft. Ibs. (40 Nm). Transmission oil cooler lines Left and right exhaust front pipes. Tighten the manifold flange fasteners to 49 ft. Ibs. (67 Nm) and the exhaust flange bolts to 32 ft. Ibs. (43 Nm). HO2S sensor connectors Crossmember. Tighten the bolts to 37 ft. Ibs. (60 Nm). Transmission mount. Tighten the bolts to 30 ft. Ibs. (41 Nm). Wiring harness heat shield Driveshaft. Tighten the flange bolts to 46 ft. Ibs. (63 Nm). Selector lever assembly Shift control rod Shift lock cable Front console assembly and wiring connectors Negative battery cable 6. Remove the engine support fixture and install the hood.

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

2. Remove the hood. 3. Install a support fixture to the engine lifting eyes. 4, lle or disconnect the following: e Negative battery cable Transfer case shift lever knob Front console assembly and wiring connectors Shift lock cable Shift control rod

Selector lever assembly Transfer case shift lever

Transfer case skid plate Front and rear driveshafts

Wiring harness heat shield Transmission mount and crossmember Right torsion bar, if equipped with Torque On Demand (TOD) system Heated Oxygen (HO2S) sensor connectors

Left and right exhaust front pipes Transmission oil cooler lines Starter motor Fuel line bracket Transmission harness connectors Flywheel under covers Torque converter Transmission flange bolts Transmission

For complete service labor times, order the Chilton Labor Guide

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5. Install or connect the following: e Transmission. Tighten the large bolts to 56 ft. Ibs. (76 Nm) and the small bolts to 30 ft. Ibs. (40 Nm). Torque converter. Tighten the bolts to-40 ft. Ibs. (54 Nm). Flywheel under covers Transmission harness connectors Fuel line bracket Starter motor. Tighten the bolts to 30 ft. Ibs. (40 Nm). Transmission oil cooler lines Left and right exhaust front pipes. Tighten the manifold flange fasteners to 49 ft. Ibs. (67 Nm) and the exhaust flange bolts to 32 ft. Ibs. (43 Nm). HO2S sensor connectors Right torsion bar, if removed Crossmember. Tighten the bolts to 37 ft. Ibs. (50 Nm). Transmission mount. Tighten the bolts to 30 ft. Ibs. (41 Nm). Wiring harness heat shield Front and rear driveshafts. Tighten the flange bolts to 46 ft. Ibs. (63 Nm). Transfer case skid plate. Tighten the bolts to 27 ft. Ibs. (37 Nm). Transfer case shift lever Selector lever assembly Shift control rod Shift lock cable Front console assembly and wiring connectors Transfer case shift lever knob Negative battery cable 6. Remove the engine support fixture and install the hood.

ADJUSTMENTS This vehicle is equipped with a hydraulic clutch linkage. No adjustment is necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the transmission. 3. Loosen the pressure plate mounting bolts in a 2-step crisscross sequence until the spring tension is relieved. 4, Remove the pressure plate and the clutch disc. To install: 5. Install a new wedge collar and wire snapring into the pressure plate.

7924NG49

Pressure plate tightening sequence

6. Using a clutch alignment tool, assemble the clutch disc and pressure plate onto the flywheel. 7. Tighten the pressure plate bolts in sequence and in two passes to 13 ft. Ibs. (8 Nm). 8. Install the transmission. 9. Road test the vehicle and check for proper clutch operation.

Hydraulic Clutch System BLEEDING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Have an assistant pump the clutch pedal slowly several times and hold it depressed. 3. Open the slave cylinder bleeder screw and allow air to escape. 4. Close the bleeder screw before releasing the clutch pedal. 5. Repeat until all air is purged from the clutch hydraulic system. 6. Refill the reservoir to the full mark.

Transfer Case Assembly

e Front and rear driveshafts

e Heated Oxygen (HO2S) sensor connectors

Left and right exhaust front pipes Transfer case control lever knob Selector lever assembly Transfer case control lever

Vehicle Speed (VSS) sensor connector 4 wheel drive switch connector 4 wheel drive actuator connector Transfer case flange fasteners Transfer case To install: 3. Install or connect the following:

Transfer case. Tighten the flange fasteners to 34 ft. Ibs. (46 Nm). 4 wheel drive actuator connector 4 wheel drive switch connector VSS sensor connector Transfer case control lever

Selector lever assembly Transfer case control lever knob Left and right exhaust front pipes HO2S sensor connectors

Front and rear driveshafts. Tighten the bolts to 46 ft. Ibs. (63 Nm). Transfer case skid plate. Tighten the bolts to 27 ft. lbs. (37 Nm). Negative battery cable

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transfer case skid plate

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

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OVERHAUL Outer CV-Joint The outer CV-joint is serviced with the axle shaft as an assembly. The outer CVjoint boot can be serviced by removing the inner CV-joint. Inner CV-Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Halfshaft from the vehicle Snapring and bearing Snapring and oil seal Mounting bracket CV-joint boot Circlip and inner joint housing Snapring and spacer Inner joint balls Snapring and inner CV-joint To install: 3. Install or connect the following:

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e Transfer case skid plate e Brake calipers and mounting bracket Brake rotor Wheel speed sensor Steering knuckle 3. Support the axle housing with a jack. Undolt the axle mounting bracket and remove the halfshaft/bracket assembly. To install: 4. Install or connect the following: e Axle/bracket assembly. Tighten the bracket flange bolts to 85 ft. Ibs. (116 Nm) and the bracket mounting bolts to 112 ft. Ibs. (152 Nm). Steering knuckle Wheel speed sensor Brake rotor Brake caliper and mounting bracket. Tighten the bracket bolts to 115 ft. Ibs. (155 Nm). Transfer case skid plate. Tighten the bolts to 27 ft, Ibs. (37 Nm). Radiator skid plate. Tighten the bolts to 58 ft.Ibs. (78 Nm). Front wheel Negative battery cable 5. Check the wheel alignment and adjust as necessary.

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REMOVAL & INSTALLATION 9308BG04

CV-joint spacer snapring—Inner CV-Joint

Inner C\V-joint and snapring Inner joint balls Spacer and snapring Inner joint housing and circlip. Add 150 grams CV-joint grease. CV-joint boot Mounting bracket Oil seal and snapring Bearing and snapring 4. Install the halfshaft and mounting bracket to the vehicle. 5. Check the wheel alignment and adjust as necessary.

Axle Shaft, Bearing and Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Rear wheel Disc brake caliper and bracket Disc brake rotor Wheel speed sensor bracket Parking brake cable and bracket Parking brake shoes Axle shaft Snapring and discard it Bearing, press it off the axle shaft with the bearing holder and oil seal To install: 3. Install or connect the following: New oil seal into the bearing housing Bearing housing onto the axle shaft Bearing, press it onto the axle shaft New snapring Axle shaft. Use new lockwashers and tighten the bearing holder nuts to 54 ft. Ibs. (74 Nm). Parking brake shoes Parking brake cable and bracket Wheel speed sensor bracket Disc brake rotor Disc brake caliper and bracket.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Driveshaft e Wheels e Brake calipers and pads The brake calipers and pads must be removed so that there is no additional drag when measuring pinion bearing preload.

3. Use.an inch Ib. torque wrench and measure and record the amount of torque required to maintain pinion rotation through several revolutions. 4, Remove or disconnect the following: e Pinion flange e Pinion seal e Pinion bearing e Collapsible spacer To install: >Use a new collapsible spacer and flange nut for assembly.

5. Install or connect the following: e Collapsible spacer e Pinion bearing e Pinion seal e Pinion flange 6. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly. 7. Take frequent bearing preload torque readings. Tighten the flange nut to achieve the preload torque readings originally recorded.

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Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut.

8. Install or connect the following: e Driveshaft e Brake calipers and pads e Wheels 9. Fill the differential with gear lubricant and check for leaks.

Timing belt service is covered in Section 3 of this manual

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STEERING AND SUSPENSION

> CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away from you. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the ignition switch to the LOCK position. Remove the key. 3. Disconnect the negative battery cable. Wait 1 minute before working around the air bags. 4. Disconnect the yellow 2-pin connector at the base of the steering column. 5. Disconnect the yellow 2-pin connector behind the glove box assembly. 6. When repairs are completed, connect the yellow 2-pin connectors. 7. Connect the negative battery cable. 8. Turn the ignition to the ON position, but don't start the engine. The AIR BAG warning light should turn on and flash on and off 7 times, and then turn off. This light sequence indicates that the SRS sys-

tem is functioning normally. If the AIR BAG

e Shock absorber. Tighten the lower bolt to 60-61 ft. Ibs. (82-84 Nm). e Bump stop. Tighten the bolts to 30 ft. Ibs. (41 Nm). ¢ Upper shock retaining nut and rubber bushing. Tighten the nut to 14-15 ft. Ibs. (19-20 Nm). e Front wheels

light doesn’t come on, or stays on longer than 7 seconds, the system must be diagnosed.

Recirculating Ball Steering Gear

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disable the air bag system. 3. Remove or disconnect the following: e Skid plates e Lower fan shroud e Stabilizer bar e Power steering pressure and return lines e Pitman arm e Steering column intermediate shaft e Steering gear To install: 4. Install or connect the following: Steering gear. Tighten the bolts to 33 ft. Ibs. (44 Nm). Steering column intermediate shaft. Tighten the pinch bolt to 18 ft. Ibs. (25 Nm). Pitman arm. Tighten the nut to 159 ft. Ibs. (216 Nm). Power steering pressure and return lines. Tighten the fittings to 33 ft. lbs. (44 Nm).

Stabilizer bar Lower fan shroud Skid plates 5. Fill the power steering fluid reservoir. 6. Check the wheel alignment and adjust as necessary. Shock Absorber

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm with a jackstand. 3. Remove or disconnect the following: e Front wheels ¢ Upper shock retaining nut and rubber bushing e Suspension bump stops e Shock absorber To install: 4. Install or connect the following:

~ Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the rear axle with jackstands. 3. Remove the rear shock absorbers. To install: 4. Install the rear shock absorbers. Tighten the upper bolt to 70 ft. Ibs. (95 Nm). Tighten the lower bolt to 58 ft. Ibs. (78 Nm). 5. Remove the jackstands.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle under the frame. 3. Support the rear axle with a jack. 4, Remove or disconnect the following: e Rear wheels e Stabilizer bar links e Parking brake cable brackets e Shock absorbers 5. Lower the rear axle with the jack to release the coil spring tension. Remove the coil springs and insulators. To install: 6. Place the coil springs on the axle assembly and the insulators on top of the springs. 7. Raise the axle assembly into position. 8. Install or connect the following: e Shock absorbers e Parking brake cable brackets

e Stabilizer bar links. Tighten the nuts to 37 ft. Ibs. (50 Nm). e Rear wheels

Torsion Bar

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Matchmark the adjusting bolt and

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4. Install or connect the following: e Upper ball joint. Tighten the mounting bolts to 42 ft. Ibs. (57 Nm) and the nut to 72 ft. Ibs. (96 Nm). e Wheel speed sensor e Front wheel

(1) Adjust Bolt, End Piece and Seat (2) Height Control Arm (3) Torsion Bar

9308BG05

Lower Ball Joint Exploded view of the torsion bar assembly

end piece, then remove the bolt, end piece, and seat. 3. Matchmark the height contro! arm to the torsion bar, then remove the height control arm. 4. Matchmark the-torsion bar to the lower control arm, then remove the torsion bar. To install: 5. Apply grease to the torsion bar splines. 6. Apply grease to the contact points of the height control arm, adjusting bolt end piece and seat. 7. Align the matchmarks and install the torsion bar.

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REMOVAL & INSTALLATION

8. Align the matchmarks and install the height control arm. 9. Install the adjusting bolt, seat and end piece. 10. Tighten the adjusting bolt to align the matchmarks.

Upper Ball Joint

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

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm with a jackstand. 3. Remove or disconnect the following: e Front wheel e Disc brake caliper and support e Brake rotor and backing plate e Wheel speed sensor e Outer tie rod end e Upper ball joint e Steering knuckle e Lower ball joint To install: e>Use new nuts, bolts and split pins for ©

assembly.

1. Knuckle 2. Lower end 3. Nut and washer, rear 4. Bolt, rear 5. Nut and washer, front 6. Bolt, front 7. Lower control arm assembly 8. Torsion bar arm bracket

9. Bushing, rear 10. Bushing, front

7924BG34

Exploded view of the control arm and ball joint components

4. Install or connect the following: Lower ball joint. Tighten the mounting bolts to 76 ft. Ibs. (103 Nm). Steering Knuckle. Tighten the lower ball joint nut to 108 ft. Ibs. (147 Nm). Upper ball joint. Tighten the nut to 72 ft. Ibs. (96 Nm). Outer tie rod end. Tighten the nut to

72 ft. Ibs. (98 Nm). Wheel speed sensor Brake rotor and backing plate Disc brake caliper and support. Tighten the support bolts to 115 ft. lbs. (155 Nm). Front wheel 5. Check the wheel alignment and adjust as necessary.

For complete service labor times, order the Chilton Labor Guide

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7924BG35

Exploded view of the lower ball joint mounting and related components

Upper Control Arm REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm with a jackstand. 3. Remove or disconnect the following: e Front wheel e Wheel speed sensor e Brake caliper e Upper ball joint e Upper control arm e>Note the alignment shim location for assembly.

To install: 4. Install or connect the following: e Upper control arm e Alignment shims in their original locations. Tighten the bolts to 112 ft. Ibs. (152 Nm). Upper ball joint. Tighten the nut to 72 ft. Ibs. (98 Nm). Brake caliper Wheel speed sensor Front wheel 5. Check the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove the upper control arm. 3. Remove the nuts and washers from the fulcrum pin. 4. Press the bushings out of the control arm. To install: : 5. Press the bushings into the control arm. 6. Install the fulcrum pin washers and nuts. 7. Install the upper control arm. 8. Raise the suspension so that there is 0.79 inches (20mm) between the bump stop and the lower control arm. Tighten the fulcrum pin nuts to 80 ft. Ibs. (108 Nm). 9. Check the wheel alignment and adjust as necessary.

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9308BG06

Upper control arm and related parts

Lower Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: * e Front wheel e Torsion bar e Lower ball joint e Stabilizer bar link e Shock absorber e Lower control arm To install: 3. Install or connect the following: e Lower control arm e Shock absorber e Stabilizer bar link e Lower ball joint e Torsion bar e Front wheel 4. Raise the suspension so that there is 0.79 inches (20mm) between the bump stop

and the lower control arm. Tighten the front control arm bolt to 116 ft. Ibs. (157 Nm) and tighten the rear control arm bolt to 145 ft. Ibs. (196 Nm). 5. Check the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Lower control arm e Bushings, press them from the control arm, using Remover/Installer J-36833 for the front bushing and Remover/Installer J-36834 for the rear bushing. To install: 3. Install or connect the following: e New bushings e Lower control arm

Wheel Bearings ADJUSTMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Brake caliper and pads e Hub dust cap e Snapring and shim e Hub flange . e Lockscrew and washer 3. Tighten the hub nut to 22 ft. Ibs. (29 Nm) to seat the bearings and then fully loosen the nut. 4. Tighten the hub nut to achieve a bearing preload of 2.6—4.0 Ibs. (1.2-1.8 Kg) for used bearings. If the bearings were replaced, set the preload to 4.4-5.5 Ibs. (2.0-2.5 Kg). 5. Install or connect the following:

For complete service labor times, order the Chilton Labor Guide

¢ Lockwasher and screw e Hub flange e Shim and snapring ¢ Hub dust cap. Tighten the bolts to at 43 ft. Ibs. (59 Nm). __e Brake caliper and pads

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e Brake rotor and hub assembly e Wheel speed sensor ring e Outer bearing e Grease seal. e Inner bearing To install: 3. Clean and inspect the bearings. Replace if necessary. 4. Apply clean wheel bearing grease to the inner and outer bearings. 5. Apply grease in the hub.

the bolts to 13 ft. Ibs. (18 Nm). e e e e e

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Brake rotor and hub assembly Hub nut. Set the bearing preload. Lockscrew and washer Hub flange Snapring and shim Hub dust cap e Brake caliper and support. Tighten the support bolts to 115 ft. Ibs. (155 Nm). e Front wheel

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JEEP 1998-02 Cherokee * Grand Cherokee ® Liberty * Wrangler

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Removal & Installation............ 18-21 GOTO RST aia, Werth zara aiee 18-38

Hydraulic Clutch System ............. 18-38 Bl@eGinig eu e tea SO Wie 18-38

18-38 18-44 18-44 18-20 18-20

| Yeee Oy io!18-4 lonition airing 20.6, PUIISUTION ete. necteen eae 18-4 18-18 Intake Manifold... ccc Removal & Installation............ 18-18

ahaa iavaatn MOM Val tar. nekctil . 18-4 ~

Front Wheel Bearings ou... 18-47 Adjusimentiizans.a.. Abonenas 18-47 Removal & Installation............ 18-48 FueliFilter sictiwara.eansain Goat 218-34 Removal & Installation............ 18-34 Fuelinjector: 810 ies Qu 1s18-37

Removal & Installation............ Dou SOFA Ue et) SV Cle) var or Removal & Installation............ Combination Manifold................. Removal & Installation............

ANA (glist aaa eh a 18-39 CVG SW GR inarsicveafaetiatedacrevactsPOT Removal & Installation........... 18-11

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L wees crane18-45 |LOT OOUTIOS i asteatiul Removal & Installation........... 18-45

PAVSURIOUITOT AER Ie, MOM ho decktecacessons. 18-2 StaatOG ct eo tec 18-2 EUAUMGL Ete fete aera: atten: 18-2

LOWER Bakle) OF Mbit doap ib amessunc: 18-46 Removal & Installation............ 18-44 Lower Control APS... 18-47 Control Arm Bushing

Engine ASSEMDIY .......ccceenseeee 18-4 Removal & Installation.............. 18-4 EX MAUSE AMTO es macroepes sceiteneto's 18-19 Removal & Installation............ 18-19 F

Removal & Installation............ 18-47 0 CL Pallee ecm NC 32 18-24 Removal & Installation............ 18-24 atten 18-26 OURAN on) haere

Front Axle Shaft, Bearing and SF eS LosiR Ges aieden s+» AMOR: 18-40 Removal & Installation............ 18-40 BA UNS cece eat cass ki wayne 18-43

Removal & Installation............ 18-26 P A ghee a Pease 18-41 PINION SCAGT Removal & Installation............ 18-41

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Removal & Installation............ 18-43

Replacement.......ccccccscseeeen 18-47

2 Gn18-33 JO d Piston and Rind zentga

POSITIONING iki aN eanad poe) R Rack and Pinion Power Steering Gear avis ainancnee Removal & Installation............ Rear Axle Shaft, Bearing and Seabts,

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Recirculating Ball Power Steering, Gea suAcweneane 6 Removal & Installation............ Rocker Arnisity:satas wseraunlaie.h

Timing Chain, Sprockets, Front Cover and Seal... Removal & Installation...

Transfer Case Assembly............... Removal & Installation............ Transmission Assembly ............+. Removal & USS es

UIDDeb Dall CON tecrgrrrrtsteoneusroeccey Removal & Installation............ Upper Control Arm ou... Control Arm Bushing Replacement. (...2.20.00008% Removal & pie eae eg ent

18-45 18-45 18-46

18-47 18-46

Valve Lashin: ic csrtestuanacutsegee 18-24 Adjustment....... rigs 18-24 Water Pump Disconnecting the negative battery cable on some vehicles may interfere

with the functions of the on-board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor >The 3.7L and 4.7L engines do not use a distributor.

REMOVAL 2.5L and 4.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Negative battery cable e Distributor cap ¢ Camshaft Position (CMP) sensor connector Distributor wiring harness from the main engine harness Cylinder No. 1 spark plug 3. Matchmark the distributor housing and the rotor. 4. Remove the distributor. 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Air Cleaner tube ¢ Distributor cap

¢ Camshaft Position (CMP) sensor connector 3. Matchmark the distributor housing and the rotor. 4. Matchmark the distributor housing and the intake manifold. 5. Remove the distributor. ‘

INSTALLATION Timing Not Disturbed

2.5L AND 4.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ~The rotor will rotate clockwise as the gears engage.

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2. Position the rotor slightly counter_ Clockwise of the matchmark made during removal. 3. Install the distributor. Ensure that the rotor moves into alignment with the matchmark. 4. Align the locating fork with the clamp bolt hole. Install the clamp and bolt. Tighten the bolt to 17 ft. Ibs. (23 Nm). 5. Install or connect the following: ¢ Cylinder No. 1 spark plug e Distributor wiring harness to the main engine harness e CMP sensor connector e Distributor cap e Air cleaner tube e Negative battery cable

FRONT >

10 O'CLOCK POSITION

7924PG30

Slot in the oil pump gear at 10 o’clock position—2.5L engine

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5. Position the base mounting slot at the 1 o'clock position and install the distributor. 6. Check that the centerline of the mounting slot aligns with the centerline of the clamp bolt hole. 7. Install the clamp and bolt. Tighten the bolt to 17 ft. Ibs. (23 Nm). 8. Remove the locking pin. 9. Install or connect the following: e CMP sensor connector e Distributor cap e Air cleaner tube e Negative battery cable

5.2L AND 5.9L ENGINES FRONT &>

9.2L AND 5.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. The rotor will rotate clockwise as the gears engage.

2. Position the roter slightly counterclockwise of the matchmark made during removal. 4 3. Install the distributor. 4. Align the distributor housing and intake manifold matchmarks and check that the distributor housing matchmark and rotor are also aligned. 5. Install or connect the following: e Distributor housing clamp and bolt. Tighten the bolt to 17 ft. Ibs. (23 Nm). e CMP sensor connector e Distributor cap e Air cleaner tube e Negative battery cable

7924PG31

Slot in the oil pump gear at 11 o’clock position—4.0L engine

DISTRIBUTOR HOUSING (TOP VIEW)

1. Before servicing the vehicle, refer to. the precautions in the beginning of this section. 2. Set the engine at Top Dead Center (TDC) of the No. 1 cylinder compression stroke. 3. Install the distributor, clamp and bolt. 4. Rotate the distributor so that the rotor aligns with the No. 1 cylinder mark on the Camshaft Position (CMP) sensor. Tighten the clamp bolt to 17 ft. Ibs. (23 Nm). 5. Install or connect the following: e CMP sensor connector

PULSE RING

4.0L 6-CYLINDER ENGINE ALIGN. HOLE

Timing Disturbed

2.5L AND 4.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Set the engine at Top Dead Center

(TDC) of the No. 1 cylinder compression stroke. 3. Position the slot in the oil pump drive gear as shown. 4. Locate the alignment holes in the plastic ring and align the correct hole with the mating hole in the distributor housing as shown. Install a locking pin. The distributor will rotate clockwise as the gears engage.

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Distributor pin alignment holes—2.5L and 4.0L engines

For complete service labor times, order the Chilton Labor Guide

484

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ADJUSTMENT Ignition timing is controlled by the Powertrain Control Module (PCM). No adjustment is possible.

Engine Assembly DISTRIBUTOR

9308PG01

Distributor rotor alignment—5.2L and 5.9L engines

e Distributor cap e Air cleaner tube e Negative battery cable 6. The final distributor position must be set with a scan tool. Follow the instructions supplied by the scan tool manufacturer. Alternator

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Alternator harness connectors e Mounting bolts and alternator >The 3.7L engine has 1 vertical and 2 horizontal bolts.

INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install the alternator and tighten the bolts to the following specifications: e 2.4L, 2.5L and 4.0L engines: 41 ft.

lbs. (55 Nm). e 3./L engine: Tighten the horizontal bolts to 42 ft. Ibs. (57 Nm), then the vertical bolt to 29 ft. Ibs. (40 Nm) e 4.7L engine: Vertical bolt and long horizontal bolt to 41 ft. Ibs. (56 Nm), short horizontal bolt to 55 ft. lbs. (74 Nm) e 9.2L and 5.9L engines: 30 ft. Ibs. (41 Nm) 3. Install or connect the following: e Alternator harness connectors e Accessory drive belt e Negative battery cable

REMOVAL & INSTALLATION Liberty

3.7L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Remove or disconnect the following: Negative battery cable Hood Air cleaner assembly Radiator Electric and mechanical fan assemblies A/C compressor, if equipped, and secure it out of the way with the lines attached. DO NOT DISCHARGE! Power steering pump, with the lines attached Alternator Coolant bottle Heater hoses Accelerator and speed control cables Lower and upper radiator hoses Engine ground straps Intake Air Temperature (IAT) sensor Fuel injection wiring connectors Throttle Position (TP) sensor Idle Air Control (IAC) motor Oil pressure sender connector Engine Coolant Temperature (ECT) sensor e Manifold Absolute Pressure (MAP) sensor ¢ Camshaft position sensor e Ignition coil wiring connector ¢ Crankshaft Position (CKP) sensor ¢ Coil pack ¢ Fuel rail e PCV hose e Vacuum hoses from the intake manifold Knock sensor connectors

Oil dipstick tube e Intake manifold e Heated Oxygen (HO2S) sensor connector

Block heater connector Front driveshaft at the differential Starter Structural cover With a manual transmission, remove the transmission Torque converter bolts and matchmark the converter Automatic transmission-to-engine bolts Exhaust front pipes e Left and right engine mounts 6. Paes a support stand under the transmission.

7. Install an engine lift plate 8. Lift the engine out of the vehicle. To install: 9. If equipped with a manual transmission, install the transmission 10. Lower the engine and install the mounts. Don’t tighten the bolts yet. 11. If equipped with an automatic transmission, perform the following steps: a. Align the torque converter housing to the engine. b. Torque the bolts to 30 ft. Ibs. (41 Nm). e Install the torque converter to flexplate bolts. Torque the bolts to 50 ft. Ibs. (68 Nm). 12. Install or connect the following: e Torque the through bolts to 45 ft. lbs. (61 Nm). e Engine ground strap e Starter motor e CKP sensor Block heater cable Structural cover.

The structural cover must be held tightly against the engine and bellhousing during tightening. The torque

for all bolts is 40 ft. Ibs. (54 Nm); the bolts must be tightened in the order shown. e Exhaust pipes. New flange clamps MUST be used! HO2S sensor connectors KS sensors Intake Manifold

Dipstick tube ie hoses to the intake maniold PCV and breather hoses Fuel rail

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STRUCTURAL COVER

9355PG01

Tighten the structural cover bolts in this order—3.7L

Ignition coil IAT sensor Fuel injector connectors TP sensor IAC motor Oil pressure sender . ECT sensor electrical connector MAP sensor CMP sensory Radiator hoses Cruise control cable, if equipped Throttle cable Heater hoses Coolant bottle Power steering pump Alternator A/C compressor Radiator Fan assemblies Air cleaner assembly Negative battery cable 13. Fill and bleed the power steering system. 14. Fill the engine with clean oil. 15. Start the engine and check for leaks, repair if necessary. Wrangler 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Evacuate the A/C system. 6. Drain the power steering fluid, if equipped. 7. Remove or disconnect the following: ¢ Negative battery cable e Air cleaner assembly

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e Upper radiator hose ¢ Accessory drive belt and fan drive assembly Transmission cooler lines, if equipped Lower radiator hose Radiator and fan shroud Starter electrical connectors Alternator wiring connectors

A/C compressor, if equipped Ignition coil wiring connector Oil pressure sender connector Wiring harness ground at the dipstick tube Heater hoses from the thermostat housing Water pump inlet tube

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a. Insert the transmission shaft into the clutch spline. b. Align the flywheel housing to the engine. c. Install the flywheel housing bolts. Torque the bolts to 28 ft. Ibs. (38 Nm). 11. If equipped with an automatic transmission, perform the following steps: a. Align the torque converter housing to the engine. b. Torque the bolts to 28 ft. Ibs. (38 Nm )

Closed Crankcase Ventilation (CCV) hoses from the cylinder head and intake manifold

Accelerator, transmission line presSure and speed control cables, if equipped Engine ground strap Power steering pressure switch, if equipped Engine Coolant Temperature (ECT) sensor Fuel injection wiring connectors Intake Air Temperature (IAT) sensor Idle Air Control (IAC) motor Throttle Position (TP) sensor Manifold Absolute Pressure (MAP) sensor Crankshaft Position (CKP) sensor Heated Oxygen (HO2S) sensor connector Vacuum hoses from the intake manifold Fuel line and bracket Power steering hoses from the steering gear, if equipped Oil filter Starter Engine support through bolts Exhaust front pipe Flywheel cover Torque converter, if equipped with automatic transmission Transmission flange bolts Left and right motor mounts Engine shock damper bracket 8. Place a support stand under the transmission. 9. Lift the engine out of the vehicle. To install: 10. If equipped with a manual transmission, perform the following steps:

Please visit our web site at www.chiltonsonline.com

e Install the torque converter to flex-

plate bolts. Torque the bolts to 50 ft. Ibs. (68 Nm). 12. Install or connect the following: Engine onto the engine brackets. When properly aligned, torque the through bolts to 60 ft. Ibs. (81 Nm). Inspection cover. Torque the bolts to 138 inch Ibs. (16 Nm). Exhaust pipe. Torque the bolts to 23 ft. Ibs. (31 Nm). Starter motor. Tighten the bolts to 33 ft. Ibs. (45 Nm). Oil filter Power steering hoses Fuel supply line to the fuel rail Fuel supply rail to the intake manifold Vacuum hoses to the intake manifold Power steering pressure switch electrical connector ECT sensor electrical connector Fuel injector connectors IAT sensor IAC motor TP sensor MAP sensor

CKP sensor HO2S sensor connector Engine ground strap Heater hoses and water pump inlet tube Cruise control cable, if equipped Throttle cable Fan shroud and radiator. Torque the bolts to 75 inch Ibs. (8 Nm). Transmission cooler lines, if equipped. Torque the bolts to 10 ft. lbs. (15 Nm). Fan drive assembly. Torque the bolts to 20 ft. Ibs. (27 Nm). Drive belt Radiator hoses Ignition coil Distributor A/C compressor

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A/C high pressure switch Alternator Oil pressure sender Harness ground at the oil dipstick tube bracket

e A/C hoses e Air cleaner assembly e Negative battery cable 13. Fill and bleed the power steering system. 14. Fill the engine with clean oil. 15. Fill and bleed the cooling system. 16. Recharge the A/C system. 17. Start the engine and check for leaks, repair if necessary. Cherokee

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Recover the A/C refrigerant. 4. Drain the engine oil. 5. Drain the power steering system. 6. Properly relieve the fuel system pressure. 7. Remove or disconnect the following: Battery Hood Air cleaner assembly Radiator hoses Fan shroud Electric cooling fan, if equipped Radiator Cooling fan Heater hoses Throttle cable Cruise control cable Transmission cable Fuel injector harness Camshaft Position (CMP) sensor connector Ignition coil wiring connector Oil pressure sender connector Body ground cable Starter solenoid connectors Fuel injection wiring harness Fuel line and bracket A/C compressor suction/discharge hose assembly Brake booster vacuum line Power steering hoses Intake manifold vacuum lines Crankshaft Position (CKP) sensor connector Engine speed sensor Oil filter Starter motor Heated Oxygen (HO2S) sensor connector ¢ Exhaust front pipe

e Flywheel housing access cover Torque converter, if equipped with automatic transmission e Transmission flange bolts e Left and right motor mounts 8. Support the transmission and lift the engine out of the vehicle. To install: 9. Lower the engine in to the vehicle and position to the transmission. 10. Install or connect the following: e Left and right motor mounts. Tighten the through bolts to 51 ft. lbs. (69 Nm). Transmission flange bolts. Tighten the bolts to 28 ft. Ibs. (38 Nm). Torque converter, if equipped with automatic transmission. Tighten the bolts to 23 ft. Ibs. (31 Nm). e Flywheel housing access cover Exhaust front pipe Engine speed sensor electrical connector

HO2S sensor connector Starter motor. Tighten the bolts to 33 ft. Ibs. (45 Nm). Oil filter Vacuum hoses to the intake manifold CKP sensor connector Power steering hoses Brake booster vacuum line A/C compressor suction/discharge hose assembly Fuel line and bracket Fuel injection wiring harness Starter solenoid connectors Body ground cable Oil pressure sender connector Ignition coil wiring connector CMP sensor connector Fuel injector harness Transmission cable Cruise contro! cable Throttle cable Heater hoses Cooling fan Radiator Electric cooling fan, if equipped Fan shroud Radiator hoses Air cleaner assembly Hood Battery 11. Fill and bleed the cooling system 12. Fill the engine with clean oil. 13. Fill and bleed the power steering system. 14. Recharge the A/C system. 15. Start the engine, check for leaks and repair if necessary.

Grand Cherokee

4.0L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. 3. 4. 5.

Drain the cooling system. Drain the engine oil. Drain the power steering fluid. Properly relieve the fuel system

pressure.

6. Recover the A/C refrigerant. 7. Remove or disconnect the following: Negative battery cable Hood Radiator hoses Upper radiator support Cooling fan and shroud Radiator

A/C condenser Heater hoses Accelerator cable Cruise control cable Transmission cable Body ground cable Power steering pressure switch connector

Engine Coolant Temperature (ECT) sensor connector Intake Air Temperature (IAT) sen-

sor Fuel injector connectors Throttle Position (TP) sensor connector

Manifold Absolute Pressure (MAP) sensor connector Crankshaft Position (CKP) sensor connector

Heated Oxygen (HO2S) sensor connector

Camshaft Position (CMP) sensor connector Ignition coil wiring connector Oil pressure sender connector Fuel line and bracket Air cleaner assembly Brake booster vacuum line

Power steering hoses Starter motor Exhaust front pipe Flywheel cover Torque converter

Transmission flange bolts Left and right motor mounts 8. Place a support stand under the transmission.

9. Lift the engine out of the vehicle. To install: 10. Lower the engine in to the vehicle and position to the transmission. 11. Install or connect the following: e Left and right motor mounts.

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Tighten the through bolts to 51 ft. lbs. (69 Nm). Transmission flange bolts. Tighten the bolts to 30 ft. Ibs. (41 Nm). Torque converter. Tighten the bolts to 23 ft. Ibs. (31 Nm). Flywheel cover Exhaust front pipe Starter motor. Tighten the bolts to 33 ft. Ibs. (45 Nm). Power steering hoses

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12. 13. 14. 15. 16. Start the engine, check for leaks and

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Exploded view of the front fascia panel—

4.7L ENGINE 1. Before servicing the vehicle, refer to Ha Ae in the beginning of this sec-

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A/C condenser Radiator Cooling fan and shroud Upper radiator support Radiator hoses Hood Negative battery cable Fill and bleed the cooling system. Fill and bleed the cooing system. Fill the engine with clean oil Recharge the A/C system.

2. Drain the cooling system.

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Timing belt service is covered in Section 3 of this manual

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Heater hoses Throttle Position (TP) sensor connector Intake Air Temperature (IAT) sensor connector Fuel injector harness connectors Engine Coolant Temperature (ECT) sensor connector Idle Air Control (IAC) valve connector Manifold Absolute Pressure (MAP) sensor connector Ignition coils Fuel line Power steering pump Oil fill tube Oil dipstick tube Heated Oxygen (HO2S) sensor con-

ATTACHING LOCATION

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nectors Engine oil filter Exhaust crossover pipe Structural cover Rubber splash shield

Starter motor Crankshaft Position (CKP) sensor connector Camshaft Position (CMP) sensor connector Torque converter Engine ground straps Left and right motor mounts Transmission flange bolts 8. Install Engine Lifting Fixture 8347 as

9302PG03

shown.

9. Place a support stand under the transmission. 10. Lift the engine out of the vehicle. To install: 11. Lower the engine in to the vehicle and position to the transmission. 12. Remove the engine lifting fixture. 13. Install or connect the following: e Transmission flange bolts. Tighten the bolts to 50 ft. Ibs. (68 Nm). Left and right motor mounts. Tighten the bolts to 45 ft. Ibs. (64 Nm). Engine ground straps Torque converter. Tighten the bolts to 23 ft. Ibs. (31 Nm). CMP sensor connector CKP sensor connector Starter motor Rubber splash shield 14. Install the structural cover as follOWS: a. Install all the bolts finger-tight. b. Hold the cover tightly against the

transmission and the engine. C. Tighten the bolts in sequence to 40 ft. bs. (54 Nm). 15. Install or connect the following: ¢ Exhaust crossover pipe

STRUCTURAL COVER

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9308PG02

Structural cover torque sequence—4.7L engine

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Engine oil filter HO2S sensor connectors Oil dipstick tube Oil fill tube Power steering pump Fuel line Ignition coils MAP sensor connector IAC valve connector ECT sensor connector Fuel injector harness connectors IAT sensor connector TP sensor connector Heater hoses Alternator A/C condenser Radiator Transmission oil cooler lines Radiator hoses Cooling fan assemblies

A/C compressor Accessory drive belt Crankcase breather tubes Cruise control cable Accelerator cable Air intake resonator Headlamp mounting module Left and right inner fender liners Front fascia Negative battery cable 16. Fill and bleed the cooling system. 17. Fill and bleed the power steering system. e Fill the engine with clean oil. 18. Recharge the A/C system. 19. Start the engine, check for leaks and repair if necessary.

5.2L AND 5.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the power steering fluid. 4. Drain the engine oil. 5. Properly relieve the fuel system pressure. 6. Recover the A/C refrigerant. 7. Remove or disconnect the following: Battery Hood Air cleaner assembly Radiator hoses Heater hoses Radiator and fan shroud Accessory drive belt Distributor cap and spark plug wires Vacuum lines

Engine control wiring harness connectors Accelerator linkage Fuel line Throttle body Oil pressure sender connector

A/C hoses Power steering hoses

Starter motor Alternator Heated Oxygen (HO2S) sensor connectors

Exhaust Y-pipe Torque converter cover Torque converter Left and right motor mounts Transmission flange bolts 8. Place a support stand under the transmission. 9. Lift the engine out of the vehicle.

To install: * 10. Lower the engine in to the vehicle and position to the transmission. 11. Install or connect the following: Transmission flange bolts. Tighten the bolts to 30 ft. Ibs. (41 Nm). Left and right motor mounts. Tighten the through bolts to 60 ft. lbs. (81 Nm). Torque converter. Tighten the bolts to 23 ft. lbs. (31 Nm). Torque converter cover Exhaust Y-pipe HO2S sensor connectors Alternator Starter motor Power steering hoses A/C hoses Oil pressure sender connector Throttle body

48.9

Fuel line Accelerator linkage Engine control wiring harness connectors Vacuum lines Distributor cap and spark plug wires Accessory drive belt Radiator and fan shroud Heater hoses Radiator hoses Air cleaner assembly Hood Battery 12. Fill and bleed the cooling system. 13. Fill and bleed the power steering system. 14. Fill the engine with clean oil. 15. Recharge the A/C system. 16. Start the engine, check for leaks and repair if necessary.

Water Pump

REMOVAL & INSTALLATION 2.5L and 4.0L Engines >The 2.5L and 4.0L engines covered use a reverse rotation water pump. The letter R is stamped on the impeller to identify. Engines from previous years may be equipped with forward rotation water pumps. Installation of the wrong water pump will cause engine over heating.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

FRONT VIEW ROTATION DIRECTION AS VIEWED

BACK VIEW. ROTATION DIRECTION

AS VIEWED

7924PG02

Reverse rotation water pump—2.5L and 4.0L engines

Heater Core replacement is covered in Section 2 of this manual

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1 - WATER PUMP 2 - TIMING CHAIN COVER S8S5PG02

Water pump tightening sequence—3.7L

e Lower hose e Water pump (8 bolts) 4. Installation is the reverse of removal.

Tighten the bolts, in sequence, to 40 ft. Ibs. (54 Nm).

4.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section, 2. Drain the cooling system.

3.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Fan and clutch assembly from the

pump ¢ Fan shroud and fan assembly. If you're reusing the fan clutch, keep it upright to avoid silicone fluid loss!

XxINDICATES STUD LOCATION BMPR

Water pump torque sequence—4.7L engine

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3. Remove or disconnect the following: « © Negative battery cable e Fan and clutch assembly from the pump e Drive belt e Lower radiator hose from the water pump e Water pump 4. Clean the mating surfaces of all gasket material. To install: 5. Install or connect the following; e Water pump using a new gasket. Torque the bolts to 40 ft. Ibs. (54 Nm) e Lower radiator hose e Drive belt e Negative battery cable 6. Fill and bleed the cooling system. 7. Start the engine, check for leaks and repair if necessary. 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Engine cooling fan and shroud ->Do not store the fan clutch assembly horizontally, silicone may leak into the bearing grease and cause contamination.

e Accessory drive belt e Water pump pulley e Lower radiator hose e Heater hose and tube e Bypass hose e Water pump To install: 4. Install or connect the following: ¢ Water pump, using a new gasket. Torque the bolts to 30 ft. Ibs. (40 Nm). Bypass hose Heater hose and tube. Use a new O-ring seal Lower radiator hose Water pump pulley. Torque the bolts to 20 ft. Ibs. (27 Nm). Accessory drive belt Engine cooling fan and shroud ¢ Negative battery cable 5. Fill and bleed the cooling system. 6. Start the engine, check for leaks and repair if necessary.

Cylinder Head

REMOVAL & INSTALLATION 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: e Negative battery cable e Crankcase Ventilation (CCV) hoses e Air cleaner assembly e Valve cover ->Keep valvetrain components in order for reassembly.

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Rocker arms Pushrods Accessory drive belt A/C compressor and bracket, if equipped

1 — ALIGNMENT DOWEL 2 ~ ALIGNMENT DOWEL 9308PG03

Alignment dowel locations—2.5L engine

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Power steering pump and bracket, if equipped Fuel line Combination manifold Thermostat housing coolant hoses Spark plugs Engine Coolant Temperature (ECT) sensor connector e Cylinder head To install:

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Cylinder head bolts may only be reused one time. If reusing a cylinder head bolt, place a paint mark on the bolt after installation. If a cylinder head bolt has a paint mark, discard it and use a new bolt. 5, Fabricate two alignment dowels from old cylinder head bolts. Cut the hex head off of the bolts, and cut a slot in each dowel to ease removal. 6. Install or connect the following: ¢ One dowel in bolt hole No. 8, and one dowel in bolt hole No. 10. e Cylinder head and gasket. e Cylinder head bolts except for No 8 and No 10. Coat the threads of bolt No. 7 with Loctite® 592 sealant. 7. Remove the alignment dowels and install the No. 8 and No. 10 head bolts.

During the final tightening sequence, bolt No. 7 will be tightened to a lower torque value than the rest of the bolts. Do not overtighten bolt No. 7.

7924PG04

Cylinder head torque sequence—2.5L engine

Brake service is covered in Section 4 of this manual

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Keep valvetrain components in order for reassembly.

Rocker arms Pushrods Accessory drive belt A/C compressor and bracket, if equipped Power steering pump and bracket, if equipped Fuel line Combination manifold Thermostat housing coolant hoses Spark plugs Engine Coolant Temperature (ECT) sensor connector e Cylinder head To install:

Cylinder head bolts may only be reused one time. If reusing a cylinder head bolt, place a paint mark on the bolt after installation. If a cylinder head bolt has a paint mark, discard it and use a new bolt. 5. Install the cylinder head with a new gasket. Coat the threads of bolt No. 11 with Loctite®F 592 sealant.

* CAUTION During the final tightening sequence, bolt No. 11 will be tightened to a lower torque value than the rest of the bolts. Do not overtighten bolt No. 11.

7924PG05

Cylinder head torque sequence—4.0L engine

6. Tighten the cylinder head bolts, in sequence, as follows: a. Step 1: 22 ft. Ibs. (30 Nm) b. Step 2: 45 ft. Ibs. (61 Nm) c. Step 3: 45 ft. Ibs. (61 Nm) d. Step 4: Bolts 1-10 to 110 ft. Ibs. (149 Nm) e. Step 5: Bolt 11 to 100 ft. Ibs. (136 Nm) f. Step 6: Bolts 12-14 to 110 ft. Ibs. (149 Nm) ~ g. Step 7: Repeat steps 4, 5 and 6 7. Install or connect the following: ECT sensor connector Spark plugs Thermostat housing coolant hoses Combination manifold Fuel line Power steering pump and bracket, if equipped A/C compressor and bracket, if equipped. Torque the bolts to 30 ft. lbs. (40 Nm). Accessory drive belt Pushrods and rocker arms in their original positions Valve cover Control cable bracket Transmission cable, if equipped Cruise control cable, if equipped Accelerator cable Air cleaner assembly CCV hoses Negative battery cable 8. Fill and bleed the cooling system. 9. Start the engine, check for leaks and repair if necessary. 3.7L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: ¢ Negative battery cable e Exhaust Y-pipe ‘ e Intake manifold e Cylinder head cover Engine cooling fan and shroud Accessory drive belt Power steering pump 5. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V6 marks on the camshaft sprockets are at 12 o'clock as shown. ¢ Crankshaft damper ¢ Front cover

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Camshaft sprocket timing marks—3.7L

6. Lock the secondary timing chain to the idler sprocket with Timing Chain Locking tool 8429. 7. Matchmark the secondary timing chain one link on each side of the V6 mark to the camshaft sprocket. e Left secondary timing chain tensioner e Cylinder head access plug e Secondary timing chain guide e Camshaft sprocket e Cylinder head

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~The cylinder head is retained by twelve bolts. Four of the bolts are smaller and are at the front of the head.

To install: 8. Check the cylinder head bolts for signs of stretching and replace as necessary. 9. Lubricate the threads of the 11mm bolts with clean engine oil.

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10. Coat the threads of the 8mm bolts

1 - SPECIAL TOOL 8429

2 - CAMSHAFT CHAIN 3 - CRANKSHAFT TIMING GEAR 9355PG05

Camshaft locking tool—3.7L

with Mopar® Lock and Seal Adhesive. 11. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence as follows: a. Step 1: Bolts 1-8 to 20 ft. Ibs. (27 Nm) b. Step 2: Bolts 1-10 verify torque without loosening

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

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Examine the head bolts for signs of stretching—3.7L engine

c. Step 3: Bolts 9-12 to 10 ft. Ibs. (14 Nm) d. Step 4: Bolts 1-8 plus % (90 degree) turn e. Step 5: Bolts 9-12 to 19 ft. Ibs. (26 Nm) 12. Install or connect the following: e Camshaft sprocket. Align the secondary chain matchmarks and tighten the bolt to 90 ft. Ibs. (122 Nm). e Secondary timing chain guide e Cylinder head access plug e Secondary timing chain tensioner. Refer to the timing chain procedure in this section. 13. Remove the Timing Chain Locking

e Accessory drive belt e Oil fill housing e Power steering pump 5. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V6 marks on the camshaft sprockets are at 12 o'clock as shown. 6. Remove or disconnect the following: e Crankshaft damper e Front cover 7. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8429. 8. Matchmark the secondary timing chains to the camshaft sprockets.

1 - TIMING CHAIN COVER 2 — CRANKSHAFT TIMING MARKS

9308PG04

Crankshaft timing marks—3.7L engine

9. Remove or disconnect the following: e Secondary timing chain tensioners e Cylinder head access plugs e Secondary timing chain guides e Camshaft sprockets e Cylinder heads ->Each cylinder head is retained by 8 11mm bolts and four 8mm bolts.

To install: 10. Check the cylinder head bolts for signs of stretching and replace as necessary.

tool.

14. Install or connect the following: Front cover Crankshaft damper. Torque the bolt to 130 ft. Ibs. (175 Nm). Power steering pump Accessory drive belt Engine cooling fan and shroud Cover Intake manifold Exhaust Y-pipe Negative battery cable 15. Fill and bleed the cooling system. 16. Start the engine, check for leaks and repair if necessary.

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: e Negative battery cable ¢ Exhaust Y-pipe e Intake manifold e Valve cover e Engine cooling fan and shroud

LEFT BANK

RIGHT BANK 9355PG03

Cylinder head bolt torque sequence—3.7L

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12 O'CLOCK

4.7L Engine

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9302PG08

Camshaft positioning—3.7L engine

11. Lubricate the threads of the 114mm bolts with clean engine oil. 12. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive. 13. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows: a. Step 1: Bolts 1-8 to 20 ft. Ibs. (27 Nm) b. Step 2: Bolts 1-10 verify torque without loosening c. Step 3: Bolts 9-12 to 10 ft. Ibs. (14 Nm) d. Step 4: Bolts 1-8 plus % (90 degree) turn e. Step 5: Bolts 9-12 to 19 ft. Ibs. (26 Nm) 14. Install or connect the following: e Camshaft sprockets. Align the secondary chain matchmarks and

tighten the bolts to 90 ft. Ibs. (122 Nm). Secondary timing chain guides Cylinder head access plugs

* Secondary timing chain tensioners. Refer to the timing chain procedure in this section.

15. Remove the Timing Chain Locking tool.

16. Install or connect the following: Front cover Crankshaft damper. Torque the bolt to 130 ft. Ibs. (175 Nm). Rocker arms Power steering pump Oil fill housing Accessory drive belt Engine cooling fan and shroud Valve covers Intake manifold Exhaust Y-pipe Negative battery cable 17. Fill and bleed the cooling system.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. . 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: e Negative battery cable Exhaust Y-pipe Intake manifold Valve covers Engine cooling fan and shroud Accessory drive belt Oil fill housing Power steering pump Rocker arms 5. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top

Dead Center (TDC) mark on the front cover,

and the V8 marks on the camshaft sprockets are at 12 o'clock as shown. 6. Remove or disconnect the following: e Crankshaft damper e Front cover 7. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8515. 8. Matchmark the secondary timing chains to the camshaft sprockets. 9. Remove or disconnect the following: Secondary timing chain tensioners Cylinder head access plugs Secondary timing chain guides Camshaft sprockets Cylinder heads ->Each cylinder head is retained by ten 11mm bolts and four 8mm bolts.

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9308PG04

Crankshaft timing marks—4.7L engine

Camshaft positioning—4.7L engine

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

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1 8-1 6 CHEROKEE ¢ GRAND CHEROKEE ¢ LIBERTY e WRANGLER ¢ Secondary timing chain guides e Cylinder head access plugs ¢ Secondary timing chain tensioners. Refer to the timing chain procedure in this section. 15. Remove the Timing Chain Locking tool 8515. 16. Install or connect the following: e Front cover ¢ Crankshaft damper. Torque the bolt to 130 ft. Ibs. (175 Nm). e Rocker arms

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Cylinder head bolt tightening sequence—4.7L engine, right cylinder head shown

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SPECIAL TOOL 8515

ACCESS

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9302PG09

Cylinder head access plug locations—4.7L engine

To install: 10. Check the cylinder head bolts for signs of stretching and replace as necessary. 11. Lubricate the threads of the 11mm bolts with clean engine oil. 12. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive. 13. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows: a. Step 1: Bolts 1-10 to 15 ft. Ibs. (20 Nm) b. Step 2: Bolts 1-10 to 36 ft. Ibs. (47 Nm) Cc. Step 3: Bolts 11-14 to 18 ft. Ibs. (25 Nm) d. Step 4: Bolts 1-10 plus % (90 degree) turn @. Step 5: Bolts 11-14 to 19 ft. Ibs. (26 Nm) 14. Install or connect the following: ¢ Camshaft sprockets. Align the secondary chain matchmarks and tighten the bolts to 90 ft. Ibs. (122 Nm).

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IDLER SPROCKET

9302PG07

Use the special tool to lock the timing chains on the idler gear—4.7L engine

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Examine the head bolts for signs of stretching—4.7L engine

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5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Accessory drive belt Alternator Air cleaner assembly Closed Crankcase Ventilation (CCV) system Evaporative emissions control system

Fuel line Accelerator linkage Cruise control cable Transmission cable Distributor cap and wires Ignition coil wiring

Engine Coolant Temperature (ECT) sensor connector

Heater hoses Bypass hose Upper radiator hose Intake manifold Valve covers

(6) (0 7924PG06

Cylinder head torque sequence—5.2L and 5.9L engines

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Distrtbutor cap and wires Transmission cable Cruise control cable Accelerator linkage

7. Fill and bleed the cooling system. 8. Start the engine, check for leaks and repair if necessary.

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REMOVAL & INSTALLATION

2.5L and 4.0L Engines

* Accessory drive belt

1. Before servicing the vehicle, refer to the

e Negative battery cable

precautions in the beginning of this section.

Keep valvetrain components in order for reassembly.

e Rocker arms e Pushrods e Exhaust manifolds e Spark plugs e Cylinder heads To install: 5. Install the cylinder heads. Use new gaskets and tighten the bolts in sequence as

CAPSCREWS

ROCKER ARMS

BRIDGE PIVOT ASSEMBLY

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. follows:

a. Step 1: 50 ft. Ibs. (68 Nm) b. Step 2: 105 ft. Ibs. (143 Nm) c. Step 3: 105 ft. Ibs. (143 Nm) 6. Install or connect the following: Spark plugs Exhaust manifolds Pushrods and rocker arms in their original positions Valve covers Intake manifold Upper radiator hose Bypass hose Heater hoses ECT sensor connector Ignition coil wiring

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PUSH RODS 7924PG07

Exploded view of the rocker arm assembly—2.5L and 4.0L engines

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

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2. Remove or disconnect the following: e Negative battery cable e Valve cover e Rocker arm bolts, loosen them evenly to avoid damaging the alignment bridges e Rocker arms ->Keep valvetrain components in order for reassembly.

To install: 3. Install or connect the following: e Rocker arms, pivots and bridges in their original positions. Torque the bolts for each bridged pair one turn at a time to 21 ft. Ibs. (28 Nm). e Valve cover e Negative battery cable 3.7L and 4.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

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8. Repeat for each rocker arm to be installed. 9. Install or connect the following: e Cylinder head cover e Negative battery cable

Intake Manifold

REMOVAL & INSTALLATION 3.7L and 4.7L Engines

5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Valve covers e Rocker arms Keep valvetrain components in order for reassembly.

To install: 3. Rotate the crankshaft so that the V8 mark on the crankshaft damper aligns with the timing mark on the front cover. The V8 mark is located 147 degrees AFTER Top Dead Center (TDC). 4. Install the rocker arms in their original positions and tighten the bolts to 21 ft. lbs. (28 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. ~ 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Air cleaner assembly Accelerator cable Cruise control cable Manifold Absolute Pressure (MAP) sensor connector Intake Air Temperature (IAT) sensor connector Throttle Position (TP) sensor con-

kk CAUTION Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down. 5. Install or connect the following: e Valve covers e Negative battery cable 9302PG13

Rocker arm service—3.7L and 4.7L engines

2. Remove or disconnect the following: e Negative battery cable e Valve covers 3. Rotate the crankshaft so that the piston of the cylinder to be serviced is at Top Dead Center (TDC) and both valves are closed. 4. Use special tool 8516 to depress the valve and remove the rocker arm. 5. Repeat for each rocker arm to be serviced.

Keep valvetrain components in order for reassembly.

To install: 6. Rotate the crankshaft so that the piston of the cylinder to be serviced is at BDC. 7. Compress the valve spring and install each rocker arm in its original position.

9302PG14

Intake manifold torque sequence—3.7 and 4.7L engines

Oil dipstick tube Fuel line Fuel supply manifold Throttle body and mounting bracket Cowl seal Right engine lifting stud Intake manifold. Remove the fasteners in reverse of the tightening sequence. To install: 5. Install or connect the following: Intake manifold using new gaskets. Torque the bolts, in sequence, to 105 inch Ibs. (12 Nm). Right engine lifting stud Cowl seal Throttle body and mounting bracket Fuel supply manifold Fuel line Oil dipstick tube Ignition coil towers Engine ground straps

A/C compressor Alternator Accessory drive belt Cruise contre! servo hose Brake booster vacuum line Canister purge vacuum line PCV valve and hose ECT sensor IAC valve connector TP sensor connector IAT sensor connector MAP sensor connector Cruise control cable Accelerator cable Air cleaner assembly Negative battery cable 6. Fill and bleed the cooling system. 7. Start the engine, check for leaks and repair if necessary.

Ignition coil wiring Engine Coolant Temperature (ECT) sensor connector Heater hose Upper radiator hose Bypass hose Closed Crankcase Ventilation (CCV) system Evaporative emissions system A/C compressor Manifold support bracket Intake manifold To install: 5. Install the intake manifold. Use a new gasket and torque the bolts in sequence as follows: a. Step 1: Bolts 1-4 to 72 inch Ibs. (8 Nm) using 12 inch |b. (1.4 Nm) increments

b. Step 2: Bolts 5-12 to 72 inch Ibs.

(8Nm) — C. Step 3: Bolts 1-12 to 72 inch Ibs. 8 Nm) d. Step 4: Bolts 1-12 to 12 ft. Ibs. (16 Nm) e. Step 5: Bolts 1-12 to 12 ft. Ibs. (16 Nm) 6. Install or connect the following: Manifold support bracket A/C compressor Evaporative emissions system CCV system Bypass hose Upper radiator hose Heater hose

ECT sensor connector Ignition coil wiring Distributor cap and wires Cruise control cable

e Transmission cable e Accelerator cable e Fuel supply manifold e Fuel line e Air cleaner assembly e Alternator e Accessory drive belt e Negative battery cable 7. Fill and bleed the cooling system. 8. Start the engine, check for leaks and repair if necessary. Exhaust Manifold

REMOVAL & INSTALLATION 4.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Battery Power distribution center Battery tray Windshield washer fluid bottle Air cleaner assembly Accessory drive belt A/C compressor A/C accumulator bracket Heater hoses Exhaust manifold heat shields Exhaust Y-pipe Starter motor Exhaust manifolds To install: 4. Install or connect the following:

5.2L and 5.9L Engines » 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Accessory drive belt Alternator Air cleaner assembly Fuel line Fuel supply manifold Accelerator cable Transmission cable Cruise control cable Distributor cap and wires

7924PG10

Intake manifold torque sequence—5.2L and 5.9L engines

For Wheel Alignment specifications, see Section 1 of this manual

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CHEROKEE ¢ GRAND CHEROKEE ¢ LIBERTY ¢ WRANGLER 2. Properly relieve the fuel system pres-

STUD BOLT &

EXHAUST MANIFOLD (RIGHT)

3. Drain the cooling system. 4. Remove or disconnect the follow-

WASHER

_STUD BOLT WASHER

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Negative battery cable Air intake hose Accessory drive belt Power steering pump and brackets, if equipped Fuel line Accelerator cable Cruise control cable, if equipped Transmission cable, if equipped Throttle Position (TP) sensor con-

BOLT & WASHER STUD BOLT & WASHER

nector

Idle Air Control (IAC) valve con-

EXHAUST MANIFOLD (LEFT) 7924PG11

Exhaust manifold fastener locations—5.2L and 5.9L engines

e Exhaust manifolds, using new gaskets. Torque the bolts to 18 ft. Ibs. (25 Nm), starting with the inner bolts and work out to the ends. Starter motor Exhaust Y-pipe Exhaust manifold heat shields Heater hoses A/C accumulator bracket A/C compressor Accessory drive belt Air cleaner assembly Windshield washer fluid bottle Battery tray Power distribution center Battery 5. Fill and bleed the cooling system. 6. Start the engine, check for leaks and repair if necessary.

teners to 20 ft. Ibs. (27 Nm), starting with the center nuts and work out to the ends. e Exhaust Y-pipe e EGR tube e Exhaust manifold heat shields e Negative battery cable 4. Start the engine, check for leaks and repair if necessary.

Combination Manifold

REMOVAL & INSTALLATION 2.9L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

nector Engine Coolant Temperature (ECT) sensor connector Intake Air Temperature (IAT) sensor connector Heated Oxygen (HO2S) sensor connector Fuel injector connectors Closed Crankcase Ventilation (CCV) system Manifold Absolute Pressure (IMAP) sensor vacuum line Brake booster vacuum line Exhaust front pipe Intake manifold and discard the gaskets Exhaust manifold and discard the gaskets To install: 5. Install or connect the following: ¢ New gasket over the locating dowels e Exhaust manifold to the studs and tighten the nuts finger-tight 6. Install the intake manifold. Torque the fasteners in sequence as follows:

3.7L, 5.2L and 5.9L Engines CYLINDER HEAD DOWELS

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Exhaust manifold heat shields ¢ Exhaust Gas Recirculation (EGR) tube e Exhaust Y-pipe e Exhaust manifolds To install: e>if the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.

3. Install or connect the following: ¢ Exhaust manifolds. Torque the fas-

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SPACER EXHAUST MANIFOLD 7924PG08

Combination manifold torque sequence—2.5L engine

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a. Step 1: Bolt 1 to 30 ft. Ibs. (41 Nm). b. Step 2: Fasteners 2-7 to 23 ft. Ibs. “(31 Nm). 7. Install or connect the following: Exhaust front pipe Brake booster vacuum line MAP sensor vacuum line CCV system Fuel injector connectors HO2S sensor connector IAT sensor connector ECT sensor connector IAC valve connector TP sensor connector Transmission cable, if equipped Cruise control cable, if equipped Accelerator cable Fuel line Power steering pump and brackets, if equipped Accessory drive belt Air intake hose Negative battery cable 8. Fill and bleed the cooling system. 9. Start the engine, check for leaks and repair if necessary. * 4.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Air cleaner assembly Accessory drive belt Power steering pump and brackets, if equipped Fuel line Fuel injector connectors Fuel supply manifold and injectors Accelerator cable Cruise control cable, if equipped Transmission cable, if equipped Throttle Position (TP) sensor connector Idle Air Control (IAC) valve connector Engine Coolant Temperature (ECT) sensor connector

Intake Air Temperature (IAT) sensor connector

Heated Oxygen (HO2S) sensor connector Closed Crankcase Ventilation (CCV) system Manifold Absolute Pressure (MAP) sensor vacuum line

BOLT TORQUE

@ - © 33 N-m (24 ft. Ibs.)

® - @ 31 N-m (23 ft. lbs.) @ - @ 33 N-m (24 ft. Ibs.)

EXHAUST MANIFOLD 7924PG12

Combination manifold torque sequence—4.0L engines

¢ Brake booster vacuum line e Exhaust front pipe e Intake and exhaust manifolds and discard the gaskets To install: 5. Install or connect the following: e New gasket over the locating dowels e Exhaust manifold to the studs and tighten the nuts finger-tight 6. Install the intake manifold. Torque the fasteners in sequence as follows: a. Step 1: Fasteners 1-5 to 30 ft. Ibs. (41 Nm). b. Step 2: Fasteners 6 and 7 to 23 ft. lbs. (31 Nm). c. Step 3: Fasteners 8-11 to 24 ft. lbs. (33 Nm) 7. Install or connect the following: Exhaust front pipe Brake booster vacuum line MAP sensor vacuum line CCV system

HO2S sensor connector IAT sensor connector ECT sensor connector IAC valve connector TP sensor connector Transmission cable, if equipped Cruise control cable, if equipped Accelerator cable Fuel supply manifold and injectors Fuel injector connectors Fuel line Power steering pump and brackets, if equipped Accessory drive belt e Air cleaner assembly Negative battery cable 8. Fill and bleed the cooling system.

9. Start the engine, check for leaks and repair if necessary.

Camshaft and Valve Lifters

REMOVAL & INSTALLATION 2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Recover the A/C refrigerant, if equipped with air conditioning. 4, Remove or disconnect the following: e Negative battery cable e Grille, if necessary e Radiator e A/C condenser, if equipped e Distributor and ignition wires e Valve cover ->Keep all valvetrain components in order for assembly.

e Rocker arms and pushrods e Hydraulic valve tappets e Accessory drive belt e Crankshaft damper e Front cover e Timing chain and gears e Camshaft To install: ef the camshaft sprocket appears to have been rubbing against the cover, check the oil pressure relief holes in the rear cam journal for debris. 5. Lubricate the camshaft with clean

engine oil.

For Maintenance Interval recommendations, see Section 1 of this manual

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RIGHT CYLINDER HEAD

7. Fill and bleed the cooling system. 8. Recharge the A/C system, if equipped. 9. Start the engine, check for leaks and repair if necessary. 3.7L and 4.7L Engines

9302PG15

Chain Tensioner Retaining Wedges

6. Install or connect the following: Camshaft Timing chain and gears Front cover Crankshaft damper Accessory drive belt Hydraulic valve tappets Rocker arms and pushrods Valve cover Distributor A/C condenser, if equipped Radiator Grille, if removed Negative battery cable 7. Fill and bleed the cooling system. 8. Recharge the A/C system, if equipped. 9. Start the engine, check for leaks and repair if necessary. 4.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Recover the A/C refrigerant, if equipped with air conditioning. 4. Remove or disconnect the following: e Negative battery cable e Grille, if necessary e Radiator ¢ A/C condenser, if equipped ¢ Distributor or camshaft sensor housing e Valve cover

e Camshaft To install: 5. Lubricate the camshaft with clean engine oil. 6. Install or connect the following: e Camshaft Thrust plate. Torque the bolts to 18

ft. Ibs. (24 Nm). Timing chain and gears Front cover Crankshaft damper Accessory drive belt Hydraulic valve tappets Cylinder head Rocker arms and pushrods Valve cover Distributor or camshaft sensor housing

A/C condenser, if equipped Radiator . Grille, if removed Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ~ 2. Remove or disconnect the following: Negative battery cable Cylinder head covers Rocker arms Hydraulic lash adjusters Keep all valvetrain components in order for assembly.

3. Set the engine at Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 4. Install Timing Chain Wedge (8350 4.7L; 8379 3.7L) to retain the chain tension-

ers. 5. Matchmark the timing chains to the camshaft sprockets. 6. Install Camshaft Holding Too! (6958 and Adapter Pins 8346 4.7L; 8428 3.7L) to the left camshaft sprocket. 7. Remove or disconnect the following: e Right camshaft timing sprocket and target wheel e Left camshaft sprocket e Camshaft bearing caps, by reversing the tightening sequence e Camshafts

e>Keep all valvetrain components in order for assembly.

Rocker arms and pushrods Cylinder head Hydraulic valve tappets Accessory drive belt Crankshaft damper Front cover Timing chain and gears Thrust plate

9302PG20

Hold the left camshaft sprocket with a spanner wrench while removing or installing the camshaft sprocket bolts—4.7L engine

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CHEROKEE e GRAND CHEROKEE ¢ LIBERTY e WRANGLER

1 8-23

4. Set the crankshaft to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 5. Remove or disconnect the following: Negative battery cable

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Accessory drive belt Power steering pump Water pump

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Radiator A/C condenser Grille Crankshaft damper Front cover Valve covers Distributor e Intake manifold

9302PG17

Keep all valvetrain components in order for assembly.

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9355PG06

CAMSHAFT SPROCKET AND CHAIN

9302PG16

Turn the camshaft with pliers, if needed, to align the dowel in the sprocket—4.7L engine

To install: 8. Install or connect the following: e Camshafts. Torque the bearing cap bolts in % turn increments, in

sequence, to 100 inch Ibs. (11 Nm). e Target wheel to the right camshaft e Camshaft timing sprockets and chains, by aligning the matchmarks 9. Remove the tensioner wedges and tighten the camshaft sprocket bolts to 90 ft. lbs. (122 Nm). 10. Install or connect the following: e Hydraulic lash adjusters in their original locations e Rocker arms in their original locations e Cylinder head covers e Negative battery cable

Rocker arms and pushrods Hydraulic lifters Timing chain and sprockets Camshaft thrust plate and chain oil tab e Camshaft To install: 6. Install or connect the following: ¢ Camshaft, secure it in position with the Camshaft Holding Tool C-3509 e Camshaft thrust plate and chain oil tab. Torque the bolts to 18 ft. Ibs. (24 Nm). e Timing chain and sprockets, by aligning the timing marks. Torque the camshaft sprocket bolt to 50 ft. lbs. (68 Nm). 7. Remove the camshaft holding tool. 8. Install or connect the following: e Hydraulic lifters in their original positions Rocker arms and pushrods in their original positions Intake manifold Distributor Valve covers Front cover Crankshaft damper

5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Recover the A/C refrigerant.

7924PG13

Camshaft holding tool C-3509—5.2L and 5.9L engines

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

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7924PG16

Oil pan alignment dowel placement—2.5L and 4.0L engines

THRUST PLATE REAR SIDE

7924P614

Thrust plate position—5.2L and 5.9L engines

e Grille e A/C condenser e Radiator e e e e

9. 10. 11. repair

Water pump Power steering pump Accessory drive belt Negative battery cable Fill and bleed the cooling system. Recharge the A/C system. Start the engine, check for leaks and if necessary.

Valve Lash

ADJUSTMENT These engines are equipped with hydraulic valve lifters. No valve clearance adjustments are necessary.

e Starter solenoid harness connections e Starter To install: 3. Connect the starter solenoid wiring connectors. 4. Install the starter and torque the bolts to the following specifications: e 2.5L engine: 33 ft. Ibs. (45 Nm). e 4.0L engine: Upper bolt to 40 ft. lbs. (54 Nm) and lower bolt to 30 ft. Ibs. (41 Nm). e 2.4L, 3.7L and 4.7L engine: 40 ft. lbs. (54 Nm). e 5.2L and 5.9L engines: 50 ft. Ibs. (68 Nm). e On the 3.7L engine, the left side exhaust pipe and front driveshaft 5. Install the negative battery cable and check for proper operation.

Starter Motor °

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Starter mounting bolts e>On the 3.7L engine, the left side exhaust pipe and front driveshaft must be disconnected.

REMOVAL & INSTALLATION 2.9L and 4.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable ¢ Exhaust front pipe

e Starter motor Bell housing access cover Oil level sensor connector, if equipped Left and right motor mounts Transmission oil cooler lines, if equipped 4. Place a jack under the crankshaft damper and raise the engine for clearance. 5. Remove the oil pan. To install: 6. Fabricate 4 alignment dowels from 1¥% in. x % in. bolts. Cut the heads off the bolts and cut a slot into the top of the dowel to allow installation/removal with a screwdriver. 7. Install or connect the following: e Dowels e Oil pan, using a new gasket. Torque the % inch bolts to 85 inch Ibs. (9.5 Nm) and the %e inch bolts to 11 ft. Ibs. (15 Nm). 8. Replace the alignment dowels with Ya inch bolts and torque them to 85 inch lbs. (9.5 Nm). 9. Install or connect the following: Left and right motor mounts Oil level sensor connector, if equipped Bell housing access cover Starter motor ' Exhaust front pipe Negative battery cable 10. Fill the engine with clean oil. 11. Start the engine, check for leaks and repair if necessary. 3.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

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Transmission oil cooler lines Starter motor Exhaust Y-pipe Structural cover e Negative battery cable 5. Fill the engine to the proper level with clean oil. 6. Start the engine, check for leaks and repair if necessary. 5.2L and 5.9L Engines

9355PG07

Oil pan bolt torque sequence—3.7L

e Engine from the vehicle e Oil pan e Oil pump pickup tube e Qil pan gasket 3. Installation is the reverse of removal. Torque the bolts, in sequence, to 11 ft. Ibs. (15 Nm). 4.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Structural cover Exhaust Y-pipe Starter motor Transmission oil cooler lines Oil pan Oil pump pickup tube Oil pan gasket To install: 4. Install or connect the following: e Oil pan gasket ¢ Oil pump pickup tube, using a new

O-ring. Torque the tube bolts to 20 ft. Ibs. (28 Nm); torque the O-ring end bolt first. e (il pan. Torque the bolts, in sequence, to 11 ft. Ibs. (15 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Oil filter e Starter motor e Cooler lines Oil level sensor connector Heated Oxygen (HO2S) sensor connector e Exhaust Y-pipe e Oil pan To install: 4. Install or connect the following: Oil pan, using a new gasket. Torque the bolts to 18 ft. Ibs. (24 Nm). Exhaust Y-pipe Heated Oxygen (HO2S) sensor connector Oil level sensor connector Cooler lines Starter motor Oil filter 5. Fill the engine with clean oil. 6. Start the engine, check for leaks and repair if necessary.

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9302PG21

Oil pan mounting bolt tightening sequence—4.7L engine

For complete service labor times, order the Chilton Labor Guide

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~~ PRIMARY TIMING CHAIN / TENSIONER

Oil Pump

REMOVAL & INSTALLATION 2.5L and 4.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Qil pan e Qil pump and pickup tube e>lf the oil pump Is not to be serviced, do not disturb the position of the oil inlet tube and strainer assembly in the pump body. If the tube is moved within the pump body, a replacement tube and strainer assembly must be installed to assure an airtight seal.

To install: 4. Install or connect the following: e Qil pump. Torque the mounting bolts to 17 ft. Ibs. (23 Nm). e Oil pan e Negative battery cable 5, Fill the engine.with the proper type and quantity of oil. 6. Start the engine, check for leaks and repair if necessary. OIL FILTER ene st

STRAINER ASSEMBLY

9355PG08

Oil pump bolt torque sequence—3.7L

3. Installation is the reverse of removal. Torque the pump bolts, in sequence, to 21 ft. lbs. (28 Nm),

4.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Valve covers e Front cover e Timing chains and sprockets e Qil pan and pickup tube

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~ PRIMARY TIMING CHAIN / TENSIONER

ATTACHING BOLTS 7924PG17

Exploded view of the oil pump assembly— 2.5L and 4.0L engine

3.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Oil Pan Timing chain cover Timing chains and tensioners Oil pump

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Oil pump and chain tensioner torque sequence—4.7L engine

e Oil pump and primary timing chain tensioner To install: 4. Install or connect the following: e Oil pump and primary timing chain tensioner. Torque the bolts in sequence to 21 ft. Ibs. (28 Nm). e Oil pan and pickup tube e Timing chains and sprockets e Front cover e Valve covers 5. Fill the engine with clean oil. 6. Start the engine, check for leaks and repair if necessary. 5.2L and 5.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Oil pan ¢ Oil pump To install: 4. Install or connect the following: ¢ Oil pump. Torque the bolts to 30 ft. lbs. (41 Nm). e Qil pan e Negative battery cable 5. Fill the engine with clean oil. 6. Start the engine, check for leaks and repair if necessary.

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Rear Main Seal

REMOVAL & INSTALLATION 2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Flywheel/converter drive plate and discard the bolt e Rear main seal To install: 3. Install or connect the following: e Rear main seal so that it is flush with the cylinder block e Flywheel/ converter drive plate. Torque the new to 50 ft. Ibs. (68 Nm) plus a 60 degrees turn e Negative battery cable 4. Start the engine, check for leaks and repair if necessary. 4.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Transmission inspection cover e Oil pan e Main bearing cap brace e No. 7 main bearing cap 4. Loosen the other main bearing cap bolts for clearance and remove the rear main seal halfs.

cap after applying sealant to the bearing cap No. 7 main bearing cap. Torque all main bearing cap bolts to 80 ft. Ibs.

(108 Nm). Main bearing cap brace. Tighten the nuts to 35 ft. Ibs. (47 Nm). Oil pan Transmission inspection cover Negative battery cable 6. Fill the engine with clean oil. 7. Start the engine, check for leaks and repair if necessary.

3.7L and 4.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission e Flexplate 3. Thread Oil Seal Remover 8506 into the rear main seal as far as possible and remove the rear main seal. To install: 4. Install or connect the following: e Seal Guide 8349-2 onto the crankshaft e Rear main seal on the seal guide

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e Rear main seal, using the Crankshaft Rear Oil Seal Installer 8349. and Driver Handle C-4171; tap it into place until the installer is flush with the cylinder block e Flexplate. Torque the bolts to 45 ft.

lbs. (60 Nm). e Transmission 5. Start the engine, check for leaks and repair if necessary. 5.2L and 5.9L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Oil pan e Oil pump e Rear main bearing cap 4. Loosen the other main bearing cap bolts for clearance and remove the rear main seal halfs.

To install: 5. Install or connect the following: e New upper seal half to the cylinder block e New lower seal half to the bearing cap 6. Apply sealant to the rear main bearing

cap 7. Install or connect the following: e Rear main bearing cap. Torque all main bearing cap bolts to 85 ft. Ibs.

(115 Nm).

MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS LOCTITE 518 (OR EQUIVALENT)

CAP ALIGNMENT SLOT

LOCTITE 518 (OR EQUIVALENT) REAR MAIN BEARING CAP

7924PG32

Sealant application locations—4.0L engine

REAR MAIN BEARING CAP 7924PG18

Sealant application locations —5.2L and 5.9L engines

Please visit our web site at www.chiltonsonline.com

e Oil pump and oil pan 8. Fill the engine with clean oil. 9. Start the engine, check for leaks and repair if necessary.

Timing Chain, Sprockets, Front s Cover and Seal

REMOVAL & INSTALLATION 2.5L and 4.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

tion. 2. Remove or disconnect the following: Negative battery cable Accessory drive belt Cooling fan and shroud Crankshaft damper Front crankshaft seal Accessory brackets Front cover Oil slinger 3. Rotate the crankshaft so that the timing marks are aligned. 4. Remove the timing chain and sprockets. To install: 5. For 2.5L engines, turn the timing chain tensioner lever to the unlock (down) position. Pull the tensioner block toward the TIMING MARKS

7924PG20

Timing chain alignment marks—2.5L and 4.0L engines

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Timing Case Cover Alignment and Seal Installation Tool 6139—2.5L and 4.0L engines

tensioner lever to compress the spring. Hold the block and turn the tensioner lever to the lock (up) position. 6. Install or connect the following: e Timing chain and sprockets with the timing marks aligned. Torque the camshaft sprocket bolt to 80 ft. lbs. (108 Nm) for 2.5L engines or to 50 ft. Ibs. (68 Nm) for 4.0L engines. 7. For 2.5L engines, release the timing chain tensioner. e Oil slinger e New front crankshaft seal to the front cover e Front cover, using a new gasket e Timing Case Cover Alignment and Seal Installation Tool 6139 in the crankshaft opening to center the front cover 8. Torque the front cover bolts as follows: a. Step 1: Cover-to-block Y% inch bolts to 60 inch Ibs. (7 Nm). b. Step 2: Cover-to-block 546 inch bolts to 16 ft. Ibs. (22 Nm). c. Step 3: Oil pan-to-cover Y% inch bolts to 85 inch Ibs. (9.5 Nm). d. Step 4: Oil pan-to-cover %e inch bolts to 11 ft. Ibs. (15 Nm). 9. Install or connect the following: e Accessory brackets e Crankshaft damper. Torque the bolt to 80 ft. Ibs. (108 Nm). ¢ Cooling fan and shroud e Accessory drive belt e Negative battery cable 10. Start the engine, check for leaks and repair if necessary.

e Negative battery cable e Valve covers e Radiator fan 4. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover,

1 - TIMING CHAIN COVER 2 - CRANKSHAFT TIMING MARKS

9355PG10

Crankshaft timing marks—3.7L

3.7L and 4.7L Engines

§=TENSIONER BLOCK

TENSIONER LEVER 7924PG19

Timing chain tensioner—2.5L engines

7924PG21

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following:

1 - TIMING CHAIN COVER 2 — CRANKSHAFT TIMING MARKS

9308PG04

Crankshaft timing marks—4.7L engine

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CHEROKEE ¢ GRAND CHEROKEE © LIBERTY * WRANGLER and the V8 or V6 marks on the camshaft sprockets are at 12 o'clock. e Power steering pump « —e Access plugs from the cylinder heads e Oil fill housing ¢ Crankshaft damper 5. Compress the primary timing chain tensioner and install a lockpin.

6. Remove the secondary timing chain - tensioners. 7. Hold the left camshaft with adjustable pliers and remove the sprocket and chain. Rotate the left camshaft 15 degrees clockwise to the neutral position. 8. Hold the right camshaft with adjustable pliers and remove the camshaft sprocket. Rotate the right camshaft 45

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degrees counterclockwise to the neutral position. hs: 9. Remove the primary timing chain and sprockets. To install: 10. Use a small prytool to hold the ratchet pawl and compress the secondary timing chain tensioners in a vise and install locking pins. :

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CYLINDER HEAD \_

LEFT CYLINDER) HEAD, 9302PG08

Camshaft positioning—4.7L engine

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9355PG09

Camshaft sprocket timing marks—3.7L

Timing belt service is covered in Section 3 of this manual

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2 - OUTER TIE ROD END 3 - LOWER BALL JOINT NUT

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4 :- LOWER CONTROL+ ARM 5 >REARLCAM BOE Lower contro! arm—Liberty

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

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5. Install or connect the Bele e Halfshaft on the axle shaft splines

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e Lower ball joint and pinch bolt. e Lower clevis bolt e Stabilizer link

¢ Hub nut. Torque to 100 ft. Ibs. (136 Nm). e Wheel

Front Axle Shaft, Bearing and Seal

REMOVAL & INSTALLATION Liberty

RIGHT SIDE SHAFT ONLY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following; Negative battery cable

1 - SNAP RING GROVE > - SLID HAMMER THREADS

3 - REMOVER BLOCKS 4 - REMOVER COLLAR 9355PG24

e Right front wheel : sed from the axle

Axle shaft remover tool—Liberty

e Axle shaft using remover 8420A

and a slide hammer To install: 3. Coat the bearing bore and seal lip with gear oil. 4. Install or connect the following: e Axle shaft and snapring ¢ Halfshaft e Front wheel e Negative battery cable

RIGHT SIDE SEAL AND BEARING ONLY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Right front wheel Halfshaft Snapring from the axle Axle shaft using remover 8420A and a slide hammer ¢ Seal, using Remover 7794A and a slide hammer ¢ Bearing, using Remover 7794A and a Slide hammer To install:

3. Coat the bearing bore and seal lip with gear oil. 4. Install or connect the following:

1 - SHAFT SEAL

2 - REMOVER Seal removal—Liberty

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FRONT AXLE SHAFT 1. Before servicing the vehicle, referto the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Front wheel e Brake caliper and rotor e Wheel speed sensor, if equipped e Axle hub nut e Wheel bearing and hub assembly e Axle shaft To install: 3. Install or connect the following: ' e Axle shaft e Wheel bearing and hub assembly e Axle hub nut; Tighten the nut to

175 ft. Ibs. (237 Nm).

Wheel speed-sensor, if equipped Brake caliper and rotor Front wheel Negative battery cable

FRONT SHAFT SEAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front axle shafts e Differential cover e Differential and ring gear assembly e Axle seals

To install: 3. Press the axle seals into the differential housing with Turnbuckle 6797 and Disc set 8110. 4. Install or connect the following: ¢ Differential and ring gear assembly, Tighten the bearing cap bolts to 45 ft. Ibs. (61 Nm). e Differential cover. Tighten the bolts to 30 ft. Ibs. (41 Nm). e Front axle shafts 5. Fill the axle assembly with gear oil and check for leaks.

Rear Axle Shaft, Bearing and | Seal

REMOVAL & INSTALLATION C-Clip Type Rear Axle Shaft 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Rear wheel Brake drum Differential cover Differential gear shaft retainer Differential gear shaft C-clip Axle shaft Axle seal Axle bearing To install: 3. Install or connect the following: e Axle bearing e Axle seal e Axle shaft e C-clip e Differential gear shaft. Use Loctite® and tighten the retainer to 14 ft. Ibs. (19 Nm). e Differential cover. Tighten the bolts to 30 ft. Ibs. (41 Nm). e Brake drum e Rear wheel 4. Fill the axle assembly with gear oil and check for leaks. Non C-Clip Type Rear Axle Shaft

1 — TURNBUCKLE 6797 2 -— DISCS 8110 9308PG05

Axle seal installation

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel pate e Brake caliper and rotor, if equipped

e Brake drum, if equipped e Axle retainer nuts e Axle shaft, seal and bearing assem-

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bly 3. Split the bearing retainer with a chisel and remove the retainer ring. 4. Press the bearing off the axle shaft. 5, Remove the axle seal and retaining — plate. To install: 6. Install the retaining plate and axle seal onto the axle shaft. 7. Pack the wheel bearing with axle grease and press the bearing on to the axle shaft. 8. Press the retaining ring onto the axle shaft. . 9. Install or connect the following: e Axle shaft, seal and bearing assembly. Tighten the nuts to 45 ft. Ibs.

(61 Nm). e Brake caliper and rotor, if equipped e Brake drum, if equipped e Rear wheel 10. Fill the axle assembly with gear oil and check for leaks.

1 — RETAINING RING 2-

3 — AXLE 4 ~ RETAINING PLATE 5 — AXLE BEARING

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9308PG06

Rear axle seal and bearing components

REMOVAL & INSTALLATION C-Clip Type 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels e Brake drums e Driveshaft 3. Check the bearing preload with an inch |b. torque wrench. 4. Remove the pinion flange and seal.

For Wheel Alignment specifications, see Section 1 of this manual

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5. Install the new pinion seal and flange. Tighten the nut to 200 ft. Ibs. (271 N m). ~ 6. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch Ibs. 7. If the preload torque is low, tighten the pinion nut in 5 inch Ib. increments until the torque value is reached. Do not exceed 350 ft. Ibs. (474 Nm) pinion nut torque. 8. If the pinion bearing preload torque

cannot be attained at maximum pinion nut torque, replace the collapsible spacer. 9. Install or connect the following: e Driveshaft e Brake drums e Wheels 10. Fill the axle assembly with gear oil and check for leaks.

Non C-Clip Type

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels

| e Brake rotors e Driveshaft 3. Check the bearing preload with an inch lb. torque wrench. 4. Remove the pinion flange and seal. To install: e>Use a new pinion nut for assembly.

5. Install the new pinion seal and flange. Tighten the nut to 160 ft. Ibs. (217 Nm). 6. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch Ibs. 7. lf the preload torque is low, tighten the pinion nut in 5 inch |b. increments until the torque value is reached. Do not exceed 260 ft. Ibs. (353 Nm) pinion nut torque. 8. If the pinion bearing preload torque can not be attained at maximum pinion nut torque, replace the collapsible spacer. 9. Install or connect the following: e Driveshaft e Brake rotors e Wheels 10. Fill the axle assembly with gear oil and check for leaks.

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

| 2. Remove or disconnect the following: e Wheels ¢ Brake rotors or drums ° Driveshaft 3. Check the bearing preload with an inch Ib. torque wrench. 4. Remove the pinion flange and seal. To install:

e>Use a new pinion nut for assembly.

5. Install the new pinion seal and flange. Tighten the nut to 160 ft. Ibs. (217 Nm ). 6. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch Ibs. 7. Ifthe preload torque is low, tighten the pinion nut in 5 inch Ib. increments until the torque value is reached. Do not exceed 260 ft. Ibs. (353 Nm) pinion nut torque. _ 8. If the pinion bearing preload torque can not be attained at maximum pinion nut torque, remove one or more pinion preload shims. 9. Install or connect the following: e Driveshaft e Brake rotors or drums e Wheels 10. Fill the axle assembly with gear oil and check for leaks.

STEERING AND SUSPENSION A Emenee + CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming

procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module.

e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. ¢ With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment. Before servicing the vehicle, also make sure to refer to the precautions in the beginning of this section as well.

DISARMING Disconnect and isolate the negative battery cable. Wait 2 minutes for the system Capacitor to discharge before performing any Service.

ARMING i

To arm the system, connect the negative battery cable.

Recirculating Ball Power Steering Gear

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the front wheels in the straight ahead position. 3. Drain the power steering system. 4. Hea or disconnect the following: e Negative battery cable Air cleaner housing Power steering pressure and return lines Column coupler shaft bolt Left front wheel assembly Pitman arm Windshield washer reservoir Steering gear To install: 5. Install or connect the following: ¢ Steering gear. Tighten the bolts to 80 ft. Ibs. (108 Nm).

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Pitman arm. Tighten the nut to 185 ft. Ibs. (251 Nm). Windshield washer reservoir Power steering pressure and return lines. Torque the fasteners to 14 ft.

hs (20 Nm).

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pinch bolt to 36 ft. Ibs. (49 Nm),

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e Negative battery cable 6. Fill and bleed the power steering fluid

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7. Start the engine, check for leaks and repair if necessary.

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9355PG26

Rack mounting points—Liberty

Front Struts

2. Remove or disconnect the following:

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Negative battery cable

REMOVAL & INSTALLATION

«Bestia

COA ee ee 6 Liberty 1. Before servicing the vehicle, refer to

the precautions in the beginning of this section.

2. Remove or disconnect the follow-

ing:

, 1 8-43

crn TRE

e Battery temperature sensor e The 4 upper strut nuts

a

e Left wheel

1. Before servicing the vehicle, refer to

e Lower clevis bracket bolt

the precautions in the beginning of this sec-

¢ Stabilizer link

tion.

e Lower ball joint from the arm

e Negative battery cable

e Fluid from the steering system 2

: .

CAUTION

Lock the steering wheel to prevent the clockspring from spinning.

Sie

e Skid plate e Wheels «> Matchmark the alignment cams.

Lower control arms Front axle Tie rod end nuts Tie rod ends from the knuckles Intermediate shaft lower coupler from the gear High pressure hose bracket Hoses from the gear Gear mounting bolts and gear 3. Installation is the reverse of removal. Observe the following torques: e Gear-to-frame bolts: 120 ft. Ibs. (162 Nm) e Intermediate shaft bolt: 36 ft. Ibs. (49 Nm) e Tie rod end-to-knuckle nut: 80 ft. lbs. (108 Nm) e Tie rod end jam nut: 55 ft. Ibs. (75 Nm) e Pressure and return lines: 25 ft. lbs. (35 Nm)

VX LN e

1 2 3 4 5

-

yy

FRONT CRADLE SPRING & SHOCK ASSEMBLY STEERING KNUCKLE CLEVIS BRACKET LOWER CONTROL ARM .

Strut and clevis assembly—Liberty

For Maintenance Interval recommendations, see Section 1 of this manual

ian ’

fl

1 8-44

JEEP

CHEROKEE ¢ GRAND CHEROKEE ¢ LIBERTY e WRANGLER e Stabilizer link-to-arm bolt: 100 ft.

e Clevis bracket e Strut 3. Installation is the reverse of removal.

Observe the following torques: e Upper strut nuts: 80 ft. Ibs. (108 Nm) Clevis bracket-to-strut bolt: 65 ft. lbs. (88 Nm) Ball joint nut: 60 ft. Ibs. (81 Nm) Clevis bracket-to-arm bolt: 110 ft. lbs. (150 Nm) Stabilizer link-to-arm bolt: 100 ft.

lbs. (136 Nm)

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air box Cruise control servo mounting nuts The 4 upper strut nuts Right wheel Lower Clevis bracket bolt Stabilizer link Lower ball joint from the arm

Clevis bracket e Strut 3. Installation is the reverse of removal. Observe the following torques: Upper strut nuts: 80 ft. Ibs. (108 Nm) Clevis bracket-to-strut bolt: 65 ft. lbs. (88 Nm) Ball joint nut: 60 ft. Ibs. (81 Nm) Clevis bracket-to-arm bolt: 110 ft. lbs. (150 Nm)

SPRING

lbs. (136 Nm) Shock Absorber

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Upper nut, washer and grommet from the upper stud e Lower fasteners e Shock absorber To install: 3. Install or connect the following: e Shock absorber. Torque the lower fasteners to 17 ft. Ibs. (23 Nm). e Upper grommet, washer, and nut to the stud. Torque it to 16 ft. Ibs. (22 Nm). Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Upper locknut and washer from the frame bracket stud, on the Grand Cherokee and Liberty e Upper mounting bolts, on the Wrangler and Cherokee ¢ Lower bolt, nut and washers from the axle shaft tube bracket e Shock absorber

To install: 3. Place the shock absorber upper end in position and tighten the fasteners to the following specifications: e Wrangler: 23 ft. Ibs. (31 Nm). ¢ Cherokee: 17 ft. Ibs. (23 Nm). e 1998 Grand Cherokee: 52 ft. Ibs. (70 Nm). e Liberty and 1999-02 Grand Cherokee: 80 ft. Ibs. (108 Nm). 4. Place the shock absorber lower end ‘in position and tighten the fasteners to the following specifications: e Wrangler: 74 ft. lbs. (100 Nm). e Cherokee: 46 ft. Ibs. (62 Nm). e 1998 Grand Cherokee: 68 ft. Ibs. (92 Nm). e Liberty and 1999-02 Grand Cherokee: 85 ft. Ibs. (115 Nm).

REMOVAL & INSTALLATION Front

EXCEPT LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheels ¢ Front driveshaft, if equipped e Lower suspension arm e Stabilizer bar links e Track bar e Drag link

SPRING RETAINER

‘

v/ VIEW_IN DIRECTION OF ARROW Z Exploded view of the front suspension—Cherokee

VIEW_IN DIRECTION OF ARROW W

7924PG25

|

JEEP 4

CHEROKEE e GRAND CHEROKEE ¢ LIBERTY e WRANGLER

*

e Brake hose brackets e Spring retainers e Coil spring

To install:

|

3. Install or connect the following: Coil spring Spring retainers. Torque the bolt to 16 ft. Ibs. (21 Nm). Stabilizer bar links. Torque the bolts to 70 ft. Ibs. (95 Nm). Track bar. Torque the bolt to 35 ft. lbs. (47 Nm). Front propeller shaft to the axle Drag link Lower suspension arm. Torque the

bolt to 133 ft. Ibs. (180 Nm). Front driveshaft, if equipped Front wheels .

LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut and place it ina Pentastar W7200 spring compressor, or equivalent. ; 3. Compress the spring, remove the

strut mount nut and remove thestrut from the compressor. 4. Installation is the reverse of removal. Torque the nut to 30 ft. Ibs. (41 Nm).

Shock absorbers Track bar Spring retainers ¢ Coil springs To install: 3. Install or connect the following: ¢ Coil springs e Spring retainers e Track bar

e¢ Shock absorbers e Stabilizer bar links e Rear wheels

LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle with a jack. 3.. Remove or disconnect the following: e Rear wheels e Shock absorbers from the axle 4. Lower the axle and tilt it to remove the springs. 5. Installation is the reverse of removal.

Leaf Springs

:

1 8-45

To install: >The weight of the vehicle must be supported by the springs when the spring eye and stabilizer bar fasteners

are tightened. 5. Install or connect the following: e Leaf spring e Spring bracket e Axle U-bolts. Torque the nuts to 52 ft. Ibs. (70 Nm). e Stabilizer bar link e Rear wheel 6. Torque the front spring eye bolt and nut to 115 ft. Ibs. (156 Nm). 7. Torque the rear spring eye bolt and nut to 80 ft. Ibs. (108 Nm). 8. Torque the stabilizer bar nuts 55 ft. lbs. (74 Nm).

Upper Ball Joint REMOVAL & INSTALLATION Except Liberty

REMOVAL & INSTALLATION Cherokee

1. Before servicing the vehicle, refer to the

precautions in the beginning ofthis section. 2. Support the vehicle at the frame rails. 3. Support the rear axle with a jack. 4. Remove or disconnect the following: e Rear wheel e Stabilizer bar link e Axle U-bolts e Spring bracket e Leaf spring

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Disc brake caliper and rotor e Wheel bearing e Axle shaft e Steering knuckle e Upper ball joint To install: 3. Install or connect the following: e Upper ball joint e Steering knuckle. Torque the nuts to 100 ft. Ibs. (135 Nm).

1 - SPRING COMPRESSOR 2 - SPRING 9355PG28

Front coil spring removal—Liberty 7907 J34503-3

Rear

EXCPET

LIBERTY

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheels e Stabilizer bar links

REMOVAL

INSTALLATION 7924PG26

Upper ball joint removal and installation

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

1 8-46 e e e e

JEEP

CHEROKEE e GRAND CHEROKEE ¢ LIBERTY eWRANGLER

Axle shaft Wheel bearing Disc brake caliper and rotor Front wheel

Liberty The upper ball joint is serviced as an assembly with the control arm. Lower Ball Joint

Upper Control Arm

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

Except Liberty

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Disc brake caliper and rotor e Wheel bearing e Axle shaft e Steering knuckle e Lower ball joint To install: 3. Install or connect the following:

~e

e Stabilizer link at the control arm e Lower ball joint nut ¢ Control arm from lower ball joint with tool C4150A 3. Installation is the reverse of removal. Torque the ball joint nut to 60 ft. Ibs. (81 Nm); the stabilizer link bolt to 100 ft. Ibs. (136 Nm); the lower clevis bracket bolt to 110 ft. Ibs. (150 Nm).

Lower ball joint e Steering knuckle. Torque the nuts to 100 ft. Ibs. (135 Nm). e Axle shaft e Wheel bearing e Disc brake caliper and rotor e Front wheel

Liberty 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Lower clevis bracket bolt from the control arm

EXCEPT LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle with a jackstand. 3. Unbolt and remove the upper control arm. To install: >The weight of the vehicle must be supported by the springs before tightening the control arm fasteners.

4. Install the control arms. 5. Torque the axle fastener to 55 ft. Ibs. (75 Nm) and the frame fastener to 66 ft. Ibs. (90 Nm).

LIBERTY-RIGHT

e Upper arm rear bolt e Upper arm front bolt e Upper arm 3. Installation is the reverse of removal. Observe the following torques: . e Front and rear bolts: 90 ft. Ibs. (122 Nm) ; e Ball joint stud nut: 60 ft. Ibs. (81 Nm)

LIBERTY-LEFT

SIDE

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Wheel Ball joint nut Ball joint from the knuckle Battery Power center Battery tray Battery temperature sensor Control arm rear bolt, by using a ratchet and extension under the steering shaft, positioned by the power steering reservoir e Control arm front bolt e Control arm 3. Installation is the reverse of removal. Observe the following torques: e Front and rear bolts: 90 ft. Ibs. (122 Nm) e Ball joint stud nut: 60 ft. Ibs. (81 Nm) Rear

SIDE

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Wheel e Upper ball joint nut e Upper Ball joint from the knuckle e Air box e Cruise control servo mounting nuts

EXCEPT LIBERTY AND 1999-02 GRAND CHEROKEE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle with a jackstand. 3. Remove or disconnect the following: e Parking brake cable and bracket ¢ Wheel speed sensor wiring bracket, if equipped e Upper control arm To install: ~The weight of the vehicle must be supported by the springs before tightening the control arm fasteners.

4. Install or connect the following: e Upper control arm e Wheel speed sensor wiring bracket, if equipped e Parking brake cable and bracket 5. Torque the control arm fasteners to 55 ft. Ibs. (75 Nm).

SPECIAL TOOL 7910 J95 19-1

1999-02 GRAND CHEROKEE REMOVAL

INSTALLATION 7924PG27

Lower ball joint removal and installation

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle with a jackstand. 3. Remove or disconnect the following:

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|

2

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ee

a7

.

“ay

e Parking brake cable brackets e Brake hose brackets © Axle ball joint e Upper control arm To install: >Use a new axle ball joint nut.

4. Install or connect the following:

e Upper control arm. Torque the frame bracket bolts to 74 ft. Ibs. (100 Nm) and the axle ball joint nut to 105 ft. Ibs. (142 Nm). e Brake hose brackets _ «© Parking brake cable brackets

LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle with a jackstand. 3. Remove or disconnect the following: e Ball joint pinch bolt from the top of the differential housing bracket. e Heat shield nuts and lower the shield e Upper arm-to-body bolts and arm 4. Installation is the reverse of removal. Observe the following torques:

e Upper arm mounting bolts: 74 ft.

lbs. (100 Nm) e Pinch bolt: 70 ft. Ibs. (95 Nm)

CONTROL ARM BUSHING REPLACEMENT The upper control arm bushings are serviced with the control arms as complete assemblies, with the exception of the front upper axle bushing, which may be replaced after removing the upper control arm.

Front Upper Control Arm Axle Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the upper control arm. 3. Press the old bushing out of the axle housing. 4. Press the new bushing into the axle housing. 5. Install the upper control arm.

Lower Control Arms

REMOVAL & INSTALLATION Front

EXCEPT LIBERTY 1. Before servicing the vehicle, refer tothe precautions in the beginning of this section.

|

JEEP

CHEROKEE ¢ GRAND CHEROKEE e LIBERTY e WRANGLER

2. Support the axle with a jackstand. 3. Remove or disconnect the following: e Wheel speed sensor wiring, if equipped e Lower control arm To install:

->The weight of the vehicle must be supported by the springs before tightening the control arm fasteners.

4. Install or connect the following: e Lower control arm e Wheel speed sensor wiring, if equipped 5. Tighten the control arm bolts to the following specifications: e Wrangler and 1998 Grand Cherokee: Axle fastener to 85 ft. Ibs. (115 Nm) and frame bracket fastener to

130 ft. Ibs. (176 Nm). Cherokee: Both fasteners to 86 ft. lbs. (115 Nm). 1999-02 Grand Cherokee: Frame bracket bolt to 115 ft. Ibs. (156 Nm) and axle bracket nut to 120 ft. lbs. (163 Nm),

LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Lower clevis bracket bolt from the control arm Stabilizer link at the control arm Lower ball joint nut Control arm from lower ball joint with tool C4150A

40_A° 1 8-47

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle with a jackstand. 3. On the Liberty, disconnect the stabilizer bar from the arm. 4. Unbolt and remove the lower control arm. e>On the Liberty’s right arm, it will be necessary to pry the exhaust pipe slightly to get to the frame rail-to-arm bolt. To install: ~The weight of the vehicle must be supported by the springs before tightening the control arm fasteners.

5. Install the lower control arm. 6. Tighten the lower control arm fasteners to the following specifications: e Wrangler and 1998 Grand Cherokee: Both fasteners to 130 ft. Ibs.

(177 Nm) e Liberty: Both fasteners to 120 ft. lbs. (163 Nm) e 1999-02 Grand Cherokee: Frame bracket nut to 115 ft. Ibs. (156 Nm) and axle bracket nut to 120 ff. Ibs. (163 Nm)

CONTROL ARM BUSHING REPLACEMENT The lower contro! arm bushings are serviced with the control arms as complete assemblies.

Front Wheel Bearings

e>Matchmark the front and rear control

arm pivot bolts.

e Front pivot bolt e Rear pivot bolt e Control arm To install: 3. Install or connect the following: e Lower control arm e Rear pivot bolt e Front pivot bolt e Ball joint nut. Torque the ball joint nut to 60 ft. Ibs. (81 Nm) 4. Align the matchmarks and tighten the pivot bolts to 125 ft. Ibs. (170 Nm). 5. The remainder of the installation is the reverse of removal. Torque the stabilizer link bolt to 100 ft. Ibs. (136 Nm); the lower clevis bracket bolt to 110 ft. Ibs. (150 Nm).

ADJUSTMENT 2-Wheel Drive

EXCEPT LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel, grease cap, cotter pin and nut cap e Wheel bearing nut, loosen it 3. While turning the rotor, tighten the nut to 25 ft. Ibs. (34 Nm) to seat the bearings. 4. Back the nut off % turn. 5. While turning the rotor, tighten the

nut to 19 inch Ibs. (2 Nm).

be,

1 8-48

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9 ooo ae

ee

ee

JEEP

CHEROKEE e GRAND CHEROKEE ¢ LIBERTY e WRANGLER

6. Install or connect the following: e Nut cap, new cotter pin and the grease cap e Wheel

THRUST WASHER

NUT RETAINER

696)

4-WHEEL DRIVE AND ALL LIBERTY MODELS The front wheel bearings are not adjustable.

REMOVAL & INSTALLATION

GREASE SEAL

OUTER AOJUSTMENT WHEEL NUT BEARING

INNER WHEEL BEARING

COTTER PIN

DUST CAP

2WD Models 7924PG28

EXCEPT LIBERTY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Brake caliper Grease cap Split pin Nut retainer Nut and washer Outer bearing Brake rotor and hub assembly Grease seal Inner bearing To install: e>Use new grease seals and split pins.

3. Pack the wheel bearings and the inside of the hub with high temperature wheel bearing grease. Add grease to the

Exploded view of the front wheel bearings—2WD models

hub until it is flush with the inside diameter

of the bearing cup. 4. Install or connect the following: Inner bearing Grease seal Brake rotor and hub assembly Outer bearing Nut and washer Nut retainer Split pin Grease cap Brake caliper Front wheel

4WD MODELS AND ALL LIBERTY MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. BRAKE

2. Remove or disconnect the following: e Front wheel e Brake caliper and rotor e Wheel speed sensor and bracket e Axle stub shaft nut (except 2-WD Liberty) e Hub and wheel bearing assembly To install: 3. Install or connect the following: e Hub assembly over the axle stub shaft. Tighten the hub bolts to 765 ft. lbs. (102 Nm) except Liberty; 96 ft. lbs. (130 Nm) for Liberty models e Axle stub shaft nut. Torque the nut to 175 ft. Ibs. (237 Nm) except Liberty; 100 ft. Ibs. (136 Nm) for 4WD Liberty models e Brake caliper and rotor e Front wheel WASHER

COTTER PIN

TONE WHEEL

(ABS)

BOLT

ASSEMBLY

NUT 7924PG29

Exploded view of the hub assembly—4WD models

as

-_

1998-00 Sportage DRIVE TRAIN........00000000.. 19-15 ENGINE REPAIR ................ 19-2

Fuel PUM oeececcccccccceeeen 19-18 Removal & Installation... 19-13

FUEL SYSTEM ................ 19-13

Fuel System Pressure uu... 19-13

STEERING AND SUSPENSION..............+.. 19-23"

Fuel System Service ‘Precautions. eee

19-13

s SMOCK ADSOTDEL .....sssaeesrssenee 19-24

IAL

HalfShalt > ane tote neieenigeeah19-20

Spindle Bearings .......--ssseseesse 19-22

"giRemoval tis nitenit 6:45 19). Jou 19-2 Axle Shaft Bearing and Seal.........19-22

Ignition Timing .......scssssseessssene 19-2 AdjustMentacc sa gitienn snes 19-2

Transfer Case Assembly............ 19-18 Removal & Installation........... 19-18

C Wem eaigilay cine (ir19-9

Removal & Installation......0..0.... 19-7

Removal & mur bainits 19-15

PRECAUTIONS.................. 19-2 A

gatas acdc

tela Grea,

[Aili aaa latereie Maeatead 19-23 D ISAT UNG etch vris nsidivdan 19-23 Precauthons ctucriniscssvle.csazre 19-23

Altemator nchnacemans: oat waldanes 19-2

Removal & Installation............ qqu92)

Garnishattian:

Rel faving. oboe aageole Ben i 19-13 H

Removal & Installation........... 19-20 Removal & Installation............ 19-22 Hydraulic Clutch System............. DOG] BagtosOLANED as cpastnrceytstele Bets 19-10 Bleeding............ peer 19-18 Removal & Installation............ 19-10

Antake Manifoldesings). mats winees 19-7 _ Transmission Assembly............. 19-15

Removal & Installation............. 49:9)“.

Locking Hibsinninn ian iin 19-20

"AFUSt MEN. c-cesesveesscceee qo772

Lower Ball Voit Peo

Clutch teenie errFup yor" Ory19-17

Removal & Installation.......... 19-20

Upper Ball Joint.......... ieee

ae 19-26

Removal & Installation........... 19-26

19-26

-Upper Control APM... 19-27

Removal & Installation............ 19217

Removal & Installation............ 19-26

Removal & Installation... Pate 19-27

anit eticvite weigh ¢aol aaah19-25

Lower Control APM ....seseeessssseeseee: 19-27

Gylinder Head eis..cccs-tewetssssseossss.- 19-5

ReplaceMent.......ssssssssssseseees 19-27

Removal & Installation... 19-25

Removal & instalationhh ae 19-5

Enaine ASSOEMDIV

Lower Control Arm Bushing

Removal & mnelaation ihonneae 19-27

.....cccccccecceececeeeaee 19-3

OWE Fieilhecs.

cellofebeldenees sseeninnenenen 19-10

Exhaust Manifold .-cccccssccccccccccsscsse Foe

CPM

Fa ae. NAR: 19-11

Eaton’ reclaton

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19-3

Rap

Front Crankshaft Seal scccccccccccccce 49:98 "Removal & Installation... 19-9

Tal liye tere Boca

19-13

Removal & Installation........... 19-13

Fuel IMjSCtOr...e.nsseseeeasesnsetesseoss 19-14 Removal & Installation........... 19-14

oes

Removal & Installation............ 19-24

Removal & Installation..........19-10

SON Fe

Upper Control Arm Bushing

TREE wagasic bre 19-27

valve natant

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bint ona pallor 19-10

adiistnenan see

19-10

Piston and Ring... ose secessesne 19-12

POSITIONING «.....-sssesssesseseereee 1Oet2

Power Steering Gear... 19-23 Adjustment............. setntarate hdrea

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SPinion:Seal.....iod. Margi. 19-23 Removal & Installation............ 19-23

ell

Removal & Installation............ 19-28

nist OT oiat at*

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19-2

CHORE

"PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from thesteam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. : e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are. pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will.reduce the motion of the module if it is accidentally deployed. Refer tothe additional air bag system precautions later in this section. e Clean, high quality brake fluid from a sealed container is essential to the safe and

ENGINE REPAIR Alternator

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: Negative battery cable Air cleaner inlet pipe front bolts Top hose from the resonance chamber Air cleaner inlet pipe Alternator electrical connectors Loosen the pivot and tensioner mounting bolts, do mot remove them Drive belt from the alternator pulley

e Drive belt tensioner e Alternator pivot bolt e Loosen the bolt at the base of the adjusting bracket and rotate the bracket up e Alternator To install: 3. Install or connect the following: Alternator e Pivot bolt and hand tighten e Rotate the bracket down on top of the alternator Belt tensioner on the adjustment bracket Tensioner mounting bolt and hand tighten it Drive belt Torque the tensioner bolt to 19 ft. lbs. (26 Nm).

|

:

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. Ifthe brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. ° Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected, e When servicing drum brakes, only disassemble and assemble one side ata time, leaving the remaining side intact for reference.

¢ Only an MVAC-trained, EPA-certified automotive technician should service the A/C system or its components.

; Torque the pivot bolt to 38 ft: Ibs. (51 Nm). Alternator electrical connectors Air cleaner inlet pipe and tighten the clamp Hose to the resonance chamber Air inlet pipe bolts and tighten, Negative battery cable

Ignition Timing ADJUSTMENT The 2.0L engine in the Sportage is equipped with a distributorless ignition system. The ignition timing is controlled by the Powertrain Control Module (PCM) through the inputofengine control system sensors. The ignition timing is set at 4 degrees

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SPORTAGE

19-3 la

BTDC fornVvehicles5 equipped with eC th manual manuc or automatic transmissions. The ignition timing cannot be adjusted. pec tale em a sie

Engine Assembly

2.. Pro Properly relieve the fuel system pressure. b ot vad the cooling system. 4. Drain the engine oil.

top of the radiator.

cat at the Ant Resin and remove the duct ¢ Accelerator cable by pulling the

: pea the transmission fluid. .

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec‘ne

throttle back and rotatingthecable until it aligns with the slot in the

Remove or disconnect the following:

° Both battery cables

pulley

e Windshield washer hose from the

e Transmission control cable

: ae

* Resonance chamber mounting bolt,

¢ 2 air duct mounting bolts from the

oe(IAC) mil e Tame Idle Air Control air hose,

14 — 22 ft-lb (19 — 30 Nem)

47 — 66 ft-lb (64 — 89 Nem)

an

9 — 13 ft-lb (12-18Nem

)

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25 — 33 ft-lb (34 - 44 Nem)

14 — 22 ft-lb (19 - 30 Nem)

22 — 29 ft-lb (29 — 39 Nem) 27 — 46 ft-lb

25 — 36 ft-lb

(38 ashen

(34 - 49 Nem)

14 — 22 ft-lb (19 -30 Nem) 1. 2.

Oil Level Gauge Thermo-Modulated Fan Bracket

3. 4. 5. 6.

EGR Pipe Exhaust Manifold Heat Shield Exhaust Manifold Coolant Inlet Pipe and Bypass Pipe

7. 8. 9. 10. 11. 12.

Engine Hanger Generator Generator Strap and Bracket Intake Manifold Assembly Intake Manifold Support Bracket Oil Filter

13. 14.

Oil Cooler Oil Pressure Switch

79240G36

Exploded view of some peripheral engine component mountings

For complete service labor times, order the Chilton Labor Guide

19-4

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ee

SPORTAGE

breather hose and vacuum line from the air intake tube Manifold Air Flow (MAF) sensor connector Loosen the air inlet hose clamp from the MAF sensor 3 bolts from the air intake tube to the throttle body Air intake hose and tube as an assembly Upper radiator hose Clutch fan nuts Cooling fan shroud bolts Fan and shroud at the same time Alternator drive belt Fan pulley Alternator electrical connectors Exhaust Gas Recirculation (EGR) solenoid valve connector on the intake manifold in front of the dynamic chamber Both heater hoses from the pipes Engine-to-body ground wire from the intake manifold and the harness bracket Brake booster vacuum hose from the dynamic chamber Fuel lines and fuel pressure regulator from the rear of the dynamic chamber Vacuum hose from the bottom of the EGR valve Purge solenoid valve vacuum hose from dynamic chamber Vacuum hoses from the top of the charcoal canister and slide the charcoal canister up and out of the bracket Lower radiator hose Cooling lines from the radiator, if equipped with an automatic transmission Radiator and raise and safely support the vehicle Lower splash panel Drive belt A/C pulley assembly A/C compressor mounting bolts and move the A/C compressor out of the way Power steering drive belt ntake manifold support bracket Starter wiring harness Starter Front exhaust pipe from the exhaust manifold Bracket bolt from the front exhaust DIpe Exhaust-to-clutch (manual transmission) or converter (automatic transmission) housing bolts and the bracket

e Clutch housing (manual transmission) or converter (automatic trans-

mission) housing bolts.. e Drive plate-to-torque converter bolts, if equipped 7. Support the transmission from underneath the vehicle. 8. Connect the engine hoist to the engine assembly. e Left and right side engine mounting bolts 9. Lift the engine up and forward slightly to provide access to three electrical connectors on the rear of the cylinder head. e Electrical connectors from the Camshaft Position (CMP) sensor, coil and condenser on the rear of the cylinder head e Engine from the vehicle To install: 10. Lower the engine enough to connect the three electrical connectors to the CMP sensor, coil and condenser on the rear of the cylinder head. 11. Position the engine to the transmission. Install the transmission bolts and tighten

the bolts. Torque according to bolt size: e e ¢ e

14mm bolts to 80 ft. Ibs. (108 Nm) 10mm bolts to 28 ft. Ibs. (38 Nm) 6mm bolts to 60 inch Ibs. (7 Nm) Right and left side engine mounting bolts. Torque the bolt s to 38 ft. lbs. (52 Nm). 12. Disconnect the engine hoist from the engine assembly. 13. Raise and safely support the vehicle. Drive plate-to-torque converter bolts, if equipped. Connect the front exhaust pipe to the exhaust manifold. Torque the flange bolts to 24 ft. Ibs. (31 Nm). Front exhaust pipe. Torque the bolts to 20 ft. Ibs. (27 Nm). e Starter Connect the starter wiring harness Intake manifold support bracket bolts and the bracket. 14. Install the power steering pump lock and mounting bolts. Install the power steering drive belt. Torque the bolts to 30 ft. Ibs. (42 Nm). A/C compressor mounting bolts. Torque the bolts to 18 ft. Ibs. (24 Nm). A/C belt pulley assembly and drive belt. Install the two A/C idler pulley bracket bolts and torque to 24 ft. lbs. (32 Nm). Lower splash panel Radiator Cooling lines to the radiator, if equipped

Lower radiator hose Slide the charcoal canister in the bracket : Vacuum hoses to the top of the charcoal canister Engine-to-body ground wire to the intake manifold and the harness . bracket Brake booster vacuum hose to the dynamic chamber . Fuel lines and fuel pressure regulator to the rear of the dynamic chamber Vacuum hose to the bottom of the EGR valve Purge solenoid valve vacuum hose to dynamic chamber EGR solenoid valve connector on

the intake manifold in front of the dynamic chamber e Heater hoses Electrical terminal connectors to the alternator Fan pulley Alternator drive belt. Torque the adjusting bolt 16 ft. Ibs. (22 Nm) and the mounting bolt to 32 ft. Ibs. (45 Nm). Fan and shroud as an assembly. Torque the five cooling fan shroud bolts to 72 inch Ibs. (8 Nm) Clutch fan nuts. Torque the nuts to 27 ft. Ibs. (37 Nm). Upper radiator hose Air intake hose and tube as an assembly Air intake tube to the throttle body and tighten the air inlet hose clamp to the MAF sensor MAF sensor electrical connector Resonance chamber mounting bolt, chamber bolt and air silencer IAC air hose, breather hose and vacuum line to the air intake tube Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley Transmission control cable Air duct mounting bolts to the top of the radiator. Torque the clamp at the air intake housing Hood Windshield washer hose to the hood 15. Fill the engine with clean engine oil. 16. Connect the battery cables. 17. Fill the cooling system. 18. Fill the transmission fluid. 19. Recharge the A/C system. 20. Start the vehicle. Check for leaks, repair if necessary.

a A

21. Road test the vehicle to check engine performance.

Water Pump

e Water pump e Tensioners from the water pump To install:

|

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Lower splash shield Upper and lower radiator hoses

Coolant reservoir tank hose Fresh air duct Fan and shroud Loosen the alternator mounting and adjusting bolts Alternator belt Fan pulley and bracket Upper and lower timing belt covers and turn the crankshaft until No. 1 cylinder is at, Top Dead Center (TDC). ; Loosen the tensioner lockbolt and pry the tensioner away from the belt Timing belt e Loosen the tensioner bolt

4. Clean the surface of any old gasket material. 5. Install or connect the following: Tensioners on the water pump Water pump and gasket. Torque the bolts to 19 ft. Ibs. 25 Nm). Timing belt . Loosen the tensioner lockbolt and allow the tensioner to rest against the belt. Torque the tensioner lockbolt to 32 ft. Ibs. (43 Nm). Upper and lower timing belt covers Fan bracket assembly and fan pulley Drive belt Cooling fan and shroud Position the radiator and torque the bracket bolts to 89 inch Ibs. (10 Nm). Torque the shroud bolts to 89 inch lbs. (10 Nm) and torque the alternator adjusting and mounting bolts Position the fresh air duct over the radiator and tighten the retaining bolt 89 inch Ibs. (10 Nm) Radiator hoses and tighten the clamps Lower splash shield

32 Ib-ft (45 Nem) 1 TIMING BELT COVERS, GASKETS AND TIMING BELT | 2 IDLER PULLEY Exploded view of the water pump mounting

3 4

COOLANT PUMP GASKET 79240G01

SPORTAGE

=.

4

Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and bring the engine to operating temperature. Check for leaks _and repair if necessary.

Cylinder Head REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Properly relieve the fuel system presSUTE.

3. Drain the cooling system. 4, Remove or disconnect the following: Negative battery cable Brake booster vacuum hose from the dynamic chamber Fuel line from the pressure regulator and the return line from the rear of the dynamic chamber Ground wire from the intake manifold Purge solenoid valve vacuum hose Upper radiator hose Intake manifold support bracket Converter flange inlet pipe Timing belt Cylinder head cover Cylinder head with the intake and exhaust manifolds attached 3 wire harness connectors at the rear of the cylinder head To install: 5. Place the new head gasket on the engine block. 6. Install or connect the following: Cylinder head with the intake and exhaust manifolds attached 3 wiring connectors at the rear of the cylinder head Cylinder head bolts in the proper sequence. Torque the bolts to 64 ft. lbs. (87 Nm). Cylinder head cover Timing belt Converter inlet pipe flange nuts. Torque the nuts to 24 ft. Ibs. (33 Nm). Upper radiator hose Vacuum hose from the intake manifold to the charcoal canister Purge solenoid vacuum hose Ground wire and harness bracket to the intake manifold. Torque the bolts to 18 ft. Ibs. (25 Nm).

Please visit our web site at www.chiltonsonline.com

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1 9-6

MOORTARE

60 in-Ib

(6.8 Nem)

-

in-Ib | 35(4-6— 52Nem)

13 - 20 ft-lb

(18 — 26Nem) —#

cS

.

fc

72 — 108 in-Ib

@

59 - 64 ft-lb (80 - 86 Nem)

35 — 52 in-Ib

Sea

(4-6 Nem)

1. 2. 3.

Ignition Coils and High Tension Leads Cylinder Head Cover Camshaft Position Sensor

7. Hydraulic Lash Adjuster 8. Cylinder Head Bolt 9. Cylinder Head

|

|

,

13. 14. 15.

Outer Valve Spting Inner Valve Spring Lower Spring Seat

10.

Cylinder Head Gasket

16.

Valve

4. Seal Plate

11.

Valve Locks

17.

Valve Stem Seal

5.

Camshaft Caps

12.

Upper Spring Seat

18.

Valve Guide

6.

Camshafts 79240637

Exploded view of the cylinder head assembly

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19- he

¢ Negative battery cable Accelerator cable bracket bolts Hoi the valve cover Air intake tube to cylinder head cover bolts Air intake tube to throttle body bolts Loosen the clamp attaching the air tube to the Mass Air Flow (MAF) sensor Idle Air Control (IAC) valve, breather hose and vacuum line from the air intake tube Air intake tube Positive Crankcase Ventilation hose (PCV) from the dynamic chamber Purge solenoid valve vacuum hose from the dynamic chamber Throttle Position (TP) sensor electrical connector IAC valve electrical connector Heater hoses Engine-to-body ground strap from the intake manifold and the harness bracket below it Brake booster vacuum line Vacuum hose from the fuel pressure regulator hose Dynamic chamber support bracket bolts Fuel injector electrical connectors Fuel pressure and return lines Intake manifold support bracket Oil filter Intake manifold bolts Bypass pipe from the heater hose Intake manifold and discard the gasket

79240604

Cylinder head torque sequence—Kia Sportage

e Fuel line to the pressure regulator and the return line to the fuel rail e Brake booster vacuum hose e Negative battery cable 7. Properly fill the cooling system. 8. Start the engine and check for leaks, repair if necessary.

Intake Manifold

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer tothe

precautions in the beginning of this section . Properly relieve the fuel system presa

' 3.; Drain the coolant. 4 Remove or disconnect the following:

Hoses Rn

aie

eee (aca 79240QG12

Intake manifold mounting bolt locations. Be sure to connect the ground cable

Timing belt service is covered in Section 3 of this manual

19-8

KIA

SPORTAGE

To install:

5. Install or connect the following: e Intake manifold with a new gasket to the cylinder head e Heater hose to the bypass pipe e Bolts and nuts attaching the intake manifold to the cylinder head. Torque the bolts to 14-22 ft. Ibs.

Torque the bolts to 18 ft. Ibs. (25 Nm). Purge solenoid valve vacuum hose to the dynamic chamber Vacuum hose to the fuel pressure regulator Coolant hoses to the throttle body

e Intake manifold support bracket. Torque the bolts to 27-38 ft. Ibs. (37-52 Nm)

IAC valve electrical connector Brake booster vacuum hose Heater hoses TP sensor electrical connector Air intake tube and hose to the throttle body. Torque the bolts to 16

e Fuel lines Fuel injector electrical connectors

ft. Ibs. (22 Nm). PCV hose to the dynamic cham-

(19-30 Nm). e New oil filter

Engine to body ground wire. Torque the bolt to 18 ft. Ibs. (25 Nm). Dynamic chamber support bracket.

Oil Level Gauge Thermo-Modulated Fan Bracket Exhaust Manifold Heat Shield Exhaust Manifold

ON ee Coolant Inlet Pipe and Bypass Pipe

ber Accelerator cable to the throttle body pulley

e Accelerator cable bracket. Torque the bolts to 10 ft. Ibs. (15 Nm). e Air intake hose to the MAF sensor e Resonance chamber IAC hose, breather hose and vacuum line to the intake manifold e Negative battery cable 6. Properly fill the cooling system. 7. Start the engine and check for leaks, repair if necessary.

Exhaust Manifold REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section .

6. Engine Hanger 7. Generator 8. Generator Strap and Bracket 9 Intake Manifold Assembly 10. 0 Intake Support Bracket

Exploded view of the intake, exhaust manifold and related components

11. 12.

Oil Filter Oil Cooler

13.

Oil Pressure Switch

93080601

spore 19-9

Oil Seal Exhaust Manifold Heat Shield

79240614

Exploded view of the exhaust manifold assembly

2. Remove or disconnect the following: Negative battery cable Air intake hose Exhaust manifold heat shield Converter inlet pipe flange locknuts

Exhaust manifold and discard the

gasket 3. Clean the mating surfaces. To install:

93080604

Install the oil seal into the oil pump housing

4. Install or connect the following:

4. Installorconnect the following.

A

isesau:

is flush with the edge ofTEE the oil Set

e Exhaust manifold with a new gas-

‘3at oe bolts to 31 ft Ibs:

ann

converter inlet . pipe. Torque the

Jimi oes bn Et Pulley woodruff key

e Exhaust manifold heat shield. Torque the bolts to 18 ft. Ibs. (25

18 ft. Ibs. (25 Nm) Timing belt

bolts to 24 ft. Ibs. (33 Nm).

Nm).

Pulley lock bolt. Torque the bolt to

Pa

¢ Negative battery cable 5. Start the vehicle and check for leaks,

stag ena i m4oe

° Negative battery cl

5. Start the engine and check for leaks, a Fepairif necessary.

Canstat

1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Properly relieve the fuel system pres-

sure. dtiebs

He

8. Drain the coolant into a suitable con-

tainer.

repair if necessary.

Front Crankshaft Seal

Fi

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: e Negative battery cable e Engine under cover e Timing belt Timing belt pulley lock bolt Timing belt pulley Pulley woodruff key Oil seal by carefully cutting it out of the oil pump housing To install: 3. Lubricate the lip of the new seal with clean engine oil.

ie

REMOVAL & INSTALLATION

pUFOP POR}

e New flange gasket and install the

e Air intake hose

Is

. |

oN Camshaft cap bolt removal sequence

Heater Core replacement is covered in Section 2 of this manual

19-10 Brice )

,

e

Starter electrical connectors Lower intake manifold bracket and install the upper bolts Starter into position. When aligned properly torque the bolts to 40 ft. lbs. (54 Nm). Torque the intake manifold bracket bolts to 40 ft. Ibs. (64 Nm). Properly position the clutch release cylinder, if equipped. Torque the bolts to 40 ft. Ibs. (64 Nm). Torque the intake manifold bracket upper bolts to 40 ft. Ibs. (54 Nm).

e Negative battery cable

REMOVAL & INSTALLATION 79240G16

Camshaft journal bolt tightening sequence

4. Remove or disconnect the following: Negative battery cable Upper timing belt cover Timing belt from the camshaft pulley Camshaft pulleys Camshaft cap bolts in the proper sequence Camshaft caps e Camshafts To install: 5. Install or connect the following: Camshafts into the cylinder head. The exhaust camshaft has a steel dowel pin at the rear for the camshaft position sensor Clean engine oil to the journals and bearings Camshaft oil seal Silicone sealant to the front camshaft cap and the camshaft position sensor mounting cap Camshaft caps in the proper sequence. Torque the bolts in three Steps to 20 ft. Ibs. (26 Nm). Camshaft pulleys Timing belt Timing belt cover Negative battery cable

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e |ntake manifold bracket upper bolts e Clutch release cylinder and move it aside, if equipped Intake manifold bracket lower bolts and remove the bracket Starter from the clutch, manual transmissions only Starter from the torque converter, automatic transmissions-only Starter electrical connectors Move the transmission wire harness aside Starter To install: 4. Install or connect the following: e Starter to the engine well

Valve Lash

ADJUSTMENT The DOHC engine uses Hydraulic Lash Adjusters (HLA’s), which automatically maintain the proper amount of valve lash. Therefore, the DOHC engine does not need manual valve lash adjustment.

93080G02

Exploded view of the starter

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable 2 Top intake manifold bracket bolts Front 3 axle housing mounting ‘bolts, 4WD only Left front bushing from the axle housing mount and lower the front axle housing Both gusset plates from the engine Transmission under cover Engine under cover Oil pan mounting bolts and using a scrapper tool separate the oil pan e Qil pan e (il strainer assembly e Oil baffle To install: 4. Clean the engine block, oil pan and baffle pan surfaces of any gasket material. 5. Apply a continuous bead of Loctite Ultra Blue 587° silicone sealant around the baffle pan. 6. Install or connect the following: e Oil baffle. Torque the bolt to 84 inch Ibs., (9.5 Nm). e Oil strainer. Torque the bolts to 84 inch Ibs. (9.5 Nm). 7. Apply a continuous bead of Loctite Ultra Blue 587° silicone sealant around the oil pan. ¢ Oil pan. Torque the bolts to 84 inch lbs. (9.5 Nm). e Transmission under cover. Torque the bolts to 84 inch Ibs. (9.5 Nm). Gusset plates to the engine. Torque the bolts to 33 ft. Ibs. (45 Nm). e Engine under cover e Front axle housing into position.

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KIA 19

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SPORTAGE

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2. Properly relieve the fuel system pressure, 3. Drain the engine oil. 4. Drain the cooling system. 5. Remove or disconnect the following: Negative battery cable Alternator belt Fresh air duct from the radiator Upper radiator hose Clutch fan and shroud Splash guard

Loosen the A/C drive belt

1 2

Power steering belt Timing belt covers Lower timing belt pulley and lock bolt and place a support under the front axle Axle attaching bolts and lower the axle enough to gain access to the oil pan

OIL BAFFLE OIL STRAINER

3 OIL PAN 4 DRAIN PLUG

Transmission under cover ¢ Oil pan

Aig 79240618

Oil pump

. Exploded view of the oil pan assembly mounting

To install:

6. Clean the engine block, oil pan and baffle pan surfaces of any gasket material. 7. Apply a continuous bead of silicone sealant around the oil pump. Do not allow sealant to get in the oil passages when applying sealant to the contact surface.

sane

i : ; preiaans Shyness pseguence

8. Install or connect the following: e New O-ring and mount the oil pump to the engine. Torque the “A bolts to 16 ft. Ibs. (22 Nm) and the “B” bolts to 33 ft. Ibs. (45 Nm). 9. Remove the upper and lower A/C compressor mounting bolts. 10. Loosen the A/C compressor bracket.

When properly aligned, torque the

O-RING

bolts to 48 ft. Ibs. (65 Nm). e |ntake manifold bracket bolts. Torque the bolts to 34 ft. Ibs. (65 Nm). e Negative battery cable 8. Fill the engine with clean oil. 9. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION ->The oil pump is externally-mounted, but still requires the removal of the oil pan to disconnect the oil pump strainer.

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

79240G19

Be sure the oil pump O-ring is in the proper location prior to installation

Brake service is covered in Section 4 of this manual

a

© 19-12 rnce Power steering pump bracket and hand tighten the bolts

.\

A/C compressor bracket

Drive Plate

A/C compressor. Torque the mounting bolts to 17 ft. Ibs. (23 Nm).

11. 12. 13. repair

Torque the power steering pump bracket bolts to 24 ft. Ibs. (33 Nm). Power steering pump. Torque the bolts to 43 ft. Ibs. (68 Nm). Timing belt gear on the crankshaft. Torque the large crank bolt to 119 ft. Ibs. (162 Nm). Oil baffle after applying sealant to the mating surface. Torque the bolt to 84 inch Ibs. (9.5 Nm). Oil strainer. Torque the bolts to 84 inch Ibs. (9.5 Nm). Oil pan Transmission under cover. Torque the bolts to 84 inch Ibs. (9.5 Nm). Both gusset plates. Torque the bolts to 33 ft. Ibs. (45 Nm). Raise the front axle into position. When aligned properly, torque the bolts to 123 ft. Ibs. (167 Nm). Timing belt and cover Alternator belt A/C and power steering belt and adjust as needed Splash shield Upper radiator hose Clutch fan and shroud as an assembly Air duct to the top of the radiator Engine under cover. Torque the bolts to 18 ft. Ibs. (25 Nm). Negative battery cable Properly fill the cooling system. Fill the engine with clean oil. Start the engine, check for leaks, and if necessary.

Adapt

(IO/

6-9 ft-lb (8 - 12 Nem)

e

| pre 3

f i fF

/

14 — 22 ft-lb (19 - 30 Nem)

§ Gag /

Rear Cover

i

71 — 76 ft-lb (96 — 103 Nem)

eS Clutch Cover (M/T)

e

16-24

M/T

ft-lb

(22 - 32 Nem) 79240G38

Exploded view of the rear main seal and related components

Rear Main Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Drain the transmission fluid. 3. Remove or disconnect the following: Negative battery cable Transmission Clutch cover and disc, if equipped Flywheel, if equipped Rear cover Rear main oil seal To install: 4. Coat the new seal with clean oil and press the seal into the cover. 5. Install or connect the following: Rear cover

Flywheel onto the crankshaft. While holding the flywheel torque the bolts in sequence: . Step 1: 30 ft. Ibs. (41 Nm). . Step 2: 60 ft. Ibs. (81 Nm). . Step 3: 73 ft. Ibs. (99 Nm). ee) eo Ce Clutch disc and cover. Torque the bolts to 16 ft. Ibs. (22 Nm). Transmission Negative battery cable 6. Fill the transmission to the proper level. 7. Start the vehicle and check for leaks, repair if necessary.

7924AG04

Piston and Ring POSITIONING

Kia 2.0L engine—compression ring positioning mark locations

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SPORTAGE SPACER TANG

:

UPPER RAIL

OIL RING UPPER RAIL

OIL RING

SPACER

LW) OIL RING SPACER ENDS

TOP RING

ce

OIL RING LOWER RAIL

LOWER

PISTON

Bae

SECOND RING

PISTON

7924AG06 7924AG05

Kia 2.0L engine—oil control ring rail and spacer positioning

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may resylt in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system presSure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.

Kia 2.0L engine—piston ring end-gap spacing

e Always use a back-up wrench when loosening and"tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

Fuel System Pressure RELIEVING

79240620

Fuel filter underhood mounting location

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the fuel pump harness connector located behind the rear seat. 3. Start the engine and allow the engine to run out of fuel. 4. Once the engine has stalled, turn the key to the OFF position and connect the electrical connector. 5. Disconnect the negative battery cable SO pressure cannot build up until work has been completed.

e Fuel hoses from the fuel filter e Fuel filter from the bracket To install: 4. Install or connect the following: Fuel filter in the bracket e Fuel filter. Torque the bolts to 95 ft. Ibs. (129 Nm). Fuel hoses on the filter and make certain that the hoses are seated properly e Fuel pump connector Negative battery cable 5. Start the engine and check for fuel leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: e Negative battery cable e Fuel pump connector

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Properly relieve the fuel system presSure. 3. Release the catch for the back seat and tilt the seat out of the way.

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

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e 2 halves of the fuel pump electrical connector : e Access plate and reposition the

¢ Fuel hose from the fuel pump e Fuel tank pressure sensor 6. Wrap the fuel pump assembly in a rag before removing the assembly from the vehicle. 7. Cover or seal the fuel tank until installing the fuel pump assembly. To install:

VA)

79240621

Removing the fuel pump through the access panel

4. Move the carpet behind the seat that covers the fuel pump access panel. 5. Remove or disconnect the following: e Negative battery cable e Fuel pump electrical connectors Bolt securing the ground wire Fuel pump access panel Hose clamps connecting the fuel hoses to the fuel pump Hoses from the fuel pump Screws securing the fuel pump to the fuel tank Gradually lift the fuel pump from the tank Plastic retaining bracket from the fuel pump assembly

» Fuel Injector

REMOVAL & INSTALLATION

>The fuel pump is part of the assembly and is replaced as a complete unit.

8. Install or connect the following: Plastic mounting bracket to the fuel pump and secure the bracket to the pump with 4 screws Fuel hose to the pump and secure with a new clamp Fuel pump into the access port on top of the fuel tank Twist the fuel pump as necessary to properly position it in the fuel tank 8 screws around the top surface of the fuel pump Fuel hoses to the pump and secure with clamps Fuel tank pressure sensor Fuel pressure sensor electrical connector Ground wire and fuel pump electrical connector

T EUEGBO@SE 2 RETAINING CLIP Sic -FUERPUME 79240G22

Exploded view of the fuel pump assembly

carpet at seat __e Negative battery cable

_

1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Air intake hose assembly Breather hoses from the air intake duct Mass Air Flow (MAF) sensor electrical connector Air intake hose bracket Accelerator cable Vacuum hose from the intake manifold to the vacuum pipe Throttle Position (TP) sensor and Idle Air Control (IAC) valve electrical connectors Coolant hoses from the throttle body Clamp and hoses from the IAC valve Brake booster vacuum hose from the dynamic chamber Cruise control vacuum hose, if equipped Bracket from the dynamic chamber Manifold bracket heater inlet hose Dynamic chamber Fuel hose from the pressure regulator Fuel injector rail clips Fuel rail Fuel injector insulators Pressure regulator Fuel injectors To install: 9. Install or connect the following: ¢ Fuel injectors to the fuel rail New insulators New injector clips Fuel rail Clamps and air hose to the fuel rail Fuel hose to the pressure regulator Dynamic chamber with a new gasket. Torque the bolts to 16 ft. Ibs. (22 Nm). IAC valve bracket bottom bolt

——

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* sorte 19-09 «

e IAC valve and TP sensor electrical connectors e Heater inlet hose © Cruise control hose, if equipped e Vacuum hose to the pressure regulator e Air hose and clamp to the air rail

IAC valve vacuum hose Manifold bracket bolts Coolant hoses to the throttle body Vacuum hose to the vacuum pipe MAF sensor bracket MAF sensor electrical connector

e Accelerator cable e Breather hoses e Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair if necessary.

DRIVE TRAIN Transmission Assembly

REMOVAL & INSTALLATION

->The removal of the manual transmis-

sion is virtually the same for 4WD and 2WD vehicles.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Drain the transmission fluid. 3. Drain the transfer case. 4. Remove or disconnect the following: Negative battery cable Rear portion of the center console Shift lever and transfer lever knobs Slide the boot cover over the shifters and remove the center console Shift lever Transfer lever Front driveshaft by removing the bolts at the front differential and the bolts at the transfer case, if equipped Bolts from the rear differential flange and the center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4 x 4 Bolts from the rear differential flange and center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4 x 2 Back-up light electrical connector and the Vehicle Speed Sensor (VSS) electrical connectors and move the wire harness aside Crankshaft Position (CKP) sensor from the transmission housing Clutch release cylinder and move it aside Front exhaust pipe bracket Front lower transmission housing bolts

Transfer case side mount, if equipped and properly support the transmission Transmission crossmember transmission mount bolts Starter from the front housing Transmission and transfer case, if equipped To install: 5. Install or connect the following: Transmission into position at the

rear of the engine

Wire harness along the right side of the transmission and route the VSS wire over the transmission to the rear of the control rod extension Transmission to engine 14mm mounting bolts. Torque the bolts to 80 ft. Ibs. (108 Nm). Transmission to engine 10mm mounting bolts. Torque the bolts to 29 ft. Ibs. (39 Nm). Transmission to engine 6mm mounting bolts. Torque the bolts to 5 ft. Ibs. (7 Nm). Exhaust pipe to the bracket. Torque the bolts to 20 ft. Ibs. (27 Nm). Starter and ground wire. Torque the bolts to 29 ft. Ibs. (39 Nm). Transmission crossmember mount. Torque the bolts to 80 ft. Ibs. (108 Nm). Crossmember to the chassis. Torque the bolts to 32 ft. Ibs. (44 Nm). CKP sensor. Torque the bolt to 5 ft. lbs. (7 Nm). . AWD indicator switch connector Back-up light electrical connector VSS electrical connector Clutch release cylinder. Torque the bolts to 29 ft. Ibs. (89 Nm). Driveshaft to the rear differential flange, 4 x 4 only Forward end of the driveshaft into the extension housing and attach the center support to the chassis Shaft to the rear differential flange.

Torque the bolts to 27 ft. Ibs. (36 Nm). Front driveshaft at the transfer case and install the bolts to the front differential, 4 x 4 only Transfer case side mount, if equipped. Torque the bolts to 38 ft. Ibs. (52 Nm). Transfer case side mount to the chassis. Torque the bolts to 38 ft. lbs. (52 Nm). Shift lever assembly. Torque the shift lever bracket bolts to 18 ft. lbs. (25 Nm). Transfer lever assembly, if equipped. Torque the bolts to 18 ft. lbs. (25 Nm). Dust cover plate over the shifter lever handles. Torque the bolts to 15 ft. Ibs. (20 Nm). Front console Shifter lever knobs Negative battery cable Fill the transfer case. 6. Fill the transmission assembly. 7. Start the vehicle and check for leaks, repair if necessary. Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Drain the transmission fluid. 3. Drain the cooling system. 4, Remove or disconnect the following: e Negative battery cable e Automatic transmission control cable from the throttle body 5. Slide the front seats forward and remove the 2 rear shift console mounting screws and set the parking brake. e Rear console and slide the front seats rearward e Front console mounting screws and untie the shifter boot draw strings e Loosen the transfer case lock nut and remove the transfer case shifter lever knob

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

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:

19-1 6 SPORTAGE Power/economy switch electrical connector Front console and shift the transfer lever to the 4L position Transfer shift lever cover plate Transfer case shift lever assembly

Radiator Side

and place the transmission in the park position Selector lever nuts Split pin from the shift selector lever Shift selector rod and spring washers Electrical connectors from the base of the selector lever _ >There is a fifth wire connection (Park Position). This wire is hard-wired, do not disconnect it.

Oil Cooler Connections

Selector lever assembly Control cable from the throttle linkage and slide the cable from the bellcrank Upper dipstick tube from the lower dipstick tube Input/Turbine speed sensor from the top rear of the transmission Shift solenoids from the lower left side of the transmission Vehicle Speed Sensor (VSS) from the center of the transfer case Input speed sensor electrical connectors Matchmark the front and rear driveshafts. Remove the attaching bolts from both flanges and remove the driveshafts Oil cooler pipes at the transmission Starter Transfer case mounting bolts Transfer case nuts from the cross-

Passenger Side 79240G24

Exploded view of the oil cooler pipe connections

member and support the transmission

Crossmember Transmission to engine mounting bolts Front lower splash shield Left side lower gusset Torque converter inspection cover Torque converter to drive plate bolts Slide the transmission away from the engine and lower the transmission slightly Crankshaft Position (CKP) sensor attaching bolt and sensor

the sensor and indicator switch wiring. Be sure the throttle cables are guided into the engine compartment without binding or attach-

ing to anything. AWD, 4WD LOW indicator switches and the VSS to the transfer case Input/turbine speed sensor and CKP sensor. Torque the bolt to 12 ft. Ibs. (16 Nm). Raise the transmission and position it to the engine. Install the upper housing bolts. Torque the bolts in the following sequence: ‘ 8. 10mm bolts to 38-60 ft. Ibs. (57-81

Vehicle

Input/Turbine

AWD, 4WD LOW indicator switches and the VSS from the transfer case 6. Lower the transmission. Be sure all wiring is clear and disconnected. Be sure the throttle cables come out without binding or attaching to anything. To install: 7. Install or connect the following: Transmission into position to attach

a

Speed Sensor

9. 12mm bolts to 51-65 ft. Ibs. (69-88 e Exhaust hanger and bracket. Torque the bolts to 38-60 ft. Ibs. (67-81 Nm). e Oil cooler pipe to the lower engine mount. Torque the bolt to 60-ft. Ibs. 79240623

Automatic transmission wiring connections

(81 Nm). ¢ Crossmember. Torque the bolts to

23-34 ft. Ibs. (31-46 Nm).

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santa 19-17 e Two transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 7 23-34 ft. Ibs. (31-46 Nm). Four transfer case nuts to the Crossmember. Torque the nuts to 23-34 ft. Ibs. (1-46 Nm). Torque converter-to-drive plate bolts. Torque the bolts to 12-20 ft. lbs. (16-27 Nm). Torque converter inspection cover. Torque the bolts to 41-62 inch Ibs. (5-7 Nm). Front splash guard. Torque the bolts to 41-62 inch Ibs. (6-7 Nm). Starter. Torque bolts to 27-40 ft. lbs. (37-54 Nm). Left side lower gusset. Torque the bolts to 38-60 ft. Ibs. (57-81 Nm). Right side lower gusset in 3 Steps: a. Install the bottom mounting bolts, but do not tighten. b. Install the top bolt to the intake manifold support’bracket and manifold. Tighten to 27—-40 ft. Ibs. (37-54 Nm). : c. Secure themanifold intake bracket by tightening the two attaching bolts to 38-60 ft. Ibs. (57-81 Nm). e (Oil cooler pipes at the transmission. Torque the lines to 42-62 inch lbs, (5-7 Nm). Two oil cooling tube clamps to the lines Driveshafts with the matchmarks aligned. Torque the bolts to the differential flanges to 20-22 ft. Ibs. (27-30 Nm) and the transfer case flange bolts to 36—43 ft. Ibs. (49-59 Nm). Undercover splash shield. Torque the bolts to 42-62 inch Ibs. (5-7 Nm). e Upper dipstick tube to the lower tube and lower the vehicle 10. Provide automatic transmission control cable slack by gently pulling the cable to the left until the cable pin has rotated sufficiently to line the automatic transmission control cable up with the slot in the rear of the throttle body bellcrank. 11. Slide the automatic transmission control cable and cable pin into the bellcrank. 12. Tighten the locknut. e Throttle kickdown cable to the mounting bracket

¢ Automatic transmission control cable to the throttle body Air silencer Shifter lever assembly to the transfer case. Torque the bolts to 72-102 inch Ibs. (22-28 Nm). Four wiring connectors under the shift selector lever Shift selector lever, do not exert any force when installing the shift selector lever Four shift selector lever nuts. Tighten to 72-102 inch Ibs. (22-28 Nm). Shift rod and washers to the selector lever and install the split pin to the shift selector lever Power/Economy switch wiring connectoy Rear console Front console and tie the shift boot draw strings Negative battery cable 13. Fill the transmission to the proper level. 14. Fill the cooling system. 15. Start the vehicle, check for leaks, and repair if necessary.

ADJUSTMENT Clutch Pedal Height 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Pull back the carpet to measure the distance from the firewall to the top of the pedal. The standard height is 9.84 in. (250 mm). 3. If adjustment is required, loosen the locknut and turn the stopper bolt. 4. After adjustment is made tighten the locknut to 12 ft. Ibs. (16 Nm).

Clutch Pedal Free-Play 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Depress the clutch pedal gently by hand and measure the amount of free-play (distance the pedal travels before resistance is felt). The proper amount of free-play is 0.5 in. (12.7mm). If the free-play is not

9.84 in (250 mm)! 79240625

Clutch pedal height and free-play adjustment points

within the proper specifications, continue with the procedure. 3. Measure from the floor pan to the middle point of the clutch pedal when the pedal is in the fully released position. The proper clutch pedal height is 7.25 in. (184mm). 4. \f the pedal height is incorrect, loosen locknut (A) and turn the pedal adjusting bolt (B) until the proper height is achieved, then retighten the locknut. 5. Remeasure the free-play. If it is still out of specification, loosen the clutch pushrod locknut (C) and turn the pushrod (D) until the proper free-play is achieved. Tighten locknut (C) securely.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: e Transmission e Pressure plate bolts and remove the clutch plate and disc To install: 3. Install or connect the following: ~ —e Clutch disc and plate using a centering tool e Clutch cover. Torque the bolts to 73 ft. Ibs. (99 Nm) and remove the centering tool e Check the release bearing condition

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

7

49-18 Mare | | y

CLUTCH MASTER CYLINDER RELEASE CYLINDER RELEASE FORK . RELEASE BEARING CLUTCH COVER CLUTCH DISC FLYWHEEL PILOT BEARING FLEXIBLE HOSE ODNANSWN=

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79240626

Exploded view of the clutch assembly

and lubricate or replace as necesSary e Transmission

Hydraulic Clutch System BLEEDING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. With an assistant in the vehicle, raise and safely support the vehicle.

3. Have your assistant pump the clutch pedal three times and hold the pedal to the floor. 4. Open the bleeder valve on the clutch Slave cylinder until the air is purged from the cylinder. 5. Tighten the bleeder valve. 6. Have your assistant release the clutch pedal. 7. Fill the clutch master cylinder if below minimum. 8. Repeat Steps 2 through 6 until no air exits from the bleeder valve.

9. Lower the vehicle.

;

10. Fill the clutch master cylinder fluid reservoir.

Transfer Case Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Drain the transfer case. 3. Remove or disconnect the following:

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TRANSFER CASE ASSEMBLY

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BEARING COVER

HI/LO SHIFT ROD

CHAIN COVER

TRANSFER CASE

FRONT COVER 93080605

Exploded view of the transfer case assembly

For Wheel Alignment specifications, see Section 1 of this manual

‘19-20 Sens : ‘.

Negative battery cable Two rear console mounting screws. Slide the console forward to clear the parking brake handle and set aside Three mounting screws from the front console. Untie the shift boot draw strings and open the boot Loosen the transfer case shift lever locknut and remove the lever knob Pull the console up to access the Power/Economy switch wiring connector. Unplug the connector and remove the console 4. Shift the transfer lever to the 4L posi-

~ e Power/Economy switch wiring connector e Front console e Lever knobs

e Front console and tie the shift boot draw strings ¢ Slide the console over the parking brake handle Rear console e Negative battery cable 7. Fill the transfer case to the proper level 8. Start the vehicle and check for leaks, repair if necessary.

f

e Matchmark the halfshaft and differential. ° Carefully pry the halfshaft from the differential e Halfshaft To install: 3. Install or connect the following: e Halfshaft with the matchmarks aligned with the differential Torque the upper and lower drop link nuts to 36 ft. Ibs. (49 Nm). e Tie rod end to the steering knuckle. Torque the locknut to 27 ft. Ibs. (36 Nm) and install a new cotter pin Upper control arm link lockbolt, spring washer and nut. Torque the

tion.

e Cover plate Retaining bolts from the transfer case and lift the shifter lever assembly straight out and properly support the transmission Matchmark the driveshafts at the flanges and remove the driveshafts Crossmember bolts e AWD light switch connector Transfer case mounting bolts located at the right center of the transfer case Transfer case nuts from the crossmember e Separate the transfer case from the transmission by striking the transfer case with a plastic mallet at the seal area 5. Lower the transfer case from the vehicle. To install:

6. Install or connect the following: Transfer case in position with a new gasket. Torque the bolts to 32 ft. lbs. (44 Nm). Crossmember. Torque bolts to 32 ft. Ibs. (44 Nm). Transfer case mounting bolts

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: Negative battery cable Both front wheels Six free wheel hub bolts and remove the hub Snapring and spacer from the hub Carefully remove the fixed cam assembly Caliper from the brake rotor Upper control arm link lackbolt, spring washer and nut Tie rod end from the steering knuckle Loosen the drop link lower locknut Loosen the four upper drop link locknuts Spread open the drop link fork with a rubber mallet

bolt to 36 ft. Ibs. (49 Nm). Fixed cam assembly Snapring and spacer in the hub e Wheel hub and the six free wheel hub bolts. Torque the bolts in two passes, 14 ft. Ibs. (17 Nm), then to 23 ft. Ibs. (31 Nm). Front wheel assemblies Negative battery cable

Locking Hubs REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Wheel assembly Six free wheel hub bolts and remove the hub Snapring and spacer from the hub Carefully remove the fixed cam assembly

located at the right center of the transfer case. Torque the bolts to 38 ft. Ibs. (52 Nm). Four transfer case nuts to the crossmember. Torque the nuts to 15 ft. Ibs. (20 Nm). Align the matchmarks on the driveshafts to the flanges. Torque the bolts to 27 ft. Ibs. (36 Nm) and remove the transmission support 4WD light switch electrical connector VSS electrical connector Shifter lever assembly. Torque retaining bolts to 20 ft. Ibs. (27 Nm). Cover plate. Torque the bolts to 15 ft. Ibs. (20 Nm).

79240G27

Removing the 4WD fixed cam assembly

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SPORTAGE 19-21 4WD ONLY

20

BOLT/WASHER FREE WHEEL HUB BODY SNAP RING SPACER FIXED CAM ASSEMBLY LOCK NUT SCREW = DONnAWNH

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ROTOR WHEEL HUB INNER BEARING INNER BEARING OUTER BEARING OUTER BEARING OIL SEAL

INNER RACE OUTER RACE OUTER RACE INNER RACE

16 17 18 19 20 21 22

BOLT & SPRING WASHER DUST COVER KNUCKLE NEEDLE BEARING OIL SEAL SPACER DRIVE SHAFT (LH) 79240G28

Exploded view of the 4WD locking hub assembly

For Maintenance Interval recommendations, see Section 7 of this manual

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To install: 3. Install or connect the following: e Fixed cam assembly e Snapring and spacer in the hub e Wheel hub and the six free wheel hub bolts. Torque the bolts in two passes, 14 ft. Ibs. (17 Nm), then to 23 ft. Ibs. (31 Nm). e Wheel assembly e Negative battery cable

Spindle Bearings REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Wheel assembly Free wheel hub and bearing Upper tie rod end from the steering knuckle Lower control arm from the steering knuckle Steering knuckle Inner oil seal Spindle bearing To install: 3. Install or connect the following:

4

93080G06

Remove the spindle bearing from the steering knucklexx

Spindle bearing using Bearing Installer tool K95B-5011-A New oil seal and apply grease to the bearing and seal lip Halfshaft end Steering knuckle to the halfshaft with the upper and lower ball joints in the mounting holes Lower control arm. Torque the lock nut to 110 ft. Ibs. (148 Nm) and install a cotter pin Tie rod end to the steering knuckle. Torque the nut to 27 ft. lbs. (36 Nm) and install a cotter pin Upper control arm. Torque the lock bolt to 36 ft. Ibs. (49 Nm).

e Free wheel hub and bearing assembly e Front wheel e Negative battery cable

Axle Shaft Bearing and Seal REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: e Negative battery cable e Wheel assembly e Rear wheel e Brake drum

. Lock Nut . Lock Washer

Bearing Oil Seal . Oil Seal Retainer AnRwWN4 Axle Shaft 9308QG07

Exploded view of the axle shaft, bearing and seal

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ScuRIEE 1 9-23 ¢ wheel speed sensor, if equipped ¢ Bearing retaining nuts « — © Axle shaft and bearing To install: 3. Install or connect the following: ¢ Oil seal retainer, oil seal and wheel bearing to the axle shaft. Torque the new lock nut to 220 ft. Ibs. (300 Nm). e>Turn the right side halfshaft lock nut clockwise and the left side halfshaft lock nut counterclockwise.

e Axle shaft assembly into the axle housing. Torque the nuts to 74 ft. lbs. (100 Nm). ¢ Wheel speed sensor, if equipped e Brake drum e Rear wheel assembly e Negative battery cable 4. Check the fluid level and top off if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Drain the gear oil. 3. Remove or disconnect the following: e Negative battery cable e Wheel assemblies e Brake drums e driveshaft e>Use an inch Ib. (Nm) torque wrench , measure and record the amount of torque required to maintain rotation of the pinion.

e Pinion flange e Pinign seal To install: 4. Install or connect the following:

STEERING AND SUSPENSION

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. 1. Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away from you. 3. Place the inflator module on a bench or other surface with the bag and trim cover _facing up. 4. With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Turn the ignition switch to the LOCK position. 3. Disconnect the negative battery cable. 4. Wait 10 minutes for the back-up power to discharge.

¢ New pinion seal lightly coated with Clean gear oil e Pinion flange 5. Rotate the pinion flange occasionally while tightening the flange nut and make certain that the pinion bearings are seated properly. 6. Take several bearing preload torque readings. Tighten the flange nut to achieve the preload torque reading. The maximum torque reading should not exceed 14 inch lbs. (1.6 Nm). e Driveshaft after aligning the matchmarks e Brake drums e Wheel assemblies e Negative battery cable 7. Fill the gear oil to the proper level. 8. Start the vehicle and check for leaks, repair if necessary.

_

ARMING

REMOVAL & INSTALLATION

Assuming the system components (air bag control module, sensors, air bag, etc.) are installed correctly and are in good working order, the system is armed whenever the battery positive and negative battery cables are connected. lf you have disarmed the air bag system for any reason, to rearm, be sure no one is in the vehicle (as an added safety measure), then connect the negative battery cable.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Center the steering wheel. 3. Drain the power steering fluid. 4, Remove or disconnect the following: Negative battery cable Left front wheel e Pitman arm-to-centerlink attaching nut Separate the Pitman arm from the centerlink with a ball joint puller Power steering hoses Coolant recovery tank and the power steering reserve tank e Set bolt from the intermediate shaft e Intermediate shaft from the steering gear Steering gear-to-frame bolts Steering gear To install: 5. Install or connect the following: e Position the steering gear to the frame. Torque the bolts to 159 ft. lbs. (215 Nm). e Pitman arm to the centerlink. Torque the bolt to 36 ft. Ibs. (49 Nm) and install a new cotter pin e Intermediate shaft to the steering gear shaft. Torque the set bolt 0 25 ft. Ibs. (34 Nm).

Power Steering Gear ADJUSTMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Place the steering gear in a vise with protective jaws. 3. Place a torque wrench on the Pitman arm end of the shaft. 4. Loosen the locknut on the adjusting bolt. 5. Slowly turn the adjusting bolt to until the breakaway torque is 66 ft. Ibs. (88 Nm). 6. Hold the adjusting bolt in position and tighten the locknut to 25 ft. Ibs. (34 Nm).

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

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¢ Drop link. Torque the nut to 145 ft. lbs. (197 Nm). e Stabilizer bar to the drop link. Torque the nut to 36 ft. Ibs. (48 Nm). ¢ Front wheels and torque the mounting block nuts to 18 ft. Ibs. (25 Nm). e Negative battery cable

| Power Steering

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Rear

Steering

eae Exploded view of the steering gear

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

Power steering hoses/lines. Torque the fasteners to 29 ft. Ibs. (34 Nm). Power steering reserve tank over the bracket and press until full engagement is reached Coolant recovery tank Left front wheel Negative battery cable 6. Fill the power steering fluid to the proper level and bleed the system. 7. Start the vehicle and check for leaks, repair if necessary.” 8. Road test the vehicle to check that the steering wheel is straight.

Shock Absorber

REMOVAL & INSTALLATION Front

The front shock absorber and coil spring are removed as a single unit. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: Negative battery cable Both front wheels Upper shock absorber mounting block nuts Stabilizer bar Drop link nut and allow the drop link to remain in place Both halves of the front fork Drop link Shock absorber and coil spring as an assembly To install: 3. Install or connect the following: ¢ Coil spring to the shock absorber and position the assembly to the upper mounting block

e Upper mounting block nuts and hand tighten them ¢ Both front forks . Torque the bolts to 36 ft. Ibs. (48 Nr).

1

Front Shock Absorber & Coil Spring Assembly

2 Front Fork 3 Drop Link Exploded view of the front shock absorber assembly

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SPORTAGE 19-25 Sipps

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Coil Spring SHOCK ABSORBER UPPER BOLT

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REMOVAL & INSTALLATION

4

i Front

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

SHOCK ABSORBER

79240632 Upper shock absorber mounting nut

2. Remove or disconnect the following: Negative battery cable Rear wheels Raise the rear axle with a floor jack to relax the’shock absorbers and support the rear axle when the shock absorber is removed. Rear safety nut, upper nut and washer Upper rubber plate Lower bolt from the shock absorber Lower the rear axle housing e Shock absorber 3. Remove the lower mounting bolt and remove the shock absorber.

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To install: 4. Install or connect the following: Bottom washer and rubber cushion on the top of the shock absorber. Position the shock absorber on the vehicle Lower bolt Rubber cushion, washer and

nut. Tighten to 53 ft. Ibs. (72 Nm) Safety nut. Torque the lower bolt to 62 ft. Ibs. (84 Nm). Rear wheels Negative battery cable

SHOCK ABSORBER

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Nut Upper retainer

Upper insulator Centering washer Spring seat

Coil spring Lower insulator Lower retainer

Dust boot

10. Rubber seat

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12. Front jounce stop

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79240633

Lower shock absorber mounting bolt

Expioded view of the front shock absorber and coil spring assembly

For complete service labor times, order the Chilton Labor Guide

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19-26 “ence 2. Remove or disconnect the following: Negative battery cable Shock absorber and coil spring as an assembly Place the shock absorber in a vice Loosen the pivot rod nut several turns While still secured in a vise compress the coil spring Piston rod nut and disassemble the coil spring as needed To install: 3. Install or connect the following: Bottom portion of the shock absorber in a vice and compress the coil spring End of the coil spring to the rubber seat and install the spring Assemble the dust boot and lower retainer, lower insulator, spring seat, boss, center washer, upper insulator and install the coil spring Hand tighten the piston rod nut. Carefully loosen the spring compressor tool and remove the tool Torque the piston rod nut to 31 ft. lbs. (42 Nm). Coil spring and shock absorber as an assembly

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Upper Ball Joint

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REMOVAL & INSTALLATION The upper ball joint is an integral part of the upper control arm. If the ball joint is worn, replacement of the upper control arm is necessary. Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheel assembly

¢ Cotter pin and lower ball joint nut e Separate the lower ball joint from the spindle with a puller tool by prying down on the spindle to separate it from the lower ball joint ¢ Lower ball joint attaching bolts e Lower ball joint To install: 3. Install or connect the following: ¢ Position the lower ball joint and install the attaching nuts and bolts. Torque the fasteners to 36 ft. Ibs. (48 Nm). Pry down and guide the spindle onto the lower ball joint. Torque the nut 87 ft. Ibs. (118 Nm) and install a new cotter pin Front wheel assembly. Negative battery cable

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: e Both rear wheels e Raise the rear axle with a floor jack to relax the shock absorbers and support the rear axle when the shock absorber is removed. -»>For easier installation, complete one side at a time.

¢ Lower mounting bolt, then the shock absorber ¢ Lower the floor jack until the coil Spring is fully expanded e Coil spring e Inspect the upper and lower rubber spring seats and jounce stop for wear or damage, replace if necesSary To install: 3. Install or connect the following: ¢ Position the spring in the upper and lower saddles e Raise the floor jack and connect the lower shock absorber bolt. Torque the bolt to 62 ft. Ibs. (84 Nm). e Rear wheels

1 2 3 4 5 6

LOWER CONTROL ARM LOWER CONTROL ARM BUSHING B DROP LINK FRONT FORK DROP LINK BUSHING LOWER CONTROL ARM BALL JOINT 79240634

Exploded view of the lower control arm and ball joint assembly

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SPORTAGE2 19-27 e>Be sure the slot in the ball joint aligns with the through-bolt during installation.

Upper Control Arm

REMOVAL & INSTALLATION —_—_—_—_—_—_—_———————

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ; 2. Remove or disconnect the following:

e Negative battery cable ¢ Front wheel assembly ¢ Bolt securing the upper ball joint to the steering knuckle e>Note the matchmark setting on the upper control arm mounting bolts before removal.

e Upper control arm mounting bolts ¢ Upper control arm from the vehicle. To install: 3. Install or connect the following: e Position the upper control arms in the frame mounting. Hand tighten the bolts e Position the ball joint in the spindle. Torque the through bolt to 36 ft. Ibs. (48 Nm).

e Align the upper control arm bolts to the previous settings. Torque bolts

to 62 ft. Ibs. (108 Nm). e Front wheel assembly 4. Check and adjust the alignment, if necessary.

UPPER CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Upper control arm assembly e Secure the control arm in a vise e Using a standard press, remove the bushing To install: 3. Install or connect the following: e Lubricate the new bushing and press it into the upper control arm e Upper control arm to the vehicle 4. Check the wheel alignment and adjust if necessary.

Lower Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Front wheel assembly Stabilizer bar Driveshaft from the differential and steering knuckle Shock absorber and coil spring from the front half of the fork Cotter pin and castle nut from the lower control arm ball joint Lower control arm ball joint from the steering knuckle Lower control arm bushing bolts from the front frame crossmember brackets Lower control arm To install: 3. Install or connect the following: Lower control arm to the front frame crossmember brackets and hand tighten the bushing bolts Lower control arm ball joint and bolt to the steering knuckle. Torque the bolt to 87 ft. Ibs. (118 Nm). New cotter pin and castle nut Torque the lower control arm bushing bolts to 206 ft. Ibs. (280 Nm). Front fork halves to the shock absorber and coil spring and position the lower portion over the lower control arm drop link holes Drop link. Torque the nut to 145 ft. lbs. (197 Nm). Driveshaft to the front differential and steering knuckle Stabilizer bar Front wheel assembly Negative battery cable 4. Check and adjust the front wheel alignment if necessary.

LOWER CONTROL ARM BUSHING REPLACEMENT

1 2 3 4

UPPER CONTROL ARM UPPER CONTROL ARM BUSHING FRONT SPINDLE REAR SPINDLE 79240631

Exploded view of the upper control arm assembly

1. Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: e Lower control arm assembly e Secure the control arm in a vise e Using a standard press, remove the bushing

Please visit our web site at www.chiltonsonline.com

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To install: 3. Install or connect the following: e Lubricate the new bushing and press it into the lower control arm e lower control arm to the vehicle 4. Check the wheel alignment and adjust if necessary.

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Wheel Bearings

ADJUSTMENT

e e

Front

1. Remove or disconnect the following: 2. Before servicing the vehicle, refer to the precautions in the beginning of this section . e Negative battery cable e Front wheel e Brake caliper from the rotor and hang it out of the way 3. Attach a dial indicator to the axle hub and measure the bearing play 4. If the play exceeds.004 inch (.10mm), check and adjust locknut torque. The bolts should be tightened to 23 ft. Ibs. (31 Nm). Rear

The rear wheel bearings are not adjustable.

e e

Inner bearing and race and a new oil seal Outer bearing and race and secure the dust cover with four screws Apply grease to the new bearings and the lip of the oil seal Hub assembly in the steering knuckle Screw the locknut against the hub assembly until there is 10 inch Ibs. (1.3 Nm) of preload on the hub Brake rotor and retaining screws Attach a run-out gauge to check the rotor run-out. The run-out should not exceed 0.004 inch (0.10mm) Brake caliper Free wheel hub fixed cam key with the locknut groove and push the on the fixed cam assembly Axle retainer snap ring Apply a light coat of sealant on the free wheel hub body. Install the body on the hub. Torque the bolts in 2 passes. Tighten the bolts on the first pass to 18 ft. Ibs. (25 Nm). Tighten the bolts on the second pass to 23 ft. Ibs. (31 Nm). Negative battery cable

Rear

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

SE

2. Remove or disconnect the following: e Negative battery cable e Rear wheels e Brake drum e Oil seal retainer flange >The axle shafts are different from side-to-side, mark the to ensure they are returned to the proper side.

e Using a slide hammer, remove the axle shaft assembly e Using a hydraulic press, remove the bearing collar and bearing from the axle e oil Seal from the differential To install: 3. Install or connect the following: e Using the appropriate seal driver, install the new axle seal into the differential >The left-hand axle is 25.5 inches (647mm) long, and the right-hand axle is 27.4 inches (697mm) long.

Using a hydraulic press, install the new wheel bearing and retainer collar to the axle shaft Axle shaft into the carrier. Torque the nuts to 75 ft. Ibs. (100 Nm). Brake drum and rear wheels Negative battery cable

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Front wheel Free wheel hub body Brake caliper Brake rotor Wheel bearing and using a screw driver, pry out the oil seal Inner and outer bearings Using a drift punch, remove the inner and outer bearing race To install: 3. Pack the new bearings with grease. 4. Install or connect the following:

Bearing Collar Bearing Axle Shatt

Rib Ring

Oil Seal Onarwn— Oil Seal Retainer

79240635

Rear axle bearing component identification

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LAND ROVER 1998-00 Discovery * Discovery Series Il * Range Rover

DRIVE TRAIN.................. 20-16 ENGINE REPAIR ................ 20-2 FUEL SYSTEM ................ 20-14 PRECAUTIONS.................. 20-2

Front Axle Shaft and Seal ............ 20-21 Removal & Installation............ 20-21 Front Axle Shaft CV-Joints .......... 20-20 Removal & Installation............ 20-20

SUSPENSION................. 20-25

Removal & Installation............ 20-19

STEERING AND

A

Front Axle Swivel HUbS ............. 20-19

Front Drive Axle Housing

AIP Bag Seep OT akboid V9020-25 PARTING creer coal see 20-25 Disaniimr cee a ea 20-25 PIOCaONSie tec. 20-25 Leo) 14a 20-29 Removal & Installation............ 20-29

ASSERROIY ole OGIO TENS 90-24 Removal & Installation............ 90-24 FUER FIE(O ee eee ree 90-14 Removal & Installation............ 90-14 FueliPuripy cen aumen’ siabatine390-14 Removal & Installation............ 20-14

RifeGUEDEASION data ct cestte20-25

Fuel Rail and Injectors ............... 90-15

DEPreSSUIIZINGy......-secesse-eecce 20-25 Ripadaiseannect st jalcncanae 20-25

Removal & Installation.......... 20-15 Fuel System Pressure ....cc.cccccs.e 20-14

Altermatonain vamp palaiiew accoe. de 20-2 Removal & ted {hetioiban 20-2 Camshaft and Valve Lifters ............ 20-9

Relieving (iy! is. ose al! aye: 90-14 Fuel System Service IONS

nen

cxbarue eeediieeee ede 20-14 |

,

Removal & Installation............ 20-9 Goi SDrmgS Hu Ris acc. e0ro-—

Ignition Timing........... JOY een a20-2 intake Maniiolde oe eras 20-6

CylinderHedd ia. easacnecmce 20-5

L

Power Steering Gear... Removal & Installation............ Power Steering PUMD............000.. Removal & Installation............

R

Rear Axle Housing Assembly

Removal & Installation...........

Rear Axle Shaft and Bearing ........ Removal & Installation............ Rear Main Seal oui... Removal & Installation............ Rocker Arms/Shafts .......cc.cececesceee Removal & Installation..............

)

SHOCK ADSOrDETS ...........secsseeese Removal & Installation...........

Starter Motor .........0.... c Hoven. ale Removal & need iT, Aaa Bs

Timing Chain, Sprockets,

Front Cover and Seal.............. 20-11 Removal & Installation............ 20-11

Removal & Installation.............. 90-6

Transfer Case Assembly.............. 20-17

Removal & Installation.............. 20-5 — Lower Balll Joint... .-sssssecseesvevees 20-31

Transmission Assembly.............. 20-16

Removal & Installation............ 20-28

D ISTHE seme icadistens ovate acti i 20-2

E

Engine Assembly aun

20-2

Removal & Installation............ 90-31 0

Removal & Installation........... 20-17

Removal & Installation............ 20-16 U

CilgP liar tashantee sei eimai 20-10) = UpDet Baia

ities aenees ett 20-31

Removal & Installation............ 20-10

Removal & Installation............ 20-31

Exhaust Manifold... 20-8 Removal & Installation............. 20-8 F

Removal & Installation........... 90211 P PiniomSaalve!. Be sure that the engine does not touch the body at the rear.

10. Remove the 2 remaining engine-totransmission mounting bolts. 11. Slowly pull the engine out to the front and lift it out. To install: 12. Install or connect the following: e Engine into the vehicle e Engine to the transmission e Upper 2 mounting bolts e Engine ground cable to the power steering pump e Motor mount bolts and tighten to 26 ft. Ibs. (35 Nm) 13. Remove the engine hoist from the lifting eyes.

1 2 3 4 5 6

7 8 9 10 11.

Viscous fan ~=~Poly V-belt Fan shroud Coolant hose Coolant hose Coolant hose at oil-water heat exchanger ‘Belt pulley of coolant pump Coolant pump Coolant pump gasket Shock absorber Bolts of shock absorber 79242101

Exploded view of the water pump mounting and related components

For complete service labor times, order the Chilton Labor Guide

21 il

MERCEDES BENZ ML320 ¢ ML430

~

¢ Water pump mounting bolts e Water pump 5. Clean and dry the gasket mating surface for the water pump.

To install: 6. Install or connect the following: e Water pump and gasket. Tighten the M6 bolts to 88 inch Ibs. (10 Nm) and the M8 bolts to 177 inch lbs. (20 Nm). e Water pump belt pulley and tighten the mounting bolts to 88 inch Ibs. (10 Nm) e Coolant hoses to the water pump e Serpentine belt and remove the locking pin e Engine cover e Fan shroud and fan 7. Fill the engine with coolant. 8. Connect the negative battery cable. 9. Read fault memory, encode the radio and normalize the power windows. 10. Start the vehicle and check for ~— leaks.

e Ignition coils e Cylinder head covers

Cylinder Head

REMOVAL & INSTALLATION

>The intake manifold system must not be disassembled.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable 3. Drain and recycle the engine coolant. e Engine cooling fan and clutch e Fan shroud

e Intake manifold e Vacuum switchover valve ¢ Camshaft Position (CMP) sensor 6. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner. .~ ¢ Serpentine belt e Power steering pump and position it aside leaving the hoses attached e Heater hose at the firewall e Exhaust system from the exhaust manifolds 7. Rotate the engine clockwise to position the crankshaft 40 degrees after top dead

>The fan clutch is equipped with righthand thread.

4. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation. e Engine cover e Air cleaner housing, resonance pipe and body 5. Properly relieve the fuel system pressure. e Fuel line

center.

The engine must not be rotated backwards.

—Sess re ae Ce WE! Vow

Sees C\ ea—_ 7

IZ \

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a.§‘% Als . The fan clutch is equipped with righthand thread.

5. Attach a guard plate to protect the radiator. e Intake resonator and pipe e Upper and lower coolant hoses e Engine ground cable from the frame ¢ Motor mounts at the front suspension supports 6. Attach an engine hoist and raise the

engine. Be sure that the engine does not contact the firewall. e Lower oil pan >The upper pan bolts are different lengths and diameters. Note their locations for installation.

e Upper pan toward the front of the vehicle. Rotate the crankshaft as necessary for clearance. To install: 7. Clean the sealing surfaces and apply a bead of silicone sealant.

meESRE 24-14 >The pan must be installed within ten minutes after the sealant is applied.

*

8. Install or connect the following: e Upper pan. Tighten the 6mm bolts to 90 inch Ibs. (10 Nm), and the 8mm bolts to 15 ft. Ibs. (20 Nm). 9. In the same manner, apply a bead of silicone sealant and install the lower oil pan. Tighten the bolts to 90 inch Ibs. (10 Nm). 10. Install or connect the following: e Motor mounts and remove the engine hoist e Engine ground cable e Upper and lower coolant hoses e Intake resonator and pipe 11. Remove the radiator guard plate. e Fan shroud, engine cooling fan, and fan clutch e Engine cover 12. Fill the cooling system and crankcase to the correct levels. 13. Connect the negative battery cable. 14. Read fault memory, encode the radio and normalize the power windows.

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

— WOnm

4 5 6

2. Remove the lower oil pan. Refer to the oil pan procedure in this section. 3. Push the chain tensioner back and remove the pump drive chain. 4. Unbolt and remove the oil pump. To install: 5. Fill the oil pump with clean engine oil and install it to the engine. Tighten the bolts to 15 ft. Ibs. (20 Nm). 6. Install the pump drive chain. 7. Install the lower oil pan. Refer to the oil pan procedure in this section.

Timing Chain, Sprockets, Tensioner and Front Cover

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to

the precautions in the pewnning of this section. 2. Disconnect the negative battery cable. 3. Drain the cooling system and engine oil. 4. Remove or disconnect the following: e Engine cover e Engine cooling fan, fan clutch, and fan shroud >The fan clutch is equipped with righthand thread.

e Upper and lower coolant hoses e Accessory drive belt and tensioner e Oil pan Sal e head covers

* WARNING The engine must not be rotated backwards.

5. Rotate the crankshaft clockwise to align the crankshaft timing marks at 40° After Top Dead Center (ATDC). Insure that the grooves in the camshafts (6 in the illustration) align with the cylinder head cover mating surface on the intake side of the cylinder heads. 6. Remove or disconnect the following: Air conditioning compressor and power steering pump and position them to the side. Do not remove the air conditioning or power steering hoses. Generator Timing chain tensioner Crankshaft pulley Air pump, if equipped Coolant Temperature (CT) sensor >The timing chain cover bolts are different lengths and diameters. Note their locations for installation.

e Timing chain cover

Copper-plated link Groove in crankshaft Mark on balance shaft sprocket Mark on right camshaft gear Mark on left camshaft gear Groove in camshaft

bien cnc n nn ce cena ween enn nenenenre

93022104

Camshaft timing marks

Brake service is covered in Section 4 of this manual

C 91 -1 9 MERCEDES BENZ

-ML320 © ML430

1 2 3

M6X 19 M6X 23 M6X43

4 5 6 7 8 9 10 17 12.

M8&x30 M8&X33 M8&X34 M8&xX70 M&xX 8&0 M8&X90 M&xX 100 M8&X110 M8&X 140

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93022105

Timing cover bolt placement

7. Lock the camshafts using the

Camshaft Locking tools 112-589-00—-32-00 and 112-589-01-32-00. e Camshaft sprockets bolts e Timing chain To install: 8. Align the copper plated links of the timing chain with the marks on the camshaft sprockets, the crankshaft sprocket, and the balancer sprocket for the 3.2L engine. The 4.3L engine uses an idler sprocket in place of the balance shaft. 9. Install or connect the following: e Camshaft sprockets along with the timing chain. Tighten the attaching bolts to 37 ft. Ibs. (50 Nm) plus 90-100 degrees.

10. Clean the sealing surfaces and apply a bead of silicone sealant to the timing chain cover. >The cover must be installed within ten minutes after the sealant is

applied.

Timing cover. Refer to the illustration for bolt placement. Tighten the bolts to 15 ft. Ibs. (20 Nm). CT sensor Timing chain tensioner Generator Crankshaft pulley and tighten the bolt to 148 ft. Ibs., then tighten another 95 degrees Ait pump, if equipped

Air conditioning compressor and the power steering pump Cylinder head covers e Oil pan Accessory drive belt and tensioner Upper and lower coolant hoses Fan shroud, cooling fan, and fan clutch 11. Fill the cooling system and the crankcase to the correct levels. e Engine cover e Negative battery cable 12. Read fault memory, encode the radio and normalize the power windows. F

it hay Tee

—

wee FS

MERCEDES BENZ 21 4 3'

eee

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. ¢ To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system ~ component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. i e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary ‘stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new ones. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Locate the electric fuel pump fuse and remove it from the fuse box. elf the fuel pump fuse cannot be located, disconnect the vehicle wiring harness from the pump itself and perform the procedure.

3. Start the engine and allow it to idle until the engine stalls from lack of fuel.

.

4. Crank the engine over for an additional 15-20 seconds. 5. Reinstall the pump fuse when repairs are completed.

Fuel Filter REMOVAL & INSTALLATION &

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable 4. Relieve the pressure in the fuel tank by opening, then tightening the filler cap. e Left rear wheel e Plastic inner fender liner The fuel lines must not be kinked.

e Fuel pipes from the fuel filter, by compressing the locking catches

52 55

Fuel pipe to engine Fuel filter with pressure regulator

77/3

Connection of spring chamber

90/11

Fuel return flow pipe

90/12

Fuel feed pipe

mit

yee

ML320 * ML430

¢ Breather hose from the filter assembly e Filter securing clip e Filter/pressure regulator To install: 5. Install or connect the following: New fuel filter/pressure regulator into the housing and tighten the securing Clip to 27 inch Ibs. (3

Nm)

Breather hose to the filter assembly Fuel lines to the filter assembly Plastic inner fender liner Left rear wheel and tighten the lug

bolts to 110 ft. Ibs. (150 Nm) Negative battery cable 6. Read fault memory, encode the radio and normalize the power windows. 7. Start the vehicle and check for leaks.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Disconnect the negative battery cable. 4. Empty the fuel tank into a suitable container.

breather

View of the fuel filter mounting location and component identification

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

79247112

a ek

f-i aeee™

he

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84 89 89/2 B4

Cover Union nut Seal Fuel gage sensor

90/10 90/11 90/12 90/13.

Fuel suction pipe Fuelreturn flow pipe Fuel feed pipe Connection for stationary heater

Arrow A M3

Connector for fuel pump Seat mounting brackets Fuel pump 79242113

Exploded view of the fuel pump and its mounting

5. Raise the left rear seat approximately 20 inches (50 cm). 6. Lift the carpeting to gain access to the fuel pump cover. 7. Remove or disconnect the following:

*e Fuel pump cover Fuel pump electrical

connector ; : Be sure not to kink the fuel pipes.

e Supply and return fuel pipes clips and the pipes

e Union nut mounting the fuel pumpto-the tank e Fuel pump from the tank To install: Lightly oil the fuel pump sealing 0-

ring to simplify the installation. 8. Install or connect the following:

© Fuel pump into the tank tie p

new union nut and O-ring. Tighten the union nut to 50 ft. Ibs. (65 Nm).

e Supply and return lines to the fuel pump e Fuel pump electrical connector e Fuel pump access cover and the rear seat 9. Fill the fuel tank. e Negative battery cable 10. Read fault memory, encode the radio and normalize the power windows. 11. Start the vehicle and check for leaks.

i

- eer,

MITSUBISHI 1998-01

Montero * Montero Sport DRIVE TRAIN...............66 22-25 ENGINE REPAIR................ 22-2 FUEL SYSTEM ................ 22-23 PRECAUTIONS.................. 22-2 STEERING AND SUSPENSION................. 22-30

Removal & Installation............ 22-15 Fuel Fitters. “ciee cvowee, bln 22-23 Removal & Installation............ 22-23 FUBHIMeGIO Gyc.2 604 Sb NOE om Bie 22-24 Removal & Installation............ 22-24 RUCEFUNIO sacecte come om ee 22-23

Air Bag aias seenceennessseaseessenssssetiass 22-30

Fuel System PreSSUure ........csceseee 29203

PSII ss tnter pltsenetana en 22-30 PRLRCALULOINS. aconsauinsdd aha -cncente 22-30

POLI GVIC an,clveceneset eae onta PAPE Fuel System Service

AlteMmatar satghapisenih aruncveetagie dene

..Prasautlons: wsllat, ctausied. ame 22-23

A

REMOVAl: si Ahoawy. sbvishonacasne 22-3 ‘Automatic Locking Hubs.............. 22-29

Removal & Installation............ 22-29

Removal & Installation............ 22-23

H Halishafiszatoldizase inscalaan 22-21

Removal & Installation........... 22-27

Axle Shaft, Bearing and Seal........22-30 Removal & TSG dinate 22-30

Hydraulic Clutch System ............. 22-27 Bleeding............. eae ve 20-27

Camshaft and Valve Lifters .......... 22-16 Removal & Installation............ 22-16 LN orien dd eh aN ied in22-26 Removal & Installation............ 22-26 EXPLA Sat Tel Peat pete pe rae22-32 Removal & Installation............ 22-32

lonition Hmririg ives Ae) ne DBC er 22-4 AUIUSUTICNL ss shee ee tee 22-4 AUP UIGCK \ ercetcer ca uses 22-4 Intake Manifold .......csccsssscessesesees 22-11 Removal & Installation............ 22-11

CValQInts saetal chin enlnisnist-sdp Banaiy a iatitBegg: Sate Se te22-27 Gylinderheadwoc

ok. 29-0

— LOWS! Ball, JOU sits connaidepeiyticse 22-33 Removal & Installation............ 22-33

Lower Control ALM... 22-34

Removal & Installation.............. 22-7

Control Arm Bushing

D DisthibUtons. 2. U.0/2000. A NOR.Oe 222

REDIACEMON ...scsaise-cssscecssneccs 22-34 Removal & Installation............ 22-34

fstallationaiogs onl wemismo: 22-2

0

Piston and RING... 22-22 Positioning ....... BREco

22-22

Rack and Pinion Steering Gear ....22-31 Removal & Installation............ 22-31 Rear Main Seal oo... ccc. 22-20 Removal & Installation............ 22-20

Recirculating Ball Power SHORTING [FCB isan nes deade a-euees 22-30 Removal & Installation............ 22-30 Rocker Arms/Shafts ......cecececee 22-9 Removal & insta aloeahiganv 22-9 Shock ADSOFDE .....cececeeeseeeeeeeee 22-31 Removal & Installation............ 22-31 Starter MOtOr ween 22-17 Removal & Installation............ 22-17 — StU. SeCOUy, TNS TOUR ae 22-32 Removal & Installation............ 22-32 TOISION Bars %... eee eee 22-33 Removal & Installation............ 22-33

Transfer Case Assembly............... 22-21 Removal & Installation........... 22-21 Transmission Assembly ............. 22-25 Removal & Hscigiinh Lee 22-29

UDDer dl alt reeetncter rence 22-33 Removal & Installation... 22-33

Upper Control Arm uu... 22-34

22-18

Removal & agi onal gi 22-34

E *ENgInG’ASSEMDAY eee. 22-4 Removal & Installation.............. 22-4

Removal & Installation............ 22-18 OF PO ee ee eeevet 22-18 Removal & Installation............ 22-18

Water PLA fit) 8, 0002 BeTee 22-6

Removal & Installation............ 99-15 F

Pinion Seal ..i..cccuce 0.1 22-30 Removal & Installation............ 22-30

RRIOVALY

2b

USIGJE Vill

BF Hsu) LDEY,

EXPQUST MAMITOND .ccinss otsncacennnnes 22-15

Front Crankshaft Seal ou... 22-15

Oil RAT. cc. cideetcan Wetec ae aera

a

Removal & Installation... 22-6

Wheel Bearings... 22-34 Adjustment.caccmumeememnaiees 22-34 Removal & Installation............ 22-34

22-2 ee

MITSUBISHI

MONTERO ¢ MONTERO SPORT ena

ee ra

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols, Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes

with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed Skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. e Clean, high quality brake fluid from a

sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. Ifthe brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; itwill damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for refer-

ence.

ENGINE REPAIR ->Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

Distributor

cap with all ignition wires connected. Remove the coil wire if necessary. 2. Matchmark the rotor and distributor housing and matchmark the distributor housing and engine. e>Do not crank the engine during this procedure. If the engine is cranked, the matchmark must be disregarded.

Only the 1998 4-cylinder engine uses a distributor ignition. All other engines are distributorless.

REMOVAL 1. Remove or disconnect the following: ¢ Negative battery cable e Distributor pick-up lead wires and vacuum hose(s), if equipped. ¢ Distributor cap retaining clips or screws and lift off the distributor

e Retaining nut and remove the distributor from the engine.

INSTALLATION Timing Not Disturbed _ 1. Position a new distributor housing 0rn

©

z Install the distributor in the engine so the rotor is aligned with the matchmark on

the housing and the housing is aligned with the matchmark on the engine. Be sure the distributor is fully seated and the distributor shaft is fully engaged. 3. Install or connect the following: Retaining nut finger-tight only. Connect the vacuum hose(s), if removed, ¢ Distributor pick-up electrical harness ‘ Distributor cap and secure Negative battery cable 4. Check and adjust the ignition timing. Naa the retaining nut to 115 ft. Ibs. (13 m). Timing Disturbed

_ 1. Install a new distributor housing Oring 2. Rotate the engine so. No. 1 piston is on TDC of compression stroke and the tim-

Ey

NER

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a

a

a

a

I

ing mark on the vibration damper is aligned

FS

Alternator

1. Bef

-

* Distributor electrical harness * Distributor cap and secure

->Some distributor caps may contain

14

N-m

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12-15Nm_

|

106 - 133 in-lb |

Valnnitiowen|eieniee

¢ Under cover * Air cleaner assembly, ducts and air intake hose

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BelOre Servicing tnevenice, reler tO

+ Negative battery cable

5. Check and adjust the ignition timing. Torque the retaining nut to 115 ft. Ibs. (13 m).

.

precautions in the beginning of this section. 2. Remove or disconnect the following:

e Negative battery cable

runners inside the cap. If so, be sure the rotor is pointing to where the No. 1 runner originates inside the cap and not where the No. 1 ignition wire plugs

|

REMOVAL

ae

9

99.3

SES

pat 41 edpa oF popnet he (a owing Retaining nut finger-tight only. Connect the vacuum hose(s), if removed

shaft is fully engaged and the housing is

ie a

MITSUBISH! ¢ MONTERO SPORT

MONTERO

into the cap.

with T on the timing indicator. 3. Position the distributor so the rotor is : gag Ags aligned with the No. 1 ignition wire on the distributor cap. Take note that the distributor

full : gag ais

yin, BeCr

BELT (FOR GENERATOR)

4, GENERATOR

3 GENERATOR BRACE ASSEMBLY

Alternator mounting and related components

For complete service labor times, order the Chilton Labor Guide

9308UG02

MITSUBISHI MONTERO e MONTERO

99-4 J °

eae SPORT

a. Remove the inspection plate.

Dri

SUL If the actuator test is not canceled, the forced drive will continue for 27

b. Matchmark the flexplate oea verter. Remove the torque converter bolts a See it converter back as

3. Install or connect the following: e Alternator. On the 2.4L torque the through-bolt to 14-18 ft. bs. (20-25 Nm) and the bracket bolt to 106-133 inch Ibs. (12-15 Nm). On

lead to engine failure. EER Ee erm E eT WLR 2. If the base timing is out of specifica, tion: 3. Check to see ifthe distributor is

pie Remove the lower bell housing

through-bolt to 38 ft. Ibs. (62 Nm) and the mounting bolt to 16 ft. Ibs. (22 Nm). e Mounting bracket, if equipped.

4. Check to see if the timing belt cover and Crankshaft Position (CKP) sensor installation is conditions. 5. Crankshaft sensing blade conditions.

° rae ¢ Mounting bracket, if equipped e Alternator

the 3.0L and 3.5L torque the

Torque the bolt to 14-18 ft. Ibs.

(20-25 Nm).

|

e Wires. Torque the nut to 124 inch

Ibs. (14 Nm).

e Drive belt(s)

aligned properly

intake hose ( e Under cover ¢ Negative battery cable

si

ee ADJUSTMENT

The ignition timing is controlled by the

ECM and isnot adjustable.TheECM determines the timing based on input from the crankshaft position sensor.

TIMING CHECK the precautions in the beginning of this sec-

al

‘aniti

2 be CUE ee SAS timing, sure of theARfollowing: The engine should be at normal operating temperature. The lights and all accessories

should be OFF.

e haneriecion: If equipped withtheanvanemissiog automatic should be in P or N. Connect scan tool MB991502 to the data link connector Set up the timing light. Start the engine and run at idle. Verify that the idle speed is

iM

throttle body and plug the lines ¢ Fuel lines ¢ Air conditioning compressor, Lie equipped and position it aside. It is not necessary to remove the lines

from the compressor.

e Radiator and shroud

¢ Cooling fan

e Heater HS a

;

° accessory

.

'

+ Power steering pump and wires from itsbrackets and position it to the side. Do not remove the hoses from the ea

tion

CAUTION The fuel injection system remains under pressure after the engine has been OFF. properly relieve fuel pres-

— sure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

2. Relieve the fuel system pressure.

1. Before servicing the vehicle, refer to

intake hose

e Linkages and cables from the

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

FIgnition ion Timing Timi =

a Remove or disconnect the following: ° Air cleaner assembly, ducts and air

Engine Assembly

e Air cleaner assembly, ducts and air

go.

ar asitwill

minutes. Driving in this state could

To install:

3. Drain the engine oil and coolant.

e Alternator and wires

¢ Ignition coil and power transistor assembly, if equipped

Manifold differential pressure (mdp) sensor connector a ftanef nas feet neE ee

ae Aeon * Throttle position (TP) sensor conaes

: ee control (\AG) motor con;

fe}

4. Drain the cooling system.

: ele teemission (EVAP) purge

5. Remove or disconnect the following:

;

oi WOVE RANE ag +: a CAUTION wait at least 90 seconds after the negative battery cable is discon-

nected to prevent possible deployment of the air bag

a Battery

¢ Hood, matchmark for reassembly e Oil dipstick e Engine undercover Lower radiator hose Starter

a icant

sensor and gauge connectors Front and injector wiring harnes s J WITINg Crankshaft position (CKP) sensor Distributor signal generator Heated oxygen (02S) sensor

Oil pressure switch connector V h

at 8. Attach an engine removal device to the engine support eyes on the engine. 9. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts. 10. Remove the engine mount nuts and

600-800 rom.

ze ne from the exhaust

tor test “taen number d 7a

signa th iat LA

11. Lower the engine into position

Check that basic timing is with in standard, it should be 3-7° BTDC.

Transmission, if equipped with a TATlAl TSCHESGn

iV Install or connect the following: e Engine mount nuts. Torque the nuts

Press the clear key on the scan tool, select forced drive stop mode

and cancel the actuator test.

6. If equipped with an automatic transmission and 2WD:

remove the engine from the vehicle.

v oa Siei reas ith ‘ Q DONS. 1orque

to 54 ft. Lbs. (74 nm).

the bolts

:

MITSUBISHI

MONTERO © MONTERO SPORT 18 ‘Remove the engine removal device and the transmission support. 14. Install or connect the following: + Transfer case, if equipped e Manual transmission, if equipped 15. If equipped with an automatic transmission, align the torque converter and flexplate and install the bolts. Torque the bolts to 33-38 ft. Lbs. (45-52 nm). 16. Install or connect the following: Inspection plate Starter Exhaust pipe to the exhaust manifold using new gaskets Lower radiator hose Heater hoses Alternator ; Power steering pump and all brackets

Air conditioning compressor Linkages and cables to the throttle body Ignition coil and power transistor assembly Manifold differential pressure (MDP) sensor connector Exhaust gas recirculation (EGR) connector — Throttle position (TP) sensor connector Idle air control (IAC) motor connector Magnetic clutch and refrigerant temperature switch connector Evaporative emission (EVAP) purge solenoid Engine coolant temperature (ECT) sensor and gauge connectors Front and injector wiring harness

Crankshaft position (CKP) sensor Distributor signal generator Heated oxygen (02S) sensor Oil pressure switch connector Vacuum hoses Radiator and shroud Cooling fan Accessory belts Engine undercover Air cleaner assembly, ducts and air intake hose Oil dipstick Battery and cables e Hood 17. Fill the engine with the specified amount of oil and fill the radiator with coolant. 18. Inspect the fuel system for leaks. 19. Check the automatic transmission fluid level, if equipped. 20. Recheck all engine adjustments.

3.0L and 3.5L Engines

EGR connector TP sensor connector IAC motor connector Magnetic clutch and refrigerant

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure.

temperature switch connector EVAP Purge Solenoid ECT sensor and gauge connectors Front and injector wiring harness

CAUTION The fuel injection system remains under pressure after the engine has been OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. 3. Drain the engine oil. 4. Drain the cooling system. 5. Remove or disconnect the following: Battery Hood, matchmark for reassembly Oil dipstick Engine undercover Starter Exhaust pipe from the exhaust manifolds Transfer case, if equipped with 4WD Transmission, if equipped with a manual transmission 6. If equipped with an automatic transmission and 2WD: a. Remove the inspection plate. b. Matchmark the flexplate to the converter; remove the torque converter bolts and move the torque converter back as far as it will go. c. Remove the lower bell housing bolts. 7. Remove or disconnect the following: Air cleaner assembly, ducts and air intake hose Linkages and cables from the throttle body Fuel lines and plug the lines Air conditioning compressor, if equipped and position it aside. It is not necessary to remove the lines from the compressor. Radiator, shroud Cooling fan Heater hoses Accessory belts Power steering pump and wires from its brackets and position it to the side. Do not remove the hoses from the pump. Alternator and wires Ignition coil and power transistor assembly, if equipped MDP sensor connector

22-5

CMP sensor CKP sensor Distributor signal Generator Compactor connector Left and right heated O2S sensor Oil pressure switch connector Vacuum hoses 8. Attach an engine removal device to the engine support eyes on the engine. 9. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts. 10. Remove the engine mount nuts and remove the engine from the vehicle. To install: 11. Lower the engine into position and install the engine mount nuts. Tighten the

nuts to 20 ft. Ibs. (27 Nm), on the Montero, tighten to 33 ft. Ibs. (44 Nm). 12. Install or connect the following: e Bell housing bolts 13. Remove the engine removal device and the transmission support. 14. Install or connect the following: Transfer case, if equipped Manual transmission, if equipped Automatic transmission, if equipped align the torque converter and flexplate and the bolts. Inspection plate Starter motor Exhaust pipe to the exhaust manifolds using new gaskets Lower radiator hose Heater hoses Alternator and wires Power steering pump and brackets Air conditioning compressor Linkages and cables to the carburetor or throttle body Ignition coil and power transistor assembly, if equipped MDP sensor connector EGR connector TP sensor connector IAC motor connector Magnetic clutch and refrigerant temperature switch connector EVAP Purge Solenoid ECT sensor and gauge connectors

Please visit our web site at www.chiltonsonline.com

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22-6

MITSUBISH| _ MONTERO * MONTERO SPORT

ea

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Front and injector wiring harness CMP sensor CKP sensor : Distributor signal Generator Compactor connector Left and right heated O2S sensor Oil pressure switch connector Vacuum hoses . Air cleaner assembly, ducts and air intake hose Accessory belts Radiator, shroud and upper hose Cooling fan Battery Oil dipstick Hood 15. Refill the engine with the specified amount of oil. 16. Refill the radiator with coolant. 17. Check fuel system for leaks. 18. Check the automatic transmission fluid level, if equipped. 19. Recheck all engine adjustments.

7924UG08

Water pump mounting—3.0L engine 24 Nm

Water Pump 7924UG09

REMOVAL & INSTALLATION

Water pump and related components— 3.5L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. lf necessary, properly release the fuel pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: e Negative battery cable

ki CAUTION Wait at least 90 seconds after the

negative battery cable is discon-

nected to prevent possible deployment of the air bag. Upper radiator shroud Accessory belts Air conditioning compressor tensioner pulley, if equipped Cooling fan and clutch assembly and the water pump pulley Thermostat and housing on 3.0L, 3.5L engines

1. Alternator brace

2. Water pump 3. Gasket

4. O-ring

12-15 Nm

9-10 ft.Ibs,

20-27 Nm 15-19 ft.Ibs. 12-15 Nm 9-10 ft.Ibs,

12-15 Nm 9-10 ft.Ibs. 7924UG06

Water pump and related components—2.4L engine

Water outlet, gasket and houses Radiator hoses from the water pump Crankshaft pulley(s) Timing belt covers. If the same timing belt will be reused, mark the direction of the timing belt's rotation, for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprockets timing marks are aligned with the engine’s timing mark indicators. Timing belt Water pump bolts are different lengths, note their positions before removing. Water pump from the block Water pipe connection and O-ring To install: _5. Clean and dry the mating surfaces of the block and water pump 6. Install or connect the following: New O-ring on the water pipe connection, wet the new O-ring with water to aid in installation Water pump, with a new gasket, Torque the bolts to 106-133 inch lbs. (12-15 Nm) on 2.4L engine, 17 ft. Ibs. (23 Nm) on 3.0L and 3.5L engines Alternator bracket bolt to 17 ft. Ibs. (23 Nm) Timing belt(s) and covers Crankshaft pulley(s) Thermostat and housing on 3.0L, 3.5L engines. Torque the bolts to 12-14 ft. Ibs. (17-20 Nm). Radiator hose to the water pump Water outlet, new gasket and houses. Torque the bolts to 12-14 ft. Ibs. (17-20 Nm). Water pump pulley Cooling fan and clutch assembly Air conditioning compressor tensioner pulley, if equipped Accessory belts Upper radiator shroud Thermostat and housing on 3,0L, 3.5L engines Negative battery cable 7. Refill the radiator with coolant. This cooling system has a self-bleeding thermostat, SO system bleeding is not required. 8. Run the vehicle until the thermostat opens and fill the overflow tank. Check for leaks. 9. Once the vehicle has cooled, recheck the coolant level.

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MITSUBISHI

MONTERO © MONTERO SPORT 4)

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7924UG10

Align the camshaft sprocket timing mark with the timing mark on the cylinder head—2.4L

;

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

3 CAUTION Some models covered by this manual may be equipped with an air bag. Whenever working near any of the Supplement Restraint System (SRS) components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Air cleaner assembly, ducts and air intake hose Accelerator, and if equipped, kickdown cable Upper radiator hose Heater hoses Fuel lines and plug Power steering, if equipped unbolt the power steering pump from its brackets and position it to the side. Do not disconnect the power steering lines. Timing belt upper cover and valve cover Manifold Differential Pressure (MDP) sensor connector Exhaust Gas Recirculation (EGR) connector

Lasoo)

hy

22-7 oa

distributor housing in relation to the cylinder head and remove the distributor. 8. Remove or disconnect the following:

(on camshaft sprocket)

Cylinder Head

-

Throttle Position (TP) sensor connector Idle Air Control (IAC) motor connector Magnetic clutch and refrigerant temperature switch connector Evaporative Emission (EVAP) Purge Solenoid Engine Coolant Temperature (ECT) sensor and gauge connectors Front and injector wiring harness Camshaft Position (CMP) sensor Crankshaft Position (CKP) sensor Compactor connector Oil pressure switch connector Vacuum hoses Oil dipstick 5. Rotate the crankshaft clockwise and align the timing mark on the camshaft sprocket with the timing mark on the cylinder head. 6. Remove or disconnect the following: e Camshaft bolt e Sprocket from the camshaft (with the timing belt attached) and allow it to rest on the lower cover. Secure the belt to the sprocket so that they do not become disengaged.

e Exhaust pipe from the exhaust

manifold ¢ Cylinder head bolts, starting from the outside and working inward ¢ Cylinder head from the engine e Intake and exhaust manifolds from the cylinder head, if necessary To install: 9. Clean the cylinder head gasket mating surfaces. 10. Install or connect the following: e Intake and exhaust manifolds to the cylinder head, if removed e New head gasket to the block and position the cylinder head assembly with all head bolts and washers. 11. Tighten the bolts in the following sequence: a. Step 1: Torque the bolts in sequence to 58 ft. Ibs. (78 Nm). b. Step 2: Loosen all bolts in sequence to 0 ft. Ibs. C. Step 3: Torque the bolts in sequence to 14 ft. Ibs. (20 Nm). d. Step 4: Turn the bolts an additional 90 degrees. e. Step 5: Turn an additional 90 degrees. 12. Install or connect the following: Camshaft sprocket to the camshaft. Torque bolt to 65 ft. Ibs. (88 Nm). Distributor, aligning the marks made during removal e Distributor cap and spark plug wires Power steering pump and adjust the belt tension Heater hoses and upper radiator hose Valve cover. Torque the bolts to 30 ft. bs. (34 Nm). Upper timing belt cover. Torque the bolts to 95 inch Ibs. (11 Nm). Fuel lines

Do not rotate the crankshaft after the camshaft sprocket is removed from the camshaft. Secure the sprocket and timing belt so there is no slack in the belt. Be sure the sprocket does not become disengaged from the timing belt. If the engine is disturbed or the timing belt moved, the camshaft timing will have to be reset. 7924UG11

e Spark plug wires e Distributor cap and wires 7. Mark the position of the rotor and

Cylinder head bolt tightening sequence— 2.4L engines

Timing belt service is covered in Section 3 of this manual

22-8

MITSUBISH Al

MONTERO ¢ MONTERO SPORT

Accelerator and kickdown cable, if equipped MDP sensor connector EGR connector TP sensor connector IAC motor connector Magnetic clutch and refrigerant temperature switch connector EVAP Purge Solenoid ECT sensor and gauge connectors Front and injector wiring harness CMP sensor CKP sensor Compactor connector Oil pressure switch connector Oil dipstick Air cleaner assembly, ducts and air intake hose Negative battery cable 13. Refill the cooling system. 14. Start the engine and check for leaks. Check the ignition timing. 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Air cleaner assembly, ducts and air intake hose Upper radiator hose Accessory drive belts Cooling fan and pulleys Air conditioning compressor, if equipped Power steering pump and mounting brackets and position them to the side, without disconnecting the lines. Timing belt covers 5. Remove the timing belt as follows: a. Rotate the crankshaft and bring the No. 1 piston to Top Dead Center (TDC) on

Install the special clips MB 99844301 to hold the auto-adjusters in place.

¢ Rocker arms and rocker arm shafts e Rocker shaft springs Take care during removal that no oil, grease or dirt comes into contact with the timing belt.

To install: 3. Disassemble the rocker assembly, checking each component for wear, scoring, or plugged oil passages. Check the roller for correct and smooth rotation. Inspect the inner diameter of each rocker for any scoring or enlargement. If wear is found inside

MD998443

Lash adjuster af 4

Insert the Lash Adjuster Holder too! MD998443 to prevent the lash adjuster from falling out—

2.4L engines

Heater Core replacement is covered in Section 2 of this manual

ere

Se a

22-1 0 MES eeyS MONTERO SPORT

. Bearing cap No. 4 . Rocker arm (B) Spring . Rocker arm (A)

Spring

. Bearing cap No. 3 . Rocker arm (B) . Spring

WOWDNOAPWN— . Rocker arm (A) 11. 12. 13. 14. 15. 16.

Spring Bearing Rocker Spring Rocker Spring Rocker

cap No. 2 arm (B) arm (A)

arm shaft (B) 17. Rocker arm shaft (A)

18. Bearing cap No. 1 7924UG15

Exploded view of the rocker arms and shafts—3.0L engine

the rocker, replace it and inspect the shaft for damage. 4. Before reassembly, coat the contact faces liberally with clean motor oil. Observe the numbers on the bearing caps so that they are replaced in the correct location. Reassemble the rocker shafts into the front bearing cap so that the notches face outward. As you continue to assemble the springs, rockers and bearing caps, remember that the arrows on the bearing caps must point in the same direction as the arrow on the head. This is particularly important ifthe rockers have been removed from both heads. 5. Install or connect the following: Rocker arms and rocker arm shafts, Torque the bolts to 23 ft. Ibs. (31 Nm). Valve cover Torque the bolts to 30 inch Ibs. (3.4 Nm). e PCV hose Breather hose 3.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable

* CAUTION Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected. e Valve cover

e Auto lash adjuster retainers SST MD998443 on the rocker arms e Rocker arms, rocker shafts and bearing caps, as an assembly To install: 3. Inspect the bearing journals on the camshaft and the cylinder head. 4. Lubricate the camshaft journals and camshaft with clean engine oil. 5. Install the rocker arms, rocker arm shaft and the rocker shaft spring as follows: a. Temporarily tighten the rocker shaft with the bolts so that the intake valve rocker arms do not push on the valves. b. Insert the rocker shaft spring from above and mount it at right angles to the plug guide. c. Before installing the exhaust rocker arms and the rocker arm shaft, mount the rocker shaft spring. d. Remove tool SST MD998443 used to hold the lash adjuster in position. e. Check to ensure that the flat side of the rocker shaft is perpendicular to the cylinder head, and facing the valves. f. Gradually tighten the bearing caps in 2 or 3 steps. In the final step, tighten to 23 ft. Ibs. (31 Nm). 6. Install or connect the following: e Valve cover and new gasket. Torque the bolt to 2-3 ft. Ibs. (3-4 Nm). e Negative battery cable 7. Start the engine and check for leaks and proper operation. 3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable e Valve cover and the semi-circular packing. Crankshaft Position (CKP) sensor, matchmark for reassembly Camshaft Position (CMP) sensor, if equipped Install auto lash adjuster retainers SST MD998443 on the rocker arms

e Rocker arms and shafts e Lash adjusters 4, Check the camshaft journals for wear or damage. Check the cam lobes for damage. Also, check the cylinder head oil holes for clogging. To install: Lubricate the valve train components with clean engine oil.

5. Bleed and install the lash adjusters to the to the original bores in the cylinder head. 6. Install or connect the following: e Rocker arms and shafts. Torque the bolts to 23 ft. Ibs. (31 Nm), e Camshaft position sensor, if removed. Torque the mounting bolts to 78 inch Ibs. (9 Nm). ¢ Camshaft Position (CMP) sensor, if equipped e Valve cover and the semi-circular packing. Torque the bolts to 2.5 ft. lbs. (3.5 Nm). e Negative battery cable 7. Run vehicle and check for leaks.

MONTERO e Murer Seu 22-1 1 | Intake Manifold

Ignition coil

CAUTION

REMOVAL & INSTALLATION

Brake booster hose and vacuum

Wait at least 90 seconds after the

{

2.4L Engine

hose cluster from the air intake

Poth battery cable is disconnected to prevent possible deploy-

plenum ¢ Air intake plenum from the intake

Fala AT cay lide Seg. onesie tae

* Fuel lines, keep the line covered or

ment of the air bag.

1. Before servicing the vehicle, refer to the

precautions in the beginning of this section. 2. Drain the engine coolant.

3. Relieve the fuel pressure. 4. Remove or disconnect the following: * Negative battery cable

manifold

: mostat site noseainiiheeer: housing

‘ iHintake hoses, breather hose and rei! tl.

e

plugged

¢ Fuel rail assembly with injectors

Wires, hoses and linkages from the

throttle body

intact * Heater hose from the manifold

e Engine Coolant Temperature (ECT) sensor

°

11 -16 ft.lbs.

oe)

|

é

15-20 Nm

1

1500

12

1. 2. 3. 4. 5. 6. 7. 8.

Air intake hose Breather hose Air intake pipe Airhose . Accelerator cable and kick down plate Throttle body Gasket Water hose

9. 10. 11. 12. 13. 14. 15.

; Han

:

15-22 Nm

10-15 Nm 7-11 Mt

.

15-20

Nm

11-14

ft.lbs.

11-14 ft.lbs.

Brake booster vacuum hose Vacuum hose connection High tension cable Ignition coil Manifold difference pressure sensor Intake manifold plenum assembly Intake manifold plenum gasket

engine shown Exploded view of the intake plenum chamber and related components—2.4L

Brake service is covered in Section 4 of this manual

7924UG39

-

— >} #4

,

99-12

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MITSUBISHI

MONTERO ¢ MONTERO SPORT e New gasket and the intake manifold to the head. Starting from the middle and working outward, tighten the retaining nuts to 14 ft. Ibs. (19 Nm). e ECT sensor e Water outlet fitting. Torque the bolts to 14 ft. Ibs. (19 Nm). e Distributor with matchmarks aligned e Fuel rail assembly to the manifold using a new O-ring e Fuel lines

e Water outlet fitting e Distributor, matchmark for reassembly e Intake manifold from the cylinder head and engine e Manifold Differential Pressure (MDP) sensor, if equipped 5. Clean and dry the mating surfaces of the manifold and cylinder head. To install: 6. Install or connect the following:

e Heater hose to the manifold e Air intake plenum with a new gasket. Tighten the retaining bolts to 12 ft. Ibs. (16 Nm). e Vacuum hoses cluster, brake booster hose and all wires, hoses and linkages to the throttle body e Ignition coil e Air intake hoses, breather hose and the air intake pipe

..

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17-20Nm 20-40Nm 12-14 ft.lbs. 14-29 ft.lbs. 10—12 Nm

1. 2. 3. 4. 5. 6. 7. 8. 9.

High pressure fuel hose connection Fuel injector harness connector Fuel rail Insulator Heater hose Wiring harness connector Water outlet fitting Water outlet fitting gasket Thermostat

10. 11. 12. 13. 14. 15. 16. 17. 18.

10 —-13 Nm

18 —25 Nm

7-9

13 — 18 ft.Ibs.

ft.lbs.

Distributor Intake manifold plenum stay Intake manifold stay Intake manifold Intake manifold gasket Thermal switch Engine coolant temperature sensor Engine coolant temperature gauge unit Air conditioning engine coolant temperature switch 7924UG40

Exploded view of the intake manifold and related components—2.4L engine shown

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MONTERO ¢ MONTERO SPORT192- 1 3

¢ Manifold Differential Pressure

teste CAUTION

i sensor, if equipped ee e Upper radiator hose ae ee ei cable

been OFF. Properly relieve fuel pres-

. Check the system for leaks. Polenaine

tec

switch is turned to the LOCK position

sure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

1. Before servicing the vehicle, refer to rehearse inni the precautions j ULE

“i CAUTION Work must b e started after 90 seconds from the time the ignition

The fuel injection system remains under pressure after the engine has

. ai| os radiator with coolant.

may

—

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and the negative battery cable is disconnected.

* Air intake hose from the throttle body ° Positive Crankcase Ventilation

3. Drain the engine coolant.

4, Removeordisconnect the following:

RS

(PCV) hose

. ae Gas Recirculation (EGR) valve

° Negative battery cable

2. Relieve the fuel pressure.

He a

F3 tem

78 Ibn

ieee - 13 Ldm

89 — 106 Ib-in

17 - 20 Nm

12 - 14 lb-ft

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1. IGNITION COILS 2. BRAKE BOOSTER VACUUM HOSE CONNECTION 3. PCV HOSE CONNECTION 4. CRANKSHAFT POSITION SENSOR AND CAM POSITION SENSOR CONNECTOR 5. ACCELERATOR CABLE BRACKET - 6. THROTTLE CABLE BRACKET

7. IGNITION POWER TRANSISTOR 8. WATER OUTLET FITTING BRACKET 9. WATER PUMP STAY 10. VACUUM HOSE CONNECTION 11, FUEL PIPE CONNECTION 12. SOLENOID VALVE AND VACUUM

:

13. 14, 15. 16. 17. 18. 19. 20. 21. 22. 23.

VCV BRACKET MOP SENSOR EGR VALVE COVER EGR PIPE CONNECTION INTAKE MANIFOLD PLENUM STAY THROTTLE CABLE CONNECTION AIR INTAKE FITTING AIR INTAKE FITTING GASKET UPPER INTAKE MANIFOLD INTAKE MANIFOLD PLENUM GASKET

NOTE *1: Vehicles for Federal *2: Vehicles for California

HOSE ASSEMBLY

7924UG41

Exploded view of the upper intake manifold and related components—3.0L 24-valve engine shown

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

BISHI O 4414 MITSU 99.22¢ MONTERO MONTER \'

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12 Nm

106 Ib-in

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. HIGH-PRESSURE FUEL HOSE CONNECTION . FUEL PRESSURE REGULATOR . INJECTOR CONNECTOR . FUEL RAIL (WITH INJECTORS) . WATER HOSE CONNECTION 6. INTAKE MANIFOLD . INTAKE MANIFOLD GASKET

7924UG42

Exploded view of the lower intake manifold and related components—3.0L 24-valve engine shown

e Manifold Differential Pressure (MDP) sensor ® Vacuum hoses from the throttle body and air intake plenum Accelerator cable and the throttle control cable Coolant hoses Engine oil filler neck bracket from the air intake plenum EGR tube from the air intake plenum Plenum brackets Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed.

¢ Fuel hose from the fuel rail e Fuel return line and vacuum hose from the fuel pressure regulator Electrical connectors from the injectors Fuel rail and injectors e Intake manifold 5. Remove the gaskets and thoroughly clean and dry the mating surfaces of the

manifold and heads. To install: 6. Install or connect the following: e Intake manifold. Torque the nuts to

16 ft. Ibs. (21 Nm) start from the center and working outward. 7. Connect the hoses and connect the wires to the coolant switches. e Fuel rail assembly and connect the fuel hoses e New gasket and the air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. Ibs. (17 Nm). Plenum brackets PCV hose and vacuum hose cluster to the plenum EGR tube EGR temperature sensor wire Wires, hoses and linkages to the

throttle body e Air intake hose to the throttle body

Upper radiator hose to the thermostat housing e Negative battery cable 8. Refill the radiator with coolant. 9. Check fuel system for leaks. 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

+ CAUTION The fuel injection system remains under pressure after the engine has

been OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. 2. Relieve the fuel pressure. 3. Partially drain the cooling system. 4. Remove or disconnect the following:

e Negative battery cable

+ CAUTION Wait at least 90 seconds after the

negative battery cable is discona to aravant possible deployment of the air bag.

y

Air intake hose from the throttle body Electrical connectors and vacuum hoses from the throttle body and air

intake plenum Accelerator cable and the throttle control cable Coolant hoses Positive Crankcase Ventilation

(PCV) hose

MITSUBISHI

ONTERO e MONTERO SPORT e Exhaust Gas Recirculation (EGR) temperature sensor connector

-

-e EGR tube from the air intake plenum — Intake manifold plenum cover Intake manifold plenum stay brackets Air intake plenuin assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed Induction control valve assembly Fuel hose from the fuel rail Fuel return line and vacuum hose from the fuel pressure regulator Electrical connectors from the injectors Fuel rail and injectors Intake manifold 5. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads. To install: 6. Install or connect the following: Intake manifold. Tighten the nuts to 16 ft. Ibs. (21 Nm). Start from the center and work outward. Fuel rail assembly and connect the fuel hoses . Induction Control valve assembly and tighten to 72 inch Ibs. (9 Nm). New gasket and air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. Ibs. (18 Nm). Plenum to engine brackets Hoses and wires to the coolant Switches PCV hose and vacuum hose cluster to the plenum EGR tube. Torque the bolts to 13 ft. lbs. (18 Nm). EGR temperature sensor wire Wires, hoses and linkages to the throttle body Air intake hose to the throttle body Upper radiator hose to the thermoStat housing Negative battery cable 7. Refill the radiator with coolant. 8. Check the system for fuel leaks. 9. Set all adjustments to specifications.

Exhaust Manifold

|

REMOVAL & INSTALLATION 2.4L Engine 1. Remove or disconnect the following: e Negative battery cable

Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

padcowl from the exhaust maniold Aspirator valve assembly, if equipped Oil dipstick and guide Oxygen (02S) sensor connector and ground cable, if equipped Exhaust pipe from the manifold Exhaust manifold and gasket from the engine

To install: 2. Install or connect the following: Exhaust manifold. Torque the M8 mounting nuts to 22 ft. Ibs. (29 Nm) and the M10 mounting bolts 36 ft. Ibs. (49 Nm). starting from the middle and working outward. O2S sensor connector and ground cable, if equipped Exhaust pipe to the manifold. Torque the nuts to 35ft. (49 Nm). Aspirator valve assembly, if removed Heat cowl to the exhaust manifold. Torque the bolts to 117 inch Ibs. (13 Nm). Negative battery cable 3. Start the engine and check for exhaust leaks. 3.0L and 3.5L Engines 1. Remove or disconnect the following: e Negative battery cable e Exhaust pipe from the exhaust manifolds e Oil dipstick, guide and O-ring e Heat shields e Exhaust manifolds 2. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage. To install: 3. Install or connect the following: e New gasket and exhaust manifold. Torque the nuts to 33 ft. Ibs. (44 Nm) on 3.0L engines and 22 ft. Ibs. (29 Nm) on 3.5L engines. e Heat shield, Torque the bolts to 10 ft. Ibs. (14 Nm). e Exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).

22-45,

¢ Oil dipstick, guide and new O-ring e Negative battery cable 4. Start the engine and check for exhaust leaks. Front Crankshaft Seal

REMOVAL & INSTALLATION 2.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section: 2. Drain the crankcase. 3. Drain and recycle the engine coolant. 4: Remove or disconnect the following:

:

Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

REMOVAL & INSTALLATION 2.4L engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery e Engine under cover e Bell housing cover e Oil pan To install: 4. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces. 5. Apply liquid gasket around the surface of the oil pan. e>Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

6. Install or connect the following: e (il pan. Torque the bolts to 61 inch lbs. (6.9 Nm). e Bell housing cover. Torque the bolts to 78 inch lbs. (8.8 Nm). e Engine under cover e Negative battery cable 3.0L engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery Engine under cover Alternator and belt Stabilizer bar Front exhaust pipe Actuator assembly and heat protector Oil dipstick Crossmember assembly Automatic transmission oil dipstick assembly Exhaust pipe support bracket Transmission stay Oil pan, lower Oil screen and baffle plate Oil pan upper To install: 4. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces. 5. Apply liquid gasket around the surface of the oil pan. e>Assemble the oil pan to the cylinder block within 15 minutes after applying the liquid gasket.

7924UG17

Apply a bead of sealant around the oil pan flange as shown—all engines are similar

6. Install or connect the following: Oil pan upper. Torque the bolts to 53 inch Ibs. (6.0 Nm). Oil screen and baffle plate. Torque the bolts to 14 ft. Ibs. (19 Nm). Oil pan, lower. Torque the bolts to 53 inch Ibs. (6.0 Nm). Transmission stay. Torque the bolts to 26 ft. Ibs. (35 Nm). Exhaust pipe support bracket. Torque the bolts to 35 ft. Ibs. (49 Nm). Automatic transmission oil dipstick assembly. Torque the bolts to 33 ft. lbs. (44 Nm). Crossmember assembly. Torque the bolts to 80 ft. Ibs. (108 Nm). Oil dipstick. Torque the bolts to 35 ft. Ibs. (48 Nm). Actuator assembly and heat protector Front exhaust pipe Stabilizer bar Alternator and belt Engine under cover Negative battery 3.5L engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Skid plate and the engine undercover Front exhaust pipe, if necessary Catalytic converter Lower oil pan Front differential carrier

Cover Oil dipstick Oil pan upper e Oil screen To install: 4. Before installing, thoroughly clean the oil pan and cylinder block mating surfaces.

6. Install or connect the following: Oil screen. Torque the bolts to 13 ft. Ibs. (19 Nm). Oil pan upper. Torque the bolts to 48 inch Ibs. (6 Nm). Oil dipstick. Torque the bolts to 39 inch Ibs. (4.8 Nm). e Cover. Torque the bolts to 84-108 inch Ibs. (10-12 Nm). Front differential carrier Lower oil pan. Torque the bolts to 84-108 inch Ibs. (10-12 Nm). e Catalytic converter e Front exhaust pipe, if necessary. Torque the bolts to 35 ft. Ibs. (49 Nm). e Skid plate and the engine undercover Negative battery cable

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the oil and remove the oil filter. 3. Remove or disconnect the following: e Negative battery cable

ki CAUTION Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

Timing belt covers, timing belts and sprockets Oil-pan and gasket Oil pump pick-up and gasket Oil pressure relief plunger plug and gasket Spring and plunger from the oil filter bracket Bracket mounting bolts and the oil filter mount and gasket Plug cap and gasket that covers the oil pump driven gear shaft. Using special tool MD998162 this is located on the right side of the front case, just above the protruding drive gear shaft. Retaining bolt from the oil pump

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‘MITSUBISHI

MONTERO ¢ MONTERO SPORT

. Drain plug

. . . . . . . . .

Oil pressure switch Oil pan Oil screen asket Oil filter bracket Gasket Relief plug Gasket Relief spring Relief plunger Plug cap O-ring Driven gear bolt Front case

. Gasket

. Crankshaft front oil seal

5 15-22 Nm

11-16 ft.lbs.

Pats

. Oil pump cover

. Oil pump driven gear . Oil pump drive gear . Left silent shaft . Right silent shaft . Silent shaft front bearing ARORA SNBRRBBRBSOU OOMPNOTAWN= . Right silent shaft rear bearing 29. Left silent shaft rear bearing

ae:

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33

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7924UG18

Exploded view of the oil pump, oil pan and related components—2.4L engine shown; other engines are similar

driven gear located behind the plug removed earlier e Front case mounting bolts and the case from the block e Case gasket from the block To install: 4. Prime the pump by pouring fresh oil into the pump intake and turning the driveshaft until oil comes out of the pressure port. Repeat this a few times until no air bubbles are present. Replace all seals on the case assembly. 5. Install a special seal guide to the

‘crankshaft, MD998285, so the smaller diameter faces outward. Coat the outer diameter of the seal with clean engine oil. 6. Install or connect the following: e New front case gasket and the front case by carefully positioning the crankshaft seal over the seal guide and lining up all bolt holes. Torque the bolts to 17 ft. Ibs. (23 Nm). 7. Remove the plug from the left side of the block. Hold the left side silent shaft by inserting a tool in the plug hole and tighten the driven gear bolt to 26 ft. Ibs. (35 Nm) e New O-ring and the plug cover e Oil filter mounting bracket gasket

¢ Mounting bracket and bolts tightening the oil filter mounting bracket bolts to 12 ft. Ibs. (16 Nm). 8. Clean or replace the oil pick-up screen and install with a new gasket. 9. Install or connect the following: e Oil pan using a new gasket e Timing sprockets, belts and covers e Negative battery cable 10. Refill the engine with the proper amount of engine oil. 11. Start the engine and check for proper oil pressure. Check for leaks. 3.0L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Timing belt Oil pressure switch Oil dipstick Oil pans from the engine Oil baffle and screen Oil pump mounting bolts and the pump from the front of the engine

e>Note the position of each oil pump case retaining bolts to facilitate installation. The bolts are of different length.

To install: : 4. Clean the gasket mounting surfaces of the pump and engine block. 5. Prime the pump by pouring fresh oil into the inlet and turning the rotors or by packing pump with petroleum jelly. Using a new gasket, install the oil pump on the engine and tighten all bolts to 10 ft. Ibs. (14 Nm). 6. Clean out the oil pick-up or replace as required. Replace the oil pick-up gasket ring and install the pick-up to the pump. 7. Install or connect the following: Oil filter and the bracket. Torque the bolts to 17 ft. Ibs. (23 Nm). Oil baffle and screen. Torque the bolts to 13 ft. Ibs. (18 Nm). Oil pans. Torque the engines to 52 inch Ibs. (5.9 Nm). Oil pressure switch. Torque the switch to 87 inch Ibs. (9.8 Nm). Timing belt Dipstick e Negative battery cable 8. Refill the engine with the proper amount of oil.

For Wheel Alignment specifications, see Section 7 of this manual

ey e ee

22-2

Da cEnGemontEn 0. SPORT

12-15 Nm

9-10 ft.lbs.

3

4

9—10 ft.lbs.

15-22 Nm ——§ 11-15 ft.lbs.

. Oil Oil Oil Oil

pressure switch fitter filter bracket filter bracket gasket

14. 15. 16. 17. 18.

Drain plug . Drain plug gasket

Oil pa n Oil screen Oil screen gasket ONNAARWN= 10. Plug 11. Relief spring 12. Relief plunger

Oil Oil Oil Oil Oil

pump pump pump pump pump

case gasket cover outer rotor inner rotor

13. Crankshaft front oil seal 7924UG19

Exploded view of the oil pump, oil pan and related components—2.4L engine shown; other engines are similar

9. Start the engine and che ck for proper oil pressure. Check for leaks.

Rear Main Seal REMOVAL & INSTALLATION 2.4L Engine

1. Before servicing the vehi cle, refer to the precautions in the beginnin g of this section. 2. Remove or disconnect th e following: e Transmission and clutch assembly, if equipped. e Flywheel or the drivep ate and the

adapter plate, if equipped. Matchmark for reassembly. e (il seal Take care not to gouge or damage the metal surrounding the seal. Inspect the sealing surface at the rear of the crankshaft. If a deep groove is worn into the surface, the crankshaft will have to be replaced. Lubricate the sealing surface with clean engine oil. To install:

3. Using a seal installer of the correct size, install the new seal into the bore of rear oil Seal case. Make certain that the flat side of the seal will face outward when the case |S installed on the engine. The inside

of the seal must be flush with the inside surface of the seal case. 4. Install or connect the following: e Rear plate and bell housing cover ¢ Flywheel or drive plate, observing the matchmarks made earlier e Transmission and related components as necessary

3.0L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission and clutch assembly, if so equipped.

"MITSUBISHI

MONTERO ¢ MONTERO SPORT

. FLYWHEEL BOLT . FLYWHEEL . REAR PLATE . BELL HOUSING COVER . OIL SEAL CASE OIL SEAL Oahwonm—

7. 8. 9. 10. 11. 12.

BEARING CAP BOLT BEARING CAP CRANKSHAFT BEARING CRANKSHAFT CRANKSHAFT BEARING CYLINDER BLOCK

(LOWER) (UPPER) 7924UG20

Exploded view of the crankshaft, rear main seal, and related components—2.4L engines

e Flywheel or driveplate and adapter plate, matchmark for reassembly. For the 3.0L engines, use the Mitsubishi tools (MB990767-01 and MIT308239) to hold the crankshaft and flywheel stationary while loosening the flywheel bolts. For the 3.5L engine, use Mitsubishi tool (MD998781) to hold the flywheel in position. 3. Remove the rear oil seal as follows: a. Cut out a portion in the crankshaft oil seal lip.

b. Cover the tip of a small prytool with a cloth and apply it to the cutout in the oil seal to pry the oil seal out.

“kk CAUTION Take care not to damage the crankshaft and oil seal case.

To install: 4 \|nspect the sealing surface at the rear of the crankshaft. If a deep groove is worn into the surface, the crankshaft will have to be replaced. Coat the sealing lip of the seal

with fresh, clean engine oil. Press the new seal into the case with a Seal installing tool. The seal must be pressed in squarely until it bottoms in the case. It is necessary to use the proper tool (MD998718-01) to fit the seal into place. 5. Install or connect the following: e Rear plate e Transmission mounting plate e Flywheel or drive plate and adapter e Transmission and related components as necessary

For Maintenance Interval recommendations, see Section 7 of this manual

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75 Nm 54 ft.lbs.

28 Nm

21 ft.lbs. 23 Nm

17ft.lbs.

—

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54 ft.lbs.

8. Bearing cap 9. Crankshaft bearing, lower

:

10.11. Grankshatt Thrust bearing

ei Oe 4 =peal bo ace

12. Crankshaft bearing, upper

6. Crankshaft rear oil seal

be lc pe arebracket

13. Knock sensor

5. Oil he case

.

7. Bearing cap bolt

vy 7924UG22

Exploded view of the crankshaft, rear main seal and related components—3.5L engine shown; 3.0L engine is similar

Piston and Ring

POSITIONING

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IDENTIFICATION MARK “1R”

DENTIEGATION | SIZE MARK

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Oil ring identification

Lower side rail 7924AG49

9302AG13

Piston ring identification

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Piston ring end-gap spacing

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Fuel System Service Precautions

Safety is the most important factor when

performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or

death. Maintenance and testing of the

before disconnecting any fuel system

FUEL FILTER

component, fitting or fuel line connection. Failure to do so may result in personal injury.

1998-02 Montero Sport and 1998-00 Montero 1. Disconnect the fuel pump electrical connector, located at the rear side of the fuel tank, 2. Start the engine. 3. After the engine stalls, turn the ignition switch OFF and reconnect the fuel pump connector. 4. Disconnect the negative battery cable, then continue with the service procedure.

vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. ° Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution when relieving fuel system pressure, to avoid exposing your skin, face and eyesto fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always placeashop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors

The fuel injection system remains under pressure after the engine has

5. Using a back-up wrench disconnect the fuel line(s) from the filter. If the filter uses a push-on type connector, press the retainer to release the connection. 6. Remove the filter from the mounting bracket. To install: 7. Position the filter to the mounting bracket in the proper direction. 8. Connect the fuel lines to the filter. Use a back-up wrench to hold the fuel filter. Torque the banjo bolt(s) to 18-25 ft. Ibs. (25-35 Nm) or the line fitting to 27 ft. Ibs.

Take a

sure before disconnecting any fuel

been OFF. Properly relieve fuel pres-

(36 Nm).

lines. Failure to do so may result in

equipped.

into contact with a spark or open

P

P

° Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary » stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose where fuel pipe is installed.

Fuel System Pressure RELIEVING

Fuel high

2001-02 Montero

pressure hose

1. Turn the ignition switch to LOCK. 2. Fold down the second seat. 3. Remove the upper and lower service hole cover. 4. Disconnect the fuel pump module connector. 5. Start the engine and let it run out of fuel. Fuel Filter

REMOVAL & INSTALLATION

>: CAUTION

fire or personal injury.

2 CAUTION

eS

EE

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SE

1. Relieve the fuel system pressure. 2. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

The fuel system is under constant pressure, even with the engine off. This pressure must be relieved

7924UG25

Always use a back-up wrench when removing or installing fuel lines to the fil-

9. Install the fuel filter protector if

10. Connect the negative battery cable. 11. Start the engine and check for leaks.

“Fuel Pump

Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion. ee

7924UG24

Fuel filter removal—Montero Sport shown

tion. 3. Disconnet the negative battery cable. 4. Remove the fuel filter protector if equipped.

REMOVAL & INSTALLATION Montero The

manufacturer recommends

draining of the fuel tank.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable

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

”

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1

2 2-24 sit

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i

CAUTION _ The fuel injection system remains under pressure after the engine has been OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion. e Rear floor carpeting e Fuel pump cover

SPORT

SSS

e Fuel pump connector and the fuel hoses e Fuel pump assembly To install: 4. Install or connect the following: e Fuel pump assembly into the fuel tank. Torque the nuts to 24 inch lbs. (2.5 Nm). Fuel lines and the fuel pump connector. Fuel pump cover. Torque the bolts to 108 inch Ibs. (12 Nm). Rear floor carpeting. Negative battery cable 5. Refill the fuel tank, if drained 6. Start the vehicle; check for leaks and proper operation.

Montero Sport 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove the fuel tank drain plug and drain the fuel from the tank.

The fuel injection system remains under pressure after the engine has been OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

4. Remove or disconnect the following: e Negative battery cable

2.5 Nm

1.8 ftibs.

2k CAUTION Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag. e Fuel tank protector, if equipped e Fuel tank from the vehicle e Fuel pump retaining screws and the pump from the tank To install: 5. Clean the seal area of the tank. 6. Install or connect the following: New gasket Fuel pump in the same position as originally installed. Fuel pump retaining screws, Torque the nuts to 22 inch Ibs. (2.5 Nm). Fuel tank. Torque the bolts to 20 ft. lbs. (27 Nm). Fuel tank drain plug and the fuel tank protector, if equipped

Negative battery cable 7. Refill the fuel tank and install the cap. 8. Check fuel system for leaks.

Fuel Injector REMOVAL & INSTALLATION 2.4L engines

34 Nm

25 ft.lbs.

1. Floor cover

5. Fuel pump and filter assembly

2. Packing 3. High-pressure fuel hose

6. Fuel tank differential pressure sensor 7. Filter

4. Fuel return hose connection

8. Fuel pump assembly 7924UG26

The fuel pump on the Montero is removed through the rear floor pan

1. Before servicing the vehicle, refer to neprecautions in the beginning of this secion. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: ¢ Accelerator cable e Air intake tube and hose

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Pad

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ae 22-25 ° itTSU MONTERO « ac e Injector connector ¢ Fuel rail and insulators ¢ Fuel injectors and insulators e Q-rings and grommets To install: 4. Install or connect the following: O-rings and grommets Fuel injectors and insulators Fuel rail and insulators. Torque the bolts to 106 inch Ibs. (12 Nm). Injector connector Pressure regulator, vacuum line and o-ring. Torque the bolts to 78 inch Ibs. (8.8 Nm). Fuel return line High pressure fuel hose and o-ring. Torque the bolts to 43 inch Ibs. (4.9 Nm). Air intake tube and hose Accelerator cable 9308UG05

_

Exploded view of fuel injector and rail on 2.4L engines other engines are similar

e High pressure fuel hose and o-ring

e Fuel returndine e Pressure regulator, vacuum line and o-ring

3.0L and 3.5L engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following:

Air cleaner assembly, ducts and air intake hose Intake manifold plenum Fuel return line Pressure regulator, vacuum line and o-ring High pressure fuel hose and o-ring Injector connector Fuel pipe and o-rings Fuel rails and insulators Fuel injectors and insulators O-rings and grommets To install: 4. Install or connect the following: O-rings and grommets Fuel injectors and insulators Fuel rail and insulators. Torque the bolts to 106 inch Ibs. (12 Nm). Injector connector High pressure fuel hose and o-ring. Torque the bolts to 43 inch Ibs. (4.9 Nm), Pressure regulator, vacuum line and o-ring. Torque the bolts to 78 inch Ibs. (8.8 Nm). Fuel return line Intake manifold plenum Air cleaner assembly, ducts and air intake hose

DRIVE TRAIN Transmission Assembly

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: Negative battery cable Transmission and transfer case shift lever assembly. On manual transmissions Transfer case protector, if equipped Front exhaust pipe from the 2 exhaust manifolds, then disconnect it from the intermediate pipe/catalytic converter (make certain to retain the bolts and nuts for reassembly). Rear driveshaft at both the rear axle and the transfer case flanges. Matchmark for reassembly. Front driveshaft from the front axle, by sliding it forward, plug the

transfer case to prevent residual fluid leakage. On 4-wheel drive vehicles Dust seal from the rear extension housing. Ground cables AWD indicator light switch connector Pulse generator connector Speed Sensor Connector Oxygen (02S) sensor connector Back-up light switch connector HI/LO detection switch connector Center differential lock detection switch connection. There may be others depending on the particular year, model and engine with which the vehicle came equipped. 4. Remove or disconnect the following: e Speedometer cable out of the transmission 5. On manual transmissions: 6. Remove or disconnect the following: e Clutch cylinder heat protector e Clutch release cylinder (with the clutch hose connected to it) from the transmission. Suspend it from

the body by using a piece of wire or a similarly safe method. e Starter motor and the heat shield 7. On automatic transmissions: 8. Remove or disconnect the following: e Bolts attaching the torque converter to the flexplate e Dipstick e Fluid cooling lines e Shift linkage at the transmission 9. Place a floor jack and a block of wood below the engine oil pan. 10. Lift the floor jack under the engine just until the weight of the engine is taken onto the jack—the engine should only barely be lifted by the jack. 11. Use a transmission jack or second floor jack to place under the transmission. Don't support the transmission yet, only lift the jack until it is slightly below the transmission. 12. Remove or disconnect the following: e Left-hand and right-hand side transmission stays from the front of the transmission, if equipped e Bell housing lower cover

For complete service labor times, order the Chilton Labor Guide

20-2

0

MITSUBISHI

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MONTERO e MONTERO SPORT

e Transfer case mounting bracket, if equipped 13. Lift the floor jack up until the transmission is being slightly supported by it. 14. Remove or disconnect the following: e Transmission-to-crossmember bolts. Lift the jack about % in. (6mm) off of the crossmember support. e Crossmember from the vehicle e Transmission mounting blots. Pull the transmission away from the engine and lower it from the vehicle. To install: 15. Lift the transmission and transfer assembly into position with the floor jack. 16. On the engine side, there are 2 centering locations. Be sure that the transmission mounting bolt holes are aligned with them before mounting the transmission and transfer assembly to the engine. Lowering the rear of the engine SLIGHTLY may help align the 2 assemblies. 17. Install or connect the following: e Transmission assembly onto the engine making sure the aligning areas stay aligned. Torque the bolts to 54 ft. Ibs. (75 Nm). 18. Lift the transmission/transfer assembly with the floor jack. Since the engine is now attached to the transmission, it also will rise slightly. Adjust its jack to keep only slight support. 19. Install or connect the following: Crossmember in place and secure with the mounting bolts. Torque the bolts to 47 ft. Ibs. (65 Nm). Transmission and transfer case assembly onto the crossmember Crossmember-to-transmission bolts. Torque the bolts to 15-18 ft. Ibs. (20-24 Nm) on Montero sport and to 36 ft. Ibs. (49 Nm) on Montero. Mounting bracket back onto the transfer case, if equipped Bell housing lower cover Left-hand and right-hand side transmission stays Starter motor and heat shield Clutch release cylinder Speedometer cable into the transmission and secure it there with the retaining ring. Center differential lock detection switch connection HI/LO detection switch connector Back-up light switch connector OvS sensor connector Speed Sensor Connector Pulse generator connector 4WD indicator light switch connector Ground cables

e Flexplate-to-torque converter bolts. Torque the bolts to 25-30 ft. Ibs. (35-42 Nm). On automatic transmissions e Dipstick tube e Shift linkage e Fluid cooler lines. Torque the line fittings to 32 ft. Ibs. (44 Nm). On automatic transmissions 20. Tap the dust seal guard back onto the rear extension housing with a rubber or plastic mallet. 21. Install or connect the following: Front driveshaft into the transfer case, then attach it to the front differential Rear driveshaft, make certain that the matchmarks line up, Front exhaust pipe to the catalytic converter and the exhaust manifolds Transfer case protector, if equipped Transmission and transfer case shift lever assembly. On manual transmissions Negative battery cable to the battery 22. Refill the transmission and transfer case with oil. 23. Start the vehicle and check for any leaks.

1 2, 3. 4. 5. 6. Us

Clutch cover assembly Clutch disc Return cli

Clutch

;

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transmission assembly 3. Insert a suitable tool in the flywheel “pilot bearing hole to keep the clutch disc from falling off. Loosen the clutch cover retainer bolts gradually in a crisscross fashion. 4. Remove or disconnect the following: e Clutch cover and disc 5. Check the release bearing for scorching, damage or strange noise. Replace, if necessary. 6. Inspect the flywheel surface for heat cracks or scoring. Reface or replace the flywheel as required. To install: 7. Apply high temperature grease to the clutch disc splines, input shaft, contact points of the release fork and inside diameter of the release bearing. ->Do not allow oil or grease to contact the clutch facing and pressure plate.

25-30 ft.ibs.

Clutch release bearing Release fork Fulcrum Release fork boot

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7924UG29

Exploded view of the typical clutch assembly components

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8. Install or connect the following: e Flywheel, align using a suitable tool e>When installing the clutch disc, be sure that the surface having the manufacturer’s stamped mark is on the pressure plate side.

e Clutch cover with the dowel pin holes in alignment with the dowel pins in the flywheel and tighten the bolt gradually in a crisscross fashion. Torque the bolts to 14 ft. Ibs. (19 Nm). e Transmission assembly e Negative battery cable 9. Road test the vehicle for proper operation.

Hydraulic Clutch System

e Have a helper depress the clutch pedal e Lock the bleeder and have the helper release the pedal e Wait 15 seconds and repeat the procedure (including the 15 second wait) until no air bubbles flow from the bleeder. Remember to close the bleeder before the pedal is released. If the bleeder is left open when the pedal is released, air will be induced into the system. 6. Ifa helper is not available, connect a small hose to the bleeder, submerge the other end in a clean container of fresh brake fluid placed in a position that is visible from the driver's seat. Pump the pedal until no air comes out of the tube.

To install: 5. Install or connect the following: New circlip, on the left side halfshaft Inner shaft. Torque the nuts to 36-43 ft. Ibs. (49-59 Nm), on the right side halfshaft Front hub/knuckle and bearing assembly Upper ball joint to the knuckle. Torque the nut to 54 ft. Ibs. (74 Nm), Lower ball joint to knuckle. Torque the nut to 108 ft. Ibs. (147 Nm). New cotter pins Tie rod end to the steering knuckle. Torque the nut to 33 ft. Ibs. (44

Nm) and a new cotter pin. Speed sensor, if removed Front brake assembly Shim and snapring to the axle shaft. Install the front hub dust cover Wheels and the undercover Negative battery cable

Transfer Case Assembly

BLEEDING

REMOVAL g INSTALLATION

When bleeding, keep the facial area well away from the slave cylinder and protect all painted surfaces from fluid contact. Brake fluid will damage painted surfaces and could cause physical injury. 1. Fill the clutch master cylinder with fresh DOT 3 brake fluid. 2. Have a helper sit in the vehicle. 3. Remove the bleeder screw cap. 4. |f the system is empty, the most efficient way to get fluid down to the cylinder is: a. Loosen the bleeder about 12 —% turn b. Place a finger firmly over the bleeder c. Have a helper pump the brakes slowly until fluid pressure is felt at the bleeder d. Once fluid is at the bleeder, close it before the pedal is released. e>if the pedal is pumped rapidly, the fluid will churn and create small air bubbles, which are difficult and time consuming to remove from the system. These air bubbles will eventually congregate and will result in a spongy pedal.

5. Once fluid has been pumped to the slave cylinder: e Open the bleeder screw

The transfer case is removed from the vehicle along with the transmission. Refer to the Transmission Removal and Installation procedure for information.

REMOVAL & INSTALLATION Outer Axle Shafts

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Undercover Wheels Hub cover dust cap Snapring from the inside of the hub and the shim Front brake caliper assembly and support with mechanics wire Speed sensor, if equipped with ABS Tie rod from the steering knuckle assembly Upper and lower ball joints from the steering knuckle assembly Front hub/knuckle assembly with the inner and outer bearings intact 3. On the left side, pull the halfshatt from the differential carrier. 4. For the right side, remove the fasteners and the halfshaft from the vehicle.

Inner Axle Shafts 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Undercover Right side wheel Right outer halfshaft Lower shock absorber mounting bolts Inner shaft from housing, using a slide hammer with tool MB990241 To install: 3. Install or connect the following: New circlip on the inner halfshaft Inner shaft into the housing, drive the axle into position. Lower shock absorber mounting bolts. Torque the bolts to 65-76 ft. lbs. (88-103 Nm). Right halfshaft assembly Undercover Wheel Negative battery cable

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

Please visit our web site at www.chiltonsonline.com

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. D.O.J. boot band (large) D.O.J. boot band (small) . Circlip D.O.J. outer race Dust cover Circlip Ball D.O.J. cage Snap ring D.O.J. inner race AG jijels: DROR maelele) J. boot band (smail)

J. boot band (large) J . DCot +RWONM-AGOONOWAR WY OW0) Ww |. assembly

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9308UG06

CV-Joint, exploded view

MONTERO e MONTERO SPORT

2. Remove or disconnect the following: Front wheel

» Driveshaft from the car Small and larger band Circlip Double Offset Joint (DOJ) outer race

Dust cover Circlip

Balls from the cage Cage from the inner race. Turn the cage so that the projections of the inner race align with the recesses of the cage. Snapring from the shaft DOJ inner race

Slide the boot off

damage. Clean all the parts thoroughly and air dry them completely before installation. Any remaining cleaning solvent can dissolve the lubricating grease. 4. Tool MB991561 can be used to crimp the bands in place. 5. Install or connect the following: BJ assembly BJ boot, slid the small end of the boot until only one shaft groove cone be seen. BJ small band, crimp the band. Fill the BJ boot with 4.6 oz (130 g) of grease. BJ larger band, crimp the band DOJ small band and boot, fill the

¢ Outer race, fill the outer race about ¥ full of grease. e Dust cover e Circlip e Large boot band, release the air from the boot then crimp e Driveshaft into the car

Automatic Locking Hubs

REMOVAL & INSTALLATION 1. Place the locking hub in the free position. To do this, shift the transfer shift lever to the 2H position, then move the vehicle 4—7 ft. (1-2 m) backwards. 2. Before servicing the vehicle, refer to

boot with grease DOJ cage onto the driveshaft so

Birfield Joint (BJ) small and larger

bands

that the smaller diameter side is

: - nies,

uPprecautions in the beginning of this secion. 3. Remove or disconnect the following:

: Hi ve

To install:

|

¢ DOJ inner race and new snap ring,

‘ pina of the vehicle

3. Check the shaft and splines for dam~ age or wear. Inspect the cage, race and balls

apply grease to the inner race e Balls into the cage, grease to the

chee ca tity ince Rael © Shim

for any sign of corrosion, wear, cracking or

ball areas of the cage and race

1. Cover . Adjustment

5. Bolts ; 6. Automatic free-wheeling He assembly

of drive shaft end play

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7. Shim

3. Shim

8. Lock washer

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Axle hub and locking hub removal and installation—automatic hubs

Timing belt service is covered in Section 3 of this manual

22-30 “aha 0) Ba SPORT e Drive flange e Front brake assembly e Speed sensor, if equipped e Lock washer e Lock nut e Front hub assembly To install: 4. Install or connect the following: e Front hub assembly e Lock nut. Torque the nut as follows: a. Step 1: Torque the nut to 119 ft. lbs. (162 Nm). b. Step 2: Loosen to 0 ft. Ibs. (0 Nm). c. Step 3: Torque the nut to 18 ft Ibs. (25 Nm). d. Step 4: Loosen the nut 30-40 degrees. 5. Install or connect the following: e Lock washer Speed sensor, if equipped Front brake assembly. Torque the bolts to 65 ft. Ibs. (88 Nm). Drive flange. Torque the bolts to 36-43 ft. Ibs. (49-59 Nm). Shim Snapring to the axle shaft Hub cover Front wheels of the vehicle

Axle Shaft, Bearing and Seal

Wheel assembly Brake line Rear brake assembly Parking brake cable and assembly Axle shaft Snapring Retainer Bearing inner race, inner and outer Oil seal Bearing case O-ring e Oil seal To install: 3. Install or connect the following: e Bearing case e Bearing inner race, outer. Press the bearing into the bearing case. e Oil seal. Press the seal using tools MB990932 and MB990938. e Bearing inner race, inner. Press the bearing into the bearing case. Axle shaft, Place into bearing case Retainer, press onto shaft Snapring Oil seal and O-ring into axle shaft 4. Axle shaft assembly into axle. e Parking brake cable end e Parking brake cable attaching bolt e Rear brake assembly e Brake line e Wheel assembly

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

ek CAUTION Some vehicles are equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.

pinion 4. Pry the pinion seal out of the differential carrier. To install: 5. Clean and inspect the sealing surface of the housing. 6. Install or connect the following: ¢ New seal into the housing until the flange on the seal is flush with the carrier. Using a seal driver. 7. With the seal installed, the pinion bearing preload must be set. e Pinion nut (a new self-locking pinion nut must be used) while holding the flange, until the turning torque is the same as before removal. The final pinion nut torque must be between

REMOVAL & INSTALLATION Rear

2. Remove or disconnect the following: e Driveshaft, matchmark for reassembly 3. Check the turning torque of the pinion before proceeding. It should be 2.6-4.5 inch Ibs. (0.4-0.5 Nm). This is the torque that must be reached during installation of the pinion nut. e Pinion nut and washer using a suitable pinion flange holding tool ¢ Companion flange from the drive

137-181 ft. Ibs. (190-250 Nm).

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

e Driveshaft, align the matchmarks 8. Check the level of the differential lubricant when finished.

STEERING AND SUSPENSION

|

accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. ¢ With the inflator module on the bench, never place anything on or close to the module that may be thrown in the event of an accidental deployment.

negative battery cable must be disconnected and at least 60 seconds must. elapse before working on the system. Failure to do so may result in deployment of the air bag.

PRECAUTIONS

DISARMING

several precautions must be observed when handling the inflator module to avoid

To avoid personal injury when working on vehicles equipped with an air bag, the

Recirculating Ball Power Steering Gear :

REMOVAL & INSTALLATION 1. On vehicles equipped with a Supplemental restraint system (SRS), turn the front wheel to the straight ahead position and remove the ignition key to prevent the steering wheel from turning. 2. Drain the power steering fluid. _ 3. Remove or disconnect the following:

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Mohresadeoe ee SPORT 22-31 rm . Shock Absorber REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to teprecautions in the beginning of this secion, 2. Remove the upper shock mounting nut, washer and bushing. ‘ Remove the lower mounting bolts. 4. Remove the shock absorber. To install: ->|f the shock absorber has a white paint mark on the lower end, be sure the mark faces the outside of the vehicle when installed.

1. CONNECTING BOLT FOR STEERING GEAR BOX AND STEERING SHAFT 2. COTTER PIN 3. CONNECTION FOR PITMAN AND RELAY. ROD

ARM

4. 5. 6. 7. 8.

PRESSURE TUBE RETURN TUBE O-RING SELF-LOCKING NUT POWER STEERING GEAR BOX 7924UG33

Exploded view of a typical power steering gear mounting

Negative battery cable Pinch bolt securing the steering shaft to the steering gear Pitman arm from the relay rod Fluid lines from the steering gear Mounting bolts securing the gear to the frame rail and steering gear To install: 4. Install or connect the following: e Steering gear on the frame rail. Torque the nuts to 40—47 ft. Ibs. (54-64 Nm). e Fluid lines to the steering gear use a new O-rings. Torque the fittings to 11 ft. Ibs. (15 Nm). e Relay rod on the Pitman arm. Torque the nut to 33 ft. Ibs. (44 Nm). e Steering shaft on the steering gear. Torque the bolt to 13 ft. Ibs. (18 Nm). e Negative battery cable 5. Refill and bleed the power steering system.

Rack and Pinion Steering Gear

REMOVAL & INSTALLATION 1. On vehicles equipped with a supplemental restraint system (SRS), turn the front wheel to the straight ahead position and remove the ignition key to prevent the steering wheel from turning. 2. Drain the power steering fluid. 3. Remove or disconnect the following: e Negative battery cable e Engine under cover e Tie rod ends e Steering hoses e Left side differential mount bracket e Intermediate shaft-to-gear box bolt e Gear mounting clamps and gear 4. Installation is the reverse of removal. Observe the following torques: e Mounting clamp bolts: 51 ft. Ibs. (69Nm) e Tie rod end ball stud nuts: 29 ft. lbs. (39Nm) e Intermediate shaft pinch bolt: 13 ft. lbs. (18Nm)

5. Install the shock absorber. Torque the lower nut to 65-76 ft. Ibs. (88-103 Nm) and the upper nut to 11 ft. Ibs. (15 Nm). 6. Test drive the vehicle and check the alignment. Rear

_ 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the rear axle assembly witha — hydraulic floor jack, so that the shock absorber may be removed. 3. Remove the upper and lower mounting nuts and bolts that attach the shock to the frame and bracket. 4, Remove the shock absorber from the vehicle. To install: 5. Install the shock absorber e 1998-00 lower bolt: 159-181 ft. lbs. (216-245 Nm) on the Montero and 16 ft. Ibs. (22 Nm) on the Montero Sport 2001-02 lower bolt: 159-181 ft. lbs. (216-245 Nm) on the Montero Sport and 113 ft. Ibs. (152Nm) on the Montero 1998-00 upper mounting nut: 11 ft. lbs. (15 Nm) on the Montero and 16 ft. Ibs. (22 Nm) on the Montero Sport 2001-02 upper mounting nut: 16 ft. lbs. (22Nm) on the Montero Sport and 33 ft. Ibs. (44Nm) on the Montero 6. Remove the floor jack from under the axle assembly.

Heater Core replacement is covered in Section 2 of this manual

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Bushing Bracket Upper pad Cup Helper rubber

Spring Lower pad 5. Installation is the reverse of removal. Torque the center nut to 17 ft. Ibs. (22Nm). Rear

MONTERO 88-103Nm*

65 — 76. Ib-ft*

1, SHOCK ABSORBER e BUMP STOPPER AND BUMP STOPPER BRACKET CLEARANCE ADJU 2. REAR ANCHOR ARM ADJUSTING NUT 3. BRAKE HOSE CONNECTION 4, HOSE CLIP 5. UPPER Lebar BALL JOINT

CONNEC 6. SPEED SENSOR BRACKET

~~

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the weight of the axle.

Uk a SIMSSTOPPER 8 UPPER Al 10, UPPER ARM BALL JOINT ASSEMBLY

3. Remove or disconnect the following: Breather hose

Caution parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition. *: Indicates

7924UG34

Common shock absorber and upper control arm components

REMOVAL & INSTALLATION 1. On vehicles equipped with a supplemental restraint system (SRS), turn the front wheel to the straight ahead position and remove the ignition key to prevent the steering wheel from turning. 2. Remove or disconnect the following: Negative battery cable Upper control arm Battery and battery tray A/C condenser Air cleaner Wheel Upper mounting nuts Lower mounting bolt/nut 3. Installation is the reverse of removal. Torque the upper mounting nuts to 32 ft. lbs. (44Nm); the lower mount nut to 119 ft. lbs. (162Nm)

REMOVAL & INSTALLATION Front

MONTERO WITH MACPHERSON STRUTS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Strut 3. Compress the coil spring until there is a clearance on both ends

4. Remove or disconnect the following: e Strut center nut

Parking brake cable attaching bolt ABS speed sensor attaching bolt Brake hose connection Lower shock mounting bolt Bolt that attaches the lateral rod to the body Stabilizer bar 4. Lower the axle and remove the coil Spring and seat 5. Installation is the reverse of removal. Torque the lateral rod-to-body bolt to 159-181 ft. Ibs. (216-245Nm).

22+2N-m

17 +1 ft-lb

12: 3.

SELF-LOCKING NUT SEAT COLLAR 4 . UPPER BUSHING 5 . SPRING BRACKET ASSEMBLY 6 . SPRING UPPER PAD 7 - CUP ASSEMBLY 8 . HELPER RUBBER

9. COIL SPRING 10. SPRING LOWER PAD 11. SHOCK ABSORBER ASSEMBLY

9355UG01

Strut exploded view

MONTERO e MONTERO!evaRe 22-33 eal Torque the nut to 54 ft. Ibs. (74 Nm). 8. Install a new cotter pin. 9. Install the front wheel. 10. Grease the upper ball joint and all other suspension components with a grease fitting.

25 Nm

19 ftilbs.?

SPRING LOWER PAD

SPRING SEAT

COIL SPRING END

Lower Ball Joint

9355UG02

Coil spring installation on strut

REMOVAL & INSTALLATION 7924UG36

MONTERO SPORT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Shock absorber lower bolt e Lower arm mounting bolt e Coil spring 3. Installation is the reverse of removal. Torque the lower arm bolt to 113 ft. Ibs. (152Nm). Torsion Bars

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower arm with a jack. 3. Remove or disconnect the following: Heat protector, right side only Bump stopper Anchor adjustment nut and arm assembly Anchor collar Torsion bar Dust covers Heat covers, right side only

Exploded view of the upper ball joint and related components—1998-00 models

3. Support the lower control arm. 4. Remove the upper ball joint from the steering knuckle. 5. Remove the ball joint from the upper control arm. . To install: 6. Install the ball joint in the upper control arm. Tighten the bolts to 18 ft. lbs. (25 Nm) for 1998-00 models; 22 ft. Ibs. (30Nm) for 2001-02 models. 7. Install the ball joint stud to the steer-

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Apply upward pressure to the lower contro! arm with a jack or an adjustable stand.

-k-< CAUTION Do not disconnect the lower ball joint stud from the steering knuckle unless the lower control arm has a stand or a jack under it. 3. Remove the ball joint stud nut/stud from the steering knuckle.

A\ CAUTION *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition.

147 +10 N-m* 109 +7ft-lb *

To install: 4. Install or connect the following: Heat covers, right side only Dust covers Torsion bar Anchor collar Anchor adjustment nut and arm assembly. Torque the nut to 32 ft.

147+10N.m* 109 +7 ft-ib * ,

~/

lbs. (44 Nm). Heat protector, right side only a

TAL14Nm 55 +10 ft-lb

Upper Ball Joint 4.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the front wheel.

FRONT WHEEL SPEED SENSOR BRACKET MOUNTING BOLT CLIP . BRAKE HOSE . UPPER ARM ASSEMBLY AND AON KNUCKLE CONNECTION

5. UPPER FRONT UPPER . UPPER oy BLY

ARM ASSEMBLY AND FRAME CONNECTION ARM ASSEMBLY ARM BALL JOINT ASSEM-

Exploded view of the upper ball joint and related components—2001-02 models

Brake service is covered in Section 4 of this manual

9355UG03

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MONTERO e MONTERO SPORT

4. Remove the ball joint retaining nuts/bolts and the ball joint from the arm To install: 5. Install the lower ball joint on the control arm. Torque the ball joint retaining nuts/bolts to 60 ft. Ibs. (81 Nm) on 1998-00 models and 2001-02 Montero Sport; 70 ft. lbs. (95Nm) on 2001-02 Montero models. 6. Install the ball stud to the knuckle. Torque the nut to 108 ft. Ibs. (147 Nm) and a new cotter pin. 7. Lubricate the ball joint with a grease gun. 8. Check and adjust the alignment if necessary.

Upper Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheel assembly Bumper stop Anchor arm assembly adjustment nut Brake hose clip and connection Upper ball joint from knuckle Brake hose clip Rebound stopper(s) Speed sensor bracket Shim Upper control arm To install: 3. Install or connect the following: Upper control arm and shim. Torque the nuts to 80 ft. Ibs. (108 Nm). Speed sensor bracket Rebound stopper(s) Brake hose clip Upper ball joint from knuckle. Torque the nut to 54 ft. Ibs. (74 Nm). New cotter pin Brake hose clip and connection Anchor arm assembly adjustment nut. Torque the nuts to 33 ft. Ibs. (44 Nm). Bumper stop Wheel assembly

Lower Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Skid plate and undercover ¢ Bumper stop

e Rear anchor assembly e Torsion bar ¢ Lower ball joint from knuckle e Stabilizer link assembly e Shock absorber mounting bolts e Lower arm shaft e Anchor arm e Lower control arm To install: 3. Install or connect the following: Lower control arm. Torque the mounting bolts to 108 ft. Ibs. (147 Nm). Anchor arm. Torque the bolt to 33 ft. Lbs. (44 Nm). Lower arm shaft. Torque the bolt to 108 ft. Ibs. (147 Nm). Shock absorber mounting bolts. Torque the bolt to 65-76 ft. Ibs. (88-103 Nm). Stabilizer link assembly Lower ball joint from knuckle. Torque the nut to 108 ft. Ibs. (147 Nm). Torsion bar Rear anchor assembly. Torque the nuts to 33ft. Ibs. (44 Nm). Bumper stop. Torque the nut to 18 ft. Ibs. (25 Nm). Skid plate and undercover

CONTROL ARM BUSHING REPLACEMENT Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Remove the lower control arm. 4, Using tool MB991522 press out the bushing To install: 5. Position the bushing with the larger end facing the front of the vehicle. 6. Using tool MB991522 press the bushing into the bracket. 7. Install the lower control arm. 8. Install the wheel.

6. Using tool MB991522, press the bushing into the bracket. 7. Install the lower control arm. 8. Install the wheel.

Wheel Bearings

ADJUSTMENT Front

1998-00 1. Tighten the wheel bearing nut to 119 ft. Ibs. (162 Nm) while turning the rotor. 2. Loosen the wheel bearing adjusting nut completely. 3. Tighten the nut to 18 ft. Ibs. (25 Nm), then loosen the nut approximately 30°. 4. Using a dial indicator, check the wheel bearing end-play. The specification is 0.002 in. (0.05mm). '5. Install the locknut.

2001-02 MONTERO The bearings are integral with the hub. No adjustment is possible.

2001-02 MONTERO SPORT 1. With the caliper removed, check the rotational starting torque. Rotational torque should be 2.7—-11.5 inch Ibs. (4-19Nm). Rotational torque can be adjusted by tightening or loosening the adjusting nut. 2. Check the hub axial. Endplay should not exceed 0.002 inch (0.05mm). If adjusting nut tightening does not bring the axial play within specifications, the bearings must be replaced. 3. Check hub endplay. Endplay should be 0.02—-0.03 inch (0.4-0.7mm). Shims are available to adjust endplay. 4. Install the hub assembly. Tighten the nut to 94-145 ft. Ibs. (127-196Nm). Loosen it completely. Tighten the nut to 18 ft. Ibs. (25Nm), then back it off 30 degrees. Rear

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Remove the lower control arm and place in a vise. 4. Using tool MB990883 remove the bushing To install: 9. Position the bushing with the larger end facing the front of the vehicle. e>Coat the bushing with a soap solution and take care not to twist.

The rear wheel bearings are not adjustable. If the bearings are noisy or « become loose, they must be replaced.

REMOVAL & INSTALLATION Front

1998-00 MONTERO WITH 2WD AND 1998-02 MONTERO SPORT WITH 2WD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

MONTERO ° Bl Outer bearing

Inner bearing

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Outer bearing

Inner bearing

MB990938-01

7924UG44

The bearing races can be removed from the hub using a drift and hammer

7924UG45A

Install the new races into the hub using the proper size driver

35-43 ft.lbs.

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Exploded view of the hub and wheel bearing assembly—Montero

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

IMONTERO O SUBISHTER 99-36U MIT SPORT MON© 2. Remove or disconnect the following: e Tire and wheel assembly ¢ Caliper assembly and suspend it from the upper arm e Dust cap Cotter pin, castellated nut lock, wheel bearing nut and washer from the spindle Outer wheel bearing Hub and rotor as an assembly Grease seal and inner wheel bear(NGinss 3. If required, press the inner and outer bearing outer races from the hub assembly. 4. |f replacement of the hub is necessary, matchmark the brake disc with the hub, then separate the hub from the disc. To install: 5. If removed, place the brake rotor on the hub, while aligning the matchmarks. Tighten the mounting bolts to 34—38 ft. Ibs. (47-52 Nm). ‘ 6. If removed, press-fit the inner and outer bearing outer races into the hub assembly. 7. Lubricate the seal lip and inside surface of the front hub with MP grease. 8. Install or connect the following: Inner wheel bearing and repack New grease seal Hub assembly on the spindle Outer wheel bearing, washer and nut, lubricate. When the bearing preload is properly set, install the nut lock and a new cotter pin. Grease cap Caliper assembly Tire and wheel assembly

1998-00 MONTERO AND MONTERO SPORT WITH 4WD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Tire and wheel assembly 3. If equipped with locking hub: a. Place the locking hub in the free position. e*A free position can be obtained by shifting the transfer shift lever to the 2H position, then moving the vehicle in reverse for approximately 3-6 ft. (1-2 m).

b. Remove the hub cover. c. Remove the snapring from the axle shaft. d. Remove the bolts and remove the automatic locking hub. 4. Remove or disconnect the following:

e Caliper assembly and suspend it from the upper arm. Lockwasher and locknut ¢ Hub and rotor as an assembly from the knuckle together with the inner and outer bearings Outer bearing, grease seal and inner wheel bearing e Inner and outer bearing outer races from the hub assembly, if required 5. If replacement of the hub is necessary, matchmark the brake disc with the hub, then separate the hub from the disc. To install: 6. Install or connect the following: Brake rotor on the hub, while aligning the matchmarks, if removed Press-fit the inner and outer bearing outer races into the hub assembly Inner wheel bearing, repack with grease New grease seal Hub assembly to the spindle Outer wheel bearing and locknut, lubricate 7. When the bearing preload is properly set, install the lockwasher. 8. If equipped with locking hubs: a. Apply a coating of semi-drying sealant to the locking hub body and front hub contact surfaces. b. Align the key of the brake B and the keyway of the knuckle spindle and loosely install the automatic locking hub assembly. Tighten the mounting bolts to 36-43 ft. Ibs. (50-60 Nm). 9. Install the wheel and tire assembly

2001-02 MONTERO The wheel bearings are not replaceable. If defective, the hub/bearing assembly must be replaced. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Tire and wheel assembly Hub cover Nut Washer Brake hose Speed sensor Caliper Rotor Dust cover Tie rod end Upper and lower arms from the knuckle Rotor shield Hub/knuckle assembly 3. Mount the assembly in a vise. Install

fm

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a

8

ver

tool MB990998, or equivalent on the hub. Tighten the nut to 188 ft. Ibs. (255Nm). Check the rotation starting torque. Torque should be 15.48 inch Ibs. (1.75Nm). Wheel bearing backlash should be 0. 4. Ifthe hub is to be replaced, remove the hub-to-knuckle bolts. 5. Installation is the reverse of removal. Observe the following torques: e Hub-to-knuckle bolts: 65 ft. !bs.

(88Nm) e Hub nut: 188 ft. Ibs. (255Nm)

2001-02 MONTERO SPORT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheel Caliper Hub cover Snapring Shim Drive flange Spring washer Nut Hub and outer bearing Oil seal Inner bearing e Races 3. Installation is the reverse of removal. 4. Install the hub assembly. Tighten the nut to 94-145 ft. Ibs. (127-196Nm). Loosen it completely. Tighten the nut to 18 ft. Ibs. (25Nm), then back it off 30 degrees. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the wheel lug nuts only 2a turn.

3. Remove or disconnect the following: e Wheel(s) from the vehicle 4. Loosen the bleeder valve on the right rear caliper and drain the brake fluid into a container. 5. Remove or disconnect the following: Rear brake hose from the hard line on the frame : Rear brake caliper Rear disc off of the rear axle Parking cable attaching bolt and ce end from the brake assemy Parking brake assembly from the end of the axle Speed sensor, on vehicles with Anti-lock Brakes (ABS) Rear axle shaft out of the axle housing. If the rear axle shaft is dif-

Tree

eee es

cat ileal ik A Mk

MITSUBISHI

MONTERO ¢ MONTERO SPORT ficult to remove, use a slide ham-

mer (impact puller) to remove it.

Do not damage the oil seal during removal. e Snapring from the inside end of the axle shaft. Remove 1 retainer bolt from the backing plate with a plastic mallet. Apply cloth tape around the edge of the bearing case for

protection. Position the axle shaft in a vise or with a similar method. Using a grinder, grind down the retainer flat, on one side, until the thickness of the retainer is only 0.04—0.08 in. (1-2mm). That is that the retainer is ground down toward the axle shaft, not toward the flange. Cut, with a chisel, the place where the retainer ring has been shaven down and remove the retainer.

22-37

4k CAUTION Be careful not to damage the bearing case and the axle shaft. e>Only the retainer ring is to be ground down, NOT the axle shaft, the axle flange, the bearing or any other component.

6. Grind the plate of special tool MB990861 with a grinder (see illustration)

Es APPLY DIAMETE

DISASSEMBLY STEPS . SNAP RING . ABS ROTOR . RETAINER . AXLE SHAFT BEARING CASE BACKING PLATE OUTER BEARING INNER RACE DUST COVER . INNER BEARING INNER RACE . OIL SEAL . BEARING OUTER RACE ot=AOOMNAONAWN— —_

ASSEMBLY STEPS a1: BEARING OUTER RACE . INNER BEARING INNER RACE . OUTER BEARING INNER RACE . OIL SEAL . DUST COVER . BACKING PLATE . BEARING CASE AXLE SHAFT RETAINER . ABS ROTOR SNAP RING =“NWOATADBONO 7924UG48

Exploded view of the typical rear axle shaft, bearings and races

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

99-3 » MITSUBISH]

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hoe

MONTERO e MONTERO SPORT

7924UG51

7924UG50 7924UG49

Using a grinder, grind the retainer, on one Remove one of the rear axle studs before attempting to grind down the retainer

* Use a chisel on the ground-down spot on

side, down to 1-2mm (0.04-0.08 in.) thickness

the rear axle bearing retainer to split the retainer, then remove it

Keep all valvetrain components in order for assembly.

¢ Camshaft bearing caps. Loosen the bolts, in several passes, in reverse of the torque sequence. e Camshafts e Valve lifters and shims

SAN AND IN PATHFINDER * XTERRA ® 0X4 GO™

: Apply liquid gasket. Use Genuine RTV silicone sealant, Part No. 999 MP-A7007, Three Bond TB 1207D or equivalent. r ; Lubricate with new engine oil.

: N-m (kg-m, in-Ib) ©} :N-m (kg-m, ft-lb)

Cylinder head gasket 624

@) Oil filler cap (3) (4) (5) 6)

Rocker cover Camshaft bracket Intake camshaft Exhaust camshaft Shim

@) Valve lifter

43) Intake valve

Valve cotter Q) Spring retainer Valve spring ‘) Spring seat a2) Valve oil seal

Exhaust valve 5) Rubber plug Cylinder head ©) Cylinder head bolt 7924VG53

Exploded view of the camshafts and related components—2.4L engine

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

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23-16 NISSAN AND INFINITI — : PATHFINDER * XTERRA © QX4 To install: 3. Install or connect the following: e Valve lifters and shims in their original positions e Camshafts 4. Install the bearing caps. Tighten the bolts in sequence in follows: a. Step 1: 17 inch Ibs. (2 Nm) b. Step 2: 80-104 inch Ibs. (9-12 Nm) 5. Install or connect the following: Camshaft sprockets and upper timing chain. Tighten the sprocket bolts to 1230-130 ft. Ibs. (167-177 Nm). Valve cover. Tighten the bolts in sequence to 69-95 inch Ibs. (8-11 Nm) Spark plug wires Air cleaner assembly Negative battery cable. 3.3L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Upper intake manifold e Valve covers ->Keep all valvetrain components in order for assembly.

Rocker arm and shaft assemblies Valve lifter guide and valve lifters. Attach a wire to the top of the lifters so that they will not drop from the lifter guide. Radiator Accessory drive belts Front cover Timing belt. Refer to the Timing Belt unit repair section. Camshaft sprockets Camshaft seals Rear timing cover Distributor Cylinder head rear covers Camshaft locating plates e Camshafts To install: 4. Install or connect the following: e Camshafts ¢ Camshaft locating plates. Tighten the bolts to 58-65 ft. Ibs. (78-88 Nm). Cylinder head rear covers Distributor Rear timing cover Camshaft seals Camshaft sprockets. Tighten the bolts to 58-65 ft. Ibs. (78-88 Nm). Timing belt

6. Replace the shims as necessary to achieve the correct valve clearance. 7. Repeat for each valve to be adjusted.

e e e e

Front cover Accessory drive belts Radiator Valve lifter guide and valve lifters e Rocker arm and shaft assemblies. Tighten the bolts to 13-16 ft. Ibs. (18-22 Nm). e Valve covers e Upper intake manifold e Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

3.3L Engines These engines are equipped with hydraulic valve lifters that do not require periodic adjustment. Starter Motor

~REMOVAL & INSTALLATION

Valve Lash

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Engine under cover e Starter harness connectors e Starter motor To install: - 3. Install or connect the following: e Starter motor. Tighten the bolts to 22-27 ft. Ibs. (30-36 Nm).

ADJUSTMENT 2.4L Engines Measure the valve clearance with the engine warm.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the valve cover. 3. Set the engine to the top of the compression stroke with the valves closed for the cylinder to be measured. 4. Check the valve clearance. The valve clearance specifications are as follows: e Intake: 0.012—0.015 in. (0.310.39mm) e Exhaust: 0.013-0.016 in. (0.330.41mm) 5. If adjustment is necessary, compress the valve spring with Tool A and insert Tool B to hold the valve in the open position as shown.

e Starter harness connectors e Engine under cover

e Negative battery cable

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Tool (A) KV10115110 (J38972-1) \

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Valve adjustment tools (A) and (B)—2.4L engine

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(J37228)

KV10111100: (37228) 9355WG02

bolts in reverse

Insert the tool between the oil pan and the

order.

block and tap it with a hammer, while 7924V638

Oil pan bolt removal sequence—2.4L engine

*

7 mm

sliding it around the edge to loosen the oil

pan

(0.28 in)

2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Engine under cover e Stabilizer bar/Front suspension member e Oil pan bolts, in the sequence shown 4. Remove the oil pan by inserting the tool shown between the cylinder block and oil pan. Do NOT damage the pan or block mating surfaces! Slide the tool by tapping on the side of it with a hammer. Pull the oil pan front the front side. To install: Jo: clean all gasket mating 6. Apply a continuous bead of sealant 0.0138-0.0177 in. (3.5—4.5mm) to the oil pan mating surface. 7. Install or connect the following: e Oil pan. Tighten the bolts in sequence to 60-72 inch Ibs. (7-8 Nm). e Stabilizer bar. Tighten the bracket bolts to 38-45 ft. Ibs. (51-61 Nm) and the link nuts to 12-16 ft. Ibs. (16-22 Nm). e Engine undercover e Negative battery cable

Groove

Bolt hole

7924VG39

Wait about 30 minutes after installation of the oil pan to allow the sealant to cure before adding oil.

Oil pan sealant application—2.4L engine shown

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

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KV10111 100—”"

Loosen

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23-1 8 NISSAN AND INFINITI

PATHFINDER ¢ XTERRA @ QX4

BOS ie!Gece 4 Bi s

Left and right motor mounts Transmission mount Starter motor Front crossmember Stabilizer bar Engine under cover Negative battery cable e>Wait 30 minutes after installation of

the oil pan to allow the sealant to cure before adding oil.

8. Fill the crankcase to the correct level. 9. Start the engine and check for leaks.

4WD MODELS Tighten in numerical order Front 7924VG40

Oil pan bolt installation sequence—2.4L engine

8. Fill the crankcase to the correct level.

9. Start the engine and check for leaks. 3.3L Engine

2WD MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Engine under cover e Stabilizer bar e Front crossmember e Starter motor e Transmission mount

® ®

e Left and right motor mounts e Power steering gear 4. Raise and support the engine for clearance. 5. Remove or disconnect the following: e Oil pan bolts in the sequence e Oil pan To install: 6. Apply a continuous bead of sealant 0.138-0.177 in. (3.5—4.5mm) to the oil pan mating surface. 7. Install or connect the following: e Oil pan. Tighten the bolts in reverse of the removal sequence to 62 inch lbs. (7 Nm). e Power steering gear

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‘Casup +YauenY - Yamam’e

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Engine under cover Stabilizer bar brackets Front driveshaft Axle halfshafts Front suspension crossmember Front differential and mounting bracket

Starter motor Transmission mount Left and right motor mounts Power steering gear Relay rod 4. Raise and support the engine for clearance. 5. Remove or disconnect the following: e Oil pan bolts in the sequence e Oil pan To install: 6. Apply a continuous bead of sealant 0.138-0.177 in. (3.5—4.5mm) to the oil pan mating surface. 7. Install or connect the following: e Oil pan. Tighten the bolts in reverse of the removal sequence to. 62 inch lbs. (7 Nm). Relay rod Power steering gear Left and right motor mounts Transmission mount

Starter motor Front differential and mounting bracket Front suspension crossmember Axle halfshafts Front driveshaft Stabilizer bar brackets Engine under cover Negative battery cable

Engine front ea 7924VG42

Oil pan bolt removal sequence—3.3L engine

e>Wait 30 minutes after installation of the oil pan to allow the sealant to cure before adding oil.

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8. Fill the crankcase to the correct level.

9. Start the engine and check for leaks.

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Set the engine to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 3. Remove or disconnect the following: e Negative battery cable Distributor cap Distributor Engine under cover Stabilizer bar e Oil pump and drive spindle To install: j

SSE

j

ATO RNS

j

j

TNE

Punch

mark

: Oil hole

Front 9355WG03

Align the punch mark with the oil hole before oil pump installation—2.4L engine

Drive spindle

Gasket 24

—

10 (0.6 - 1.0, 4.3 - 7.2) Pump body

Gasket )

Rotor Inner

39 . 49 Pump cover

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thy, fe

(J6 -10 (0.6 - 1.0, 4.3 - 7.2)

(4.0 - 5.0

29 - 36)

SS

(0) 11-15 (1.1- 1.5, 8-11)

Regulator

valve set

(0): Nem (kg-m, ft-lb) 7924VG44

Exploded view of the oil pump assembly—2.4L engine

For Wheel Alignment specifications, see Section 1 of this manual

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NISSAN AND INFINITI PATHFINDER © XTERRA * QX4

oil, then align the punch mark on the spindle and the hole in the oil pump as shown. 5. Install or connect the following: e Oil pump and drive spindle. Tighten the mounting bolts to 96-132 inch Ibs. (11-15 Nm) e Stabilizer bar e Engine under cover e Distributor e Distributor cap e Negative battery cable 6. Start the engine and check for leaks. 7. Check the ignition timing and adjust as necessary. 3.3L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4, Remove or disconnect the following: Negative battery cable Accessory drive belts Radiator hoses Crankshaft pulley Front cover Timing belt. Refer to the Timing Belt unit repair section. Crankshaft timing sprocket Oil pan Oil pump pickup tube e Oil pump To install: 5. Install or connect the following:

Seal rubber (29

Oil pump. Tighten the large bolts to 16-22 ft. Ibs. (22-29 Nm) and the small bolts to 55-74 inch Ibs. (6-8 Nm). Oil pump pickup tube. Tighten the ~ flange bolts to 12 ft. Ibs. (16 Nm) and the bracket bolt to 55-74 inch lbs. (6-8 Nm). Oil pan Crankshaft timing sprocket Timing belt Front cover Crankshaft pulley Radiator hoses Accessory drive belts Negative battery cable 6. Fill the cooling system. 7. Fill the crankcase to the correct level. 8. Start the engine and check for leaks. Rear Main Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission e Flywheel e Rear main seal To install: 3. Install the seal so that it is flush with the retainer housing. 4. Install or connect the following:

'

,

e Flywheel. Tighten the bolts to 61-69 ft. Ibs. (83-93 Nm). e Transmission

Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION 2.4L Engine ~ 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Set the engine to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 5. Remove or disconnect the following: ; Negative battery cable Air cleaner assembly Spark plug wires Cooling fan and shroud Distributor Valve cover Accessory drive belts Power steering pump and brackets

A/C compressor and bracket Idler pulleys Water pump pulley Crankshaft pulley Front crankshaft seal Oil pump and drive spindle

Oil pump cover

Front

Oil pump housing

pSeee re ‘

Gasket > | Use new nuts for assembly.

* 3. Install the shock absorber and tighten the nuts to 30-37 ft. Ibs. (40-50 Nm),

Coil Spring REMOVAL & INSTALLATION Pathfinder and QX4

~e e ¢ ¢ e

Coil spring Spring upper seat Upper strut bearing Strut mount bracket Upper strut mount. Tighten the pis-. ton rod nut to 43-58 ft. Ibs. (59-78 Nm). 6. Remove the spring compressor and install the strut assembly to the vehicle. 7. Check the wheel alignment and adjust, as necessary.

REAR

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut assembly. 3. Compress the coil spring and remove the piston rod nut. 4. Remove or disconnect the following: e Upper strut mount e Strut mount bracket e Upper strut bearing e Spring upper seat e Coil spring To install: ->Use new fasteners for assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle at the frame. 3. Support the axle with a floor jack. 4. Remove or disconnect the following: e Rear wheels e Shotk absorbers e Stabilizer bar links e Lateral control rod ¢ Coil springs To install: >Use new fasteners for assembly.

e Lateral control rod. Tighten the nut to 80-94 ft. Ibs. (108-127 Nm). e Stabilizer bar links. Tighten the nuts to 30-35 ft. Ibs. (41-47 Nm). e Shock absorbers e Rear wheels

Leaf Springs REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle at the frame. 3. Support the axle with a floor jack. 4. Remove or disconnect the following: e Rear wheels e Shock absorbers e Axle U-bolts and spring pad e Spring shackle e Front mount bolt/pin e Leaf spring To install: ->Use new fasteners for assembly.

5. Install or connect the following: e Leaf spring. Tighten the front

5. Install or connect the following: e Coil springs

5. Install or connect the following:

Upper spring seat

{0} 108 - 147 (11.0 - 15.0, 80 - 108)—

Upper link

$4 (GO) 25 - 32 (2.6 -3.3, 19- Es

eS) 9

Shock absorber Coil spring

y Stabilizer bar——

cS

connecting rod

LO

Panhard rod

108 - 147 (11.0 - 15.0, 80 - 108)

26 - 32 (2.6 - 3.3, 19 - 24)

9 [Da3-65 (44-66, 32-41)

coe

Stabilizer bar

Front

Ko} : Nem (kg-m, ft-lb) —- Lower link 7924VG69

Rear suspension component identification—Pathfinder

Brake service is covered in Section 4 of this manual

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93-34 NISSAN AND INFINITI PATHFINDER @ XTERRA@ QX4

SEC. 380 ¢ 430 e 431

0} 78 ~ 98 (8.0 - 10.0, 58 — 72)

When installing rubber parts, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full.

a

€9 (0)117 - 147 (12-15, 86-108)

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Spare tire, jack, hand tools and mats in designated positions. :

Up

4 (O} 40- 50 (4.1 - 5.1, 30- 37) = mS

(0) 43 - 55 (4.4 - 5.6, 32 - 41)

©

(0) 41.2 - 47.1 (4.2 - 4.8, 30 - 35)

Front

©} : N-m (kg-m, ft-lb)

(03 118 - 147 (12-15, 87 -108) 9355WG06

Leaf springs and rear suspension components—Xterra with 2.4L engine shown

mount bolt to 86-108 ft. Ibs. (117-147 Nm). Spring shackle. Tighten the nuts to 58-72 ft. Ibs. (78-98 Nm). Axle U-bolts and spring pad.

66-87 ft. Ibs. (89-118 Nm) and the small nut to 33-44 ft. Ibs. (45-60 Nm). 8. Tighten the adjustment bolt to achieve the measurement (L) noted earlier. Tighten the locknut to 22-30 ft. Ibs. (30-40 Nm).

Tighten the nuts to 72-80 ft. Ibs.

9. If a new torsion bar is being installed,

(98-108 Nm). e Shock absorbers e Rear wheels

set length (L) as follows: e 2 wheel drive: 2.13 inches (64mm) ¢ 4 wheel drive: 2.76 inches (70mm)

Mee 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Move the dust cover, if equipped. 3. Matchmark the torsion bar to the control arm mount and the anchor arm. 4. Measure the adjustment bolt protrusion as shown and note the length (L) for assembly. 5. Loosen the adjustment bolt so that all tension is released. 6. Remove the torsion bar mount from the control arm and remove the torsion bar. To install: 7. Align the matchmarks and install the torsion bar. Tighten the large mount nut to

Upper Ball Joint

Torsion bar matchmarks REMOVAL & INSTALLATION Xterra

The upper ball joint is serviced with the upper control arm as an assembly.

Lower Ball Joint

REMOVAL & INSTALLATION Xterra 9308VG13

Adjustment bolt measurement (L)

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Pathfinder and QX4

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Upper Control Arm

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to 8 precautions in the beginning of this secion. 2. Remove or disconnect the following: e Front wheel e Torsion bar e Shock absorber e Stabilizer bar link e Axle halfshaft, if equipped ¢ Lower ball joint ¢ Control arm mounting bolts e Lower control arm To install: 3. Install or connect the following: Lower control arm. Tighten the moynt bolts to 80-105 ft. Ibs.

1. Before servicing the vehicle, refer to

¥ Ne SA etsTighten the nut to

B714t th lbs, (18191 Ni Axle halfshaft, if equipped barlink Stabilizer

Te ees in the beginning of this sec2. Support the lower control arm. 3. Remove or disconnect the following: ¢ Front wheel

Shock absorber

Torsion bar Pont wines

e Shock absorber

e Upper ball joint e Control arm mounting bolts e Upper control arm To install: 4. Install or connect the following: e Upper control arm. Tighten the mounting bolts to 72-87 ft. Ibs. (98-118 Nm). e Upper ball joint. Tighten the nut to 58-108 ft. Ibs. (78-147 Nm). e Shock absorber e Front wheel 5. Check the wheel alignment and adjust, as necessary.

CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the contro! arm. from the vehicle. 3. Remove the control arm bushing with

a press.

|

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ow Ser)

Sebeitt: Use a new split pin for assembly.

1. Before servicing the vehicle, refer to

the precautions in the beginning of this section.

¢ Dust cap ¢ Split pin

+ Spindle nut cap

e Spindle nut Bearing washer Outer bearing

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

4

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AND |NFI INIT|

(£9-J0 PATHFINDER

XTERRA © OX4

e Hub and brake rotor assembly e Inner grease seal ; e Inner wheel bearing To install: 3. Install or connect the following: e Inner wheel bearing Inner grease seal Hub and brake rotor assembly ae

id

Outer bearing Bearing washer eeeeee Spindle nut. Adjust the wheel bearings. Spindle nut cap Split pin Dust cap Brake caliper and support Front wheel

4 Wheel Drive

ie ot) fa

;

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel Brake caliper and support Locking hub or driveplate Snapring Spindle washer Thrust washer Lockwasher Wheel bearing locknut Outer bearing Hub and brake rotor assembly Inner grease seal Inner wheel bearing

‘Toinstall: : 5 yobaltitie® 3. Install or Abani the oyatnetie Inner wheel bearing Inner wheel bearing Inner grease seal Hub and brake rotor assembly Outer bearing Wheel bearing locknut. Adjust the wheel bearings. Lockwasher Thrust washer Spindle washer Snapring Locking hub or driveplate Brake caliper and support Front wheel

i

SUBARU 1998-01

Forester DRIVE TRAIN.................- 24-23 ENGINE REPAIR............... .24-2 FUEL SYSTEM ................ 24-20 PRECAUTIONS.................. 24-2

F Front Crankshaft Seal... 24-11 Removal & Installation............ 24-11 FUCLPITeiS Gamer tiemenbe boat24-20

SUSPENSION................. 24-31

PUCITMIECIOl eee

STEERING AND

Removal & Installation........... 24-20

A Aig Batytlicpameibabe tat cll naa:koe

Removal & Installation............ 24-29 | (Fuel Putten ee te 94-20

SAIN ete aaa Shree 24-31 LE CANIS atte: ai inter ect

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24-22

Removal & Installation........... 24-20

ian 24-31

Fuel System PresSUre ...cccccecccccce 94-20

cr 24-2

RealieviriGiae sek ihre late nar 94-20)

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Fuel System Service

Removal & Installation............ 24-17 Oil Pump QUeeer, 2s apes 24-19 Removal & Installation............ 24-19

_ Piston'and'Ring)..2)

050 ay

24-19

POSTIOMING soc: te. meee serene 24-19

je lsteeblsts Rack and Pinion Steering Gear....24-32

Removal & Installation............ 24-32

Rear Main Seal........... eeatectbaii24-19

Removal & Installation............ 24-19 Starter

o4-17

Hom SRS 5 Rage A HN

Hebi? Hisercnin's ag“xe

Removal & Installation............ 24-17

Camshaft and Valve Lifters .........24-11 Removal & Installation.......... 24-11

Halfshafts......cccsssessessnsen 24-26 Removal & Installation.......... 24-26

SUUb..ssssssessetrseeneen siessennsenen 24-33 Removal & Installation.......... 24-33

UT sag lado Daciiaane POR Siha Rey ae ee

Tene fy.ae RaatSe csapa VSN ares baie

Transfer Case Assemblly............... 24-26 ,

Cot Spring eae os 24233"

—|gnitlon Timing ..2 oe ee 24-2

Transmission Assembly............. 24-23 Removal & BAG ohhSie 24-23

Removal & Installation............ 94-25

i

Removal & Installation........... 24-33

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Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam _and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or ifyou have taken brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS Soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument pane! components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury, and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. e Clean, high quality brake fluid from a sealed container is essential to the safe and

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys-

tem(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

ENGINE REPAIR ->Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

ix

2. Remove or disconnect the following: e Negative battery Cable e Wires Belt cover Drive belt Mounting bolts Alternator

Distributor

Install or connect the following: e Alternator e Mounting bolts ¢ Drive belt. Adjust the tension to 0.276—-0.354 in. (7-9mm) for new or 0.354-0.433 in. (9-11mm) for used. Torque

the slider bolt to 4-6 ft. Ibs. (6-10 Nm) and the lockbolt to 16.5 ft. Ibs. (19.5 Nm). e Belt cover e Wires ¢ Negative battery Cable

The Forester is equipped with a distributorless ignition system. Alternator

Ignition Timing

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

INSTALLATION

ADJUSTMENT re

9308XG01

View of alternator mounting

The ignition timing is controlled by the engine control computer and is not

SUBARU 94-3 2

FORESTER adjustable. To check the ignition timing proceed as follows: 1. Before servicing the vehicle, refer to a.precautions in the beginning of this secion. 2. Warm up the engine, then turn the ignition OFF. 3. Connect a timing light to the No. 1 spark plug wire according to the manufactures directions. 4. Start the engine. With the vehicle at idle check the timing. 5. The timing should be 7-23 degrees BIDC at 700 RPM. 6. If the timing is not correct, there could be a problem in the ignition control system.

Engine Assembly

¢ Camshaft Position (CMP) sensor connector ¢ Knock Sensor (KS) connector e Alternator connector and terminal ¢ Air conditioning compressor connectors, if equipped Accelerator cable Cruise control cable, if equipped Brake booster hose Heater inlet and outlet hoses Alternator drive belt Wires from the spark plugs on the left side of the engine Power steering pump line bracket Power steering pump, leaving the lines connected and position it aside Exhaust Y-pipe Lower starter nuts Lower engine-to-transmission nuts Front engine mount-to-crossmem-

bef nuts Starter 8. If equipped with an automatic transmission, perform the following:

REMOVAL & INSTALLATION

CAUTION The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the engine oil and coolant. 4. Discharge and recover the air conditioning system. 5. Remove or disconnect the following: Negative battery cables and battery Engine undercover Radiator hoses and fan motor harness Radiator Air conditioning compressor and cap the lines Air intake duct Air cleaner element and upper cover Evaporative Emissions (EVAP) canister and bracket Front Oxygen (02S) sensor 6. If equipped with California emissions specifications, disconnect the rear 02S senSor. 7. Remove or disconnect the following: e Engine ground terminal e Crankshaft Position (CKP) sensor connector

a. Remove the torque converter service hole plug. b. Matchmark the torque converter-todriveplate. c. Rotate the engine to remove the torque converter-to-driveplate bolts as they become accessible. 9. Remove or disconnect the following: e Flywheel cover, if equipped with a manual transmission e Pitching stopper e Fuel delivery, return and evaporation hoses 10. Support the engine with a suitable lifting device attached to the engine lifting eyes.

11. Slightly raise the engine. 12. Raise the transmission with a floor jack. 13. If equipped with a manual transmission, pull the engine forward then up and out of the vehicle to clear the transmission mainshaft. 14. If equipped with an automatic transmission, pull the engine forward then up and out of the vehicle. To install: 15. If equipped with a manual transmis-

sion, apply a small amount of grease to the splines of the mainshaft. 16. Position the engine in the engine compartment and align it with the transmission. 17. Install the engine. Torque the upper bolts to 34—40 ft. Ibs. (44-54 Nm). 18. Remove the lifting device and floor jack. 19. Install or connect the following: e Pitching stopper. Torque the bolts to 49 ft. Ibs. (67 Nm) on the body side and 40 ft. Ibs. (54 Nm) on the bracket side. e Flywheel cover, if equipped with a manual transmission 20. If equipped with an automatic transmission, perform the following: a. Align the matchmarks, install the torque converter-to-driveplate bolts while rotating the engine and tighten to 20 ft. lbs. (26 Nm). b. Install the service hole cover. 21. Install or connect the following: e EVAP canister and bracket e Power steering pump. Tighten the

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For complete service labor times, order the Chilton Labor Guide

24-

- SUBARU FORESTER

retainer bolts to 22—36 ft. Ibs. (29-47 Nm). Accessory drive belt Starter. Torque the bolts to 34-40 ft. Ibs. (44-52 Nm). Lower engine-to-transmission nuts. Tighten them to 34—40 ft. Ibs. (44-52 Nm). Lower engine mounting nuts. Tighten them to 61 ft. Ibs. (83 Nm) in the inner most elliptical hole in the front crossmember so the clearance is 0.16-0.24 in. (4-6mm). Exhaust Y-pipe with new gaskets and nuts Brake booster hose Heater inlet and outlet hoses Accelerator cable Cruise control cable, if equipped

Engine harness connectors Engine ground terminal CKP sensor connector CMP sensor connector Knock sensor connector Alternator connector and terminal Air conditioning compressor connectors, if equipped Front 02S sensor, and if removed, the rear O2S sensor. Air cleaner element and cover Air conditioning lines with new Orings, if equipped. Torque the bolts to 23 ft. Ibs. (31 Nm). Radiator Engine undercover Negative battery cable 22. Fill the crankcase to the proper level with clean engine oil.

23. Fill and bleed the cooling system. 24. Charge the air conditioning system using an approved recovery/recycling machine. 25. If equipped, check the automatic transmission fluid level and add Dexron®Il if necessary. 26. Start the engine and allow it to reach normal operating temperature. Check for leaks. Water Pump

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

7-10 ft. Ibs.

(9)

(1)

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Water by-pass hose A (AT vehicles)

(2) Water by-pass pipe (AT vehicles) (3) Water by-pass hose B (AT vehicles)

(4) Water pump (5) Gasket

(6) (7) (8) (9)

Heater hose Thermostat

4.3 - 5.1 ft. Ibs 6-7N

Gasket Thermostat case

ASSY 7924XG01

Exploded view of the water pump mounting and related components

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¢ Water pipe bypass pipe retaining bolt e Accessory drive belts e Timing belt and tensioner ¢ Camshaft Position (CMP) sensor e Left side camshaft pulleys and left side rear timing belt cover

e e e e

Tensioner bracket

7Te24xG02

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* Water pump. Torque the bolts, in sequence, to 84-120 inch Ibs.

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Cylinder Head REMOVAL & INSTALLATION

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(1) (2)

7. Start the engine and allow itto reach operating temperature.

installation. 5. Install or connect the following:

tainer. _ 3. Remove or disconnect the followme

e Radiator fan motor assembly e Radiator outlet hose e Engine undercover e Negative battery cable 6. Fill the system with coolant.

4. Clean the gasket mating surfaces

thoroughly. Always use new gaskets during

Left side rear timing belt cover, left side camshaft pulleys and tensioner bracket CMP sensor Timing belt and tensioner Accessory drive belts Water pipe bypass pipe retaining bolt

e Radiator hose and heater hose from the water pump e Water pump retainer bolts e Water pump To install:

Water pump bolt tightening sequence

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

Cylinder head Cylinder head gasket 7924XG03

Exploded view of the cylinder head mounting

Please visit our web site at www.chiltonsonline.com

24-6

Forester ° Oil dipstick tube attaching bolt on the left cylinder head Cylinder head bolts in the proper sequence. Leave bolts 1 and 3 installed loosely to prevent the cylinder head from falling. 6. Separate the cylinder head from the block. Use a plastic-faced hammer, if needed. 7. Remove bolts 1 and 3. Remove the cylinder head and gasket. _ 8. Clean all gasket material from both mating surfaces.

To install: 9. Inspect the cylinder head for warpage. Warpage should not exceed 0.0020 in. (0.05mm). 10. Install the cylinder head(s) on the block using new gaskets. Secure in place

i

with the mounting bolts. Coat each bolts with clean engine oil, and hand-tighten.

:

;

Cylinder head bolt loosening sequence

41. Tighten the cylinder head bolts as

follows: a. Step 1: Torque the bolt to 22 ft. Ibs. (29 Nm) b. Step 2: Torque the bolt to 51 ft. Ibs. (69 Nm) c. Step 3: Loosen all bolts by 180 degrees, then loosen an additional 180 degrees. d. Step 4: Bolts 1 and 2: 25 ft. Ibs. (24 Nm) e. Step 5: Bolts 3, 4, 5 and 6: 11 ft. lbs. (15 Nm). f. Step 6: All bolts: turn an additional 80-90 degrees. g. Step 7: All bolts: turn an additional 80-90 degrees.

Do not exceed 180 degrees total tightening.

Ee

e Oil dipstick tube attaching bolt on

Cylinder head torque sequence—2.5L engine

| 2. Properly relieve the fuel system

pressure.

3. Remove or disconnect the follow-

ing: ¢ Negative battery cable ¢ Oxygen (02S) sensor. If equipped with California emissions, disconnect the rear O2S sensor. + Engine undercover a e Exhaust Y-pipe and lower it just enough to clear the studs in the heads. Do not allow the Y-pipe to hang without support. e Accessory drive belts

12. Install or connect the following: the left cylinder head

e Engine accessories and brackets

from the side of the engine the cylinder head is being removed

¢ Connector bracket attaching bolt, if necessary 4. On the left cylinder head, remove the CMP sensor. 5. Remove or disconnect the following: e Fuel pipes e Intake manifold and gasket

e Timing belt, camshaft sprockets, and related components e Valve covers, camshafts and related components

e Valve covers, camshafts and related components

¢ Camshaft sprocket, timing belt, and related components

as

e Intake manifold. Torque the bolts to 21-25 ft. Ibs. (28-34 Nm). ¢ Fuel delivery pipes 13. On the left cylinder head, install the CMP sensor. | 14. Install or connect the following: e Connector bracket attaching bolt

¢ Spark plug wires e Engine accessories and brackets ¢ Accessory drive belts e Exhaust Y-pipe. Torque the fasten-

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¢ Front 02S and rear 02S, if removed. Negative battery cable 15. Start the engine and allow it to reach operating temperature. 16. Check for leaks. ‘Intake Manifold

REMOVAL & INSTALLATION 1998

+ CAUTION The fuel injection system remains under pressure after the engine has been turnedOFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. 1. Before servicing the vehicle, refer to the precautions in thebeginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: Negative battery cable Mass Air Flow (MAF) sensor connector Air intake duct, air cleaner upper cover and the air cleaner element Accelerator cable and the cruise control cable, if equipped V-belt covers Power steering v-belt Power steering hose brackets from intake manifold Power steering pump and seat aside, do not disconnect hoses Spark plug wires from coil Positive Crankcase Ventilation (PCV) hose and vacuum hose from intake manifold Cruise control diaphragm vacuum hose, if equipped Engine coolant hoses from throttle body and Idle Air Control (IAC) solenoid valve Air bypass hose from IAC solenoid valve Brake booster hose Exhaust Gas Recirculation (EGR)

pipe

Coolant temperature sensor and thermometer connector Knock Sensor (KS) connector Camshaft Position (CMP) sensor connector Crankshaft Position (CKP) sensor connector Oil pressure switch connector Fuel hoses from fuel pipes Intake manifold ee cable from the intake manifold Throttle Position (TP) sensor Ignition coil Fuel injectors Idle Air Control (IAC) solenoid valve Purge control solenoid valve Exhaust Gas Recirculation (EGR) solenoid valve Engine harness and band from intake manifold IAC solenoid valve from the intake manifold Throttle body from the intake manifold and discard the gasket Fuel pipes from intake manifold EGR and the purge contro! solenoid valves To install: 5. Install or connect the following: EGR and the purge control solenoid valves Fuel pipes to the intake manifold Throttle body to the intake manifold and use a new gasket. Torque the bolts to 16 ft. Ibs. (22 Nm). IAC solenoid valve to the intake manifold. Torque the bolts to 5 ft. lbs. (6.5 Nm). Engine harness and band to in take manifold EGR and the purge control solenoid valves TP sensor IAC solenoid valve Purge control solenoid valve

Harness band Ground cable from the intake manifold Intake manifold. Torque the bolts to 18 ft. Ibs. (25 Nm). Fuel hoses Oil pressure switch connector CKP sensor connector CMP sensor connector

2 47

SSS

¢ KS connector e Coolant temperature sensor and thermometer connector

Engine harness bracket to transmission housing and connect connectors nepipe. Torque to 25 ft. Ibs. (34 N Brake booster hose Engine coolant hoses to throttle body and IAC solenoid valve Brake booster hose Air bypass hose and coolant hose to IAC solenoid valve Engine coolant hoses to the throttle body and IAC solenoid valve

Cruise control diaphragm vacuum hose, if equipped PCV hose and vacuum hose to intake manifold Spark plug wires to coil Power steering pump. Torque the bolts to 15 ft. Ibs. (20 Nm). Power steering hose brackets to intake manifold Power steering V-belt V-belt covers Accelerator cable and the cruise control cable, if equipped Air intake duct, air cleaner upper cover and the air cleaner element

Negative battery cable

1999-01

> CAUTION The fuel injection system remains under pressure after the engine has been turnedOFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Fuel filler cap Negative battery cable Air intake duct, air cleaner upper cover and the air cleaner element Accelerator cable and the cruise control cable, if equipped Resonator chamber V-belt covers

Timing belt service is covered in Section 3 of this manual

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Intake manifold gasket LH Intake manifold gasket RH

(3) (4) (5) (6) (7) (8) (9) (10) (11)

Fuel injector pipe insulator Fuel injector pipe O-ring A O-ring B Fuel injector

(12) (13) (14) (15) (16)

Insulator Fuel injector cap

Plate Sealing Gasket Engine coolant hose B Air by-pass hose Idle air control solenoid valve Engine coolant hose A

(17) Nipple (Equipped cruise contro! model) (18) Plug (19) PCV valve (20) Purge control solenoid valve (21) Nipple (22) BPT (23) BPT holder bracket (24) Back pressure hose (25) EGR vacuum hose A (26) EGR vacuum pipe

(27) (28) (29) (30) (31) (32)

(33) Pressure sensor (34) Pressure sources switching solenoid valve (35) Vacuum hose A (36) Vacuum hose B (37) Bracket (Except Canada spec. vehicles) (38) Bracket (For Canada spec. vehicles) (39) Collar (40) Intake manifold

EGR vacuum hose C EGR valve Gasket © EGR vacuum hose B EGR solenoid valve EGR pipe 7924XG06

Exploded view of the intake manifold

3

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SUBARU FORESTER

Power steering V-belt Power steering hose brackets from intake manifold Power steering pump and seat aside, do not disconnect hoses Spark plug wires Positive Crankcase Ventilation (PCV) hose and vacuum hose from intake manifold Engine coolant hoses from throttle body Brake booster hose Air cleaner case stay and engine harness bracket Coolant temperature sensor connector

Fuel pipe assembly and pressure regulator e>The intake manifold sits on pins that protrude from the cylinder heads. Be sure the pins remain in the cylinder heads.

To install: 7. Install or connect the following: Fuel pipe assembly and pressure regulator Right side fuel pipes, tighten clamps Fuel injector pipe Left side fuel pipes, tighten clamps

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° Throttle Position (TP) sensor

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manifold. Torque the bolts to 15 ft. lbs. (20 Nm). Power steering hose brackets to the right side of the intake manifold Power steering V-belt V-belt covers Resornator chamber. Torque the bolts to 25 ft. Ibs. (33 Nm). Accelerator cable and the cruise control cable Air cleaner assembly Negative battery cable 8. Refill the cooling system. 9. Start the engine, and bleed the cooling system.

Cla :

Exhaust Manifold Due to the unique design of the Subaru engine an exhaust manifold is not used.

The exhaust enters directly into the front Y-

¢ Ground cable from the intake mani-

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pipe.

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REMOVAL & INSTALLATION

dig eee (IAT) and ; ner paul elie ait ir Control (IAC) soleno| . Throttle Position (TP) sensor and

¢ Engine harness to intake manifold and harness bands ° Pressure regulator vacuum hose to.

air control solenoid Air bypass from throttle body Throttle body from the intake manifold and discard the gasket Air bypass hose from air assist solenoid Air assist injector solenoid valve Pressure regulator st spent ‘oldvacuum hose

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intake manifold

Air assist injector solenoid valve Air bypass hose to air assist solenoid Throttle body to the intake manifold using new gaskets. Torque the retaining bolts to 16 ft. Ibs. (22 Nm). TP sensor and air control sole-

noid

e Air bypass hoses to the manifold

¢ Fuel injectors

Purge control solenoid valve Air bypass hose from purge control solenoid valve Harness bands Engine harness from intake manifold Purge control solenoid valve

° Injector pipe e Fuel pipes from the intake manifold

Fuel injectors and securing clips e Air bypass hoses from the manifold 5. Loosen the right and left fuel hose to injector clamps. 6. Remove or disconnect the following: e Left and right side fuel pipes e Fuel injector pipe

e IAC solenoid valve to the intake

manifold using a new gasket. Tighten the retaining bolts to 60 inch lbs. (7 Nm). IAT and pressure sensor use new

O-ring. Torque the bolts to 1.4 ft. lbs. (2.0 Nm). Ignition coil and ignitor assembly

e Ground cable from the intake manifold ° Air cleaner case stay and engine harness bracket Brake booster hose

Engine coolant hoses to the throttle body. PCV hose and vacuum hose to intake manifold Spark plug wires Power steering pump to intake

|

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NOT perform any work until the sys-

.

tem has completely cooled. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Front Oxygen (02) sensor electrical

connectors

e Rear Oxygen (02) sensor electrical connectors

Center exhaust pipe from front exhaust pipe Nuts that secure the exhaust pipe to the cylinder head Front pipe-to-front catalytic converter mounting nuts 3. Discard the gaskets.

To install: 4. Clean all gasket surfaces completely.

5. Install or connect the following: e Catalytic converter to front exhaust pipe using new gasket. Torque the bolts to 22 ft. Ibs. (30 Nm). e Exhaust pipe to the cylinder head using new gaskets. Torque the mounting nuts to 22 ft. Ibs. (30 Nm).

Heater Core replacement is covered in Section 2 of this manual

24-1

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ft. Ibs. (Nm)

(1) (2) (3) (4) (5) (6) (7) (8)

Upper front CTR Lower front CTR Band RH Band LH Upper front LH Lower front LH

exhaust pipe cover

(12) Rear exhaust pipe

(26) Rear oxygen sensor (Except

exhaust pipe cover

(13) Self-locking nut (14) Gasket

(27) Front catalytic converter

exhaust pipe cover exhaust pipe cover

(15) (16) (17) (18) (19) (20) (21)

Front exhaust pipe Lower front exhaust pipe cover

(22)

RH (9) Upper front exhaust pipe cover RH (10) Gasket

(23) (24) (25)

(11) Spring

Muffler Cushion rubber Clamp Upper center exhaust pipe cover Center exhaust pipe Clamp B Upper rear catalytic converter cover Lower rear catalytic converter cover Gasket Front oxygen sensor Rear oxygen sensor (California spec. vehicles)

California spec. vehicles) | (28) Lower front catalytic converter cover (29) Upper front catalytic converter cover

7924XG07

Exploded view of the exhaust system and related components

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SUBARU

FORESTER e Exhaust pipe to the center pipe using new gaskets. Torque the mounting nuts to 26 ft. Ibs. (35 Nm). e Rear Q2 sensors electrical connectors e Front O2 sensors electrical connectors e Negative battery cable 6. Start the engine and check for exhaust leaks.

e e e e e

Negative battery cable Timing belt covers Timing belt Camshaft sprockets Spark plug wires 3. On the left cylinder head, remove the

Camshaft Position (CMP) sensor. 4. Remove the valve covers and gaskets 5. Loosen the intake camshaft cap bolts in sequence, in small increments. e>Be sure to keep the intake and exhaust bearing caps and camshafts in proper order for assembly. Also note the positioning and location of the camshafts for reinstallation.

Front Crankshaft Seal

REMOVAL & INSTALLATION The front crankshaft seal is mounted in the oil pump. The removal and installation is covered in the oil pump procedure.

6. Remove or disconnect the following: e Intake camshaft bearing caps, then the camshaft e>When removing the exhaust camshaft, the valve lifter and valve shim may fall out. Have an assistant help keep the lifters and shims in the proper order.

Camshaft and Valve Lifters

REMOVAL & INSTALLATION

1998 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

e Exhaust camshaft cap bolts, loosen them, in sequence, in small increments e Exhaust camshaft bearing caps e Camshafts

Intake camshaft (LH) Exhaust camshaft (LH) Intake camshaft cap (LH) Exhaust camshaft cap (LH)

(5)

Rocker cover gasket (LH)

(6) (7)

Rocker cover (LH) Spark plug cord

24-1 1 4

To install: ->Lubricate the camshaft bearings prior to camshaft installation.

7. Install the camshafts so the base circle (non-lobe portion) of the camshafts are in contact with the lash adjusters. This will position the lobes of the camshafts away from the valves.

=The left camshaft will need to be rotated for timing belt alignment.

8. Apply Three Bond® 1215 fluid packing to the front bearing cap mating surfaces. 9. Install or connect the following: e Bearing caps. Torque the caps in Sequence in 2 progressive steps to 14 ft. Ibs. (20 Nm). e New oil seals in the cylinder heads using a seal installation tool.

Only rotate camshafts the specified amount. If the camshafts are rotated beyond the specified amount, the valves will contact each other and cause severe internal damage.

ft. Ibs. (Nm)

(1) (2) (3) (4)

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Exploded view of the camshaft mounting

Brake service is covered in Section 4 of this manual

7924XG08

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FORESTER front edges of the gasket at the camshaft opening. Torque the bolts

;

f

to 3.6 ft. Ibs. (5 Nm).

|

¢ CMP sensor, if removed e Spark plug wires ¢ Camshaft sprockets. Torque the retaining bolts to 58 ft. Ibs. (78 Nm). Be sure to secure the sprockets when tightening the bolts.

v

5_/€ =}

2 SY

} |

(Kale):

MAS

(o)

Pe

pt

m3, IGF ANCA G2) BX EO)

->Check the timing sprockets for proper

)

alignment

6 Timing belt

e Negative battery cable 13. Check the fluid levels and start the

Greed = I oA Cerna mic °° Omwfalate AV J B

(

F

)

(

engine. 14, Allow the engine to reach operating

|

) |

( D)

temperature and check for leaks 7924XG09

Camshaft bearing cap removal sequence—exhaust camshaft shown, intake camshaft is the

1999-01

same

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Timing belt covers e Timing belt

a 10. For correct timing belt alignment, rotate the left-hand intake camshaft 80 degrees clockwise and the left-hand exhaust camshaft 45 degrees counterclockwise.

11. If new camshafts were installed, check and adjust the valve lash. 12. Install or connect the following: e Valve covers using a new gasket be sure to apply liquid sealant to the

Left side cylinder head intake camshaft

Exhaust camshaft

Exhaust a

camshaft Ng

ih ene camshaft

7924XG26

Cutaway view of the camshaft positioning

'

’

ronestin 24-13 ¢ Camshaft sprockets e Spark plug wires ¢ (il level gauge guide and Camshaft Position (CMP) sensor support

e Positive Crankcase Ventilation (PCV) hose ¢ Valve cover ¢ Rocker arm assembly 3. Remove the camshaft cap as follows: a. Bolts “A” through “B” in alphabetical sequence b. Loosen bolts “C” through “J” equally all the way in alphabetical sequence c. Bolts “K” through “P” in alphabetical sequence using tool 499497000 7924x610

4. Remove or disconnect the following:

Camshaft bearing cap tightening sequence—intake camshaft shown, exhaust camshaft order is

theeaae

:

NS Camshaft

¢ Oil seal, if necessary ¢ Plug from the rear side of the camshaft

To install:

rect

a,

Lubricate the camshaft bearings prior to camshaft installation.

5. Install or connect the following: ¢ Camshaft ¢ Camshaft cap. Apply liquid gasket on the edge of the cam cap mat-

Fluid :

packing

ing surface 0.12 inch (3mm) thick

_ — ¢ ——

= pee

Apply the fluid packing as shown to prevent oil leaks

(g)

je =

9308XG08

Camshaft cap removal sequence

6. Temporarily tighten bolts “G” through “J” in alphabetical sequence 7. Install the valve rocker assembly. Torque the bolts “A” through “H” to 18 ft. lbs. (25 Nm). 8. Torque bolts “I” through “N” to 13 ft. lbs. (25 Nm) in alphabetical sequence using tool 499497000 9. Torque bolts “O” through “X” to 7.2 ft. Ibs. (10 Nm) in alphabetical sequence 10. Install or connect the following: Oil seal to the camshaft using tool 499597000 oil seal guide and 49958700 oil seal installer Plug to the rear side of the

camshaft using tool 499587700 oil

°

Seal installer Valve cover Oil level gauge guide and CMP sensor support PCV house Spark plug wires Camshaft sprockets. Torque the bolts to 58 ft. Ibs. (78 Nm). Timing belt Timing belt covers. Torque the bolts to 3.6 ft. Ibs. (5 Nm).

Negative battery cable

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

| a

24-14 Forester 4. Check the valve clearance: e Intake valve: 0.0071-0.0087 in. (0.18-0.22mm). e Exhaust valve: 0.0090-0.0106 in. (0.23-0.27mm). 5. lf any valve needs adjustment, perform the following, while referring to the accompanying illustrations a. Rotate the notch of the lifter outward by 45 degrees. b. Install part “A” of the Replacer onto

=

~ the camshaft.

AACS ie

iG

1 a ee

i TB i

PIOtgy Ao) Ged to! i a

5

F

C

5)

OG

c. Install part “B” of the Replacer as

shown.

4

d. Install part “C” and turn until part “B” pushes the lifter away.

(oi

7) C@:

e. Insert tweezers into the notch of the valve lifter, and take out the shim. f. Measure the thickness of the

ae

shim, then using the chart select and install a new shim and recheck the

Camshaft cap tightening sequence

clearance.

the air intake duct with the air

Valve Lash ADJUSTMENT

ee

cleaner assembly

¢ Blowby hose.

Se og ne Ot oe

° pa pd ne

->The valve adjustment should be per-

formed while the engine is cold. A

Shim Replace Kit 498187100 will be needed to perform the valve adjust-

: Veheones Pe

Valve covers

¢ Blowby hose

: age

the arrow mark on the camshalt Is set

ment.

to the position as shown.

4998

~The checking or adjusting the

=o

° Upper and center timing belt cover

e Washer tank

8. Check the engine oil level.

‘We vehicle.

the precautions in the beginning of this section. 2. Remove or disconnect the following: e Battery cables and tray e Upper and center timing belt cover mounting bolts e Engine undercover ¢ Timing belt cover lower mounting bolts, then the covers ¢ Mass Air Flow (MAF) sensor, and

TOO Position the lifter notch as shown, to remove the shim

A

, bn

° Battery and tray

exhaust valve is performed from under

1. Before servicing the vehicle, referto

7. Install or connect the following: e Spark plug wires

aisn the Beat ote a ye

until

6. Remove the adjusting tools.

7924KG36 . .-. then part “B” under part “A” as shown

5,

Mes caaree

< 7924XG35

7924XG37

7924XG33

Exploded view of the shim replace kit

First install part “A” of the tool to the

Turn

camshaft.

; be removed

. .

part “C” until

justi

” We ea

i ae

a

err

m ie ee

S

ee

e

ee

ee

rorestin 24-10 1999-01

Position arrow mark

“ices eee

1. Before servicing the vehicle, refer to

this AIRS:

the precautions in the beginning of this section, 2. Adjustment should be performed

RONG Oh ail

when engine is cold.

WINe

Camshaft

Ig

sprockets RH

ing:

;

O

e Negative battery cable

>=seta Se , x

(RH)

3. Remove or disconnect the follow-

an

\ (pm

e Engine coolant reservoir tank e Timing belt cover on the left hand

atin PET SE De: wow

,

SRL

Nae

side

hethivionsiimmtasecaneusetsef

\ NS Ar issef LON Zs A

#1=IN. #3 EX.

4. When inspecting Nos. 1 and 3 cylinders eae Aeioeae , e Air intake duct as a uni Resonator chamber Spark plug wires from Nos. 1 and 3

7924XG39

Position the camshaft as shown to adjust No. 1 intake valve ang No. 3 exhaust valve

Ne | Kee Gaa>

YS

Ro

;

as

rears |

¢ Battery and battery tray e Window washer motor connectors

front and rear

S

(RH)

e Rear gate glass washer hose from

Position arrow mark bee ieee this area. =

Blowby house from valve cover Engine undercover Timing belt cover on the right hand side e Valve cover on the right hand side 5. When inspecting Nos. 2 and 4 cylin-

ders remove the following:

6)

O

sprockets

cylinders

the washer motor Washer tank mounting bolts and secure out of the way

#

Spark plug wires from Nos. 2 and 4

es rte

AS 7924XG40

Position the camshaft as shown to adjust No. 3 intake valve and No. 2 exhaust valve

cylinders

Blow by house from valve cover Timing belt cover on the right hand side e Valve cover on the left hand side 6. Set No. 1 cylinder to Top Dead Center

(TDC). «When arrow mark on the left hand side comes exactly to the top, No. 1 cylinder piston is brought to TDC of the compression stroke.

7. Check the valve clearance: e Intake valve: 0.0071-0.0087 in.

(0.18-0.22mm). e Exhaust valve: 0.0090-—0.0106 in. (0.23-0.27mm). 8. lf any valve needs adjustment, perform the following: a. Loosen the valve rocker nut and

Position arrow mark between

his

ie

area.

7924XG41

Position the camshaft as shown to adjust No. 2 intake valve and No. 4 exhaust valve

Screw. b. Place a thickness gage in at as, horizontal a direction as possible with respect to the vale stem and face.

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

6 L

‘ ;

24-16 Forester oN cath ae ° SAOhoy—1 6)

Position arrow mark between this area.

+ agg Le

Camshaft

a

sprockets (RH)

r

ZA, eyyni, Le

#1 EX. #4 IN.

7924XG42

Position the camshaft as shown to adjust No. 4 intake valve and No. 1 exhaust valve

Intake valve (mm): S = (V + T) - 0.20 Exhaust vaive (mm): S = (V + T) — 0.25

S: Shim thickness to be used V: Measured valve clearance

T: Shim thickness required

| PartNo.| 13218AC230 13218AE000 13218AC240 13218AE010 13218AC250 13218AE020 13218AC260 13218AE030 13218AC270

| |

13218ac280_ 13218aC290_

|____s321gacaso

~—_—CThickness mm (in) 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30

.

| |

|

Thickness mm (in)

(0.0874) (0.0878) (0.0882) (0.0886) (0.0890) (0.0894) (0.0898) (0.0902) (0.0906)

13218AC480 13218AC490 13218AC500 13218AC510 13218AC520 13218AC530 13218AC540 13218AC550 13218AC560

2.32 0.0013) | 2.33 (0.0017) |

2.47(0.0072)

|

2.52 2.53 2.54 2.55 2.56 2.57 2.58 2.59 2.60

t32tsacsso 13218aC590_

| |

t2NBAEOBO

|

(0.0992) (0.0996) (0.1000) (0.1004) (0.1008) (0.1012) (0.1016) (0.1020) (0.1024)

2.62(0.1031) 2.63: (0.1035)

77 (0.1001) —_—*s 2.81 (0.1106) 7924XG38

Valve adjusting shim chart

ele

ese

wee

ee

Pe

SUBARU FORESTER

#1

3) #4

Cou

tpn

| 3

Piston

iN —,

©)

24-17

#3. Piston

|

|

= Camshaft

1

See

sprocket (LH)

#2

Piston 9308XG05

Position the camshaft for adjustment to valves

c. Adjust the-screw until proper clearance is obtained. d. Tighten the rocker nut after adjusted. 9. Install or connect the following: Valve covers left and right Timing belt covers Blowby houses to valve covers Spark plug wires Washer tank Rear gate glass washer hose to the washer motor Washer motor connectors Battery and battery tray Engine undercover Resonator chamber Air intake duct unit Engine coolant reservoir tank

To install: 3. Install or connect the following: e Starter. Torque the mounting bolts to 37 ft. Ibs. (50 Nm). e Wires e Air intake duct and assembly e Negative battery

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

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery e Air intake duct and assembly e Wires e Starter

9308XG02

View of the starter mounting

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

wa :

24-18 UA, T1: 3.6 ft. Ibs. (5Nm) T2: 3.6 ft. Ibs. (5GNm)

oe

T5: 32.5 ft.Ibs.(44Nm)

T3: 4.7 ft. Ibs. (6.4Nm)

)

ee et

eee

ee

(22) iF

T4: 7 ft. Ibs. (10Nm)

(32)

(1)

Plug

(2) (3) (4) (5) (6) (7) (8) (9)

Washer Relief valve spring Relief valve Oil seal Oil pump case Inner rotor Outer rotor Oil pump cover

(10) Oil filter (11) Oil cooler pipe and hose ASSY (AT vehicles) (12) Connector (AT vehicles) (13) Oil cooler (AT vehicles) (14) O-ring (AT vehicles)

(15) Nipple (AT vehicles) (16) Gasket (AT vehicles) (17) Oil cooler connector (MT vehicles) (18) Gasket (MT vehicles) (19) Oil filter connector (MT vehicles)

(29) (30) (31) (32) (33)

Gasket Oil level gauge guide Oil pan Oil level gauge Metal gasket

(34) Drain plug

(20) O-ring (21) (22) (23) (24) (25) (26) (27) (28)

Oil pump ASSY Oil pressure switch Oil filler duct O-ring Cylinder head cover Baffle plate O-ring Oil strainer 7924XG28

Oil pan and lubrication components

ee eee

ee

ee

fe

og

i

al

1 Ye) See

SUBARU

FORESTER 24-1 9

eee

2. Drain the oil from the engine. 3. Remove or disconnect the following: e Air intake duct ¢ Oxygen (02S) sensor connectors

e ¢ e e

Pitching stopper Upper radiator brackets Engine undercover

Rear 02S sensor connector, if equipped e Exhaust front Y-pipe and center pipe e Nuts which secure the front engine mounts to the front crossmember 4. Support the engine with a suitable lifting device and lift the engine slightly. 5. Remove the oil pan. 6. Clean all gasket material from both mating surfaces. To install: 7. Install the drain plug with a new gasket. Torque the bolt to 33-36 ft. Ibs. (43-47 Nm). 8. Apply a continuous bead of sealer to ~ a new oil pan gasket. 9. Install the oil pan assembly. Torque the bolts to 36-48 inch Ibs. (4-5 Nm). 10. Lower the engine onto the front crossmember.

11. Install or connect the following: Front engine mount nuts. Torque the nuts to 69 ft. Ibs. (51 Nm). Exhaust front Y-pipe with new gaskets. Torque the nuts that secure the pipe to the engine to 23 ft. Ibs.

(30 Nm). O2S sensor connectors Pitching stopper. Torque the front bolt to 36 ft. Ibs. (49 Nm) and the rear bolt to 42 ft. Ibs. (57 Nm). e Upper radiator brackets e Air intake duct e Engine undercover 12. Refill the engine to the proper level

with the recommended oil and run the » engine. 13. Check for leaks.

e Engine undercover ¢ Water pipe and hose between oil cooler and water pump e Radiator e Crankcase Position (CKP) Sensor ¢ Camshaft Position (CMP) Sensor e Belt(s) and rear tensioner ¢ Crankshaft pulley e Water pump ¢ Timing belt, and belt guide, if equipped Oil pump mounting bolts and carefully pry the pump from the engine block

3. Using a seal removal tool, pry the oil seal from the housing. To install: 4. Utilizing the appropriate seal installer 5. Install or connect the following; ¢ New oil seal and press it into the housing using the appropriate driver e Clutch assembly/flywheel, if equipped e Flywheel/flexplate and tighten the bolts to 53 ft. Ibs. (72 Nm), if equipped e Engine into the vehicle

Piston and Ring Use extreme care not to damage the engine block or the oil pump during removal of the pump.

POSITIONING

To install: 5. Apply a continuous bead sealant to the mating surfaces of the oil pump. 6. Install or connect the following: New front seal to the oil pump coat the inside of the seal with engine oil New O-ring to the oil pump Oil pump. Torque the bolts to 56 inch lbs. (6.4 Nm). Timing belt, and belt guide, if equipped e Water pump e Crankshaft pulley e Belt(s) and rear tensioner e Camshaft Position (CMP) Sensor e Crankcase Position (CKP) Sensor Radiator Engine coolant pipe Engine undercover Negative battery cable 7. Refill the cooling system. 8. Refill the engine to the proper level with the recommended oil.

Rear Main Seal

Upper ring gap

7924AGC2

Compression ring end-gap spacing—2.5L engine

7924AGC3

Upper, spacer and lower oil ring end-gap spacing—2.5L engine

REMOVAL & INSTALLATION REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil into a separate container. 4. Remove or disconnect the following: ¢ Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Engine from the vehicle e Clutch assembly/flywheel, if equipped with manual transmission ¢ Torque converter flexplate from the crankshaft, if equipped with an automatic transmission

‘ 2nd ring gap

Crankshaft

Connecting

Side mark

i™,

.

ae Piston Rings

7924AGC4

Piston and connecting rod assembly positioning—2.5L engine

For Wheel Alignment specifications, see Section 1 of this manual

ie

24-2

SUBARU

FORESTER

ee ATe

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure Se to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e Jo avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system presSure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed, 7 Pt eee a”

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the fuel pump harness at the fuel pump, under the rear seat access panel. 3. Crank the engine for 5 seconds or more to relieve the fuel pressure. If the engine starts during this time, allow it to run until it stalls. 4. Connect the fuel pump harness after repairs are completed.

Fuel Filter

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Locate the fuel filter in the engine compartment on the left inside fender. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: e Negative battery cable e Fuel delivery hoses from the fuel filter e Fuel filter from its holder To install: 5. Install or connect the following: e Fuel filter into its mounting bracket e Fuel delivery hoses and tighten the hose clamps e Negative battery cable

Fuel Pump

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the rear seat cushion and access panel. 3. Properly relieve the fuel system pressure. 4. Disconnect the negative battery cable. 5. Clean any debris away from the fuel pump mounting to prevent it from entering the tank. e Fuel pump electrical connector e Fuel delivery and return hoses e Fuel pump mounting nuts e Fuel pump out of the fuel tank To install: 6. Replace the sealing gaskets for the fuel pump. 7. Install or connect the following: e Fuel pump into the tank. Torque the mounting nuts in sequence to 39 inch Ibs. (4.4 Nm). Fuel delivery and return hoses Fuel pump electrical connector Fuel filler cap e Negative battery cable 8. Start the vehicle and check for leaks. 9. Install the fuel pump access cover and rear seat cushion.

Fuel System Pressure RELIEVING e>This procedure must be performed prior to servicing any component of the fuel injection system.

7924XG11

View of fuel filter mounting

ee

ee eo eee

Pe os

ee

a n ie- f

fonestin 24-21 (1)

(2)

(3)

(4) (5)

(6)

= (7) (8) Lip

yy’ (¥

Re +

2) er oe ee

|

‘i

Q\ (12)

(4)

(11)

(10) (9)

(1)

Purge control solenoid valve

(5)

Fuel pump

(9)

(2)

Roll over valve

(3) (4)

Pressure control solenoid Quick connector

(6) (7) (8)

Fuel tank pressure sensor Vent control solenoid valve Air filter

(10) Fuel cut valve (11) Fuel tank (12) Fuel filter

Canister

7924XG12

Fuel system component locations

7924XG13

Fuel pump mounting nut tightening sequence

For Maintenance Interval recommendations, see Section 1 of this manual

o

a

24-22

,

SUBARU

i

FORESTER

a i:

ee

|

Se

Sn :

ee

REMOVAL & INSTALLATION 1998 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. ~ 3. Remove or disconnect the following: e Negative battery cable Electrical connector from injector e Fuel injector from fuel rail To install: 4. Replace old O-rings and insulator

(A)

O-ring B

(B)

(C)

_ri O rINg A ini Fuel injector

(D)

insulator

E (

with new. 5. Install or connect the following: e Fuel injector from fuel rail. Torque the a mounting Net bolts to 2.5 ft. Ibs.

° Electrical connector to injector

eeeliact injector

e Negative battery cable

Cu

oh

p

9308XG04

1999-01

View of fuel injector removal—1998 models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable Air duct and cleaner assembly Resonator chamber Spark plug wires No. 1 and 3 V-belt covers Power steering pump belt Power steering pipe bracket from manifold Power steering pump and sea

w

ee

Xi

phe

pra onWas ees

oy,

Cs)

aside

() (G gow

Wires from fuel injector Injector pipe from intake mani-

¢

fold

Fuel injector

Cji_—&

To install:

_——

4. Install or connect the following: . Fuel injector

psit a PhS

9308XG03

View of fuel injector removal on 1999-01 models

Injector pipe to intake manifold Wires to fuel injector Power steering pump Power steering pipe bracket to manifold Power steering pump belt V-belt covers Spark plug wires No. 1 and 3 Resonator camber Air duct and cleaner assembly Negative battery cable

avs,

-

er wa

1

ieee@

oe ee ae ee >

17

ee

ronesrin 24-20

SS

S

SSS

DRIVE TRAIN

|

Transmission Assembly REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. On automatic transmission vehicles, drain the automatic transmission fluid and the front differential. 3. Remove or disconnect the following: Negative battery cable Air intake and chamber, then the chamber stays Air cleaner case stay Front and rear Oxygen (02S) sensor connectors, if equipped Transmission harness connector, if equipped with an automatic transmission Transmission ground terminal

Neutral position switch connector, if equipped with a manual transmission Backup light switch connector, if

equipped with a manual transmission ¢ 2 Vehicle Speed (VSS) sensor connectors e Starter e Pitching stopper 4. On automatic transmission vehicles, remove the timing hole inspection plug. Matchmark the torque converter-to-driveplate and remove the 4 bolts which hold torque converter to driveplate. 5. Remove or disconnect the following: e Automatic transmission fluid dipstick and tube e Clutch slave cylinder, on manual transmission vehicles 6. Install engine support assembly ST 41099AA02Q. (Also available as part no. 927670000). 7. Remove or disconnect the following: e Bolt securing the right upper side

9, Remove or disconnect the following: Center exhaust pipe from rear pipe and hanger bolt Rear exhaust pipe and heat shield cover ; Hanger bracket from the right side of the transmission Transmission cooler lines Rear driveshaft, matchmark for reassembly Center bearing bracket ->Plug the opening at the rear of the extension housing to prevent oil from flowing out.

Shifter stay and rod from the transmission, on manual transmission Gear shift cable from the transmission select lever, on automatic transmission Swaybar from the transverse link Parking brake cable bracket from the transverse link and bolt holding the transverse link to the crossmember on each side, lower the transverse link

of the transmission to the engine e Engine undercover e Front Y-pipe 8. Disconnect connector from rear 02S sensor

42 (57)

36 (49)

ON

“Xe

(1) (2) (3) (4) (5) (6) (7)

Pitching stopper Spacer Cushion C Front plate Rear cushion rubber Rear crossmember Cushion D

ft. Ibs. (Nm)

(8) (9)

51 (69)

Center crossmember Rear plate

(10) Front crossmember 101 (137)

7924XG14

Exploded view of the manual transmission mounting

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

; 24-| 24 SuBAR FORESTER (1)

42 (57)

28 (38)

0 @ ~

36 (49)

Use a small punch to remove the spring pin. Discard old spring pin and always install a new pin.

10. Disconnect the halfshaft from transmission on each side. Be sure to remove the axle shaft from the transmission by pushing the rear of the tire outward. 11. Remove the engine-to-transmission mounting nuts 12. Support the transmission with a jack. ->Do not place jack under the transmission oil pan, otherwise the oil pan may be damaged.

13. Remove or disconnect the following: e Rear transmission crossmember e Transmission To install: 14. Install or connect the following: e Special tool 498277200 to torque converter clutch case e Transmission to the engine e Transmission crossmember. Torque the front nuts/bolts to 51 ft. Ibs. (69

Nm) and the rear nuts to 101 ft. lbs. (137 Nm), on manual transmissions e Transmission crossmember. Torque

the inner nuts/bolts to 25 ft. Ibs. (34 Nm) and the rear nuts to 51 ft. lbs. (69 Nm), on automatic transmissions 15. Remove the transmission jack. 16. Install or connect the following: e Transmission-to-engine mounting nuts. Torque the nuts/bolts to 37 ft. lbs. (50 Nm). Torque converter-to-driveplate bolts on automatic transmission vehicles. Torque the bolts to 18 ft. Ibs. (25 Nm). Clutch slave cylinder on manual transmission vehicles. Torque the mounting bolts to 27 ft. Ibs. (37 Nm). 17. Remove special tool 927670000. 18. Install or connect the following: e Pitching stopper e Halfshaft to transmission and Spring pin into place e>Always use new spring pin. Be sure to align the axle shaft and shaft from the transmission at chamfered holes and install shaft splines correctly.

Lower ball joint to knuckle Sway bar to the crossmember. Torque the clamp bolts to 18 ft. Ibs. (25 Nm). Shift control rod, shifter stay to the transmission and the spring, on manual transmission vehicles Gear shift cable to the select lever, on automatic transmission vehicles Fluid cooler lines Driveshaft. Tighten the bolts to 23 ft. Ibs. (31 Nm). Center bearing bracket. Torque the bolt to 38 ft. Ibs. (52 Nm). Heat shield cover, if removed e Center exhaust pipe from rear pipe and hanger bolt Rear exhaust pipe and heat shield cover Hanger bracket from the right ae of the transmission Y-pipe with new gaskets and nuts

Rear 02S sensor connector Automatic transmission fluid dipstick tube Transmission connector bracket Starter. Torque the mounting bolts to 37 ft. Ibs. (50 Nm). Front and rear 02S sensor connectors

-

My

i |i oe

as”

es

a

|-

site

Sa

oe

Ao

ae WA,

Loe

ronestin 24-20 Transmission harness connector, on automatic transmission vehicles e

e

Transmission ground terminal Neutral position switch connec-

tor, on manual transmission vehicles Backup light switch connector, on manual transmission vehicles 2 VSS connectors Air intake and chamber, and the camber stays Negative battery cable 19. On automatic transmission vehicles,

fill the automatic transmission fluid with

Dexron®ll or Ill or equivalent. 20. On manual transmission vehicles, check and fill the transmission with 75W-90 gear oil. 21. Road test the vehicle.

Clutch

ADJUSTMENT This vehicle is equipped with a hydraulic Clutch that is self-adjusting, therefore no adjustment is possible or necessary.

REMOVAL & INSTALLATION

CAUTION The clutch driven disc may contain asbestos, which has been determined to be a cancer-causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch surface. When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

‘a E

|

cA

i *

'

f

bs

‘

ft. Ibs

(9) Lever (10) Clutch release lever sealing

(1)

Operating cylinder

(2) (3)

Washer Clutch hose

(4)

Bracket

(12) Pivot

(5)

Pipe

(13) Release lever

(6)

Master cylinder ASSY

(7) (8)

Clevis pin Snap pin

(14) Clip (15) Release bearing

(17) Clutch disc (18) Flywheel

(11) Retainer spring

(16) Clutch cover 7924XG17

Exploded view of clutch system

For complete service labor times, order the Chilton Labor Guide

a

9 4-26 SUBARU

a ee ee

hot

z

FORESTER

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. . 2. Remove or disconnect the following: e Negative battery cable e Transmission

Removing the bolts on one side of the pressure plate will warp the pressure plate, rendering it useless. 3. Gradually unscrew the six 6mm bolts that hold the pressure plate assembly on the flywheel. Loosen the bolts only 1 turn at a time, working around the pressure plate. Do not unscrew all the bolts on one side at one time. 4. Remove or disconnect the following: e Clutch plate and disc e 2 retaining springs, the throwout bearing and the release fork e>Do not disassemble either the clutch cover or disc. Inspect the parts for wear or damage and replace any parts as necessary. Replace the clutch disc if there is any oil or grease on the facing. Do not wash or attempt to lubricate the throwout bearing, because it is sealed and permanently lubricated. If it requires replacement, the bearing may be removed and a new one installed in the holder by means of a press.

To 5. of the 6.

install: Fit the release fork boot on the front transmission housing. Install or connect the following: e Release fork ¢ Throwout bearing assembly and secure it with the 2 springs

e>Coat the inside diameter of the throwout bearing and the release lever contact points with grease.

¢ Clutch alignment tool through the clutch cover and disc, then insert the end of the tool into the needle bearing 7. Tighten the pressure plate bolts following the illustrated sequence, 1 turn at a time, until the proper torque is reached. Tighten to 12 ft. bs. (16 Nm),

When installing the clutch pressure plate assembly, be sure that the 0 marks on the flywheel and the clutch pressure plate assembly are at least 120 degrees apart. These marks indicate the direction of residual unbalance. Also, be sure that the clutch disc is installed properly, noting the FRONT and REAR markings. 8. Install the transmission.

Hydraulic Clutch System BLEEDING e>To properly bleed the system, it must be bled at the slave cylinder and at the damper. Each of these has an air bleeder on it.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Connect a vinyl tube to the air bleeder on the damper and put the other end in a jar with clean clutch fluid.

76(3)=( 1) 8% (ip x \.

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7924XG18

Clutch cover alignment and tightening sequence

Bleeding the hydraulic clutch at the slave cylinder

be we '

i

->Do not let the fluid level fall too low in the master cylinder. Do not release the pedal with the bleeder open.

3. With the help of an assistant depressing the clutch pedal, slowly open the bleeder valve. Close the bleeder valve and release the pedal. Repeat this process until no air bubbles appear in the jar. 4. Move the tube to the bleeder on the slave cylinder and repeat the process. Check the operation of the clutch after the bleed procedure is complete. Transfer Case Assembly

REMOVAL & INSTALLATION The transfer case is an integral part of the transmission.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Wheel Axle nut Stabilizer link from transverse link Transverse link from housing Halfshaft-to-transmission roll pin and discard it e Halfshaft from the transmission 3. Using Axle Shaft puller 926470000 and Plate 927140000, remove the halfshaft from the hub. To install: 4. Install the halfshaft into the hub. 5. Using Halfshaft installer 922431000 and adapter 927390000, pull the halfshaft through the hub, 6. Install and temporarily tighten a new axle nut. 7. Install or connect the following: ‘ Halfshaft onto the transmission, Pane the halfshaft roll pin ole New roll pin Transverse link to housing. Torque the nut to 36 ft. Ibs. (49 Nm). Stabilizer link New axle nut. Torque the nut to 197 ft. Ibs. (186 Nm) and stake the nut. Wheel Negative battery cable

SUBARU 9A. FORESTER

&

"31

9.5 (13)

A > (Bia

~

(22)

re.

137 (186)

ft. Ibs. (Nm)

(1)

Spring pin

(10) Boot (DOJ)

(19) Tone wheel

(2) (3) (4)

Baffle plate (DOJ) Outer race (DOJ) Snap ring

(11) Boot (BJ) (12) BJ ASSY (13) Baffle plate

(20) Hub bolt (21) Hub (22) Axle nut

(5) (6) (7) (8) (9)

Inner race (DOJ) Ball Cage Circlip Boot band

(14) (15) (16) (17) (18)

Oil seal (IN) Snap ring Bearing Housing Oil seal (OUT) 7924XG19

Exploded view of the front halfshaft—manual transmission

Please visit our web site at www.chiltonsonline.com

«

24-28 SUBARU

pat

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Pe

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ft. Ibs. (Nm)

(1) (2) (3) (4) (5) (6) (7) (8) (9)

O-ring Baffle plate (FTJ) Spring pin Outer race (FTJ)

Snap ring Trunnion Free ring Circlip Boot band

(10) Boot band

(11) (12) (13) (14) (15)

Boot (BJ) BJ ASSY Baffle plate Oil seal (IN) Snap ring

(19) (20) (21) (22)

Tone wheel Hub bolt Hub Axle nut

(16) Bearing (17) Housing

(18) Oil seal (OUT) 7924XG20

Exploded view of the front halfshaft—automatic transmission

wd

SUBARU FORESTER

Oe ST2

ST1 ST2

926470000 927140000

AXLE SHAFT PULLER PLATE 7924XG29

Be sure not to damage the threads when removing the front or rear halfshafts

ST1 ST2

922431000 927390000

AXLE SHAFT INSTALLER ADAPTER 7924XG30

To avoid using a hammer when installing the halfshafts, use the proper tools as shown

Timing belt service is covered in Section 3 of this manual

24-30 SupAne,

©

(18)

SS th aa

(19)

9.5 (13)

wae 37 (186)

ft. Ibs. (Nm) (1) Baffle plate (DOJ) (2) Outer race (DOJ) (3) Snap ring (4) Inner race (5) Ball (6) Cage (7) Circlip (8) Boot band (9) Boot (DOJ)

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Boot (BJ) BJ ASSY Oil seal (IN. No. 2) Oil seal (IN. No. 3) Housing Bearing Snap ring Oil seal (OUT) Tone wheel

(19) Hub bolt (20) Hub (21) Axle nut

7924XG21

Exploded view of the rear halfshaft

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Rear

CV-Joints

1. Before servicing the vehicle, refer to the «precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable e Axle nut Anti-lock Brakes (ABS) and parking brake cable bracket Lateral link assembly to rear housing Trailing link assembly from the rear housing bolt and nut Halfshaft-to-differential roll pin Halfshaft from the differential 3. Using Axle Shaft puller 926470000 and Plate 927140000, remove the halfshaft from the hub. To install: 4. Install the halfshaft into the rear housing. 5. Using Halfshaft Installer 922431000 and adapter 927390000, pull the halfshaft into place. 6. Install and temporarily tighten a new axle nut. 7. Install or connect the following: Halfshaft-to-differential align roll pin holes and slide the halfshatt onto the splines New roll pin Trailing link assembly to the rear housing. Torque bolt and new nut to 84 ft. Ibs. (113 Nm). Trailing link assembly-to-rear housing bolt and nut. Torque the new nut to 101 ft. Ibs. (137 Nm). Stabilizer bracket ABS and parking brake cable bracket New axle nut. Torque the nut to 137 ft. Ibs. (186 Nm): Wheel Negative battery cable

REMOVAL & INSTALLATION Front

INNER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

e e ¢ ¢ e

Front wheel(s) Halfshaft and place in vise Boot bands and slide boot down Circlip from CV-joint outer race Outer race from shaft, wipe off all grease 3. Matchmark Tri-pot spider assembly for reassembly. e Snapring and Tri-pot e CV-oint boot To install: 4. Install or connect the following: e C\V-joint boot and fill with 1.06-1.41 02. of grease e Tri-pot spider assembly and snapring ¢ Outer race, fill with 3.53-3.88 oz. of grease

¢ Circlip to CV-joint outer race 5. Slide boot onto outer race 6. New band on the boot

OUTER The outer boot is the only thing that is replaceable the outer CV-joint is not disassembled. Rear

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

rorestin 24-31

_ 2. Remove or disconnect the following: ¢ Front wheel(s) e Half shaft and place in vise Boot bands and slide boot down Circlip from CV- joint outer race ¢ Quter race from shaft, wipe off all grease 6 balls Snapring and inner race Cage from the shaft e CV boot To install: 3. Install or connect the following: e CV-joint boot and fill with 0.76-1.06 oz. of grease e Cage to the shaft with the cut out portion facing the shaft end e Inner race and snapring 4. Install the cage to the inner race. e>Fit the cage with the protruded part aligned with the track on the inner race then turn by a half pitch.

5. Install the outer race and snapring: then, fill with 2.82-3.17 oz. of grease 6. Coat the cage pockets with

grease. 7. Install or connect the following: e 6 balls into cage, align the inner race and cage e Outer race and circlip 8. Slide boot on to outer race 9. New band on the boot

OUTER The outer boot is the only thing that is replaceable the outer C\V-joint is not disassembled.

STEERING AND SUSPENSION injury and unnecessary system repairs.

ok CAUTION

PRECAUTIONS

All vehicles are equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module,

hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment.

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

Heater Core replacement is covered in Section 2 of this manual

24-3

‘< Ong)

SUBARU

FORESTER Rack and Pinion Siesrind Gear —

2. Disconnect the negative battery cable. 3. Disconnect the positive battery cable. 4. Wait more than 20 seconds to allow the air bag system to deplete its backup power before starting work. 5. To rearm the air bag system, reconnect the positive, then the negative battery cables.

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(20) (21) ©

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° Negative battery cable Soe rant whee

e Engine undercover e Y-pipe e Tie rod end cotter pin and nut

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

)-

11 (15)

&

— 99 (27)iit

2. Remove or disconnect the following:

REMOVAL & INSTALLATION

(32

(19)

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(34) (33)

(14)

(16)

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“4WD” mark Front of vehicle

Wheel Brake hose clip . Union bolt from the brake caliper, if equipped with disc brakes and move the brake hose out of the way Brake hose and pipe from strut and drum, if equipped with drum brakes 3. Support rear with jack. 4. Remove or disconnect the following: 5. Remove or disconnect the following: e Retainer nuts securing the strut bearing cap to the strut tower, from inside the vehicle e Lower nuts and bolts securing the Strut to the rear wheel housing e Strut To install: 6. Install or connect the following: Strut on to the vehicle, making sure to position the strut with the “4WD” mark on the strut mount facing the outside of the vehicle as shown in the illustration. Torque the retaining nuts to 15 ft. Ibs. (20 Nm). Strut and mount cap. Torque the strut mount cap bolts to 14.5 ft. lbs. (20 Nm). Strut to the rear wheel knuckle assembly. Torque the retainer nuts/bolts to 145 ft. Ibs. (196 Nm). Union bolt, if equipped with disc brakes. Torque the bolt and to 13 ft. lbs. (18 Nm). Brake hose to brake pipe, if equipped with drum brakes. Torque to 10 ft. Ibs. (15 Nm). Brake hose clip Wheel

e Strut mount cap

7. Bleed the brakes.

pool saa soring REMOVAL & INSTALLATION

Rear

Do not remove the large nut on top of the strut assembly unless the coil spring is properly compressed with a suitable spring compressor. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheel assembly e Caliper, leaving the line connected and suspend it out of the way

Front and Rear

kk CAUTION Do not remove the large nut on top of the strut assembly unless the coil spring is properly retained with a spring compressor. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Strut mount cap located at the right rear interior quarter trim

2k CAUTION Do not remove the large nut on top of the strut assembly unless the coil spring is properly compressed with a spring compressor. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut assembly. 3. Place the strut assembly in a vise

Brake service is covered in Section 4 of this manual

24-34 SURAR,

i iy rs

45 (20)

(17)

(3)

. peccepsel de (26)eee te b;

36 (49)

(19)

ae eas

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29 (39)

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(26)

6

22 (29)

(28)

13 (48)

ft. Ibs. (Nm)

412 (152)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Front crossmember Bolt ASSY Housing Washer

Stopper rubber (Rear) Rear bushing Stopper rubber (Front) Ball joint Transverse link Cotter pin Front bushing Stabilizer link Clamp Bushing Stabilizer Jack-up plate (Except MT model)

(17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32)

Dust seal Strut mount Spacer Upper spring seat Rubber seat Dust cover Helper Coil spring Damper strut Adjusting bolt Castle nut Self-locking nut Adapter front crossmember Clip Dynamic damper (MT model) Jack-up plate (MT model) 7924XG23

Exploded view of the front suspension

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(1) (2)

Stabilizer Stabilizer bracket

(15) Trailing link front bushing (16) Trailing link bracket

(3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Stabilizer bushing Clamp Floating bushing Stopper Stabilizer link Rear lateral link Bushing (C) Bushing (A) Front lateral link Bushing (B) Trailing link rear bushing

(17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27)

Trailing link

(28) Self-locking nut

ft. Ibs. (Nm)

Cap (Protection) Washer Rear crossmember Strut mount cap Strut mount ; Rubber seat upper Dust cover Coil spring Helper Rubber seat lower Damper strut 7924XG24

Exploded view of the rear suspension

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

24-3

a

SUBARU

FORESTER

witha holding tool and install a spring

compressor. 4. Compress the spring slightly. 5. Loosen but do not remove the bearing cap locknut. 6. Unload the spring seat using the spring compressor, then remove the locknut.

7. Remove or disconnect the following: e Strut bearing cap, mounting insulator bracket and upper spring seat Coil spring and compressor. If the spring is being replaced, slowly release the spring from the compressor and compress the new coil spring. Strut boot and rebound bumper from the strut, inspect and replace if worn Strut retainer nut and the strut insert from the assembly To install: 8. Install or connect the following: Strut into the chamber Retainer nut. Tighten the nut until snug. Rebound bumper and the boot to the strut piston rod Coil spring on the strut assembly Upper spring seat, mounting insulator and bearing cap Locknut. Tighten it to 36—-43 ft. Ibs. (47-56 Nm). Spring compressor from the coil spring e Strut Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Front wheel ¢ Ball joint castle nut cotter pin, discard the cotter pin e Castle nut ¢ Ball joint from the lower control arm assembly ¢ Ball joint from the steering knuckle To install: 3. Install or connect the following: e Ball joint to the steering knuckle. Torque the bolt to 36 ft. Ibs. (49 Nm). ¢ Ball joint to the lower control arm.

Torque the castle nut to 29 ft. Ibs. (39 Nm). Then, tighten the castle nut an additional 60 degrees until the slot in the castle nut is aligned: with the cotter pin hole in the ball joint. e New cotter pin e Wheel e Negative battery cable Lower Control Arm

|

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheel assembly Stabilizer link Ball joint from housing Mounting bolts e Control arm To install: 3. Install or connect the following: ¢ Control arm to stabilizer. Torque the nut/bolt to 22 ft. Ibs. (29 Nm). e Control arm to crossmember. Torque the nut/bolt to 72 ft. Ibs. (98 Nm). ¢ Control arm to rear mount. Torque the bolts to 181 ft. Ibs. (245 Nm). e Ball joint to housing, Torque the nut to 36 ft. Ibs. (49 Nm). e Wheel assembly

CONTROL ARM BUSHING REPLACEMENT Front Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Control arm 3. Press the bushing out using Installer/Remover tool 927680000 To install: 4. Press the bushing in using Installer/Remover tool 927680000 5. Install or connect the following: e Control arm e Wheel Rear Bushing

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

e Wheel e Control arm and matchmark the bushing for reassembly e Nut and bushing To install: 3. Install or connect the following: e Bushing into control arm and align the matchmark. Torque the nut to 137 ft. lbs. (186 Nm). e Control arm e Wheel Wheel Bearings

we

ADJUSTMENT The wheel bearings are not adjustable.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the steering knuckle assembly. 3. Position the steering knuckle in a Soft-jawed vise. 4. Press the hub from the steering knuckle. If the inner bearing race remains in the hub, press it out. 5. Remove or disconnect the following: e Rotor shield e Inner and outer seals e Snapring from the steering knuckle 6. Press the inner bearing race to remove the outer bearing. 7. Remove the Anti-lock Brakes (ABS) tone ring, if equipped 8. Press the wheel lugs from the hub. >To prevent deforming the hub, do not hammer the lugs out.

To install: 9. Press new wheel lugs into the hub. 10. If equipped, clean all foreign material from the hub and tone ring. Install the tone ring. 11. Clean the inside of the steering « knuckle. 12. Remove the plastic lock from the inner race and press a new greased bearing into the hub by pressing the outer race. 13. Install the snapring into its groove. 14. Press a new outer oil seal until it contacts the bottom of the housing. 15. Press a new inner oil seal until it contacts the circlip. 16. Apply grease to the oil seal lips.

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927080000 927420000

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HUB REMOVER

7924XG32

Use the proper tools to separate the hub from the housing to prevent damage

17. Install the rotor shield and tighten the bolts to 10 ft. Ibs. (14 Nm). 18. Attach the hub to the steering knuckle. 19. Press a new bearing into the hub by driving the inner race. 20. Install the steering knuckle on the vehicle.

Drum and brake line, if equipped with drum brakes Parking brake cable Rear stabilizer from lateral link Trailing link to the housing Lateral link to the housing Halfshatt Anti-lock Brakes (ABS), speed sensor from the backing plate, if

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Loosen the parking brake adjustment. 4. Remove or disconnect the following: e Wheel e Axle nut e Caliper, leaving the line connected if equipped with disc brakes and Suspend it aside, then remove the rotor

equipped Strut from the housing e Housing assembly 5. Using hub stand 92708000 and Hub Remover 927420000 6. Remove or disconnect the following: e Hub from the rear housing e Backing plate from the housing. e Quter, inner and sub oil seals. e Snapring 7. Remove the bearing by pressing the inner race. To install: 8. Clean the housing thoroughly.

Do not remove the plastic lock from the inner race when installing the bearing.

9. Install the new bearing into the housing by pressing the outer race. 10. Pack the bearing with grease. 11. Install the snapring. 12. Using installer 927460000 seal driver, press in a new outer seal until it comes in contact with the snap-ring. 13. Using installer 927450000 seal driver, press in a new inner seal until it contacts the bottom. 14. Install or connect the following: e New sub oil seal, apply grease to the oil seal lip e Backing plate. Torque the bolts to 38 ft. Ibs. (52 Nm). 15. Using installer 927450000 bearing driver, press in the hub into the housing. 16. Install or connect the following: e Housing to the strut. Torque the bolts to 108 ft. Ibs. (147 Nm). e Halfshaft

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

24-38 Forester e Lateral linktothe housing. Torque the bolt and new nut to 101 ft. Ibs. (137 Nm). e Trailing link to the housing. Torque the bolt and new nut to 94 ft. Ibs. (127 Nm).

e Stabilizer to rear lateral link e Parking brake cable and brake e Brake line, if equipped with drum brakes e Rotor and caliper, if equipped with disc brakes

e ABS speed sensor, if equipped e New axle nut and tighten it to 137 ft. Ibs. (186 Nm). Stake the nut. e Wheel e Negative battery cable 17. Adjust the parking brake cable.

TOYOTA AND LEXUS

7

1998-01

Toyota-RAV4 * 4Runner « Highlander * Lexus-RX300 BRAKES

.............cceees 25-104

DRIVE TRAIN.................. 25-65 ENGINE REPAIR................ 25-2 FUEL SYSTEM ................ 25-60 PRECAUTIONS.................. 25-2

STEERING AND SUSPENSION................. 25-90

.

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SL paar si 25-90 VERIO” Grantee 25-90

ak teh ar, Pvak.foyse 25-2

Mutt -imaatnonscs 25-4,

saan pone 25-2 Automatic Transmission/Transaxle Apsemminlyaeidn odah hinilsae. ie25-70 Removal & Installation............ 25-70 Axle Shaft; Bearing and Seal........25-88

7

Removal & Installation............ 25-88 | B

Blake Baisaire sees Gress 25-104 Removal & Installation.......... 25-104. Pa fe aln uU

CaliBer ns .easse.< ta ey alae 29-104 Removal & Installation.......... 25-104

Camshaft and Valve Lifters .......... 20-31

Removal & Installation........... 25-37 Clutch ASSEMDIY......c.:.sssseeeeeeeen 25-68

0-2 i fea Drv 25-68 Removal & Installation........... 25-69 CONSONNG se ee lliem 25-97

‘Removal & Installation............ 95-97

CVsointge

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ott

95-84

Cylinder Head ........ssssssssseesssssee 25-22 stale a

Rear Maln'Seal si. Peteucla 25-59 Removal & Installation............ 20-09

Removal & Installation............ De ho

OMOC AD SONGN nc heer rere 25-93

Fuel System Pressure ...soo-s.0e......25-60 ReLGVING ssccccccccssssscescserveveseese2D-60

Removal & Installation............25-93 SPINE BearingS ...........s..eceeee10.20-88

FURST MRC

inna rec tpoacteteanen 25-62

Fuel System Service

Precautions.:...scieccassssessstsististi25-60

H Halfshattait.uavniash-nan a ooiuns 25-78 Removal & Installation........... 25978)” — Hydraulic Clutch System............ 25-70 Bleeding e220", 609 eo 18oF25-70

L Lower Ball. UOiMt......ccsseesnisecomasiens 25-98

Transfer Case Assembly............. 25-11 Removal & Installation............ 20-17

AQTUSITNICOL: 2. MO cnanare 25-4 (ptake Manifold is astibarereroe 25-28 Removal & Installation............ 25-28 Removal & Installation............ 25-98

Lower Control APM ...ssssssscssscsesee 25-99 Control Arm Bushing

Replacement......ccccssse0.25°102 Removal & Installation............ 25-99 M

Manual Transmission

Front Cover and Seal..............00: 25-56 Removal & Installation............ 29-56 Seal Replacement ..............0000 29-58 seine

—-Upper Ball Joint... sess 29-98 Removal & Installation............ 25-98

Upper Control Arm .........sssssvse+20-99 Control Arm Bushing Replacement.........sssseseee 25-99 Removal & Installation............ 20-99

ASSOITBIG!, 0) (eR PONSA OE RT Ie 25-65 Removal & Installation............25-65

ban

iene,

Removal & Installation............ 25-52

Removal & Installation............ 95-33

Installation .......ssoresstensere:20-88

laren MOOR, scsi ra yeeclqut eanedea Removal & Installation............ 20-51 o Strub: ganar ke nel tee25-94 Removal & Installation............ 25-94 Strut Overhaul... eee 25-97

b . T Timing Chain, Sprockets,

GIMP UMD F-). csscakae ee. 25-53 Removal & Installation............ 95-53

Exhaust Manifold... 25-33

Removal, Packing and

Ignition Timing .........cccssssee 25-4

fala

eae& eelatinn 13a. 25-4

Positioninguaag amaccaueacauc 25-59

Power Rack And Pinion Stecring Gear QagingE Is wan 25-90 Removal & Installation............ 25-90 R

BLICT INGUO SS: Moreuomerk eee 95562 Removal & Installation............ 25-62

POPPIN chon:ache lane: stcaehAVC. 5-2 CSS Myhs emblyeannngsaiveenis. 25-4 Ca

il PBAIE

F

Front Crankshaft Seal oc... 25-36 Removal & Installation............ 25-36 Fuel FIG: 20", 08 ealoiriay: wes |25-61 Removal & Installation............ 25-61

Pion Sear.

oe Bi eee. 25-89

PISEOM ANG! Ri

Gasccazssanrcesesrassaneeens 25-59

Removal & Installation............ 25-89

V Valve Lash REN

Cohn Ow BOOS FORE,

Adjustment... iy alt asia 25-41 i Se

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EMOVAl & INSTANAUON..........2. i nee ea NT RE Aiea JUSUMEN....seseesseestersseeseeees ? Removal & Installation.......... 25-102

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TOYOTA AND aie RAV4 e 4RUNNER e: HIGHLANDER e Rx300

—————K

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PRECAUTIONS

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Before servicing any vehicle, pleasebe Sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work ina well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

¢ The EPA warns that prolonged con- tact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as Soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. e NEVER disconnect the negative battery cable with the ignition ON or the engine running. Removing power from the computer control module with the ignition ON may destroy the module. e Clean, high quality brake fluid from a sealed container is essential to the safe and

| proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine ‘damage. ° Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. e Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR e>Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor All models are equipped with a distibutorless ignition system.

Alternator REMOVAL On some models, the alternator is

mounted very low on the engine. On these

models, it may be necessary to remove the gravel shield and work from beneath the vehicle in order to gain access to the alternator. Replacing the alternator while the engine is cold is recommended. A hot engine can result in personal injury.

2.0L RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Electrical wiring from the alternator

¢ Loosen the adjusting lockbolt and the pivot bolt. ¢ Loosen the adjusting bolt to relieve

tension on the drive belt, if equipped with air conditioning e Drive belt e>|t may be necessary to remove other belts for access.

e Pivot bolt and the adjusting lockbolt e Alternator

2.4L Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Electrical wiring from the alternator e Drive belt

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4. Properly relieve the fuel system pressure. 5. Remove or disconnect the following: e Both battery cables e Battery and tray 6. Drain the engine coolant. 7. Drain the engine oil. 8. Remove or disconnect the following: Intake air cleaner and case assembly Cruise control actuator, if equipped Upper suspension brace Upper and lower radiator hoses Radiator Automatic transmission oil cooler lines Any connectors, hoses and sensors that would interfere with engine removal Engine Control Module (ECM) engine wiring harness from inside the glove box; then, pull the harness into the engine compartment Compressor ->It may be necessary to remove the air conditioning compressor lines in order to remove the engine.

Automatic transmission shifter cable from the transaxle Header pipes from the exhaust manifolds Left and right fender apron seals Halfshafts Front driveshaft, for 4WD Stabilizer links and the steering intermediate shaft Power steering pump Engine undercover Engine hanger to the engine Engine sling device to the engine hangers Right-hand motor mount and moving control rod Front suspension lower braces 9. Lower the engine, transaxle and front Suspension member as an assembly from the vehicle. To install: 10. Raise the engine, transaxle and front Suspension member as an assembly into the vehicle. 11. Install the front suspension lower braces, and tighten the fasteners, as follows: e Bolt A: 134 ft. Ibs. (181 Nm) ¢ Bolt B: 24 ft. Ibs. (32 Nm) e Nut C: 27 ft. Ibs. (36 Nm) 12. Install or connect the following: ¢ Moving control rod. Tighten the bolts to 47 ft. Ibs. (64 Nm). e Right-hand motor mount. Tighten the bolts to 23 ft. Ibs. (32 Nm). ¢ Engine sling device from the

RX300

engine hangers Engine undercover Power steering pump hoses Stabilizer links and the steering intermediate shaft Front driveshaft, for 4WD Halfshafts Left and right fender apron seals Header pipes to the exhaust manifolds Automatic transmission ajar cable to the transaxle Air conditioning compressor to the engine 13. Push the wiring harness into the glove box. 14. Install or connect the following: e ECM Any connectors, hoses and sensors that were removed Automatic transmission oil cooler lines Upper and lower radiator hoses and fit the radiator Front upper suspension brace. Tighten the nuts to 59 ft. Ibs. (80 Nm). Cruise control actuator, if removed Intake air cleaner and case assembly 15. Fill the engine oil to proper level. 16. Fill the engine with coolant. 17. Install or connect the following: Battery tray and battery Battery cables Heater air duct

18. 19. 20. 21.

Left and right ventilator louvers Window washer hoses from the ventilator louvers Top cowl seal and panel Wiper and blade assembly Hood New oil filter Refill the engine with oil. Refill the engine with engine coolant. Install the engine undercovers. Start the engine and check for leaks.

2.7L 4Runner

2WD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Engine undercover 4. Drain the engine coolant. 5. Drain the engine oil and the transmission oil.

6. Remove or disconnect the following: e Hood Radiator Drive belt for the alternator and the water pump pulley. e Accelerator cable from the throttle body e Actuator cover and the cruise control cable from the actuator, if equipped with cruise control 7. Remove or disconnect the air cleaner assembly, as follows: e Intake Air Temperature (IAT) sensor and the Mass Air Flow (MAF) meter connectors e 3 wire clamps and the engine wiring harness

e Air cleaner hose clamp, loosen it e MAF meter, resonator and the air cleaner assembly 8. Install or connect the following: ' e Air conditioning compressor, if equipped with air conditioning e Alternator connector e Heater hoses 9. Disconnect the following hoses: e Brake booster vacuum hose e Evaporative Emissions (EVAP) hose e 2. air hoses for the power steering idle-up e Fuel return hose e Fuel inlet hose 10. Remove the power steering pump from the engine. 11. Disconnect the engine wiring harness, as follows: Glove box door Finish No. 2 panel, lower it 4 ECM connectors 2 cassette connectors and the 2 wire Clamps from the lower finish panel e Igniter Ground strap from the cowl top panel 2 engine wiring harness clamps. 2 engine wiring harness retainerto-cowl panel nuts and the engine wiring harness 12. Install or connect the following: e Heated Oxygen (HO2S) sensor ¢ Front exhaust pipe

13. Remove the shift lever assembly for a manual transmission, as follows: 14. Remove or disconnect the following: e Shift lever knob e 4 screws and the shift lever boot ¢ 6 bolts, the shift lever assembly and baffle 15. Remove or disconnect the following: e Driveshaft ¢ Speedometer cable

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e Clutch release cylinder, if equipped with a manual transmission ¢ Cross-shaft, if equipped with an automatic. transmission e Starter wire 16. Place a jack under the transmission and remove the engine rear mounting bracket. 17. Install a rear engine hanger in the correct direction. 18. Attach the engine hoist chain to the 2 engine hangers.

19. Remove or disconnect the following: e Engine front mounting insulatorsto-frame bolts/nuts e Engine/transmission assembly e Engine To install: 20. Install or connect the following: e Transmission to the engine e Chain hoist to the engine hangers e Engine/transmission assembly into the engine compartment

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e Right and left mounting insulators to the body mountings and temporarily install the bolts/nuts 21. Raise the transmission onto the frame 22. Remove the chain hoist. 23, Remove the bolt and the rear engine hanger. 24. Install the engine rear mounting bracket and tighten to: e Bolt A: 13 ft. Ibs. (19 Nm) e Bolt B: 19 ft. Ibs. (26 Nm) 29. Install or connect the following: Tighten the left and right engine mounting insulator bolts and nuts to 28 ft. Ibs. (38 Nm). Starter wire Clutch release cylinder, for a manual transmission. Tighten the clutch line bolt to 29 ft. Ibs. (39 Nm) and the clutch release cylinder bolts to 108 inch Ibs. (13 Nm). Cross-shaft, for an automatic transmission. Tighten the bolt to 29 ft. lbs. (39 Nm) and the nut to 13 ft. lbs. (18 Nm). Speedometer cable Driveshaft Shift lever assembly, for a manual transmission 26. Install the front exhaust pipe, as follows: New gaskets and the front exhaust pipe assembly. Tighten the 3 new nuts to 46 ft. Ibs. (62 Nm). Support bracket. Tighten the bolts to 29 ft. Ibs. (39 Nm). 3-way catalytic converter with a new gasket to the tail pipe. Tighten to 29 ft. Ibs. (39 Nm). HO2S sensor Engine wiring harness Power steering pump All hoses previously removed Alternator wire Air conditioning compressor, if removed. Tighten the bolts to 18 ft. lbs. (25 Nm). Intake air connector. Tighten the bolts to 13 ft. Ibs. (18 Nm). Air cleaner assembly Throttle cable to the throttle body Cruise control cable to the actuator and the actuator cover, if disconnected

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

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27. Refill the engine oil, coolant and transmission oil. 28. Start the engine and check for leaks.

29. Check the ignition timing. 30. Install or connect the following: e Engine undercover e Hood 31. Road test the vehicle and recheck the fluid levels.

4wD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Transmission e Engine undercover 4. Drain the engine coolant. 5. Drain the engine oil. 6. Remove or disconnect the following: e Hood Radiator Drive belt for the alternator and the water pump pulley Accelerator cable from the throttle body Actuator cover and the cruise control cable from the actuator, if equipped with cruise control Air cleaner assembly Intake air connector Air conditioning compressor, if equipped with air conditioning Alternator connector e Heater hoses 7. Disconnect the following hoses: Brake booster vacuum hose Evaporative Emissions (EVAP) hose 2 air hoses for the power steering idle-up With Automatic Disconnecting Differential (ADD) Vacuum hose Fuel return hose ¢ Fuel inlet hose 8. Remove the power steering pump from the engine. 9. Disconnect the engine wiring harness, as follows: 10. Remove or disconnect the following: ¢ Glove box door e Lower the finish No. 2 panel ¢ Engine Control Module (ECM) connectors e 2 cassette connectors and the 2

wire clamps from the lower finish panel Vacuum Switching Valve (VSV) connector for the EVAP and clamp e Igniter Ground strap from the cowl top panel | 2 engine wiring harness clamps 2 engine wiring harness retainerto-cowl panel nuts and the engine wiring harness 11. Install a rear engine hanger in the correct direction. 12. Attach the engine hoist chain to the 2 engine hangers. 13. Remove or disconnect the following: e Engine front mounting insulatorsto-frame bolts and nuts e Engine, making sure that the engine is clear of all wiring and hoses e Engine To install: 14. Attach a chain hoist to the engine hangers. 15. Install or connect the following: e Engine into the engine compartment e>Keep the engine level and align the right and left mounting and body mountings

e Right and left mounting insulators to the body mountings and temporarily install the bolts and nuts 16. Remove the chain hoist. 17. Remove the bolt and the rear engine hanger. 18. Install or connect the following: Tighten the right and left engine mounting insulator bolts/nuts to 28 ft. Ibs. (38 Nm). Engine wiring harness Alternator wire Power steering pump All hoses Air conditioning compressor. Tighten the bolts to 18 ft. Ibs. (25 Nm). Intake air connector. Tighten the

bolts to 13 ft. Ibs. (18 Nm). Air cleaner assembly Throttle cable to the throttle body Cruise control cable to the actuator and the actuator cover, if removed Radiator e Hood 19. Fill with engine with oil and the coolant system with coolant. 20. Install or connect the following: e Transmission e Engine undercover ¢ Negative battery cable

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3.4L 4Runner

2WD 1. Before servicing the vehicle, refer to the precautions in the beginning of this secthon. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Hood e Battery e Engine under covers 4. Drain the engine coolant. 5. Drain the engine oil. e Radiator - e Fan with the fluid coupling and fan pulleys e Air cleaner cap e Mass Air Flow (MAF) meter and the resonator e Air cleaner case and filter 6. Disconnect the following hoses: e Heater hoses e Brake booster vacuum hose e Evaporative Emissions (EVAP) hose e Fuel return hose e Fuel inlet hose 7. Detach the starter wire and connectors, aS follows: e Ground strap, by removing the bolt e 3 starter wire clamps and connector 8. Detach the alternator connector and wire. 9. Disconnect the engine wiring harness, as follows: e Glove box door ¢ Lower the finish No. 2 panel . e 4ECM connectors e 2 cassette connectors and the 2 wire clamps from the lower finish panel ¢ Engine wiring harness clamp 10. Remove or disconnect the following: Igniter connector Ground strap Vacuum Switching Valve (VSV) connector for the Evaporative Emissions (EVAP) Vapor pressure sensor connector and clamp Vapor connector for the vapor pressure sensor and clamp 2 engine wiring harness retainerto-cowl panel nuts and pull out the engine wiring harness Driveshaft from the transmission

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e Nut and the control cable 11. Place a jack under the transmission. 12. Remove or disconnect the following: e Transmission rear mounting bracket by removing the 8 bolts ¢ Bolt and the air conditioning compressor wire clamp, if equipped with air conditioning 13. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. Ibs. (40 Nm). 14. Attach the engine hoist chain to the 2 engine hangers. 15. Remove or disconnect the following: ¢ 4 engine front mounting insulatorsto-frame bolts and nuts e Engine and transmission To install: 16. Install or connect the following: e Engine e Engine mounts to the body mountings. Install the bolts and nuts but do not tighten at this time. 17. Remove the engine chain hoist the No. 2 engine hanger. 18. Install or connect the following: Air conditioning wire with the bolt, if equipped with air conditioning Transmission mounting bracket. Tighten the frame bolts to 43 ft. Ibs. (58 Nm) and the mounting insulator bolts to 13 ft. Ibs. (18 Nm). Tighten the engine mounting nuts and bolts to 28 ft. Ibs. (38 Nm). Control cable Front exhaust pipe Speedometer cable Driveshaft All engine wiring harness, hoses and cables Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch Ibs. (5.4 Nm). Air cleaner case and air filter MAF meter, resonator and the air cleaner cap Radiator 19. Fill the engine with oil. 20. Fill the engine and radiator with coolant. 21. Install or connect the following: e Engine undercover e Battery e Hood 22. Start the engine and check for leaks. 23. Make any necessary adjustments and road test the vehicle.

4WD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Transmission e Hood

3. Release the fuel system pressure. 4. Remove or disconnect the following: e Battery e Engine undercovers 5. Drain the engine coolant. 6. Drain the engine oil. 7. Remove or disconnect the following: e Radiator e Fan with the fluid coupling and fan pulleys e Air cleaner cap e Mass Air Flow (MAF) meter and the resonator 8. Disconnect the following hoses: Heater hoses Brake booster vacuum hose Evaporative Emissions (EVAP) hose Automatic Disconnecting Differential (ADD) vacuum hose Fuel return hose Fuel inlet hose 9. Detach the starter wire and connectors, as follows: e Ground strap, by removing the bolt e 3 starter wire clamps and connector 10. Detach the alternator connector and wire. 11. Disconnect the engine wiring harness, as follows: e Glove box door e Lower the finish No. 2 panel e 4ECM connectors e 2 cassette connectors and the 2 wire clamps from the lower finish panel e Engine wiring harness clamp 12. Disconnect the following:

Igniter connector Ground strap Vacuum Switching Valve (VSV) connector for the EVAP Vapor pressure sensor connector and clamp Vapor connector for the vapor presSure sensor and clamp 13. Remove or disconnect the following: e 2 engine wiring harness retainerto-cowl panel nuts and wiring harness e Air conditioning compressor wire clamp, if equipped with air conditioning

95.47 | :

14. If necessary, install a No. 2 engine hanger with 2 bolts. Tighten the 2 bolts to 30 ft. Ibs. (40 Nm).

15. Attach the engine hoist chain to the2

engine hangers. 16. Remove or disconnect the following: ¢ 4 engine front mounting insulatorsto-frame bolts and nuts e Engine To install: 17. Install or connect the following: e Engine ¢ Engine mounts-to-body mountings. Install the bolts and nuts but do not tighten at this time.

_ 18. Remove the engine chain hoist the No. 2 engine hanger. 19. Install or connect the following: e Air conditioning wire with the bolt, if equipped with air conditioning ¢ Tighten the engine mounting nuts and bolts to 28 ft. Ibs. (38 Nm). Engine wiring harness Engine wiring harness clamp All wires, hoses and cables Fan with the fluid coupling and fan pulleys. Tighten the nuts to 48 inch Ibs. (5.4 Nm). e Air cleaner case and air filter e MAF meter, resonator and the air cleaner cap e Radiator 20. Fill the engine with oil. 21. Fill the engine and radiator with coolant. 22. Install or connect the following: e Transmission and refill it with transmission oil e Engine undercover e Battery e Hood 23. Start the engine, make any necessary adjustments and check for leaks.

Water Pump REMOVAL & INSTALLATION RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Right-hand engine undercover 3. Drain the engine coolant from the radiator and engine. 4. Remove or disconnect the following:

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Timing belt Lower radiator hose from the water inlet Timing belt tension spring and the No. 2 idler pulley Crankshaft Position (CKP) sensor connector clamp Alternator drive belt adjusting bar 2 water pump-to-water bypass pipe nuts * ake 3 water pump bolts in the sequence Water pump cover from the water bypass pipe e Water pump and water pump cover assembly e Gasket and 2 O-rings from the water pump and water bypass pipe e 3 bolts, water pump and gasket, from the water pump cover To install: 5. Install or connect the following: e Water pump to the water pump cover, using a new gasket. Tighten the 3 bolts to 78 inch Ibs. (9 Nm). e New O-ring and gasket to the water pump cover e New O-ring to the water bypass

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Water pump cover to the water bypass pipe; do not install the nuts at this time Water pump. Tighten the 3 bolts, in sequence, to 78 inch Ibs. (9 Nm), Water pump cover to the water pump pipe. Tighten the 2 bolts to 82 inch Ibs. (9 Nm). e Alternator drive belt adjusting bar. Tighten the bolt to 20 ft. Ibs. (27 Nm). ¢ CKP connector clamp e No. 2 idler pulley and timing belt ten-

sion spring e Lower radiator hose e Timing belt e Negative battery cable 6. Fill the engine and radiator with

engine cootant. 7. Start the engine and check for leaks. 8. Install the right-hand engine under-

cover. 2.4L Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. 4. Remove or disconnect the following: e Alternator e Water pump pulley e Water pump 5. Installation is the reverse of removal. Torque the pump bolts and nuts to 80 inch lbs. (QNm) and the pulley bolts to 19 ft. Ibs. (26Nm). 3.0L Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. 4, Remove or disconnect the following: Right front wheel Right fender apron seal Accessory drive belts Upper engine mount and stay Alternator and bracket Crankshaft pulley Timing belt covers Transverse engine mounting bracket Timing belt Timing belt idler Camshaft pulley

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Torque the water pump bolts and nuts to 71 inch Ibs. (Nm),

RX 300 1. Before servicing the vehicle, referto the precautions in the beginning of this sec- — lion. =. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. 4. Remove or disconnect the following: ¢ Wiper and blade assembly ¢ Top cowl seal and panel ¢ Window washer hoses, from the ventilator louvers e Left and right ventilator louvers e Heater air duct e Front upper suspension brace e Timing belt

5. Mark the left and right camshaft pul-

leys with a touch of paint. 6. Remove or disconnect the following: e Right and left camshaft pulleys bolts e Pulleys from the engine ->Be sure not to mix up the pulleys.

No. 2 idler pulley by removing the bolt 3 clamps and engine wire from the rear timing belt cover 6 No. 3 timing belt cover-to-engine bolts Water pump nuts/bolts Water pump and gasket from the engine To install: 7. Check that the water pump turns smoothly. Also check the air hole for coolant leakage. 8. Apply liquid sealer to the gasket, water pump and engine block. 9. Install or connect the following: e Water pump, using a new gasket. Tighten the nuts/bolts to 53 inch lbs. (6 Nm). ¢ Rear timing belt cover. Tighten the 6 bolts to 74 inch Ibs. (9 Nm). e Engine wire with the 3 clamps to the rear timing belt cover e No. 2 idler pulley. Tighten the bolt to 32 ft. Ibs. (43 Nm). After tightening the bolt, be sure the idler pulley moves smoothly.

e Right-hand camshaft pulley, with the flange side outward.

For Wheel Alignment specifications, see Section 1 of this manual

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95-20) WovoTa ano LEXUS ¢ HIGHLANDER

e RX300

RAV4 e 4RUNNER

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Exploded view of the components to gain access to the water pump—RX 300

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TOYOTA AND LEXUS 95-21

RAV4 ¢ 4RUNNER ¢ HIGHLANDER ¢ RX300 Be sure to align the knock pin hole _on the camshaft pulley with the knock pin on the camshaft.

->Be sure to align the knock pin hole on the camshaft pulley with the knock pin on the camshaft.

° Tighten the camshaft bolt to 65 ft. Ibs. (88 Nm), using the removal fools

* Tighten the camshaft bolt to 94 ft. Ibs. (125 Nm), using the removal ins

e Left-hand camshaft pulley, with the flange side inward.

e Timing belt e Front upper suspension brace, for

Gasket

No.3 Timing Belt Cover

RX 300. Tighten the nuts to 59 ft. lbs. (80 Nm). 10. Fill the engine coolant.

11. Install or connect the following: * Heater air duct

+ Left and right ventilator louvers

* Window washer hoses to the ventilator louvers ¢ Top cowl seal and panel e Wiper and blade assembly e Negative battery cable 12. Start the engine. 13. Top off the engine coolant and check for leaks. 2.7L 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Engine undercover 3. Drain the cooling system. 4. Remove or disconnect the following: e 2 bolts and the air pipe, for the California vehicles Upper radiator hose from the radiator Oil dipstick guide, by removing the bolt Power steering drive belt, by loosening the lockbolt and adjusting bolt to the idler pulley, if equipped with power steering No. 2 fan shroud, by removing the 2 Clips No. 1 fan shroud, by removing the 4 bolts Loosen the idler pulley nut and adjusting bolt and remove the air conditioning drive belt, if equipped with air conditioning

6 (60, 53 in.-Ibf)

N-m (kgf-cm, ft:lbf) |: Specified torque @ Non-reusable part

Exploded view of the water pump and related components—RX 300

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79242616 Water pump mounting bolt locations— 2.7L 4Runner

For Maintenance Interval recommendations, see Section 17 of this manual

a

95-22 TOYOTA AND LEXUS

:

RAV4 e A4RUNNER @ HIGHLANDER ® RX300

5. Remove the alternator drive belt, fan (with fan clutch), water pump pulley and the fan shroud, as follows: e Stretch the belt and loosen the water pump pulley mounting nuts e Loosen the lock, pivot and the adjusting bolts for the alternator e Alternator drive belt e 4 water pump pulley mounting nuts " e Fan (with fan clutch) and the water pump pulley 6. Remove the water pump and discard the gasket. To install: 7. Clean all gasket mounting surfaces. 8. Install or connect the following: e Apply a thin layer of liquid sealant to a new gasket e Place the gasket and water pump into position. Tighten the 14mm head bolts A to 18 ft. Ibs. (25 Nm) and the 12mm head bolts to 78 inch Ibs. (9 Nm). 9. Install the water pump pulley, fan shroud, fan (with fan clutch) and the alternator drive belt, as follows: e Fan (with the fan clutch), water pump pulley and the fan shroud in position e Water pump pulley mounting nuts but do not tighten the nuts at this time e Alternator drive belt e Stretch the alternator belt tight. Tighten the fan nuts to 16 ft. Ibs.

(21 Nm). e Adjust the alternator drive belt 10. Install or connect the following: Adjust the drive belt, if equipped with air conditioning No. 1 fan shroud, by installing the 4 bolts No. 2 fan shroud, with the 2 clips Adjust the power steering drive belt Oil dipstick guide, with the bolt Upper radiator hose to the radiator Air pipe, If removed Negative battery cable 11. Fill and bleed the cooling system. 12. Start the engine and check for leaks. 13. Install the engine undercover. 3.4L 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. Remove or disconnect the following: e Timing belt e Thermostat

¢ No. 2 oil cooler hose from the water pump

e Water pump 5. Thoroughly clean the mating surfaces. To install: 6. Apply sealant (PN 08826-00100) to the water pump.

79242G17

Cylinder head bolts installation sequence—2.O0L engine

Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. 7. Install or connect the following: e Water pump. Tighten the bolts to 14 ft. Ibs. (20 Nm). e No. 2 oil cooler hose e Thermostat e Timing belt e Negative battery cable 8. Fill the cooling system. 9. Start the engine and check for leaks.

Cylinder Head REMOVAL & INSTALLATION Rav4

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Right-hand engine undercover 4. Drain the engine coolant. 5. Remove or disconnect the following: Camshafts Cylinder head bolts in several

passes Cylinder head with the intake manifold Air hose from the intake manifold 2 bolts and the air tube Intake manifold and gasket Air hose from the cylinder head port

e Air hose ¢ Fuel delivery pipe and the injectors ¢ Oil pressure switch To install: 6. Install or connect the following: e Oil pressure switch e Fuel injectors and the delivery pipe e Air hose to the cylinder head port e Intake manifold with new gaskets. Tighten the nut/bolts to 14 ft. Ibs. (19 Nm).

e Air tube with the 2 bolts e Air hose to the intake manifold 7. Clean the gasket mating surfaces using care not to damage the aluminum components, replace the gasket; then, lower the cylinder head onto the engine. Be sure the dowel pins are aligned and no hoses or wires are between the head and cylinder block. 8. Tighten the cylinder head bolts in 2 progressive steps, as follows: a. Apply a light coat of engine oil to the cylinder head bolts. b. Tighten the cylinder head bolts, in several passes, in sequence, to 36 ft. Ibs. (49 Nm). c. Mark the front of the cylinder head bolt with paint. d. Retighten the cylinder head bolts by 90 degrees in sequence. e. Retighten an additional 90 degrees and be sure that the paint mark is now positioned toward the rear. 9. Install or connect the following: e Intake and exhaust camshafts e Negative battery cable 10. Refill the engine with coolant, start the engine, warm up and check for leaks. 11. Bleed the cooling system and top off coolant as necessary. 12. Install the right-hand engine undercover. ; 13. Check ignition timing and road test the vehicle for proper operation.

2.4L Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this $ection. 2. Remove or disconnect the following: Front center suspension brace Timing chain Coolant Transfer case oil Radiator hoses Power steering hoses Heater hoses Fuel rail lines Camshaft timing oil control valve Front driveshaft

TOYOTA AND LEXUS RAV4 ¢ 4RUNNER @ HIGHLANDER ¢ RX300

25-23 +

93552G01

Apply a bead of RTV sealant as shown— 2.4L engine cylinder head

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Cylinder head bolt loosening sequence—3.0L Highlander 79247618

Cylinder head bolt tightening sequence— 2.4L engines

e Rear engine mount insulator (4wd) e Transverse engine mount bracket (4wd) e Intake manifold e All wires and cables connected to the head e Exhaust manifold e Camshafts 3. Loosen the 10 head bolts evenly, a little at a time in several passes and lift off the head. Check the head bolt length. Any bolt longer than 6.465 in. (164.2mm) * should be replaced. 4. Installation is the reverse of removal. Install the head gasket with the lot number stamp upward. Apply a bead of RTV sealer as shown. The head must be installed within 3 minutes of applying the sealer, and the head bolts must be tightened with 15 minutes. The head bolts must be tightened in sequence, in several passes, to 58 ff. Ibs. (79Nm), then, an additional 90 degree turn each. 3.0L Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Coolant Engine oil Exhaust pipes Exhaust manifold Camshaft cover Upper center front suspension brace Air cleaner Intake air surge tank Fuel rail Heater hoses Intake manifold Radiator hose Water outlet Right front wheel Right fender apron seal Accessory drive belts Engine roll stopper rod Right engine mount Alternator and brackets Crankshaft pulley Timing belt covers Transverse engine mounting bracket Timing belt Timing belt tensioner Power steering pump Ignition coil pack

Camshafts The hexagonal bolt, using an 8mm hex wrench, then the 8 head bolts Cylinder head

A 12 Pointed Head Bolt

far. Front

Cylinder head bolt tightening sequence— 3.0L Highlander

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

TOYOTA AND LEXUS

-RAV4 e 4RUNNER © HIGHLA NDER

e RX300

3. Installation is the reverse of removal. Measure the head bolts. The minimum diameter of the stretch portion of each bolt should be at least 8.75mm (0.3775 in.). Replace any bolt that does not measure up. The head gasket is installed. with the R mark upwards. Install the 8 head bolts first, tightened in sequence, in 2 equal steps, to 40 ft. Ibs. (64Nm). Then tighten each an additional 90 degrees. Finally, install the hex bolt, torqued to 14 ft. Ibs. (19 Nm).

RX 300 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wiper and blade assembly e Top cowl seal and panel e Window washer hoses from the ventilator louvers e Left and right ventilator louvers e Heater air duct 3. Relieve the fuel pressure. 4. Remove or disconnect the following: e Turn the ignition key to the OFF position e Negative battery cable e>Wait at least 90 seconds from the

time the negative battery was disconnected to start work.

5. Drain the cooling system. 6. Remove or disconnect the following: Accelerator and throttle cables, if equipped with an automatic transaxle Air cleaner cover, air flow meter and the air duct Front upper suspension brace Cruise control actuator and bracket, if equipped 2 engine ground straps Right engine mounting support Radiator hoses 2 heater hoses Fuel feed and return lines from the fuel rail assembly Pressure hose from the hydraulic motor e \-bank cover 7. Disconnect the following vacuum hoses: Fuel pressure control Vacuum Switching Valve (VSV) Fuel pressure regulator Cylinder head rear plate Intake air control valve VSV Exhaust Gas Recirculation (EGR) vacuum modulator EGR valve

79242619

Cylinder head bolt loosening sequence—RX 300

8. Disconnect the following wiring and hoses: e Intake air control valve e Fuel pressure regulator e EGR VSV 9. Remove the 2 nuts and the emission control valve set. 10. Disconnect the following hoses; e Brake booster vacuum hose e PCV hose e Intake air contro! valve vacuum hose 11. Remove or disconnect the following: e Data Link Connector (DLC) from the mounting bracket e 2 ground straps from the intake chamber e Hydraulic motor pressure hose from the intake chamber Right Oxygen (Oz) sensor connector from the power steering pressure tube 2 nuts and the power steering pressure tube from the intake chamber Both power steering air hoses Engine hanger and the intake chamber support EGR pipe and gaskets 12. Disconnect the following wiring: ¢ Throttle Position (TP) sensor connector e Idle Air Control (IAC) valve connector e EGR gas temperature connector ¢ Air conditioning idle up connector 13. Disconnect the following vacuum hoses: e 2 vacuum hoses from the Thermal Vacuum Valve (TVV) ¢ Vacuum hose from the cylinder head rear plate

~ e Vacuum hose from the charcoal canister 14. Remove or disconnect the following: e Air assist hose and the 2 water bypass hoses e Air intake chamber

ie12 Pointed Head Bolt

fare Front

79242620

Cylinder head bolt tightening sequence— 3.0L (1MZ-FE) engine

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TOYOTA AND LEXUS 20-20 ;

RAV4 ¢ 4RUNNER @ HIGHLANDER e FXS00 Left engine wiring harness and move it aside Wiring harness from the rear of the engine Right engine wiring harness and move it aside Ignition coils and move them aside ¢ Timing belt Camshaft pulleys and the timing belt rear cover Cylinder head rear plate Water inlet pipe Air assist hose and vacuum hose Intake manifold and fuel rail assembly Water outlet EGR pipe from the right exhaust manifold Front exhaust pipe and exhaust manifolds Dipstick assembly and the power Steering pump bracket Valve covers and the Camshaft Position (CMP) sensor Camshafts 15. Be sure the engine is at/or near ambient temperature and remove the 2 (1

on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the installation sequence. Carefully lift the head from the engine; if necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area. elf the cylinder head bolts are loosened out of sequence, warpage or cracking could result.

16. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces. To install: 17. Place the new cylinder head gasket onto the cylinder block. 18. Install the cylinder head, in sequence, using several steps, as follows: e Cylinder head onto the gasket

e Cylinder head bolts lubricated with clean engine oil e Tighten the bolts in sequence in 3 steps to 40 ft. Ibs. (54 Nm).

->lf any bolt does not meet the torque, replace it.

e Mark the forward edge of each bolt with paint, then tighten each bolt,

in proper sequence, an additional 90 degrees.

e Check that each painted mark is a a 90 degrees angle to the ron e>The paint mark applied to the bolt in the 9 o’clock position and should now be in the 12 o’clock position.

e Remaining 8mm bolts, lubricated with engine oil. Tighten both bolts to 13 ft. Ibs. (18 Nm). 19. Install the camshafts. 20. Check and adjust the valves. 21. Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads. 22. Install or connect the following: e Cylinder head covers, using new gaskets Dipstick and power steering pump bracket Exhaust manifolds. Tighten the nuts to 36 ft. Ibs. (49 Nm). EGR pipe to the right exhaust manifold Water outlet Intake manifold and the fuel rail assembly. Tighten the intake manifold nuts/bolts to 11 ft. Ibs. (15 Nm). Air assist hose and the 2 water bypass hoses Water inlet pipe and cylinder head rear plate Timing belt rear cover and camshaft pulleys Timing belt Spark plugs and ignition coils Right engine wiring harness Wiring harness to the rear of the engine Left engine wiring harness Air intake chamber EGR pipe, using new gaskets 23. Connect the following vacuum hoses: e The 2 TVV vacuum hoses e The vacuum hose to the rear cylinder head plate e Charcoal canister vacuum hose 24. Connect the following electrical wiring: e TP sensor connector e \AC valve connector e EGR gas temperature connector ¢ Air conditioning idle up connector 25. Install or connect the following: e Engine hanger and the intake

chamber support Both power steering air hoses Power steering pressure tube to the intake chamber Ossensor connector to the pressure tube. Both ground straps, to the intake chamber DLC to the bracket 26. Connect the following hoses: e Power brake booster vacuum hose e PCV hose e IAC valve vacuum hose 27. Install or connect the following:

Emission control valve set and

related vacuum hoses and connectors V-bank cover

Pressure hose to the hydraulic motor Fuel lines to the fuel rail assembly Heater and radiator hoses Right engine mounting support both engine ground straps Upper front suspension brace, if removed. Tighten the nuts to 59 tt lbs. (80 Nm). Cruise control actuator and bracket Air cleaner, air flow meter and air duct assembly Accelerator and throttle cables, if equipped with an automatic transaxle 28. Fill the cooling system. 29. Install or connect the following: e Negative battery cable e Heater air duct Left and right ventilator louvers Window washer hoses from the ventilator louvers e Top cowl seal and panel e Wiper and blade assembly 30. Start the engine and check for leaks. 31. Bleed the air from the cooling system. 32. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation. 33. Recheck the coolant and engine oil levels. 2.7L 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the fuel system pressure. 3. Disconnect the negative battery cable. 4. Drain the engine coolant.

For complete service labor times, order the Chilton Labor Guide

25-26

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TOYOTA AND LEXUS RAV4 © 4RUNNER @ HIGHLANDER ¢ RX300

5. Remove or disconnect the following: Air cleaner cap Mass Air Flow (MAF) meter and resonator Accelerator cable from the throttle body, if equipped with a manual transmission Accelerator and throttle cables from the throttle body, if equipped with an automatic transmission Cruise control cable from the actuator, if equipped with cruise control Intake air connector Air hose for Idle Air Control (IAC) Vacuum sensing hose Wire clamp for the engine wiring harness Oil dipstick guide Power steering belt Power steering pulley, pump and bracket Positive Crankcase Ventilation (PCV) hoses Distributor Spark plug wires from the spark plugs Engine wiring harness Air conditioning compressor, if equipped with air conditioning Oil pressure sensor Engine Coolant Temperature (ECT) sensor connector ECT sender gauge connector Exhaust Gas Recirculation (EGR) gas temperature sensor connector Vacuum Switching Valve (VSV) connector 2 vacuum hose from the VSV Ground strap from the cowl top panel Engine wiring harness from the air intake chamber Throttle Position (TP) sensor connector IAC valve connector Crankshaft Position (CKP) sensor connector Knock Sensor (KS) connector Data Link Connector 1 (DLC1) from the bracket Engine wiring harness clamp EGR pipe Intake chamber stay Air intake chamber assembly 6. Disconnect the following hoses: e Evaporative Emissions (EVAP) hose from the throttle body ° Brake booster vacuum hose from the union ¢ Water bypass hose from the water bypass pipe

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¢ Water bypass hose from the cylinder head rear cover 7. Remove or disconnect the following:

Injector connectors Fuel inlet pipe Hoses and the fuel return pipe Delivery pipe and injectors Intake manifold Front exhaust pipe Exhaust manifold and gasket Water outlet Cylinder head rear cover Spark plugs Front engine hanger Engine wiring harness brackets Cylinder head cover 8. Set No. 1 cylinder to Top Dead Center (TDC) of the compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (1 and 2 dots) of the camshaft gears should form a straight line in respect to the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees). 9. Remove or disconnect the following: e Chain tensioner and gasket e Camshaft timing gear e Exhaust camshafts 10. Remove the intake camshaft, as follows: a. Uniformly, loosen and remove the bearing cap bolts in the reverse order of the tightening in several passes, in sequence. b. Remove the bearing caps and camshaft. Make a note of the bearing cap positions for proper installation. elf the camshaft is not being lifted out straight and level, reinstall the No. 3

bearing cap with the 2 bolts. Then, alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.

11. Remove or disconnect the following: Valve lifters and shims

e>Arrange the valve lifters and shims in correct order.

Cylinder head, by uniformly loosen and remove the cylinder head bolts in the reverse order of the tightening, in sequence, using several

passes To install: 12. Before installing, thoroughly clean the gasket mating surfaces and check for

warpage. 13. Apply sealant (PN 08826-00080) as shown. Place a new head gasket on the block and install the cylinder head. 14. Install the cylinder head as follows: a. Lightly coat the cylinder head bolts with engine oil. b. Install the bolts and tighten, in several passes, in the sequence. Tighten all

bolts to 29 ft. Ibs. (39 Nm).

\

c. Mark the front of the bolt with paint and retighten bolts 90 degrees in the proper sequence. d. Retighten an additional 90 degrees. Check that the painted mark is now facing rearward. 15. Install or connect the following: e Tighten the 2 front mounting bolts to 15 ft. Ibs. (21 Nm). e Valve lifters and shims in their proper locations. Check that the valve lifter rotates smoothly by hand. e Intake and exhaust camshafts 16. Set No. 1 cylinder to TDC compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (1 and 2 dots) of the camshaft gears should form a straight line in respect to the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees). 17. Install the timing gear, as follows: a. Place the gear over the straight pin of the intake camshaft.

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Cylinder Head Gasket

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79242618 93552G01

Apply a bead of RTV sealant as shown— 2.7L engine cylinder head

Cylinder head bolt tightening sequence— 2.7L engines

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RAV4 ¢ ARUNNER @ HIGHLANDER ¢ RX300

b. Hold the intake camshaft with a wrench. Install and tighten the bolt to 54 ft. Ibs. (74 Nm). c. Hold the exhaust camshaft and install the bolt and distributor gear. Tighten the bolt to 34 ft. Ibs. (46 Nm). 18. Install or connect the following: e Chain tensioner, using a new gasket (mark toward the front) ¢ Recheck the valve timing ¢ Check and adjust the valve clear-

ance © Spark plugs ¢ Semi-circular plug 19. Recheck the engine for proper valve timing. 20. Install or connect the following: e Cylinder head cover, using a new gasket Engine wiring harness brackets Front engine hanger. Tighten the bolts to 30 ft. Ibs. (42 Nm). Cylinder head rear cover. Tighten the bolts to 10 ft. Ibs. (13 Nm). Water outlet, using a new gasket.

Tighten the bolts to 14 ft. Ibs. (20

Nm).

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Upper radiator hose Exhaust manifold. Tighten the bolts to 36 ft. Ibs. (49 Nm). e Remaining components

e Negative battery cable 21. Fill the engine and radiator with engine coolant. 22. Start the engine and check for leaks. 23. Check the ignition timing. Road test the vehicle for proper operation. 24. Recheck all fluid levels. 3.4L 4Runner 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Relieve the fuel system pressure. 4. Remove the engine undercover. 5. Drain the cooling system. 6. Remove or disconnect the following: e Front exhaust pipe e Air cleaner cap e Mass Air Flow (MAF) meter and the resonator 7. Disconnect the following cables: e Actuator cable with the bracket, if equipped with cruise control e Accelerator cable e Throttle cable, if equipped with an automatic transmission

8. Disconnect the following hoses: e Heater hose e Brake booster vacuum hose e Evaporative Emissions (EVAP) hose ¢ Automatic Disconnecting Differential (ADD) vacuum hose, for 4wheel drive ¢ Fuel inlet and fuel return hose 9. Remove or disconnect the following: e Spark plug wires with the ignition coils e Spark plugs e Intake chamber stay ¢ No. 2 timing belt cover e Air intake chamber assembly 10. Remove the following connectors and hoses: Throttle Position (TP) sensor con-

16. Remove or disconnect the following: Bolt and the No. 2 idler pulley Camshaft Position (CMP) sensor No. 3 timing belt cover Alternator from the engine Alternator bracket Power steering pump and move it aside without disconnecting the pump lines | Exhaust crossover pipe and gaskets, by removing the 6 nuts Left-hand exhaust manifold, by removing the heat insulator and 6 nuts Right-hand exhaust manifold, by removing the heat insulator and 6 nuts 8 bolts, seal washers, cylinder head cover and gasket.

nector

Idle Air Control (IAC) valve connector Positive Crankcase Ventilation (PCV) hoses Water bypass hoses Air assist hose from the throttle body Intake air connector 11. Disconnect the engine wiring harness protector, as follows: e 6 injector connectors e Engine Coolant Temperature (ECT) sensor and sender gauge connectors e Engine wiring harness protector from the cylinder head 12. Remove or disconnect the following: e Fuel pressure regulator e Intake manifold assembly 13. Set the No. 1 cylinder.at Top Dead Center (TDC) of the compression stroke, as follows: a. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing belt cover. b. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360 degrees). 14. Remove or disconnect the following: ¢ Timing belt tensioner, by alternately loosening the 2 bolts e Timing belt 15. Remove the camshaft timing pulleys, as follows: a. Using Variable Pin Wrench Set 09960-10010, remove the pulley bolt, the timing pulley and the knock pin. b. Remove the 2 timing pulleys with the timing belt.

->Remove both cylinder head covers

Semi-circular plugs Right exhaust and intake camshafts Left exhaust and intake camshafts Valve lifters and shims from the cylinder head; arrange the valve lifters and shims in correct order 17. Remove the cylinder heads, as follows: e Bolt and ground strap e Cylinder head (recessed head) bolt on the cylinder head, using an 8mm hexagon wrench; then, repeat the procedure for the other side. e 8 cylinder head (12-pointed head) bolts, on each cylinder head. ->Loosen the bolts in several passes, in the reverse order of the tightening sequence.

e 16 cylinder head bolts and plate washers e Cylinder head To install: 18. Clean all surfaces. 19. Install or connect the following: e New cylinder head gaskets e Cylinder heads 20. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. 21. Tighten the cylinder head bolts using several passes, in Sequence, as follows: e Step 1: 25 ft. Ibs. (34 Nm) e Step 2: Mark the front of the cylinder head bolt with paint e Step 3: Turn 90 degrees e Step 4: Check that the painted mark

Please visit our web site at www.chiltonsonline.com

4

95-28 lovorn AND LEXUS RAV4 ¢ 4RUNNER @ HIGHLANDER

e RX300 ¢ 3 engine wiring harness clamps 31. Install or connect the following: e 6 injector connectors e ECT sender gauge connector e ECT sensor connector e Intake air connector

12 Pointed Head Bolt

¢ Air intake chamber assembly. ON

Tighten the bolts and nuts to 13 ft. lbs. (18 Nm)... Intake chamber stay

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No. 2 timing belt cover. Tighten the bolts to 80 inch Ibs. (9 aD). PCV hoses Water bypass hoses Air assist hose to the throttle body IAC valve connector

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9348YG99

Cylinder head torque sequence—3.4L (5VZ-FE) engine

is now at a 90 degrees angle to the front 22. Install the recessed head cylinder head bolts, as follows: e Step 1: Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts e Step 2: Tighten the cylinder head bolts, using a 8mm hexagon wrench, to 13 ft. Ibs. (18 Nm). e Bolt and ground strap 23. Install or connect the following: e Valve lifters and shims e>Check that the valve lifter rotates

smoothly by hand.

e Right intake and exhaust camshafts e Left intake and exhaust camshafts 24. Check and adjust the valve clearance. 2. Install or connect the following: Semi-circular plugs Cylinder head covers. Uniformly, tighten the bolts, in several passes, to 53 inch Ibs. (6 Nm). Exhaust manifolds with new gaskets. Tighten the nuts to 30 ft. Ibs. (40 Nm). Exhaust manifold heat insulators. Tighten the nuts to 71 inch Ibs. (8 Nm). Exhaust crossover pipe. Tighten the nuts to 33 ft. Ibs. (45 Nm). Power steering pump Alternator bracket. Tighten the fasteners to 14 ft. Ibs. (18 Nm). Alternator

e No. 3 timing belt cover. Tighten the bolts to 80 inch Ibs. (9 Nm). e CMP sensor. Tighten it to 71 inch Ibs. (8 Nm). e Timing belt e No. 2 timing belt idler bolt. Tighten the bolt to 30 ft. Ibs. (40 Nm). ->Check that the pulley bracket moves smoothly.

e Left camshaft timing pulley 26. Set the No. 1 cylinder to TDC of the compression stroke, as follows: a. Connect the timing belt to the left camshaft timing pulley. b. Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover. c. Install the right camshaft timing pulley and the timing belt. d. Set the timing belt tensioner. Alternately, tighten the bolts to 20 ft. Ibs. (28 Nm). 27. Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner. 28. Check the valve timing. 29. Install or connect the following: e New gaskets and the intake manifold assembly. Tighten the bolts and nuts to 13 ft. Ibs. (18 Nm). e Intake manifold stay. Tighten the bolts to 14 ft. Ibs. (18 Nm). ¢ Fuel pressure regulator 30. Connect the engine wiring harness to the intake manifold, as follows: e Engine wiring harness to the cylinder head

TP sensor connector CMP sensor connector to the No. 2 timing belt cover e 3 spark plug wire clamps 32. Connect the following hoses: e Brake booster vacuum hose e EVAP hose e Automatic Disconnecting Differential (ADD) vacuum hose, for 4wheel drive ) e Fuel inlet and fuel return hose

e Heater hose | 33. Install or connect the following: e (il dipstick and guide, using a new O-ring e Spark plugs e Spark plug wires, with the ignition coils e Alternator drive belt 34. Connect the following cables: e Actuator cable with the bracket, if equipped with cruise control Accelerator cable Throttle cable, if equipped with an automatic transmission MAF meter, resonator and air cleaner cap Front exhaust pipe e Negative battery cable 35. Fill the radiator with engine coolant. 36. Start the engine and check for leaks. 37. Check the ignition timing. 38. Install the engine undercover. 39. Road test the vehicle. ‘ 40. Recheck all fluid levels.

_Intake Manifold REMOVAL & INSTALLATION RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

TOYOTAAND LEXUS RAV4 e 4RUNNER « e HIGHLANDER e RX300

2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: « ¢ Negative battery cable e Air cleaner assembly ° uti body from the intake mani0 4. Disconnect the engine wire from the intake manifold, as follows: e 4 injector connectors e 2 engine wire clamps from the intake manifold wire brackets e Engine wire protector from the right-hand side of the intake manifold by removing the bolt e Engine wire from the wire clamp 5. Remove the EGR valve, EGR pipe and modulator, as follows: e Both vacuum hoses from the Exhaust Gas Recirculation (EGR) Vacuum Switching Valve (VSV) e Vacuum modulator from the clamp on the intake manifold e Loosen the cylinder head side of the EGR pipe union nut e Both nuts, the EGR valve, pipe assembly and gasket e Vacuum modulator 6. Disconnect the following hoses: e Fuel filter vacuum sensor hose on the intake manifold e Brake booster vacuum hose from the intake manifold e Ground strap from the intake manifold 7. Remove or disconnect the following: Intake manifold stay by removing the 2 bolts Control cable from the clamp on the rear side of the intake manifold, if equipped with automatic transmission Air hose from the intake manifold Air tube from the intake manifold, by removing the 2 bolts 6 bolts and 2 nuts from the intake manifold Intake manifold To install: 8. Install or connect the following: e Intake manifold. Tighten the 6 bolts

and 2 nuts to 14 ft. Ibs. (19 Nm). e Air tube with the 2 bolts e Air hose to the intake manifold e Control cable to the clamp on the rear side of the intake manifold, if equipped with an automatic transmission

° ‘Intakemanifold stay, Tighten both bolts to 31 ft. Ibs. (42 Nm). 9. Connect the following hoses: ¢ Ground strap to the intake manifold e Brake booster vacuum hose to the intake manifold e Fuel filter vacuum sensor hose to the intake manifold 10. Install the EGR valve, EGR pipe and the vacuum modulator, as follows: e Vacuum modulator e EGR valve and pipe. Tighten both nuts to 108 inch Ibs. (13 Nm) and the union nut to 43 ft. Ibs. (69 Nm). e Vacuum hoses 11. Install or connect the following: e Engine wire and injectors >The No. 1 and No. 3 injector connectors are brown, and the No. 2 and No. 4 injector connectors are gray.

¢ Throttle body to the intake manifold e Air cleaner assembly e Negative battery cable

2.4L Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Release the fuel system pressure. 4. Drain the engine coolant. 5. Remove or disconnect the following: Air cleaner cap Mass Air Flow (MAF) meter and the resonator Accelerator cable from the throttle body, if equipped with a manual transmission Accelerator and throttle cables from the throttle body, if equipped with an automatic transmission Cruise control cable from the actuator, if equipped with cruise control Intake air connector Air hose for. Idle Air Control (IAC) Vacuum sensing hose Wire clamp for the engine wiring harness Positive Crankcase Ventilation (PCV) hoses. Engine wiring harness Air conditioning compressor connector, if equipped with air conditioning e@ eee e Oil pressure sensor connector Engine Coolant Temperature (ECT) sensor connector ECT sender gauge connector

25-29

Exhaust Gas Recirculation (EGR) gas temperature sensor connector

Vacuum Switching Valve (VSV) connector, for the EGR e 2 vacuum hoses, from the VSV for the EGR e Ground strap, from the cowl top panel Engine wiring harness, from the air intake chamber Throttle Position (TP) sensor connector

IAC valve connector e Crankshaft Position (CKP) sensor connector e Knock (KS) sensor connector ¢ Data Link Connector 1 (DLC1), from the bracket Engine wiring harness clamp EGR pipe Intake chamber stay Air intake chamber assembly 6. Disconnect the following hoses: e Evaporative Emission (EVAP) hose, from the throttle body e Brake booster vacuum hose, from the union Water bypass hose, from the water bypass pipe Water bypass hose, from the cylin-

der head rear cover Injector connectors Fuel inlet pipe Hoses and the fuel return pipe. 7. Remove the delivery pipe and injectors, as follows: e Delivery pipe, together with the 4 injectors e 4 insulators from the 4 spacers e 4 injectors, from the delivery pipe e Q-ring and grommets, from each injector e 4 spacers, by carefully prying them out

8. Remove the intake manifold. To install: 9. Install or connect the following: Intake manifold. Tighten the bolts to 22 ft. Ibs. (29 Nm). Injectors and the delivery pipe Fuel return pipe Fuel inlet pipe, with a new gasket. Tighten the bolts to 22 ft. Ibs. (29 Nm). Injector connectors Air intake chamber assembly. Tighten the bolts to 15 ft. Ibs. (21 Nm). 10. Connect the following hoses:

Timing belt service is covered in Section 3 of this manual

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Evaporative Emissions (EVAP) hose, to the throttle body e Brake booster vacuum hose, to the e

union ° Water bypass hose, to water bypass

15. Road test the vehicle for proper operation. . 16. Recheck all fluid levels.

e IAC valve connector ° CKP sensor connector

pipe

: | 3.0L Highlander

* KS sensor connector

e Water bypass hose, to cylinder head rear cover 11. Install or connect the following: e Air intake chamber stay. Tighten the bolts to 15 ft. Ibs. (20 Nm). e EGR pipe. Tighten bolts to 13 ft. Ibs. (18 Nm), nut “A” to 14 ft. Ibs. (19 Nm) and nut B to 15 ft. Ibs. (20 Nm). e Air conditioning compressor con-

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DLC1 to the bracket Engine wiring harness clamp PCV hoses Intake air connector. Tighten the bolts to 13 ft. Ibs. (18 Nm). e Cruise contro! cable to the actuator, if equipped with cruise control e Accelerator cable to the throttle body, if equipped with a manual

nector e Oil pressure sensor connector

transmission e Accelerator and throttle cables to

e ECT sensor connector e ECT sender gauge connector

1. Before servicing the vehicle, refer to

ihe naan in the faolnalas of this section bea! 4 ie Lracte tees: pressure ay Draih and recycle the engine coolant 5 Whenua ar disconnect the follow. ing: iss Accelerator cable

¢ Throttle cablé oTAi cleaner

the throttle body, if equipped with an automatic transmission

e EGR gas temperature sensor connector

« Any wiring or hoses interfering with rani

12. Fill the engine and radiator with engine coolant. 13. Install or connect the following:

e VSV connector for the EGR

° 2ses hose to the VSV for the EGR

« Right side engine mount stay y

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e Air cleaner cap, MAF meter and resonator assembly

e Ground strap to the cowl top panel

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90179-10194 (6) “The delivery pipes with injectors will be attached to the manifold.

¢ Other fuel related components such as the No. 2 fuel pipe and pulsation damper, if needed Delivery pipes from the intake manifold 6. Clean and inspect the intake manifold mating surfaces. Scrape all old gasket material off. ‘

To install: 7. Install or connect the following: e Delivery pipes with injectors to the intake manifold. ->Be sure to place 4 spacers in position on the manifold. Temporarily install 4 bolts to retain the delivery pipes to the manifold. Inspect the injectors for smooth rotation.

e Tighten the delivery pipes bolts to 84 inch Ibs. (10 Nm), once the injectors are properly seated No. 2 fuel pipe with union bolts and gaskets. Tighten the bolts to 24

ft. Ibs. (32 Nm). No. 1 fuel pipe with pulsation damper, using 4 new gaskets. Tighten the damper to 35 ft. Ibs. (32 Nm) and the bolt to 11 ft. Ibs. (15 Nm). Fuel pressure regulator, if removed Intake manifold. Tighten the 9 bolts and 2 nuts in a crisscross pattern

to 11 ft. Ibs. (15 Nm). ->Be sure the gasket is in place properly prior to tightening.

8. Retighten the water outlet mounting

nuts/bolts to 11 ft. Ibs. (15 Nm), if loosened. 9. Install or connect the following: e Air assist hose and water inlet pipe,

using a new O-ring: by applying a small amount of soapy water. Tighten the fastener(s) to 14 ft. Ibs. (20 Nm). Ground strap Vacuum hoses removed to the air intake chamber and vacuum tank Any remaining components, using new gaskets. Tighten the air intake chamber nuts/bolts to 32 ft. Ibs. (43 Nm), the EGR pipe nuts to 108 inch Ibs. (12 Nm) and the emission control valve set to 69 inch Ibs. (8 Nm). Air cleaner assembly Heater hoses Throttle cable with bracket onto the throttle body Accelerator cable, by adjusting it, if equipped with an automatic transaxle 10. Refil the cooling system 11. Install or connect the following: e Negative battery cable e Heater air duct 12. Start the engine and inspect for leaks.

RX 300 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wiper and blade assembly Top cowl seal and panel Window washer hoses from the ventilator louvers Left and right ventilator louvers Heater air duct Front upper suspension brace 3. Properly relieve the fuel system pressure. 4. Remove the battery and battery tray. 5. Drain and recycle the engine coolant. 6. Remove or disconnect the following: Accelerator cable Throttle cable Air cleaner cap assembly Any wiring or hoses interfering with removal Right side engine mount stay Radiator and heater hoses in the way of the intake manifold removal V-bank cover All the vacuum hose and wiring for the emission contro! valve set Air intake chamber and discard the gasket Exhaust Gas Recirculation (EGR) pipe and discard the gaskets

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° Hydraulic motor pressure hose from the air intake chamber e Engine wiring harnesses from the left side, right side, rear and No. 3 timing belt cover e Front exhaust pipe, if necessary e Timing belt, camshaft timing pulleys, No. 2 idler pulley and No. 3 timing belt cover Cylinder head rear plate 2 bolts, nuts and plate washers with the intake manifold. >The delivery pipes with injectors will be attached to the manifold.

¢ Other fuel related components such as the No. 2 fuel pipe and pulsation damper, if needed ¢ Delivery pipes from the intake manifold 7. Clean and inspect the intake manifold mating surfaces. Scrape all old gasket ° material off. To install: 8. Install or connect the following: ¢ Delivery pipes with injectors to the intake manifold. ->Be sure to place 4 spacers in posi-

tion on the manifold. Temporarily install 4 bolts to retain the delivery pipes to the manifold. Inspect the injectors for smooth rotation. e Tighten the delivery pipes bolts to 84 inch Ibs. (10 Nm), once the injectors are properly seated No. 2 fuel pipe with union bolts and gaskets. Tighten the bolts to 24

ft. Ibs. (32 Nm). No. 1 fuel pipe with pulsation damper, using 4 new gaskets. Tighten the damper to 35 ft. Ibs. (32 Nm) and the bolt to 11 ft. Ibs. (15 Nm). Fuel pressure regulator, if removed Intake manifold. Tighten the 9 bolts and 2 nuts in a crisscross pattern to 11 ft. Ibs. (15 Nm). ->Be sure the gasket is in place properly prior to tightening. 9. Retighten the water outlet mounting nuts/bolts to 11 ft. Ibs. (15 Nm), if loosened. 10. Install or connect the following: e Air assist hose and water inlet pipe, using a new O-ring, by applying a small amount of soapy water. Tighten the fastener(s) to 14 ft. Ibs. (20 Nm).

Heater Core replacement is covered in Section 2 of this manual

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95-32 TOYOTA AND LEXUS RAV4 4RUNNER ¢ HIGHLANDER © RX300 Ground strap Vacuum hoses removed to the air intake chamber and vacuum tank Any remaining components, using new gaskets. Tighten the air intake chamber nuts/bolts to 32 ft. Ibs. (43 Nm), the EGR pipe nuts to 108 inch lbs. (12 Nm) and the emission control valve set to 69 inch Ibs. (8 Nm). Air cleaner assembly Heater hoses Battery and tray Throttle cable with bracket onto the throttle body Accelerator cable, by adjusting it, if equipped with an automatic transaxle Front upper suspension brace. Tighten the nuts to 59 ft. Ibs. (80 Nm). 11. Refill the cooling system 12. Install or connect the following: Negative battery cable Heater air duct Left and right ventilator louvers Window washer hoses from the ventilator louvers e Top cowl seal and panel e Wiper and blade assembly 13. Start the engine and inspect for leaks.

2.7L 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Release the fuel system pressure. 4. Drain the engine coolant. 5. Remove or disconnect the following: Air cleaner cap Mass Air Flow (MAF) meter and the resonator Accelerator cable from the throttle body, if equipped with a manual transmission Accelerator and throttle cables from the throttle body, if equipped with an automatic transmission Cruise control cable from the actuator, if equipped with cruise control Intake air connector Air hose for Idle Air Control (IAC) Vacuum sensing hose Wire clamp for the engine wiring harness Positive Crankcase Ventilation (PCV) hoses. Engine wiring harness Air conditioning compressor connector, if equipped with air conditioning

Oil pressure sensor connector Engine Coolant Temperature (ECT) sensor connector ECT sender gauge connector Exhaust Gas Recirculation (EGR) gas temperature sensor connector Vacuum Switching Valve (VSV) connector, for the EGR 2 vacuum hoses, from the VSV for the EGR Ground strap, from the cowl top panel Engine wiring harness, from the air intake chamber Throttle Position (TP) sensor connector IAC valve connector Crankshaft Position (CKP) sensor connector Knock (KS) sensor connector Data Link Connector 1 (DLC1), from the bracket Engine wiring harness clamp EGR pipe Intake chamber stay Air intake chamber assembly 6. Disconnect the following hoses: Evaporative Emission (EVAP) hose, from the throttle body e Brake booster vacuum hose, from the union Water bypass hose, from the water bypass pipe e Water bypass hose, from the cylinder head rear cover Injector connectors Fuel inlet pipe ¢ Hoses and the fuel return pipe. 7. Remove the delivery pipe and injectors, as follows: ¢ Delivery pipe, together with the 4 injectors ¢ 4 insulators from the 4 spacers e 4 injectors, from the delivery pipe e O-ring and grommets, from each injector ¢ 4 spacers, by carefully prying them out 8. Remove the intake manifold. To install: 9. Install or connect the following: Intake manifold. Tighten the bolts to 22 ft. Ibs. (29 Nm). Injectors and the delivery pipe Fuel return pipe Fuel inlet pipe, with a new gasket. Tighten the bolts to 22 ft. Ibs. (29 Nm). Injector connectors Air intake chamber assembly. Tighten the bolts to 15 ft. Ibs. (21 Nm).

10. Connect the following hoses: e Evaporative Emissions (EVAP) hose, to the throttle body e Brake booster vacuum hose, to the union

e Water bypass hose, to water bypass pipe ¢ Water bypass hose, to cylinder head rear cover 11. Install or connect the following: Air intake chamber stay. Tighten the bolts to 15 ft. Ibs. (20 Nm). EGR pipe. Tighten bolts to 13 ft. lbs. (18 Nm), nut “A” to 14 ft. Ibs. (19 Nm) and nut B to 15 ft. Ibs. (20 Nm). Air conditioning compressor connector Oil pressure sensor connector ECT sensor connector ECT sender gauge connector EGR gas temperature sensor connector

VSV connector for the EGR 2 vacuum hose to the VSV for the EGR Ground strap to the cowl top panel Engine wiring harness to the air intake chamber TP sensor connector IAC valve connector CKP sensor connector KS sensor connector DLC1 to the bracket Engine wiring harness clamp PCV hoses Intake air connector. Tighten the bolts to 13 ft. Ibs. (18 Nm). Cruise control cable to the actuator, if equipped with cruise control Accelerator cable to the throttle body, if equipped with a manual transmission Accelerator and throttle cables to the throttle body, if equipped with an automatic transmission 12. Fill the engine and radiator with engine coolant. 13. Install or connect the following: e Air cleaner cap, MAF meter and resonator assembly e Negative battery cable 14. Start the engine and check for leaks. 15. Road test the vehicle for proper operation. 16. Recheck all fluid levels. 3.4L 4Runner

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

--TOVOTRIRND LEXUS| RAVA e SRUNNER e¢ HIGHLANDER e RX300

Brake booster vacuum hose, to the intake air connector 2 fuel return hoses Engine wiring harness to the intake manifold Air intake chamber assembly to the engine. Tighten the bolts and nuts to 14 ft. Ibs. (18.5 Nm). Intake chamber stay. Tighten the bolts to 30 ft. Ibs. (40 Nm). New O-ring to the oil filler tube Oil filler tube end into the tube hole in the oil pan Oil filler tube and No. 1 throttle cable clamp No. 2 timing belt cover. Tighten the bolts to 80 inch Ibs. (9 Nm). PCV hoses Water bypass hoses Air assist hose to the throttle body IAC valve connector TP sensor connector Brake booster vacuum hose EVAP hose Automatic Disconnecting Differential (ADD) vacuum hose, for 4Wheel drive Fuel inlet and fuel return hose 3 spark plug wire clamps to the No. 2 timing belt cover CMP connector to the No. 2 timing belt cover Spark plug wires with the ignition coils Heater hose Actuator cable with the bracket, if equipped with cruise control Accelerator cable Throttle cable, if equipped with automatic transmission MAF meter, resonator and the air cleaner cap Negative battery cable

7924YG38

Intake manifold bolts and nuts—4Runner with 3.4L engine

2. 3. 4. 5. 6.

Disconnect the negative battery cable. Relieve the fuel system pressure. Remove the engine undercover. Drain the cooling system. ; Remove or disconnect the follow-

ing:

Air cleaner cap Mass Air Flow (MAF) meter and the resonator Actuator cable with the bracket, if equipped with cruise control Accelerator cable Throttle cable, if equipped with automatic transmission 7. Disconnect the following hoses: Heater hose Brake booster vacuum hose Evaporative Emissions (EVAP) hose Automatic Disconnecting Differential (ADD) vacuum hose, for 4Wheel drive Fuel inlet and fuel return hose 8. Remove or disconnect the following: Spark plug wires, with the ignition coils Intake chamber stay No. 2 timing belt cover Air intake chamber assembly Throttle Position (TP) sensor connector Idle Air Control (IAC) valve connector Positive Crankcase Ventilation (PCV) hoses Water bypass hoses Air assist hose from the throttle body Intake air connector Engine wiring harness Fuel return hose

Vacuum hose, from the fuel pressure regulator Ground strap, from the intake air connector Data Link Connector 1 (DLC1), from the bracket 6 injector connectors Engine Coolant Temperature (ECT) sensor and sender, gauge connectors Engine wiring harness protector from the cylinder head Fuel pressure regulator Intake manifold assembly Intake manifold stay Intake manifold, delivery pipes and the injectors assembly with the gaskets To install: 9. Install or connect the following: New gaskets Intake manifold assembly. Tighten the bolts and nuts to 13 ft. Ibs. (18 Nm). Intake manifold stay. Tighten the bolts to 14 ft: Ibs. (18 Nm). Fuel pressure regulator Engine wiring harness to the cylinder head, by installing the 3 bolts 3 engine wiring harness clamps 6 injector connectors ECT sender gauge connector ECT sensor connector Intake manifold. Tighten the bolts and nuts to 14 ft. Ibs. (18.5 Nm). DLC1 to the bracket on the intake manifold e Ground strap to the intake manifold, by installing the bolt

10. 11. 12. 13. 14.

Fill the radiator with engine coolant. Start the engine and check for leaks. Install the engine undercover. Road test the vehicle. Recheck all fluid levels.

Exhaust Manifold

REMOVAL & INSTALLATION RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Brake service is covered in Section 4 of this manual

2. Remove or disconnect the following:

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TWC Heat Insulator

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Exploded view of the exhaust manifold and components—RAV4

e Negative battery cable e Front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench: discard the gasket e Main Oxygen (02) sensor and the sub Oxygen (Oz) sensor connectors e 6 bolts and the upper manifold heat

insulator

e 2 right-hand exhaust manifold stay-

to-cylinder block bolts ¢ 6 nuts, the exhaust manifold and pate caer (TWC) y ¢ Exhaust manifold and front catalytic

converter

To install: 3. Install or connect the following: e Catalytic converter to the exhaust manifold. Tighten the nuts/bolts to 22 ft. Ibs. (29 Nm). e Exhaust manifold and the front TWC assembly. Tighten the 6 nuts,

in several passes to 36 ft. Ibs. (49

Nm).

e Front exhaust pipe to the TWC, using a new gasket. Tighten the 3 nuts to 46 ft. Ibs. (62 Nm). e Negative battery cable 4. Start the engine and be sure that there are no exhaust leaks. i

2.4L Highlander

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e Right-hand manifold stay. Tighten

vias aT 88Tae eps ia 3

both bolts to 31 ft. Ibs. (42 Nm). e Manifold upper heat insulator with the 6 bolts and attach the main

We ginning 2. Remove or disconnect the following: © Clamp from th Hieaatet PENA ego

Oxygen (Q2) and the sub Oxygen

(02) sensor connectors

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RAV4 ¢ 4RUNNER ¢ HIGHLANDER ¢ RX300 ~e Front abhi! pipe and gaskets from the exhaust manifold ¢ Heat insulator e Exhaust manifold and gasket To install: 3. Install or connect the following: e Exhaust manifold and gasket. Tighten the nuts to 36 ft. Ibs. (49 Nm). Heat insulator. Tighten the bolts and nuts to 48 inch Ibs. (5.5 Nm). Front exhaust pipe assembly to the exhaust manifold. Tighten the nuts to 46 ft. Ibs. (62 Nm). Support bracket. Tighten the bolts to 29 ft. Ibs. (39 Nm). Clamp. Tighten the bolt to 14 ft. lbs. (19 Nm). 4. Start the engine. 5. Check for exhaust leaks. 3.0L Highlander

FRONT MANIFOLD e>Removing the oil filter helps gain access to a lower bolt in the front exhaust manifold.

1. Before servicing the vehicle, refer to

e Engine Seas e Negative battery cable

REAR MANIFOLD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Engine undercovers Front exhaust pipe from both exhaust manifolds, from below the

engine Exhaust Gas Recirculation (EGR) pipe from the rear exhaust manifold, by removing the 4 nuts Heated Oxygen (HO2) sensor wiring, from the right exhaust manifold Exhaust manifold stay 6 exhaust manifold nuts and the exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold to the engine, using a new gasket. Tighten the 6 nuts to 36 ft. Ibs. (49 Nm). Exhaust manifold stay. Tighten the

nut/bolt to 15 ft. Ibs. (20 Nm).

the precautions in*the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Engine undercovers e Front exhaust pipe from the exhaust manifolds, by removing the

HOzsensor wiring to the exhaust manifold EGR pipe to the exhaust manifold and the engine, using new gaskets. Tighten the 4 nuts to 108 inch Ibs. (12 Nm). Front exhaust pipe to the exhaust manifold, use a new gasket. Tighten both nuts to 46 ft. Ibs. (62 Nm). e Engine undercovers e Negative battery cable

nuts e>Check for access to some of the

manifold lower bolts, if so remove any possible.

e Heated Oxygen (HO2) sensor e Exhaust manifold stay, by removing the bolt and nut e Remaining exhaust manifold nuts; then, separate the exhaust manifold from the engine To install: 3. Install or connect the following: e Exhaust manifold, using a new gasket. Uniformly, tighten the bolts to 36 ft. Ibs. (49 Nm). e Exhaust manifold stay. Tighten the nut/bolt to 15 ft. Ibs. (20 Nm). e Heated Oxygen (HO2) sensor to the exhaust manifold e Front exhaust pipe to the exhaust manifold, using a new gasket. Tighten both nuts to 46 ft. Ibs. (62 Nm).

RX 300 FRONT MANIFOLD Removing the oil filter helps gain access to a lower bolt in the front exhaust manifold. -

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec~ tion.

2. Remove or disconnect the following: e Negative battery cable e Engine undercovers ¢ Front exhaust pipe from the exhaust manifolds, by removing the nuts e>Check for access to some of the manifold lower boits, if so remove any

° Heated aaah (HO2) sensor e Exhaust manifold stay, by removing the bolt and nut e Remaining exhaust manifold nuts; then, separate the exhaust manifold from the engine To install: 3. Install or connect the following: Exhaust manifold, using a new gasket. Uniformly, tighten the bolts to 36 ft. Ibs. (49 Nm). Exhaust manifold stay. Tighten the nut/bolt to 15 ft. Ibs. (20 Nm). Heated Oxygen (HO) sensor to the exhaust manifold Front exhaust pipe to the exhaust manifold, using a new gasket. Tighten both nuts to 46 ft. Ibs. (62 Nm). Engine undercovers Negative battery cable

REAR MANIFOLD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Engine undercovers Front exhaust pipe from both exhaust manifolds, from below the engine Exhaust Gas Recirculation (EGR) pipe from the rear exhaust manifold, by removing the 4 nuts Heated Oxygen (HOz) sensor wiring, from the right exhaust manifold Exhaust manifold stay 6 exhaust manifold nuts and the exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold to the engine, using a new gasket. Tighten the 6 nuts to 36 ft. Ibs. (49 Nm). Exhaust manifold stay. Tighten the nut/bolt to 15 ft. Ibs. (20 Nm). HOzsensor wiring to the exhaust manifold EGR pipe to the exhaust manifold and the engine, using new gaskets. Tighten the 4 nuts to 108 inch Ibs. (12 Nm). Front exhaust pipe to the exhaust manifold, use a new gasket. Tighten both nuts to 46 ft. Ibs. (62 Nm). e Engine undercovers e Negative battery cable

possible.

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

TAANDLEXUS 95-36 TOVO RAV4 e 4RUNNER © HIGHLANDER .

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2.7L 4Runner

3.4L 4Runner

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

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

2. Remove or disconnect the follow-

ing:

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To 3.

4. 5.

e Clamp from the support bracket e Support bracket e Front exhaust pipe and gaskets from the exhaust manifold e Heat insulator e Exhaust manifold and gasket install: Install or connect the following: Exhaust manifold and gasket. Tighten the nuts to 36 ft. Ibs. (49 Nm). Heat insulator. Tighten the bolts and nuts to 48 inch Ibs. (5.5 Nm). Front exhaust pipe assembly to the exhaust manifold. Tighten the nuts to 46 ft. Ibs. (62 Nm). Support bracket. Tighten the bolts to 29 ft. Ibs. (89 Nm). Clamp. Tighten the bolt to 14 ft. lbs. (19 Nm). Start the engine. Check for exhaust leaks.

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Tighten the manifold nuts to 14 ft. lbs. (18 Nm) and the clamp nuts to 71 inch Ibs. (8 Nm). ¢ Crossover pipe to the exhaust manifold, using a new gasket. Tighten

2. Remove or disconnect the following:

e Exhaust crossover pipe, from the exhaust manifold by removing the 3 nuts e Exhaust Gas Recirculation (EGR) pipe, from the exhaust manifold, on the left manifold equipped with an EGR valve e Exhaust manifold heat insulator, by removing the 3 nuts e Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold, using a new gasket. Tighten the nuts to 30 ft. Ibs. (40 Nm). e Exhaust heat insulator. Tighten the nuts to 71 inch Ibs. (8 Nm), e EGR pipe to the exhaust manifold, if equipped with an EGR valve.

a2)

the nuts to 33 ft. Ibs. (45 Nm).

Front Crankshaft Seal

REMOVAL & INSTALLATION >For complete Timing Belt Removal and Installation procedures, see Section 3 of this manual.

RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ~The front oil seal can be removed

from the engine without removing the oil pump.

2. Remove or disconnect the following: e Negative battery cable e Timing belt covers and the timing belt e Front crankshaft gear from the crankshaft, using Crankshaft Gear Puller tool 09950-50010

Be sure not to damage any part of the crankshaft. 7924YG43

Exhaust crossover pipe mounting nut locations—3.4L 4Runner

7924YG39

Front exhaust pipe to exhaust manifold nut and bolt locations—4Runner 2.7L

¢ Cut off the oil seal lip e Oil seal, using a suitable tool. Wrap the edge of the tool with a rag or tape to prevent damaging the crankshaft. To install: 3. Install or connect the following: ¢ New seal, by applying a thin layer of liquid sealer to the outside of the Seal ; Apply multi purpose grease to the new oil seal lip New oil seal, by tapping it in until its Surface is flush with the oil pump body edge, using the Oil Seal Installer tool 09226-00010 and a hammer ¢ Timing belt and timing belt covers e All other components ¢ Negative battery cable 4. Start the engine and check for leaks. 3.0L Highlander and RX 300

7924YG44

Exhaust manifold nuts—2.7L 4Runner

Exhaust manifold nuts—3.4L 4Runner

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

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2. Remove or disconnect the following: e Engine coolant reservoir tank and the alternator belt e Right front wheel and the splash shield e Power steering pump drive belt, by loosening both bolts e Both ground wire connectors e Right engine mounting stay e Engine moving control rod and the No. 2 right engine mount bracket e>To extract the engine bracket and control rod, raise the engine slightly.

e No. 2 alternator bracket e Crankshaft pulley bolt, using a prybar and wrench or Crankshaft Pulley Holding tool 09213-54015 and Flange Holding too! 09330-00021 e Crankshaft pulley, using a puller e No. 1 timing belt cover 3. Remove the No. 2 timing belt cover, as follows: e Engine wire protector from the No. 3 (rear) timing belt cover e Engine wire protector clamp from the No. 3 timing belt cover e 5 bolts from the No. 2 timing belt cover e No. 2 cover To install: 4, Install or connect the following: e No. 2 timing belt cover, using a new gasket e>install it evenly to the part of the belt cover shaded black. After installation, press down on it so that the adhesive sticks to the belt cover firmly.

No. 2 timing belt cover. Tighten the 5 bolts to 74 inch Ibs. (8 Nm). Engine wire protector clamp to the No. 3 timing belt cover Engine wire protector to the No. 3 timing belt cover with the bolt No. 3 timing belt cover, using a new gasket Tighten the 4 No. 1 timing belt cover bolts to 74 inch Ibs. (8 Nm). Crankshaft pulley. Tighten the bolt to 159 ft. Ibs. (215 Nm). No. 2 alternator bracket. Tighten the nut to 21 ft. Ibs. (28 Nm). Do not tighten the pivot bolt at this time. No. 2 right engine mounting bracket and the moving control rod Right engine mount stay Both ground wire connectors Drive belts by adjusting them

e Coolant reservoir e Right front splash shield and wheel e Negative battery cable 5. Start the vehicle and check for any leaks, 6. Recheck the ignition timing. 3.4L 4Runner e>There are 2 methods to replace the oil seal, which are as follows:

OIL PUMP BODY INSTALLED 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following; e Negative battery cable e Timing belt and crankshaft pulley e Cut off the oil seal lip, using a knife e Pry,out the oil seal, using a suitable tool

Be careful not to damage the crankshaft.

_ 2. Remove or disconnect the following: e Negative battery cable ¢ Cylinder head cover and the upper timing belt cover 3. Rotate the crankshaft to set the engine at Top Dead Center (TDC)/compression for the No. 1 cylinder. e>Due to the small thrust clearance on both the intake and exhaust camshafts, the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may be caught in the cylinder head causing the head to break or the camshaft to seize.

4, Remove the camshaft timing sprocket and the timing belt. 5. Set the knock pin of the intake camshaft at 10-45 degrees Before Top Dead Center (BTDC) of camshaft angle. This angle will help to lift the exhaust camshaft level and evenly by pushing No. 2 and No. 4 cylinder camshaft lobes of the exhaust camshaft toward their valve lifters. 6. Secure the exhaust camshaft sub-

To install: 3. Install or connect the following: Apply multi-purpose grease to the new oil seal lip Tap in the new oil seal until its surface is flush with the oil pump case edge, using Seal Driver tool 09309-37010 and a mallet Crankshaft pulley and the timing belt Engine undercover, if removed Negative battery cable

OIL PUMP BODY REMOVED 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec+ion. 2. Carefully pry out the seal using a Suitable tool. 3. Apply multi-purpose grease to the new oil seal lip. 4. Using Seal Driver tool 09309-37010, drive the new seal into place.

79242623

Exhaust camshaft bolt removal: step 1— RAV4 2.0L

Second

Camshaft and Valve Lifters

REMOVAL & INSTALLATION RAV4 79242624

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

Exhaust camshaft bolt removal: step 2—

RAV4 2.0L

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

95-38 TOYOTA AND Lexus

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) RAV4 ¢ ARUNNER @ HIGHLANDER e RX300 gear to the main gear using a service bolt. The manufacturer recommends a bolt 0.63-0.79 in. (16-20mm) long with a thread diameter of 6mm and a 1mm thread pitch. When removing the exhaust camshaft, be sure that the torsional spring force of the sub-gear has been eliminated. 7. Remove the No. 1 and No. 2 rear bearing cap bolts and remove the cap. Uniformly loosen and remove bearing cap bolts No. 3 to No. 8 in several passes and in the proper sequence. Do not remove bearing cap bolts No. 9 and 10 at this time. Remove the No. 1, 2 and 4 bearing caps. 8. Alternately loosen and remove bearing cap bolts No. 9 and 10. As these bolts are loosened check to see that the camshaft is being lifted out straight and level.

the intake camshaft level and evenly by pushing No. 1 and No. 3 cylinder camshaft lobes of the intake camshaft toward their valve lifters. 11. Remove the No. 1 and No. 2 front bearing cap bolts and remove the front bearing cap and oil seal. If the cap will not come apart easily, leave it in place without the bolts. 12. Uniformly loosen and remove bearing cap bolts No. 3 to No. 8 in several phases and in the proper sequence. Do not remove bearing cap bolts No. 9 and 10 at this time. Remove No. 1, 3 and 4 bearing caps. 13. Alternately loosen and remove bearing cap bolts No. 9 and 10. As these bolts

elf the camshaft is not lifting out Straight and level retighten No. 9 and 10 bearing cap bolts. Reverse the order of steps 5 through 7 and reset the intake camshaft knock pin to 10-45 degrees BTDC and repeat steps 5 through 7 again. Do not attempt to pry the camshaft from its mounting.

9. Remove the No. 3 bearing cap and exhaust camshaft from the engine. 10. Set the knock pin of the intake camshaft at 80-115 degrees BTDC of camshaft angle. This angle will help to lift

Third

79242627

Intake camshaft bolt removal: step 1—

RAV4 2.0L

are loosened and after breaking the adhesion on the front bearing cap, check to see that the camshaft is being lifted out straight and level. elif the camshaft is not lifting out straight and level retighten No. 9 and 10 bearing cap bolts. Reverse steps 10 through 12, than start over from step 10. Do not attempt to pry the camshaft from its mounting.

14. Remove the No. 2 bearing cap with the intake camshaft from the engine. 15. Remove the valve adjusting shims from the engine. Be sure to replace the shims to their original location. To install: 16. Install the valve adjusting shims to the engine. 17. Before installing the intake camshaft, apply multi-purpose grease to the thrust portion of the camshaft. ‘18. Position the camshaft at 80-115 degrees BIDC of camshaft angle on the cylinder head. 19. Apply sealant to the front bearing cap. 20. Coat the bearing cap bolts with clean engine oil. 21. Tighten the camshaft bearing caps evenly and in several passes to 14 ft. Ibs. (19 Nm) in the proper sequence. 22. Set the knock pin of the camshaft at 10-45 degrees BTDC of camshaft angle.

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No.1

No.2

No.3

No.4

Camere Siete be o| | Fa ba bal bs CEROROMOHO _ 79242630 79242628

Intake camshaft bearing cap positioning— 79242G25

Exhaust camshaft bolt removal: step 3—

Intake camshaft bolt removal: step 2—

RAV4 2.0L

RAV4 2.0L

RAV4 2.0L

79242626

79242629

Intake camshaft knock pin alignment—

Intake camshaft bolt removal: step 3—

RAV4 2.0L

RAV4 2.0L

79242G31

Intake camshaft bolt tightening sequence—RAV4 2.0L

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RAV4 ¢ 4RUNNER ¢ HIGHLANDER ¢ RX300 Assembly Reference Marks

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79242632

Camshaft timing mark alignment—RAV4

2.0L

79247635

Exhaust camshaft knock pin alignment—RAV4 2.0L

28. Install the camshaft timing pulleys and the timing belt. 29. Adjust the valve clearance. 30. Install the head cover and the upper timing cover, Reconnect the negative battery cable. 31. Start the engine and check for leaks. 32. Check and adjust the ignition timing.

OTO? 79247633

Exhaust camshaft bearing cap position-

ing—RAV4 2.0L

3.0L Highlander and RX 300 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Timing belt and idler pulley e Camshaft timing pulleys e Cylinder head covers

Service Bolt (B)

7924Z2G34

Exhaust camshaft bolt tightening sequence—RAV4 2.0L

23. Apply multipurpose grease to the thrust portion of the camshaft. 24. Position the exhaust camshaft gear with the intake camshaft gear so that the , timing marks are in alignment with one another. Be sure to use the proper alignment marks on the gears. Do not use the assembly reference marks. 25. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals. 26. Coat the bearing cap bolts with clean engine oil. 27. Tighten the camshaft bearing caps evenly and in several passes to 14 ft. Ibs. (19 Nm). Remove the service bolt from the assembly.

c. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps, keeping them in the correct order. d. Remove the exhaust camshaft from the engine. e. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the proper sequence. Remove the bearing caps, keeping them in order, remove the oil seal, then lift out the intake camshaft. 4, Remove the exhaust and intake camshafts from the left side cylinder head, as follows:

->The thrust clearance on both the intake and exhaust camshafts is very small; the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may be caught in the cylinder head, causing the head to break or the camshaft to seize.

3. Remove the exhaust and intake camshafts from the right side cylinder head, as follows: a. Turn the camshaft with a wrench until the 2 pointed marks drive and driven gears are aligned. (The right camshaft gears have 2 marks apiece; the left side camshaft gears have 1 mark each.) b. Secure the exhaust camshaft subgear to the main gear using a service bolt. A bolt 0.63—-0.79 in. (16—20mm) long with a 6mm thread diameter and.a 1mm pitch is recommended. When removing the exhaust camshaft be sure the sub-gear is not loaded; all the force must be eliminated.

79242644

Right intake camshaft bearing cap bolt loosening sequence—3.0L engine

Exhaust

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Right side exhaust camshaft bearing cap bolt loosening sequence—3.0L engine

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

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TOYOTA AND LEXUS

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79242650

79242646

79242648

Right intake bearing caps must be placed

Left intake camshaft bearing cap bolt loosRight exhaust bearing caps must be placed in their proper locations—3.0L

ening sequence—3.0L engine

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in their proper locations—3.0L engine

engine Exhaust

7924ZG51

79242647

Left side exhaust camshaft bearing cap bolt loosening sequence—3.0L engine

a. Turn the camshaft with a wrench until the pointed marks on the drive and driven gears are aligned. (The right camshaft gears have 2 marks apiece; the left side camshaft gears have 1 mark each.) b. Secure the exhaust camshaft subgear to the main gear using a service bolt. A bolt 16—20mm long with a 6mm thread diameter and a 1mm pitch is recommended. When removing the exhaust camshaft be sure the sub-gear is not loaded; all the force must be eliminated. c. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps. Keep the caps in the correct order. d. Remove the exhaust camshaft from the engine. e. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the reverse order of the installation sequence. Remove the bearing caps, keeping them in order, remove the oil seal, then lift out the intake camshaft. 5. Remove the valve lifter shims and hydraulic lifters. Identify each lifter and shim as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in a sealed container.

7924Z2G49

Right exhaust camshaft bearing cap bolt tightening sequence—3.0L engine

To install: 6. Install the valve lifters into their original positions and install the shims. Check valve clearance and replace the shims as necessary. 7. When reinstalling, remember that the camshafts must be handled carefully and kept straight and level to avoid damage. 8. Before installing the camshafts in either cylinder head, apply multi-purpose grease to each camshaft. 9. Install the right camshafts, as follows: a. Position the intake camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical. The mark should be at the “3 o'clock” position. b. Apply sealant to the No. 1 bearing cap. c. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. Ibs. (16 Nm) in the proper sequence. d. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical. The mark should be at the “9 o'clock” position and must align with the marks on the other gear. e. Apply a light coat of clean engine oil to the bolt threads and under the bolt

Right intake camshaft bearing cap bolt tightening sequence—3.0L engine

head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. Ibs. (16 Nm) in the proper sequence. f. Remove the service bolt. 10. Install the left camshafts, as follows: a. Position the intake camshaft on the head so that the alignment mark is at a 90 degrees angle from vertical. The mark should be at the “9 o'clock” position. b. Apply sealant to the No.1 bearing

cap.

Exhaust

79242652

Left exhaust bearing caps locations and bolt tightening sequence—3.0L engine

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4. Remove or disconnect the following: e Right front wheel e Right fender splash shield e Right fender apron seal e No.1 engine undercover

& Bearing Cap No. 1 peanagacan Nee 9355YG05

Intake camshaft cap bolt tightening sequence—2.4L Highlander

¢ Coil pack e Cylinder head cover 5. Set the No.1 piston at TDC compression.

Bearing Cap No. 2: Bearing Cap No. 3

6. Remove or disconnect the following: e Timing chain tensioner No.1 is 7. Loosen the camshaft timing gear set 79242653

Left intake camshaft bearing cap locations and bolt tightening sequence—3.0L engine

c. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. Ibs. (16 Nm) in the proper sequence. d. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical. The mark should be at the “3 o'clock” position and must align with the marks on the other gear. e. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. Ibs. (16 Nm) in the proper sequence. f. Remove the service bolt. 11. Install or connect the following: e New camshaft oil seals, lubricated with multi-purpose grease e No. 3 (rear) timing belt cover e Camshaft timing gears e Idler pulley, timing belt and covers 12. Check and adjust the valve clearance. 13. Install the cylinder head (valve) covers, 14. Start the engine. Check the ignition timing. 15. Test drive the vehicle. 16. Check all fluid levels.

olt. s 8. Raise the camshaft and remove the set bolt. 9. Remove or disconnect the following: e Timing gear and chain e Exhaust camshaft 10. Loosen the intake camshaft cap bolts in several passes, in the sequence shown. Remove the caps. Remove the camshaft. 11. Installation is the reverse of removal. Tighten the cap bolt, in several passes, in the sequences shown, to:

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Exhaust camshaft cap bolt tightening sequence—2.4L Highlander

e Front caps: 22 ft. lbs. (30Nm) e All other caps: 80:inch Ibs. (Nm) 12. See the Timing Chain Removal and Installation procedure. 2.7L 4Runner

9355YG03

Exhaust camshaft cap bolt loosening sequence—2.4L Highlander

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9355YG04

Intake camshaft cap bolt loosening sequence—2.4L Highlander

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. 4, Remove or disconnect the following: Air cleaner cap Mass Air Flow (MAF) meter and the resonator Accelerator cable from the throttle body, if equipped with a manual transmission Accelerator and throttle cables from the throttle body, if equipped with an automatic transmission Cruise control cable from the actuator, if equipped with cruise control Intake air connector Air hose for Idle Air Control (IAC) Vacuum sensing hose Wire clamp for the engine wiring harness Positive Crankcase Ventilation (PCV) hoses Spark plug wires from the spark plugs

For Wheel Alignment specifications, see Section 7 of this manual

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RAV4 e 4RUNNER ¢ HIGHLANDER ¢ RX300

Engine wiring harness clamps and harness Air conditioning compressor connector, if equipped with air conditioning Oil pressure sensor connector Engine Coolant Temperature (ECT) sensor connector Engine coolant temperature sender gauge connector Exhaust Gas Recirculation (EGR) gas temperature sensor connector Vacuum Switching Valve (VSV) connector for the EGR 2 vacuum hoses from the VSV for the EGR Ground strap from the cowl top panel Engine wiring harness from the air intake chamber Throttle Position (TP) sensor connector IAC valve connector Crankshaft Position (CKP) sensor connector Knock (KS) sensor connector Data Link Connector 1 (DLC1) from the bracket Engine wiring harness clamp EGR pipe Intake chamber stay Air intake chamber assembly. eeeee ®@ Evaporative Emission (EVAP) hose from the throttle body Brake booster vacuum hose from the union Water bypass hose from the water bypass pipe Water bypass hose from the cylinder head rear cover Front engine hanger Engine wiring harness brackets Cylinder head cover 5. Set No. 1 cylinder to Top Dead Center (IDC) compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (1 and 2 dots) of the camshaft gears should form a straight line in respect to the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees). 6. Remove the chain tensioner and gasket. 7. Remove the camshaft timing gear as follows: a. Remove the 2 semi-circular plugs. b. Place matchmarks on the camshaft timing gear and No. 1 timing chain. c. Hold the hexagon head portion of the exhaust camshaft with a wrench and remove the fastener and distributor gear.

7924YG47

Camshafts TDC/compression timing marks. Marks with 1 and 2 dots will be in straight line on cylinder head surface—2.7L 4Runner

Main Gear

Bolt

7924YG48

Secure the exhaust camshaft sub-gear to the main gear with a service bolt—2.7L 4Runner

7924YG49

Loosen and remove the exhaust camshaft bearing cap bolts in sequence—2.7L 4Runner

7924YG50

Loosen and remove the intake camshaft bearing cap bolts in sequence—2.7L 4Runner

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camshaft. Make a note of the bearing cap positions for proper installation. 9. Remove or disconnect the following: e Intake camshaft bearing cap bolts in several passes, in the sequence shown ¢ Bearing caps and camshaft. Make a note of the bearing cap positions for proper installation.

7924YG51

Tighten the intake camshaft bearing cap bolts in sequence—2.7L 4Runner

Straight Pin

7924YG52

Engage both camshaft gears while matching the timing marks—2.7L 4Runner

7924YG53

Tighten the exhaust camshaft bearing cap bolts in sequence—2.7L 4Runner

d. Hold the hexagon head portion of the intake camshaft with a wrench and remove the bolt. e. Remove the camshaft timing gear and chain from the intake camshaft and leave on the slipper and damper. 8. Remove exhaust camshafts: a. Bring the service bolt hole of the driven sub-gear upward by turning the hexagon head portion of the exhaust camshaft with a wrench. b. Secure the exhaust camshaft sub-

gear to the driven gear with a service bolt (6mm diameter, 0.63—-0.79 inches in length and 1.0mm in thread pitch). When removing the camshaft, be sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

c. Uniformly loosen and remove the bearing cap bolts in several passes, in the sequence shown. d. Remove the bearing caps and

elf the camshaft is not being lifted out Straight and level, reinstall the No. 3 bearing cap with the 2 bolts. Then, alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.

e Valve lifters and shims from the cylinder head. Arrange the valve lifters and shims in correct order. To install: 10. Install the valve lifters and shims in their proper locations. Check that the valve lifter rotates smoothly by hand. 11. Install the intake camshaft, as follows: a. Apply engine oil to the thrust portion of the intake camshaft. b. Position the intake camshaft with the knock pin facing upward. c. Install the bearing caps in their proper locations. Apply a light coat of engine oil to the threads and install the cap bolts. Uniformly tighten the cap bolts, in sequence ,to 12 ft. Ibs. (16 Nm). 12. Install the exhaust camshaft, as shown: a. Apply engine oil to the thrust portion of the intake camshaft. b. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks (1 and 2 dots) on each other. c. Roll down the exhaust camshaft onto the bearing journals while engaging the gears with each other. Install the bearing caps in their proper locations. d. Apply a light coat of engine oil to the threads and install the cap bolts. Uniformly tighten the cap bolts in the sequence shown to 12 ft. Ibs. (16 Nm). e. Remove the service bolt from the driven sub-gear. Check that the intake and exhaust camshafts turns smoothly. 13. Set No. 1 cylinder to Top Dead Center (TDC) of the compression stroke: CrankShaft pulley groove align with 0 mark on timing cover and camshafts timing marks with 1 dot and 2 dots will be straight line on the cylinder head surface.

For Maintenance Interval recommendations, see Section 1 of this manual

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The fuel filter is located in the engine compartment, at the inlet line to the fuel rail.

4, Remove or disconnect the following; e Inlet and outlet lines from the filter e Fuel filter To install: 5. Install or connect the following:

e Fuel filter, using new O-rings. Tighten the lines to 22 ft. Ibs. (29 Nm) e Negative battery cable 6. Start the engine and check for leaks, Highlander The fuel filter is in the tank as part of the pump assembly and is not a normal maintenance item. 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable

5

RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly release fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel filter's protective shield 4, Place a pan under the delivery pipe to catch the dripping fuel and slowly loosen the union bolt or flare nut to bleed off the fuel pressure. 5, Drain the remaining fuel. 6. Remove or disconnect the following: e Inlet and outlet lines e Fuel filter To install: 7. Coat the flare nut, union nut and bolt threads with engine oil. 8. Hand-tighten the inlet line to the fuel filter. e>When tightening the fuel line bolts to the fuel filter, use a torque wrench. The tightening torque is very important, as under or over tightening may cause fuel leakage. Insure that there is no fuel line interference and that there is sufficient clearance between it and any other parts.

9. Install or connect the following: e Fuel filter. Tighten the inlet bolts to 22 ft. Ibs. (30 Nm). e Delivery pipe using new gaskets. Tighten the union bolt to 22 ft. Ibs. (30 Nm).

7924Z2G59

Exploded view of the fuel filter—RX300

SST

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7924YG90

Exploded view of the fuel delivery components—2.7L engines

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

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95-§2 TOvOTA AND LEXUS RAV4 e 4RUNNER ¢ HIGHLANDER

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Fuel Inlet Pipe

@ Gasket

Fuel inlet Hose

@ Non-reusable part 7924SG28

Always use new gaskets when replacing the fuel filter—3.4L

>The fuel filter is located in the engine compartment, at the inlet line to the fuel rail.

e Plug the filter inlet and outlet lines e Fuel filter e Bracket from the fuel filter To install: 4. Install or connect the following: e Fuel filter bracket to the fuel filter e Fuel filter. Tighten the 2 bolts to 14 ft. lbs. (20 Nm). e New gaskets. Tighten the union bolts to 22 ft. Ibs. (30 Nm). e Negative battery cable 5. Start the engine and check for leaks.

REMOVAL & INSTALLATION RAV4 and RX 300

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Left-hand rear seat assembly Floor service hole by pulling back the carpet; then, remove the 4 Screws Fuel pump and sender gauge connector ->Loosen the fuel cap to relieve any fuel pressure within the tank.

e Fuel pipe union bolt and both gaskets e Fuel pump outlet pipe e Return vent hose from the fuel pump e 8 fuel pump bolts and the pump assembly from the tank To install: 4. Install or connect the following: Fuel pump to the fuel tank. Tighten the 8 bolts to 31 inch Ibs. (3.5 Nm). Return vent hose to the fuel pump Outlet pipe to the fuel pump, using new gaskets. Tighten the union bolts to 22 ft. Ibs. (29 Nm). Fuel pump and sender gauge connector Floor hole cover with the 4 screws Carpet Left rear seat assembly Negative battery cable Fuel cap 5. Start the vehicle and check for leaks. 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel pressure. 3. Disconnect the negative battery cable from the battery. 4. Drain the fuel from the fuel tank. 5. Remove or disconnect the following: e Fuel tank e Fuel pump connector from the clamp

e Access plate bolts, then pull out the fuel pump assembly from the fuel tank Gasket(s) from the pump bracket Fuel pump connector Bracket from the lower side of the fuel pump A Fuel pump from the fuel hose Rubber cushion, the clip and the fuel filter at the bottom of the fuel pump To install: 6. Install or connect the following: Fuel pump filter to the fuel pump with a new clip Fuel pump to the fuel pump bracket Fuel hose to the outlet port of the fuel pump Fuel pump connector Fuel pump assembly with a new gasket(s). Tighten the bolts to 31 inch Ibs. (4 Nm). Fuel pump connector to the clamp Fuel tank All electrical and fuel connections Negative battery cable 7. Refill the fuel tank and check for leaks. Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel pressure. 3. Remove or disconnect the following: e Both rear seats e. Carpet e Service hole cover e Connector e Joint clip and pull out the fuel tube e Vent tube set plate e Pump and gauge assembly 4. Installation is the reverse of removal.

Fuel Injector

REMOVAL & INSTALLATION 2.0L 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ 2, Remove or disconnect the follow-

ing: e Air cleaner assembly e Cylinder head cover ¢ Throttle body from the intake manifold e Distributor

TOYOTA AND LEXUS

RAV4 ¢ 4RUNNER ¢ HIGHLANDER © RX300 3. Remove or disconnect the engine wire from the intake manifold, as follows: e 4 injector connectors ¢ Both engine wire clamps from the intake manifold wire brackets e Engine wire protector from the right side of the intake manifold ¢ Engine wire clamp 4. Remove or disconnect the Exhaust Gas Recirculation (EGR) valve, as follows: ¢ Vacuum hose from port E of the Vacuum Switching Valve (VSV) e EGR hose from the vacuum modulator e Loosen the EGR pipe nut from the cylinder head ¢ Both nuts, EGR valve, pipe assembly and gasket 5. Disconnect the engine compartment

R/B No. 2 6. Remove or disconnect the fuel inlet hose and delivery pipe, as follows: Union bolt, both gaskets and the fuel inlet hose from the fuel filter outlet

Air assist hose from the intake manifold port Air assist hose Loosen,both delivery pipe-to-cylinder head bolts Delivery pipe from the 4 injectors Delivery pipe and fuel inlet hose assembly 7. Remove or disconnect the following: e 4 injectors and spacers

Be careful not to drop the injectors and spacers. e Q-rings, insulator and grommet from each injector To install: 8. Install or connect the following: e New O-rings, insulator and grommet, lubricated with gasoline, to each injector e 4 injectors and spacers 9. Install or connect the fuel inlet hose and delivery pipe, as follows: Delivery pipe and fuel inlet hose assembly Delivery pipe to the 4 injectors. Tighten both delivery pipe-to-cylinder head bolts to 9 ft. Ibs. (13 Nm). Air assist hose Air assist hose to the intake manifold port Union bolt, new gaskets and the fuel inlet hose to the fuel filter out-

let. Tighten the union bolt to 22 ft.

lbs. (29 Nm). 10. Connect the engine compartment R/B No. 2 11. Install or connect the EGR valve, as follows: ¢ New gasket, pipe assembly and EGR valve. Tighten the nut to 9 ft. lbs. (13 Nm) and the union nut to 43 ft. Ibs. (59 Nm). e EGR hose to the vacuum modulator e Vacuum hose from port E of the VSV 12. Install or connect the engine wire to the intake manifold, as follows: e Engine wire clamp e Engine wire protector to the right side of the intake manifold e Both engine wire clamps to the intake manifold wire brackets e 4 injector connectors 13. Install or connect the following: e Distributor e Throttle body to the intake manifold e Cylinder head cover e Air cleaner assembly

2.4L 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Air cleaner and hoses e Fuel line from the rail e Injector connectors e Injector wiring harness e Fuel rail with injectors e Injector spacers from the head 4. Installation is the reverse of removal. Coat the new o-rings with clean fuel. Before tightening the fuel rail bolts, make sure that each injector rotates smoothly. Tighten the bolts to 15 ft. Ibs. (2ONm). 3.0L Highlander 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Coolant e \-bank cover e Battery e Air cleaner assembly e Upper front suspension brace e Intake air Surge tank e Fuel supply line

25-63

e Injector connectors ¢ Fuel rail with injectors 4. Installation is the reverse of removal. Coat the new o-rings with clean fuel. Before tightening the fuel rail bolts, make sure that each injector rotates smoothly. Tighten the bolts to 84 inch Ibs. (10Nm).

RX300 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Outer front cowl top panel assemy Air cleaner cap with hose Negative battery cable. Work must be started approximately 90 seconds or longer after the negative battery cable has been disconnected, if equipped with an air bag. Coolant Accelerator and throttle cables V-bank cover Emission valve control set No. 2 EGR pipe Hydraulic motor pressure pipe from the water inlet and air inlet chamber Air intake chamber assembly Injector wiring Air assist pipe from the bracket on the No. 1 fuel pipe Air assist hoses from the intake manifold Fuel return hose from the No. 1 fuel pipe Fuel inlet hose for the fuel filter 2 union bolts holding the No. 2 fuel pipe to the delivery pipes Fuel return hose from the fuel pressure regulator Union bolt for the right hand delivery pipe, 2 gaskets, 2 bolts, left hand delivery pipe together with the 3 injectors and the No. 2 fuel pipe Union bolt for the delivery pipe and 2 gaskets from the No. 2 fuel pipe The 3 bolts, right hand delivery pipe together with the 3 injectors and the No. 1 fuel pipe The 4 spacers from the intake manifold The 6 injectors from the delivery pipes The two O-rings and two grommets from each injector To install: 3. Install or connect the following: e 2 new grommets to each injector

For Wheel Alignment specifications, see Section 1 of this manual

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25-64 TOYOTA AND LEXUS

RAV4 ¢ ARUNNER ¢ HIGHLANDER ¢ RX300

New O-rings, with a light coat of fuel, to each injector Injectors The 4 spacers on the intake manifold Right hand delivery pipe and the No. 1 fuel pipe together with the 3 injectors in position on the intake manifold Bolt holding the right side delivery pipe, temporarily, to the intake manifold Left hand delivery pipe and the No. 2 fuel pipe together with the 3 injectors in position on the intake manifold Fuel return hose to the fuel pressure regulator 4. Temporarily install the 2 bolts holding the left hand delivery pipe to the intake manifold. 5. Temporarily install the No. 2 fuel pipe to the left side delivery pipe with the union bolt and 2 new gaskets. 6. Check that the injectors rotate smoothly. If they do not, replace the Orings. 7. Position the injector connector outward. Tighten the 4 bolts holding the delivery pipes to the intake manifold and tighten to 7 ft. Ibs. (10 Nm). Tighten the bolt holding the No. 1 fuel pipe to the intake manifold to 14 ft. Ibs. (20 Nm). Tighten the 2 union bolts holding the no. 2 fuel pipe to the delivery pipes to 24 ft. Ibs. (32 Nm). 8. Install or connect the following: Fuel inlet and return hoses. Union bolt: 22 ft. Ibs. (30 Nm) Fuel return hose to the No. 1 fuel pipe. Pass the fuel return hose under the heater hoses. Air assist hoses to the intake manifold Air assist pipe to the bracket on the No. 1 fuel pipe Fuel injector wiring connectors Air intake chamber assembly Hydraulic motor pressure pipe to the intake chamber. Bolts: 69 inch lbs. (8 Nm) No. 2 EGR pipe with new gaskets, tighten to 9 ft. Ibs. (12 Nm) Emission control valve set V-bank cover Air cleaner hose Throttle and accelerator cables Coolant Air cleaner cap with hose Outer front cowl top panel assembly Negative battery cable

2.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Throttle body Fuel injector electrical connectors Crankshaft Position (CKP) sensor connector e Knock Sensor (KS) connector e Data Link Connector 1(DLC1) and wire clamp from the brackets e Vacuum line from the fuel pressure regulator e Fuel return hose from the pressure regulator e Union bolt and gaskets Fuel inlet pipe from the fuel rail Fuel rail with the injectors attached

The injectors are only retained by their O-rings and will tend to drop out of the fuel rail. e A insulators from the four spacers e Fuel injectors from the fuel rail e Q-ring and grommet, discard them To install: 4. Install or connect the following:

e New grommets and O-rings on each injector, lubricated with a light coat of gasoline

e Fuel injectors, with the electrical connector facing upwards ¢ New insulators and spacers on the intake manifold 5. Temporarily install the bolts holding the delivery pipe to the intake manifold. 6. Check that the injectors rotate smoothly. 7. \nstall or connect the following: Tighten the delivery pipe-to-intake manifold bolts to 15 ft. Ibs. (21 Nm). Injector electrical connectors Fuel inlet pipe with new gaskets. Tighten the union bolt to 22 ft. Ibs. (29 Nm) and the bolt to 14 ft. Ibs. (20 Nm). Fuel return pipe to the fuel pressure regulator Vacuum line to the pressure regulator Throttle body Negative battery cable

3.4L Engine

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

Gasket ———-©®

Delivery Pipe P \

Fuel Inlet Pipe

\Injector——_—— Insulator —9

Injector Connector Knock Sensor Connector Crankshaft Position

Sensor Connector

DLC1

93165620

Fuel injector arrangement and related components—2.7L engines

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Fuel injector arrangement and related components—3.4L engine

2. Depressurize the fuel system. 3. Remove or disconnect the following: e Air cleaner hose ¢ Upper half of the intake manifold ¢ Fuel pressure regulator ¢ Fuel inlet pipe + Fuel injector electrical connections ° Fuel rail with the injectors

86825668

Install new O-rings and grommets on each injector—3.4L engine

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e Spacers on the intake manifold 5. Temporarily install the bolts to hold the delivery pipes to the intake manifold.

6. Check that the injectors rotate

smoothly. If they do not, the O-rings have probably been installed incorrectly. 7. Install or connect the following: e Fuel injector electrical connectors e Fuel pipe with new gaskets. Tighten the bolts to 25 ft. Ibs. (34 Nm) and the delivery pipes-tointake manifold bolts to 10 ft. Ibs. (13 Nm). e t ¢ Fuel pipe union with new gaskets.

iene clamp bolt to 71 inch

¢ Spacers from the intake manifold ¢ Injectors from the delivery pipes * O-rings and grommets, discard them To install: 4. Install or connect the following: + New grommets and O-rings on each injector, lubricated with a light coat of gasoline

s. (8 Nm). * Fuel pressure regulator 8. Inspect the vacuum lines and connections. Look for any loose connections, sharp bends or damage. 9. Install or connect the following: ° Air cleaner e Air cleaner hose 10. Start the engine and check for vacuum and fuel leaks.

DRIVE TRAIN Manual Transmission Assembly REMOVAL & INSTALLATION

2WD RAV4 —;

,

1. Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

tion.

2. Remove or disconnect the following: * Negative battery cable ° Air cleaner case assembly with hose ¢ Engine coolant reservoir tank

. rent wire clamp setnut

os Remove the clutch release cylinder, as follows: aa e Clutch line bracket-to-transaxle se bolts e Release cylinder and line 4. Remove or disconnect the following:

¢ Ground cable from the transaxle

* Vehicle Speed Sensor (VSS) and

backup light switch connector ¢ Control cable by removing the 4 clips and washers ¢ 4 upper side transaxle-to-engine bolts

e Left mount insulator

9. Install a engine support to the PIO pen aicorte sg . Support rack and pinion to the engine support fixture with a rope. 7. Remove or disconnect the following: e Front wheels

e Left and right-hand engine underpavers

8. Drain the transaxle oil. 9. Remove the left and right halfshafts,

10. Remove the front exhaust pipe, as

follows:

¢ 3 exhaust manifold nuts and gasket

For Maintenance Interval recommendations, see Section 1 of this manual

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95-66 OvOTA AND Lexus

RAV4 e¢ 4RUNNER e HIGHLANDER e RX300

12. Remove the engine mounting center-

b. Disconnect the ring from the center

e Both exhaust pipe-to-center

member by removing the 4 bolts.

exhaust pipe.

exhaust pipe bolts

13. Jack up the transaxle slightly. 14. Remove or disconnect the following: . ¢ Left mounting bracket from the mounting insulator by removing the set bolt

c. Remove the 2 set bolts and nuts of the power steering rack and pinion assembly. d. Remove the suspension crossmember assembly with the sway bar by removing the 2 nuts and 6 bolts.

e Exhaust pipe 11. Remove the front suspension crossmember assembly with the sway bar, as follows: a. Support the front suspension crossmember with a jack.

Air Intake Connector

Clutch Release sont and Line

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Center Drive Shaft

@ Boot Clamp

@ Snap Ring Straight Pin

Outbord Joint Shaft

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Center Bearing “(QO

Inboard Joint

@ Snap Ring

2WD A/T

O-Ring Tripod

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Dust Cover

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Front halfshaft exploded view (2WD with automatic transmission and 4WD)—RAV4

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

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25- 30TOYOTA AND LEXUS RAV4 ¢ 4RUNNER ¢ HIGHLANDER RX300 e Negative battery cable e Engine undercover 3. Drain the transaxle. 4. Remove or disconnect the following:

Anti-lock Brake System (ABS) sensor by removing the bolt, if equipped Cotter pin, lock cap and the locknut holding the halfshaft to thesteering knuckle Tie rod ends, from the steering knuckle Sway bar link, from the lower control arm Lower ball joint, from the lower control arm Halfshaft from the axle hub, using a plastic hammer 5. If working on a 2WD right-hand halfshaft and the vehicle is equipped with a manual transaxle, perform the following to remove the halfshatt: e Snapring from the center bearing bracket, using a brass bar and hammer e Bolt and the center bearing bracket e Halfshaft with the center halfshaft e 2 bolts and the center bearing bracket 6. If working on a 2WD right-hand halfshaft and the vehicle is equipped with an automatic transaxle, perform the following to remove the halfshatt: e 2 bolts of the center bearing bracket and pull out the halfshaft together with the center bearing case and center halfshaft e 3 bolts and the center bearing bracket 7. lf working on a 2WD left-hand, perform the following: e Halfshaft, using a brass bar and hammer e Snapring from the transaxle 8. If working of a 4WD right-hand halfshaft, perform the following: e Halfshaft, using a brass bar and hammer e Snapring from the transaxle

e Q-ring 9. If working on a 4WD left-hand side, perform the following: e Air cleaner e Transaxle case protector e Halfshaft, by prying it out using a hub wrench ¢ Snapring To install: 10. If working on a 4WD left-hand side, perform the following:

e e e e

Snapring Halfshaft to the transaxle Transaxle case protector Air cleaner 11. If working of a 4WD right-hand halfshaft, perform the following: e Snapring to the transaxle e New O-ring e Halfshaft to the transaxle 12. If working on a 2WD left-hand, perform the following: e Snapring e Halfshaft to the transaxle 13. If working on a 2WD right-hand halfshaft and the vehicle is equipped with an automatic transaxle, perform the following to remove the halfshaft: e Center bearing bracket. Tighten the 3 bolts to 47 ft. Ibs. (64 Nm). e Halfshaft together with the center bearing case and center halfshaft. Tighten both bolts to 47 ft. Ibs. (64 Nm). 14. If working on a 2WD right-hand halfShaft and the vehicle is equipped with a manual transaxle, perform the following to remove the halfshaft: e Center bearing bracket e Halfshaft with the center halfshaft e Center bearing bracket. Tighten the bolt to 24 ft. Ibs. (32 Nm). e Snapring to the center bearing bracket 15. Install or connect the following: e Halfshaft to the axle hub e Lower ball joint to the lower control arm. Tighten the nuts/bolt to 94 ft. lbs. (127 Nm). Sway bar link to the lower control arm. Tighten the nut to 47 ft. Ibs. (64 Nm) for 3-door or to 83 ft. Ibs. (113 Nm) for 5-door. Tie rod end to the steering knuckle. Tighten the nut to 36 ft. Ibs. (49 Nm). New tie rod end cotter pin Halfshaft to the axle hub. Tighten the locknut to 159 ft. Ibs. (216 Nm). Lock cap and cotter pin ABS speed sensor with the bolt, if equipped 16. Fill the transaxle with gear oil (manual transmission) or ATF (automatic transmission). 17. Install or connect the following: e Engine undercover e Wheels ¢ Negative battery cable 18. Check the ABS sensor signal.

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RAV4 Rear

1. Before servicing the vehicle, refer to the precautions in the beginningof this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheels e Anti-lock Brake System (ABS) speed sensor from the axle assembly by removing the bolt, if equipped ¢ Cotter pin, lock cap and the nut holding the halfshaft to the axle carrier 3. Place matchmarks on the halfshaft and side gear shaft. 4. Remove or disconnect the following: e Halfshaft from the differential side gear shaft, by removing the 4 nuts and washers - e Halfshaft from the axle carrier, using a plastic hammer To install: 5. Install or connect the following: e Halfshaft to the axle carrier e Halfshaft to the differential side gear shaft, by aligning the marks. Tighten the 4 nuts to 41 ft. Ibs. (56 Nm). e Nut, lock cap and the cotter pin to hold the halfshaft to the axle carrier. Tighten the nut to 152 ft. Ibs. (206 Nm). e ABS sensor. Tighten the bolt to 69 inch lbs. (8 Nm). e Rear wheels e Negative battery cable 6. Check the ABS sensor signal. Highlander Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheels Fender apron seal Transaxle fluid Transfer case oil (4wd) ‘ Hub nut Stabilizer bar link Speed sensor Tie rod end Lower arm from the ball joint 3. Slide the halfshaft from the hub, then, carefully, pry the shaft from the transaxle. 4. Installation is the reverse of removal. Torque the hub nut to 217 ft. Ibs.

(294Nm).

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Rear halfshaft removal and installation (4WD only)—RAV4

Highlander Rear a

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

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tion.

e Control arms

2. Remove or disconnect the following:

Wheel Speed sensor

Driveshaft Strut rod

e Caliper e Rotor

© Parking brake assembly © Strut lower bolts and nuts

e Hub and axle shaft

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

5

95-87 TO’ OTAAN DLEXUS _

RAV4 e 4RUNNER ¢ HIGHLANDER

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3. Installation is the reverse of removal.

r— Torque the hub bolts to 59 ft. Ibs. (80Nm). RX 300 Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheels e Cotter pin and locknut cap

e»Have an assistant depress the brake pedal and loosen the bearing locknut.

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Fender apron seal Tie rod end, from the steering knuckle Steering knuckle, from the lower control arm Halfshaft from the axle hub, using a plastic hammer Cover the outer boot with a rag Halfshaft from the transaxle, using the proper tools To install:

3. Reverse the removal procedures to complete installation, tightening fasteners to

specifications. Drive Shaft (RH)

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4. Fill the transaxle with gear oil, install the fender apron, check front end alignment and test drive. elif the cotter pin holes do not align, always correct by tightening the nut until the next hole aligns.

5. Install a new cotter pin. RX 300 Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Rear Engine Mounting Insulator

@Lock Bolt

,

Snap Ring Drive Shaft (LH)

Lower Suspension Arm

@ Boot Clamp Cotter pin @ No.2 Dust Deflector

ABS Speed Sensor

Lock Cap

Inboard Joint Shaft

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Dust Cover

:

Center Bearing

Dust Cover

: Specified torque Non-reusable part 79242G73

Exploded view of front halfshaft—RX 300

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RAV4 ¢ 4RUNNER ¢ HIGHLANDER ¢ RX300

:

aya! Negative battery cable e Rear wheels e Anti-lock Brake System (ABS) speed sensor from the axle assem-

bly by removing the bolt, if

equipped ¢ Cotter pin, lock cap and the nut holding the halfshaft to the axle carrier 3. Place matchmarks on the halfshaft and differential side gear shaft.

4. Remove or disconnect the following: ¢ 4 nuts, washers and the halfshaft from the differential e Halfshaft from the axle carrier

e ABS sensor e Rear wheels e Negative battery cable

To install:

4Runner

5. Install or connect the following: e Halfshaft into the axle carrier. Tighten the 4 nuts to 51 ft. Ibs. (69 Nm). e Halfshaft. Tighten the locknut to 159 ft. Ibs. (216 Nm).

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Exploded view of the rear halfshaft—RX 300 model with 4WD

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

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RAV4 e 4RUNNER ¢ HIGHLANDER e RX300

4. Remove the halfshaft locknut, as follows: e Grease cap e Cotter pin and the lockcap e Locknut, while applying the brakes 5. Remove or disconnect the following: e Halfshaft, using a brass bar and a hammer e Lower control arm e Halfshaft, by pushing the steering knuckle outward e Snapring from the inboard shaft To install: 6. Install or connect the following: e Snapring to the inboard shaft e Halfshaft e Steering knuckle e Lower control arm. Tighten the nut to 105 ft. Ibs. (142 Nm). 7. Connect the halfshaft, as follows: e Set the snapring opening side facing downward e Strike the inboard joint into the differential, using SST 09631-10030 and a hammer e Check that the halfshaft cannot be pulled out by hand 8. Install or connect the following: e Locknut, while applying the brakes. Tighten it to 174 ft. Ibs. (235 Nm). e Grease cap e Front wheel

93082652

View of the bearing-to-dust cover clear-

ance-2WD RAV4 With M/T

105.0 - 106.0 mm

(4,134 - 4.173 in.) =

93082653

View of the dust cover-to-center drive dis-

tance-2WD RAV4 With M/T

RH

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9. Fill the differential with oil.

Lubricate the balls with grease to keep them from falling.

e Inboard joint tulip, by aligning the matchmarks e New snapring ¢ Temporarily, install the inboard joint boot packed with grease from the kit

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Do not disassemble the outboard joint.

¢ Dust cover from the center driveshaft, using a press, for 2WD on the right side e Dust cover from the inboard joint tulip, using too! 09950-00020 and a press, for 2WD on the left side and 4WD 7. Disassemble the center driveshaft, as follows:

between the dust cover and the bearing is 0.039 in. (1.0mm) 11. Install or connect the following: e Right dust cover (2WD), until the distance from the tip of the center drive is 3.39-3.34 in. (86—87mm) to the inner edge of the dust cover e Left side dust cover (2WD and AWD), using a press 12. Temporarily install new outboard/inboard joint boots using new clamps, as follows: a. Warp tape around the driveshaft splines. b. Install the new outboard joint boot onto the driveshaft. c. Install the new inboard joint boot onto the driveshaft. 13. Install the tri-pot joint, as follows: e Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks e Tri-pot joint onto the driveshaft, using a press

93082657

Measuring the front halfshaft

lengths-RAV4 with 2WD A/T and 4WD

Snapring Bearing case, uSing a press Straight pin from the bearing case, using a pin punch and hammer e Dust cover, using tool 0995000020 and a press

e Snapring Bearing, uSing a press 8. Remove the No. 2 dust deflector, using a screwdriver and hammer. To assemble: 9. Install a new No. 2 dust deflector, using a press. 10. Assemble the center driveshaft, as follows: e Straight pin into the bearing case, using a pin punch and hammer e New bearing, using tools 0995960010, 09950-70010 and a press

e New snapring 14. Install the outboard joint boot packed with grease from the boot kit. 15. Install the inboard joint tulip, as follows: e Pack the inboard joint boot with grease from the boot kit e |nboard joint tulip, by aligning the matchmarks e Temporarily, install the inboard joint boot packed with grease from the kit 16. Install the boot clamps to both boots, as follows: e Both boots to the shaft grooves e Halfshaft length should be 33.055-33.449 in. (839.6-849.6mm) for the right side on 2WD with A/T, 21.397-21.791 in. (543.5-553.5mm) for the left side on 2WD with A/T, 19.92920.323 in. (506.2-516.2mm) for the right side on 4WD or

For Wheel Alignment specifications, see Section 1 of this manual

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RAV4 e 4RUNNER ¢ HIGHLANDER ¢ RX300

19.803-20.197 in. (603-511mm) for the left side on 4WD e Both new boot clamps boot e Bend the band and lock it using a screwdriver

RAV4 Rear 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the inboard and outboard joint boot clamps. 3. Disassemble the inboard joint tulip,

as follows: e Matchmark the tri-pot, inboard joint tulip or center driveshaft to the driveshaft

using tools 09309-36010, 09316-20011 and a press. 7. Temporarily install new outboard/ inboard joint boots using new clamps, as follows: a. Warp tape around the driveshaft splines. b. Install the new outboard joint boot onto the driveshaft. c. Install the new inboard joint boot onto the driveshaft. 8. Install the tri-pot joint, as follows: e Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks e Tri-pot joint onto the driveshaft, using a brass bar and hammer

kt WARNING Do not use punch marks. e Inboard joint tulip from the driveshaft 4. Remove the tri-pot joint, as follows: e Snapring e Matchmark the tri-pot joint to the driveshaft

Do not use punch marks.

e Tri-pot joint, using a brass bar and hammer

Do not tap the roller. 5. Remove or disconnect the follow-

ng:

e Inboard and outboard joint boots Do not disassemble the outboard joint.

e No. 2 dust deflector from the center driveshaft, using a screwdriver and hammer To assemble: 6. Install a new No. 2 dust deflector,

Be careful not to tap the roller. e New snapring 9. Install the outboard joint boot packed with grease from the boot kit. 10. Install the inboard joint tulip, as follows: e Pack the inboard joint boot with grease from the boot kit e Inboard joint tulip, by aligning the matchmarks e |nboard joint boot packed with grease from the kit 11. Install the boot clamps to both boots, as follows: e Both boots to the shaft grooves Halfshaft length should be 23.392— 23.795 in. (594.4-604.4mm) for the right side or 21.590-21.984 (548.4-558.4mm) for the left side New boot clamps boot Bend the band and lock it using a screwdriver 4Runner

OUTBOARD JOINT The outboard joint is replaced with halfshaft; no overhaul is possible or necessary.

INBOARD (TRI-POT) JOINT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the halfshaft from the vehicle. 3. Remove the large clamp from the inboard joint. 4. Remove the small clamp, using side cutters, from the inboard joint. 5. Slide the inboard joint boot toward the outboard joint. 6. Matchmark the inboard joint to the halfshaft. 7. Remove the inboard joint housing from the halfshaft. 8. Remove the snapring from the end of the halfshaft. 9. Matchmark the halfshaft to the tri-pot joint. 10. Remove the tri-pot from the halfshaft, using a brass bar and a hammer.

¢ WARNING Do not tap on the tri-pot joint.

11. Remove the inboard and outboard boots from the halfshaft.

+ WARNING Do not disassemble the outboard joint.

To assemble: 12. Wrap vinyl tape around the halfshaft splines to prevent damaging the boots. 13. Install the outboard and inboard boots to the halfshaft with the small end clamps. 14. Assemble the tri-pot joint to the halfshaft with the beveled side facing the outboard joint and align the matchmarks. 15. Install the tri-pot joint, using a brass bar and a hammer.

Do not tap on the roller. |

:

16. Install the snapring.

17. Lubricate the outboard joint with V2 of the 18. joint 19. to the

grease supplied with thekit. Assemble the boot to the outboard Assemble the inboard joint housing halfshaft by aligning the matchmarks.

20. Temporarily install the boot onto the

93082658

Measuring the rear halfshaft lengths-RAV4

tri-pot housing. 21. Make sure the boots are positioned in the shaft grooves. 22. With the halfshaft positioned at the

standard length of 20.898-21.095 in.

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25-88 TOYOTA AND LEXUS RAV4 ¢ 4RUNNER ¢ HIGHLANDER e RX300 (525.8-535.8mm), make sure that the boots are not stretched or contracted. 23. Install a new inboard joint clamp. 24. Crimp the large clamp with tool 09521-24010 so that the crimp clearance is 0.039--0.059 in. (1.0-1.5mm). 25. Install the halfshaft.

Spindle Bearings

REMOVAL, PACKING AND INSTALLATION 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Shock absorber Grease cap Driveshaft Cotter pin and lockcap Locknut, with an assistant applying the brakes Speed sensor and harness from the steering knuckle, if equipped with Anti-lock Brake System (ABS) Brake line from the steering knuckle Caliper and rotor Lower ball joint bolts and the joint from the steering knuckle Cotter pin and axle hub nut Steering knuckle Bearings from the steering knuckle To install: 3. Install or connect the following: e \Bearings to the steering knuckle Steering knuckle Cotter pin and axle hub nut. Tighten the nut to 80 ft. Ibs. (108

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To install: 3. Install or connect the following: e Axle shaft Steering knuckle Tighten the axle hub nut to 80 ft. lbs. (108 Nm) and the locknut to 174 ft. Ibs. (235 Nm). Cotter pin Lower ball joint bolts Caliper and rotor Brake line to the steering knuckle Speed sensor and harness to the steering knuckle, if equipped with Anti-lock Brake System (ABS) Locknut, using an assistant to apply the brakes Axle shaft’s cotter pin and lock cap Grease cap Shock absorber

Axle Shaft, Bearing and Seal

REMOVAL & INSTALLATION Front

4RUNNER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Shock absorber Grease cap Axle shaft's cotter pin and lock cap Locknut, using an assistant to apply the brakes Speed sensor and harness from the steering knuckle, if equipped with Anti-lock Brake System (ABS) Brake line from the steering knuckle Caliper and rotor Lower ball joint bolts Cotter pin and loosen the axle hub

Front wheel

Rear 4RUNNER

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

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RAV4 ¢ 4RUNNER ¢ HIGHLANDER @ RX300 2. Remove or disconnect the following: ‘e Rear wheel e Brake drum 3. Check the bearing backlash and axle shaft deviation, as follows: a. Using a dial indicator, check that the backlash in the bearing shaft direction. The maximum is 0.027 in. (0.7mm). b. If the backlash exceeds the maximum, replace the bearing. c. Using a dial indicator, check the deviation at the surface of the axle shaft outside the hub bolt. Maximum is 0.0039 in. (0.1mm). d. If the deviation exceeds the maximum, replace the axle shaft. 4, Remove or disconnect the following: Anti-lock Brake System (ABS) speed sensor from the axle housing, if equipped Axle shaft assembly by removing the 4 nuts from the backing plate. + O-ring from the axle housing Bearing and retainer (differential side) and ABS speed sensor rotor, if equipped Snapring from the axle shaft Axle shaft Inspect the axle shaft and flange runouts. The axle shaft run-out should be 0.079 in. (2.0mm) and the flange runout should be 0.004 in. (0.1mm).

e Outer seal e Bearing from the axle shaft To install: 5. Install or connect the following: Bearing from the axle shaft Outer seal Axle shaft Snapring to the axle shaft Bearing and retainer (differential side) and ABS speed sensor rotor, if equipped O-ring to the axle housing Axle shaft assembly. Tighten the 4 backing plate nuts to 48 ft. Ibs. (66 Nm). Anti-lock Brake System (ABS) speed sensor to the axle housing, if equipped Brake drum Rear wheel

Rear

REMOVAL & INSTALLATION Front

4RUNNER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the differential oil. 3. Remove or disconnect the following: ¢ Front driveshaft by matchmarking it e Companion flange nut, by loosen the staked portion e Companion flange, using a screwa extractor e (il seal, using an extractor To install: 4. Install a new oil seal, to a depth of

0.059 in. (1.5mm) below the lip, using a seal driver. 5. Lubricate the seal lip with multi-purpose grease. 6. Install or connect the following: e Companion flange, coat the threads with multi-purpose grease e New companion flange nut. Tighten it to 89 ft. Ibs. (120 Nm). 7. Measure the bearing preload, using a torque wrench. The correct preload should be 5-9 inch Ibs. (0.6—-1.0 Nm) for a used bearing or 10-17 inch lbs. (1-2 Nm) for a new bearing. elf the preload is greater that specified, replace the bearing spacer. If the preload is less than specified, tighten the companion flange nut in 9 ft. Ibs. (13 Nm) increments until the correct preload is achieved. Maximum torque for the nut is 165 ft. Ibs. (223 Nm). If

the value is exceeded, the bearing spacer must be replaced; do not back off the flange nut to lower the torque or preload.

8. Install the front driveshaft by aligning the matchmarks. 9. Check the companion flange run-out: maximum allowable run-out is 0.003 in. (0.10mm). 10. Stake the pinion flange nut. 11. Refill the differential with oil.

4RUNNER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the differential oil. 3. Remove or disconnect the following: ¢ Driveshaft by matchmarking it e Companion flange nut, by loosen the staked portion e Companion flange, using a screwtype extractor e Oil seal, using an extractor To install: 4. Install a new oil seal, to a depth of 0.059 in. (1.5mm) below the lip, using a Seal driver. 5. Lubricate the seal lip with multi-purpose grease. 6. Install or connect the following: e Companion flange, coat the threads with multi-purpose grease e New companion flange nut. Tighten it to 89 ft. Ibs. (120 Nm). 7. Measure the bearing preload, using a torque wrench. The correct preload should be 5-9 inch Ibs. (0.6—1.0 Nm) for a used bearing or 10-17 inch Ibs. (1-2 Nm) for a new bearing. elf the preload is greater that specified, replace the bearing spacer. If the preload is less than specified, tighten the companion flange nut in 9 ft. Ibs. (13 Nm) increments until the correct preload is achieved. Maximum torque for the nut is 165 ft. Ibs. (223 Nm). If the value is exceeded, the bearing spacer must be replaced; do not back off the flange nut to lower the torque or preload.

8. Install the driveshaft by aligning the matchmarks. 9. Check the companion flange run-out: maximum allowable run-out is 0.003 in. (0.10mm). 10. Stake the pinion flange nut. 11. Refill the differential with oil.

HIGHLANDER AND RX300 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the differential oil. 3. Remove or disconnect the following:

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e Front bearing e Spacer To install: 4. Install or connect the following e New spacer e Bearing e Slinger e New seal

STEERING AND SUSPENSION

Gear

>: CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components,

the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands and ensure that the bag and trim cover are pointed way. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING To avoid personal injury when working on vehicles equipped with an air bag, the negative battery cable must be disconnected and at least 90 seconds must elapse before working on the system. Failure to do so may result in deployment of the air bag.

REMOVAL & INSTALLATION RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable.

> CAUTION To avoid personal injury when working on air bag equipped vehicles, work must be started after 90 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative battery terminal is disconnected. If the air bag system is disconnected with the ignition switch at the ON or ACC, diagnostic codes will be set. When removing the air bag, take care not to pull the air bag wiring harness. When carrying the wheel pad, carry it with the upper surface facing away. When storing it, keep the upper surface of the pad facing upward. 3. Turn the key to the LOCK position and lock the steering wheel in place. 4. Place a drain pan under the steering rack. 5. Remove or disconnect the following: Front wheels Right and left-hand engine undercovers Right and left-hand tie rod ends from the steering knuckle Front exhaust pipe Sway bar with the links 6. Disconnect the No. 2 intermediate shaft from the rack and pinion, as follows: a. Loosen the top bolt. b. Remove the lower bolt holding the

Seal installation depth: 2.0mm +/0.3mm

e Companion flange e New nut. Coat the threads with

clean differential oil. Torque the nut to 80 ft. Ibs. (108Nm). 5. The remainder of installation is the reverse of removal.

7 No. 2 intermediate shaft to the rack and pinion. . c. Shift the No. 2 intermediate shaft and place matchmarks on the control valve shaft and the No. 2 intermediate shaft. d. Disconnect the No. 2 shaft from the rack and pinion. 7. Install or connect the following: e Pressure feed and return tubes from the rack and pinion, using a line wrench e Pressure feed and return tube clamps, by removing the bolt e Right and left lower control arms, from the steering knuckle 8. Remove the front suspension crossmember assembly, as follows: Both centermember set nuts, holding the centermember to the middle of the crossmember. Both rack and pinion assembly set bolts and nuts from the crossmember. Securely suspend the steering gear assembly. Support the suspension crossmember with a jack. Both bolts from the suspension crossmember Suspension crossmember with the lower Suspension arms 9. Remove the rack and pinion. To install: 10. Install or connect the following: e Rack and pinion 11. Install the crossmember to the vehicle, as follows: ¢ Suspension crossmember with the lower control arms. Tighten both bolts to 152 ft. Ibs. (206 Nm). e Rack and pinion. Tighten the nuts/bolts to 83 ft. Ibs. (113 Nm). ¢ Centermember to the crossmember. Tighten both set nuts to 82 ft. Ibs. (112 Nm). 12. Install or connect the following: ¢ Right and left lower control arms

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e Right and left-hand engine under- | covers

e Pressure feed and return tubes clamps Pressure feed and return tubes to the rack and pinion. Tighten the tubes to 26 ft. Ibs. (36 Nm), using a torque wrench with a fulcrum length of 11.81 inches (300mm).

e Front wheels 13. Fill the power steering unit and bleed the system. Check for leaks. 14. Check and/or adjust the front wheel alignment.

¢ Steering column No. 2 intermediate

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Highlander

the marks and tighten the upper and lower pinch bolts to 26 ft. Ibs. (35 Nm). Stabilizer bar links. Tighten the nuts to 22 ft. Ibs. (29 Nm). Front exhaust pipe with new gaskets. Tighten the bolts to 35 ft. Ibs. (48 Nm) and the nuts to 46 ft. Ibs. (62 Nm). Right and left-hand tie rod ends to the steering knuckle. Tighten the nuts to 36 ft. Ibs. (49 Nm) and install new cotter pins.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e>Wait at least 90 seconds before working on the vehicle to allow the | Supplemental Restraint System (SRS) system to disarm.

f>Matchmark the shaft and gear. .

° Stabilizer bar end links — e Pressure and return lines e Steering gear e Installation is the reverse of removal. Observe the following torques: 1 te e Rack mounting bolts: 52 ft. Ibs. (70Nm) ; e Stabilizer bar end links: 55 ft. Ibs. (74Nm) 7 e Intermediate shaft bolt: 26 ft. Ibs. ~ (35Nm) e Tie rod end nuts: 36 ft. Ibs. (49Nm)

RX 300 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: _e Negative battery cable

e Steering wheel e Front wheels e Tie rod ends e Intermediate shaft

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Exploded view of the power steering gear and related compenents—RX 300 models

TOYOTA AND LEXUS 25-93

RAV4 ¢ 4RUNNER @ HIGHLANDER e>Wait at least 90 seconds before working on the vehicle to allow the Supplemental Restraint System (SRS) system to disarm.

e Right and left side fender apron seals -e Right and left tie rod ends 3. Place matchmarks on the intermediate shaft. 4. Remove or disconnect the following: Pinch bolt and the intermediate shaft out from under the vehicle Power steering line clamp Pressure and feed lines Stabilizer bar, unbolt it but do not remove it Heated Oxygen (HOz) sensor Both gear assembly set bolts and nuts, by lifting the stabilizer bar Gear assembly from the left side of the vehicle To install: 5. Install or connect the following: e Gear assembly to the left side of the vehicle

*: WARNING Be careful not to damage the power steering lines. Tighten the gear assembly set bolts and nuts to 134 ft. Ibs. (181 Nm), by lifting the stabilizer bar

HOzsensor Stabilizer bar. Tighten the bolt to 14 ft. Ibs. (19 Nm) and the nut to 29 ft. lbs. (39 Nm). Pressure and feed return lines. Tighten them to 18 ft. Ibs. (25 Nm). Line clamps. Tighten the nut to 84 inch Ibs. (10 Nm). Intermediate shaft, by aligning the joint and main shaft matchmarks. Tighten to 26 ft. Ibs. (5 Nm). Tie rod ends Fender apron seals. Securely tighten the bolts. 6. Remove or disconnect the following: e Steering wheel pad e Steering wheel 7. Position the front wheels facing straight-ahead. Do this with the front of the vehicle on jackstands. 8. Center the spiral cable. 9. Install the steering wheel at the straight-ahead position. Temporarily tighten the wheel set nut. Attach the wiring. 10. Bleed the power steering system. 11. Check the steering wheel center

point. Tighten the steering nut to 26 ft. Ibs.

(35 Nm). 12. Check and/or adjust the front wheel alignment. 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Right and left tie rod ends from the knuckle Intermediate shaft from the steering rack, by matchmarking it Pressure feed and the return tubes, using SST 09631-22020 Mount bracket and the grommet, from the power steering rack

assembly

¢ Power steering rack and pinion To install: 3. Install or connect the following: ¢ Power steering rack and pinion. Tighten the mounting bolts to 65 ft. lbs. (88 Nm). e Grommet and mount bracket to the gear assembly. Tighten the bolts to 65 ft. Ibs. (88 Nm). e New O-ring e Pressure feed and return tubes. Tighten the line fittings to 14 ft. Ibs. (19 Nm). e |ntermediate shaft to the steering rack, by aligning the matchmarks e>lf installing a new rack assembly, be sure the steering wheel and the rack are centered.

e Right and left tie rod ends. Tighten nuts to 67 ft. Ibs. (90 Nm). e New cotter pins e Negative battery cable 4. Check the steering wheel center point. 5. Check the fluid level and bleed the power steering system. 6. Check the front wheel alignment.

Shock Absorber

REMOVAL & INSTALLATION RAV4 REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

RX300

.

2. Remove the rear wheel. 3. Support the No. 1 control arm with a floor jack. 4. Remove or disconnect the following: e Suspension cap from inside the vehicle e Both upper shock absorber nuts, retainers and cushion e Shock absorber from the lower control arm by removing the bolt and 2 retainers e Shock absorber To install: 5. Install or connect the following: Shock absorber Shock absorber to the lower control arm retainers. Tighten the bolt to 27 ft. Ibs. (37 Nm). Shock absorber to the chassis cushion and retainers. Tighten both nuts to 18 ft. Ibs. (25 Nm). Suspension cap Wheel 4Runner

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Shock from the lower control arm e 3 upper nuts e Shock absorber To install: 3. Install or connect the following: e Shock absorber. Tighten the 3 nuts to 47 ft. Ibs. (64 Nm). e Lower shock-to-lower control arm. Tighten the bolt to 101 ft. Ibs. (135 Nm). e Wheels 4. Check the vehicle alignment.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Lower the floor jack to take tension off of the spring. 4. Remove or disconnect the following: e Shock absorber from the rear axle housing e Nut, retainers and the cushions holding the shock absorber to the frame e Shock absorber with the washers and bushings

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To install: 5. Install the shock absorber to the frame with the washers and bushings. 6. Tighten the shock absorber-to-frame nut to the following values: e 4Runner models: 14 ft. Ibs. (20 Nm) 7. Connect the shock absorber to the rear axle housing. Tighten the bolt to the following specifications: e 4Runner models: 47 ft. Ibs. (64 Nm) 8. Install the wheels.

REMOVAL & INSTALLATION RAV4 RAV4 is equipped with front strut and rear shock absorber type suspension arrangement. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Wheel ->Do not support the weight of the vehicle on the suspension arm. e Brake hose from the strut

e Anti-lock Brake System (ABS) electrical connection to the strut bolt, if equipped eit is not necessary to disconnect the brake hose from the brake caliper.

e Strut from the steering knuckle e Suspension support bracket from the top of the strut tower e Strut To install: 3. Install or connect the following: Suspension support bracket to the top of the strut tower Strut to the strut tower. Tighten the 3 nuts to 59 ft. Ibs. (80 Nm). Steering knuckle to the strut lower bracket. Tighten the nuts to 117 ft. lbs. (158 Nm). ABS electrical connector to the strut. Tighten the bolt to 48 inch lbs. (5.4 Nm). Brake line to the strut. Tighten the bolt to 14 ft. Ibs. (19 Nm). 4. If the brake lines were opened, add brake fluid and bleed the brake system. 5. Install or connect the following: e Wheel e Negative battery cable

i 6. Check and/or adjust the front wheel alignment. Highlander

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e>Do not support the weight of the vehicle on the suspension arm; the arm will deform under its weight.

2. Remove or disconnect the following: e Wheel e Stabilizer bar link Brake hose and the Anti-lock Brake

System (ABS) speed sensor wire from the strut Strut lower end from the steering knuckle lower arm e 3 upper strut mounting plate-toupper wheel arch nuts e Strut To install: 3. Install or connect the following: e Tighten the 3 suspension supportto-wheel arch nuts to 59 ft. Ibs. (80 Nm). e Tighten the strut-to-steering knuckle arm bolts to 155 ft. Ibs. (210 Nm). e Sway bar link to the strut. Tighten the nut to 55 ft. Ibs. (74 Nm). e ABS speed sensor and the brake hose to the strut, if equipped e Wheel 4. Check and/or adjust the front wheel alignment.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ->Do not support the weight of the vehicle on the suspension arm; the arm will deform under its weight.

2. Remove or disconnect the following: e Wheel e Brake hose and the Anti-lock Brake System (ABS) speed sensor wire from the strut ¢ Sway bar link from the strut 3. Loosen, but do not remove the 2 lower bolts. 4. Support the axle carrier with a jack and remove cap. 5. If the strut is being disassembled, loosen the center nut. 6. Remove the 3 mounting nuts. 7. Lower the carrier and remove the 2 lower nuts and bolts.

8. Installation is the reverse of removal. Observe the following torques: e 3 mounting nuts: 29 ft. bs. (39Nm)

e 2 lower nuts: 188 ft. Ibs. (255Nm) e Center nut: 36 ft. Ibs. (49Nm) e Stabilizer link: 29 ft. Ibs. (39Nm)

RX 300 FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ->Do not support the weight of the vehicle on the suspension arm; the arm will deform under its weight.

2. Remove or disconnect the following: e Wheel e Brake hose and the Anti-lock Brake System (ABS) speed sensor wire from the strut e Sway bar link from the strut 3. Matchmark on the strut lower bracket and camber adjust cam, if equipped. 4. Remove or disconnect the following: e Strut lower end from the steering knuckle lower arm e 3 upper strut mounting plate-toupper wheel arch nuts e Strut To install: 5. Align the upper suspension support hole with the strut piston or end, so they fit properly. 6. Install or connect the following: e Strut piston rod end to the upper suspension support. Tighten the new nut to 29-40 ft. Ibs. (39-54 Nm). ->Do not use an impact wrench to tighten the nut.

e Lubricate the suspension support bearing with multi-purpose grease. ¢ Pack the upper support space with multi-purpose grease, also, after installation. Tighten the 3 suspension supportto-wheel arch nuts to 47 ft. Ibs. (64 Nm). Tighten the strut-to-steering knuckle arm bolts to 156 ft. Ibs. (211 Nm). Sway bar link to the strut. Tighten the nut to 29 ft. Ibs. (39 Nm). ABS speed sensor and the brake hose to the strut, if equipped e Wheel 7. Check and/or adjust the front wheel alignment.

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Strut assembly exploded view—RAV4

Timing belt service is covered in Section 3 of this manual

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TOYOTA AND LEXUS

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_ RAV4 ¢ 4RUNNER ¢ HIGHLANDER ¢ RX300 we

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° Anti-lock Brake System (ABS) sensor from the strut bracket

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e Flexible brake hose from the strut e Sway bar link from the strut e Loosen the 2lower strut mounting

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4. Remove or disconnect the following: ¢ 3 upper strut mounting nuts

the rear axle * Strut, by lower To install: 5. Install or connect the following:

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Spring Bumper

Coil Spring

Lower insulator

Stabilizer Bar Link

ABS Speed Sensor Wire Harness

ABS Speed Sensor Wire Harness

N-m (kgf-cm, ft-lbf)

|: Specified torque

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e Axle carrier by aligning the 3 upper mounting studs. Tighten the nuts to 29 ft. Ibs. (39 Nm). 6. Lower the axle carrier. 7. Install or connect the following: e Tighten, both lower mounting bolts to 188 ft. Ibs. (255 Nm). ¢ Sway bar link. Tighten the nut to 29 ft. Ibs. (39 Nm). Flexible brake hose and the ABS sensor to the strut Rear wheels and the deck side cover . Negative battery cable

=:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e>lf equipped, be careful not to damage the oil seal, driveshaft boot and/or seed sensor rotor when removing the steering knuckle.

e Shock absorber (strut assembly) 3. Install a nut/bolt to the bracket at the lower portion of the strut assembly and secure it in a vise. 4. Compress the coil spring with a spring compressor.

The proper tools must be used for this procedure. The spring on the Strut.is under high pressure and can cause Serious injury if not properly removed and installed.

5. Remove or disconnect the follow-

ing: e Center retaining nut, by holding the spring seat e Support, dust seal, spring seat, insulator and spring from the strut assembly To install: 6. Install the spring bumper and lower insulatortothe strut assembly. 7. Compress the coil spring and fit the lower end of the spring into the spring seat ap. : "3 Install or connect the following: ¢ Upper insulator, spring seat, dust seal, support and spring seat. Tighten the new retaining nut to 34 ft. Ibs. (47 Nm) for the RAV4 and

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TOYOTA AND LEXUS 95- 97

RAV4 e 4RUNNER © HIGHLAND *ER RX300

RX300; 36 ft. Ibs. (49Nm) for the Highlander; 18 ft. Ibs. (25Nm) for the 4Runner. ¢ Strut “e Wheel 9. If required, bleed the brake system and check for leaks. 10. Check and/or adjust the front wheel alignment.

REMOVAL & INSTALLATION e>For vehicles with MacPherson struts, see Strut Overhaul in this section.

STRUT OVERHAUL

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Rear

RAV4 i Belore servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Axle shaft, if equipped with 2WD Halfshaft, if equipped with 4WD Brake drum Both brake line clamp bolts Parking brake cable clamp bolt Anti-lock Brake System (ABS) speed sensor and wiring harness, if equipped with ABS Rear axle hub with the brake, by removing the 4 bolts 3. Support the hub securely. 4, Support the control arm with a floor jack. 5. Remove or disconnect the following: e Shock absorber from the control arm, by removing the bolt The control arm must be supported before removing the bolt for the shock absorber. Leave the floor jack under the control arm. Later, the floor jack will be lowered to remove the coi! spring.

e Cotter pins and nuts by supporting the lower and upper suspension arms 6. Disconnect the upper and lower control arms from the control arm, using tool 09628-62011 7. Remove the coil spring and control arm, as follows: e Matchmark the toe adjust cam and body.

¢ Coil spring and upper insulator, by loosening the bolt and lowering the — control arm. ¢ Bolt, toe-adjust cam, 2 attachments, nut and control arm ¢ Bolt and spring bumper To install: 8. Install or connect the following: e Spring bumper. Tighten the bolt to 108 inch Ibs. (13 Nm). ¢ Control arm, 2 attachments, toeadjust cam, bolt and nut; do not tighten the bolt at this time e Spring and upper insulator 9. Raise the control arm with a floor jack. 10. Install or connect the following: Upper and lower suspension arms to the control arm. Tighten the nuts to 76 ft. Ibs. (103 Nm). New cotter pins Sock absorber to the control arm. Tighten the bolt to 27 ft. Ibs. (37 Nm). Rear axle hub with the brake. Tighten the 4 bolts to 59 ft. Ibs. (80 Nm). ABS speed sensor and wiring harness, if equipped. Tighten the ABS speed sensor to 69 inch Ibs. (8 Nm) and the wiring harness to 108 inch lbs. (13 Nm). Parking brake cable clamp. Tighten the bolt to 14 ft. Ibs. (19 Nm). Both brake line cable clamps. Tighten the bracket bolt to 13 ft. lbs. (18 Nm) and the clamp bolt to 108 inch Ibs. (13 Nm). Brake drum Rear halfshaft, if equipped with 4WD Axle shaft, if equipped with 2WD Rear wheel 11. Lower the rear of the vehicle and stabilize the Suspension. 12. Install or connect the following: e Align the matchmarks to the toeadjust cam. Tighten the bolt to 98 ft. Ibs. (132 Nm). e Negative battery cable 13. Check and/or adjust the wheel alignment

4RUNNER 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel assemblies. 3. Support the axle housing with a floor jack.

Heater Core replacement is covered in Section 2 of this manual

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25-98 TOYOTA AND LEXUS

RAV4 ¢ 4RUNNER ¢ HIGHLANDER @ RX300 —

4. Remove or disconnect the following: e Brake drum e Parking brake cable from the brake shoe e Parking brake cable from the axle housing. 5. Place matchmarks on the flanges for the driveshaft and differential. 6. Remove or disconnect the following: Driveshaft from the differential Brake hose line from the brake hose Brake hose-to-brake bracket clip Brake hose from the body Anti-lock Brake System (ABS) wiring harness bracket, if equipped with ABS Shock absorbers from the axle housing Lateral control rod nuts/bolts Control rod from the suspension Coil spring, by lower the rear axle housing To install: 7. Install or connect the following: e Coil springs into position and raise the axle housing.

>: CAUTION

Be sure to fit the lower end of the coil Spring into the gap of the spring seat on the lower control arm. Lateral control rod to the suspension. Tighten the bolts/nuts to 64 ft. Ibs. (86 Nm). Shock absorbers to the axle housing. Tighten the bolt to 47 ft. Ibs. (64 Nm). ABS wiring harness bracket, if equipped Brake hose to the bracket

Clip Brake line to the brake hose. Tighten the tube. Parking brake cable bracket to the axle housing. Tighten to 108 inch lbs. (13 Nm). Parking brake cable to the brake shoes Driveshaft to the differential, by aligning the matchmarks. Tighten bolts/nuts to 54 ft. Ibs. (73 Nm). 8. Fill the differential with the proper amount and type of oil. 9. Install the brake drum. 10. Bleed the brake system. 11. Install the wheel assemblies. 12. Lower the vehicle and bounce the vehicle several times to stabilize the suspension.

ness clamp to the steering knuckle, if equipped. Tighten the bolts to 72 inch Ibs. (8 Nm). Halfshaft, if disconnected. Tighten the nut to 174 ft. Ibs. (235 Nm). Grease cap Strut Front wheel 8. Check the alignment

13. Tighten the lower control arm to 107 ft. Ibs. (145 Nm). Upper Ball Joint

REMOVAL & INSTALLATION 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheels e Strut assembly e Grease cap 3. lf equipped with 4WD, disconnect the halfshaft, as follows: e Cotter pin and lockcap e Locknut, while applying the brakes 4, Remove or disconnect the following: e Anti-lock Brake System (ABS) speed sensor and wiring harness clamp from the steering knuckle, if equipped with ABS e Brake line bracket from the steering knuckle e Front brake caliper and the rotor e Lower ball joint 5. Remove the steering knuckle with the axle hub, as follows: Cotter pin and loosen the nut Steering knuckle from the upper control arm, using SST 0995040010 Steering knuckle Upper ball joint Wire and the boot Snapring Upper ball joint, using SST 0995040010 and a deep socket wrench. To install: 6. Install the upper ball joint, as follows: e New ball joint with a new snapring ¢ New boot secured with a new wire 7. Install or connect the following: Steering knuckle with the axle hub to the upper control arm. Tighten the nut to 80 ft. Ibs. (108 Nm). New cotter pin Lower ball joint. Tighten the 4 bolts to 59 ft. Ibs. (80 Nm). Rotor and caliper. Tighten the caliper bolts to 90 ft. Ibs. (123 Nm). Brake line bracket to the steering knuckle. Tighten it to 21 ft. Ibs. (28 Nm). ABS speed sensor and wiring har-

Lower Ball Joint ~

REMOVAL & INSTALLATION RAV4 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Front wheel(s) Steering knuckle with the axle hub Dust deflector, by prying it from the knuckle Cotter pin and nut from the ball joint stud Lower ball joint from the steering knuckle, using a 2-jaw puller To install: 3. Install or connect the following: e Lower ball joint onto the steering knuckle. Tighten nut to 94 ft. Ibs. (127 Nm). New cotter pin ABS speed sensor, by aligning it the dust deflector hole New dust deflector, using a driver Steering knuckle and hub Front wheel(s) Negative battery cable

79242681

Use a 2-jaw puller to remove the lower

ball joint—RAV4

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

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TOYOTA AND LEXUS RAV4 ¢ 4RUNNER e HIGHLANDER e RX300

2. Remove or disconnect the following: e Wheel e Hub nut ¢ Caliper and rotor ¢ Lower control arm from the ball joint ¢ Tie rod end e Halfshaft e Ball joint from the knuckle 3. Installation is the reverse of removal. Observe the following torques: e Ball stud nut: 90 ft. Ibs. (123Nm) e Lower arm-to-ball joint: 94 ft. Ibs. (127Nm) Tie rod end: 36 ft. Ibs. (49Nm)

To install: 5. Install or connect the following: e Lower ball joint to the lower control arm. Tighten the 4 bolts to 59 ft. lbs. (80 Nm). e Nut. Tighten it to 105 ft. Ibs. (142 Nm). e Tie rod end to the steering knuckle. Tighten the nut to 66 ft. Ibs. (90 Nm). e Wheel

Upper Control Arm

ave

REMOVAL & INSTALLATION

RX300 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Steering knuckle with the axle hub e Dust deflector, by prying it from the knuckle: e Cotter pin and nut from the ball joint e Ball joint from the steering knuckle, by removing the 2 bolts e Lower ball joint, using a Ball Joint Separator tool 09628-62011 To install: 3. Install or connect the following: e Lower ball joint. Tighten the nut to 76 ft. Ibs. (103 Nm) and both bolts to 94 ft. Ibs. (127 Nm). e New cotter pin e Wheel 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Disconnect the tie rod end, as follows: e Loosen the 4 bolts ¢ Cotter pin and nut from the tie rod end e Tie rod end from the steering knuckle, using SST 09610-20012 4. Remove the lower ball joint, as follows: ¢ Cotter pin and the nut from the lower ball joint e Lower ball joint from the lower suspension arm e Lower ball joint

4Runner

4wD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Shock and coil spring assembly e Anti-lock Brake System (ABS) speed sensor wire harness clamp 3. Disconnect the upper ball joint, as follows: e Cotter pins and loosen the nut e Upper ball joint from the control arm, using a ball joint separator e Support the steering knuckle e Nut 4. Detach the control arm, by removing the nut, bolt, washers and lowering the arm. To install: 5. Install or connect the following: e Upper control arm with the washer, bolt and nut. Tighten the nut to 87 ft. Ibs. (115 Nm). e Upper ball joint to the control arm. Tighten the mounting nut to 80 ft. lbs. (105 Nm). e New cotter pin e ABS speed sensor wire harness clamp. Tighten it to 71 inch Ibs. (8 Nm ® Shock and coil spring assembly 6. Check and/or adjust the alignment.

(eo) tia e re 29-9

2. Remove the upper control arm from the vehicle. 3. Pry up the bushing flange, using a chisel and a hammer. 4. Using tools 09613-26010, 0961320060 and 09950-00020 and a shop press, remove the bushing. To install: 5, Using tools 09223-00010, 0950635010 and a shop press, press the new bushing into the upper control arm. 6. Install the upper control arm to the ety Torque the nuts to 87 ft. Ibs. (115 m). 7. Check and/or adjust the alignment.

Lower Control Arm

REMOVAL & INSTALLATION 4Runner

2WD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Steering gear assembly e Stabilizer bar link e Shock absorber from the lower control arm 3. Support the upper control arm and the steering knuckle securely. 4. Remove or disconnect the following: e Cotter pin and nut from the lower

CONTROL ARM BUSHING REPLACEMENT 4Runner

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

Brake service is covered in Section 4 of this manual

ball joint

.

e Lower ball joint from the control

arm ¢ Bolts, nuts, adjusting cams and lower control arm, by placing matchmarks on the front and rear adjusting cams e 2 spring bumpers, using tool SST 09922-10010 To install: 5. Install or connect the following: e 2 spring bumpers. Tighten the spring bumpers to 17 ft. Ibs. (23 Nm). e Lower control arm and adjusting cams. Tighten the nuts and bolts to 96 ft. Ibs. (130 Nm), e Lower ball joint to the control arm e Cotter pin and nut to the lower ball joint. Tighten the nut to 105 ft. Ibs. (142 Nm).

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Lower Suspension Arm

Apply multi-purpose grease to the oil seal lip.

* Hub into the steering knuckle e New inner oil seal, using a seal driver Apply multi-purpose grease to the oil seal lip.

Lower ball joint to the steering knuckle. Tighten the nut to 94 ft. lbs. (127 Nm). New cotter pin Dust deflector, by aligning it with

the ABS’speed sensor hole Knuckleto the lower strut and install the bolts Lower ball joint to the lower arm. Tighten the bolts to 94 ft. Ibs. (127 Nm). Tie rod end to the steering knuckle. Tighten the nut to 36 ft. Ibs. (49 Nm). Halfshaft to the hub and knuckle Tighten the lower strut nuts to 117 ft. Ibs. (158 Nm). ABS speed sensor. Tighten the bolt to 69 inch Ibs. (8 Nm). Rotor to the hub, by aligning the matchmark Brake caliper. Tighten the mounting bolts to 79 ft. Ibs. (107 Nm). Axle locknut, using an assistant to apply the brakes. Tighten the nut to 159 ft. Ibs. (216 Nm). Lockcap and a new cotter pin e Wheel e Negative battery cable 11. Turn the wheel by hand, verify that the wheel turns without noise and without binding. 12. Check the signal from the ABS senSor.

REAR The wheel bearings are not replaceable. If the bearing has failed, replace the hub/bear-

ing assembly. See the Halfshaft Removal and Installation procedure. Highlander

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

2. Remove the hub/knuckle assembly. See the Halfshaft Removal and Installation procedure. Mount the assembly in a vise. 3. Remove or disconnect the following: e Dust deflector e Snapring e Hub from the spindle and mount the hub in a vise. e Dust cover 4. Press out the bearings, inner bearing first. is 5. Press in the new bearings. 6. Installation is the reverse of removal.

REAR The wheel bearings are not replaceable. If the bearing has failed, replace the hub/bearing assembly. See the Halfshaft Removal and Installation procedure.

RX 300 The front wheel bearings and 4wd rear wheel bearings are serviced as a unit with the hub and are not replaceable. See the Halfshaft Removal and Installation procedure.

REAR WITH 2WD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Brake drum, if equipped 3. If equipped with disk brakes, remove the following: e Flexible brake hose from the rear strut assembly e Brake caliper and support it on using wire e Brake rotor 4. Remove or disconnect the following: e Anti-lock Brake System (ABS) Speed sensor connector e 4rear axle hub assembly nuts e Hub assembly To install: 5. Install or connect the following:

¢ New hub assembly. Tighten the nuts to 59 ft. Ibs. (80 Nm). e ABS speed sensor 6. If equipped with disc brakes, install the following: e Brake rotor e Brake caliper. Tighten the mounting bolts to 34 ft. Ibs. (47 Nm). Flexible brake hose to the rear strut assembly. Tighten the mounting bolt to 21 ft. Ibs. (29 Nm). 7. Install or connect the following: e Brake drum, if equipped e Wheels 8. Test drive the vehicle. 4Runner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheels e Shock absorber e Grease ca 3. On 4WD, remove the halfshaft, as follows: ¢ Cotter pin and lockcap e Locknut, while applying the brakes 4, Remove or disconnect the following: e Anti-lock Brake System (ABS) speed sensor and wiring harness clamp from the steering knuckle, if equipped with ABS e Brake line bracket from the steering knuckle e Front brake caliper and rotor ¢ 4 bolts and the lower ball joint 5. Remove the steering knuckle with the axle hub, as follows: e Cotter pin and Joosen the nut . e Steering knuckle, using SST 09950-40010 6. Clamp the axle hub in a soft jaw vise. 7. Remove or disconnect the following: Grease cap, for 2WD Inside oil seal, for 4WD 4 bolts and shift the brake dust cover towards the hub side Axle hub from the steering knuckle, using SST 09710-30021 Bearing spacer and Anti-lock Brake System (ABS) speed sensor rotor/spacer Oil seal (outside) from the steering knuckle, using a flat pry bar 8. Remove the bearing from the steering knuckle, as follows:

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

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TOYOTA AND LEXUS _

-LAND CRUISER*SEQUOIA ¢ Lxa70_

Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle:

e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precau-

tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged con-

tact with used engine oil may cause a

number of skin disorders, including can-

cer. You should make every effort to minimize your exposure to used engine oil.

Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. e NEVER disconnect the negative battery cable with the ignition ON or the engine running. Removing power from the computer control module with the ignition ON may destroy the module. e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You

ey ->Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor

All models are equipped with a distibuforless ignition system.

should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e Timing belt maintenance is extremely

important. Many models utilize an interfer-

ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. e Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR Alternator

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable e Accessory drive belt

e Engine under cover Radiator Power steering pump pulley Alternator harness connectors Alternator

INSTALLATION 1. Install or connect the following: e Alternator. Tighten the fasteners to

29 ft. Ibs. (39 Nm).

‘

TOYOTA AND LEXUS LAND CRUISER e SEQUOIA e LX470

e Alternator harness connectors ° Power steering pump le e Radiator e Engine under cover ¢ Accessory drive belt e Negative battery cable 2. Fill the cooling system.

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e A/C compressor e Power steering pump 6. Attach a hoist to the engine lifting eyes.

- 3. Start the engine and check for leaks. laniiian Tin

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ADJUSTMENT

7. Remove or disconnect the following: e Transfer case skid plate e Left and right motor mounts

e Transmission mount crossmember

All engines are equipped with a Distributorless Ignition System (DIS). No timing adjustment is possible.

Engine Assembly

Transmission shift lever assembly Transfer case shift lever and rod Exhaust front pipes Stabilizer bar Front and rear driveshafts

an

REMOVAL & INSTALLATION Sequoia 1. Before servicing the vehicle, refer to the precautions: in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling System. 4. Drain the engine oil. 5. Remove or disconnect the following: Battery and tray Hood Engine appearance cover Air intake pipe Engine under covers Coolant recovery tank Radiator hoses. Radiator and fan shroud Accessory drive belt Cooling fan and pulley Powertrain Control Module (PCM) harness connectors and pass the wiring harness through the firewall Accelerator cable Power steering vacuum hoses Alternator harness connectors Heater hoses Engine control wiring harness and grommet at the firewall Ground cable connector Fuel lines Evaporative Emissions (EVAP) canister hoses Wire clamp at right inner fender Negative battery cable at the relay box and right inner fender Positive battery cable Center console

8. Attach a hoist to the engine lifting eyes and raise the powertrain out of the

vehicle. To install: 9. Lower the powertrain into the vehicle. 10. Install or connect the following: e ransmission mount crossmember. Tighten the bolts to 37 ft. Ibs. (50 Nm) and the nuts to 59ft. Ibs. (74 Nm). Transfer case skid plate Left and right motor mounts. Tighten the fasteners to 22 ft. Ibs. (30 Nm). Power steering pump. Tighten the bolts to 13 ft. Ibs. (17 Nm). A/C compressor. Tighten the bolts

to 36 ft. Ibs. (49 Nm). Front driveshaft. Tighten the fasteners to 59 ft. Ibs. (80 Nm). Rear driveshaft. Tighten the fasteners to 78 ft. Ibs. (106 Nm). Stabilizer bar. Tighten the bracket bolts to 13 ft. Ibs. (18 Nm) and the link nuts to 18 ft. Ibs. (25 Nm), Exhaust front pipes Transfer case shift lever and rod Transmission shift lever assembly Center console Positive battery cable Negative battery cable at the relay

box and right inner fender Wire clamp at right inner fender EVAP canister hoses Fuel lines Ground cable connector Engine control wiring harness and grommet at the firewall Heater hoses Alternator harness connectors Power steering vacuum hoses Accelerator cable PCM harness connectors Cooling fan and pulley Accessory drive belt

e e ¢ e e e e e

Radiator and fan shroud Radiator hoses Coolant recovery tank Engine under covers Air intake pipe Engine appearance cover Hood Battery and tray 11. Fill the crankcase to the correct level. 12. Fill the cooling system. 13. Start the engine and check for leaks. Land Cruiser and LX470

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Remove or disconnect the following: Battery and tray Hood Engine appearance cover Air intake pipe Engine under covers Coolant recovery tank Radiator hoses Radiator and fan shroud Accessory drive belt Cooling fan and pulley Powertrain Control Module (PCM) harness connectors and pass the wiring harness through the firewall Accelerator cable Power steering vacuum hoses Alternator harness connectors Heater hoses Engine control wiring harness and grommet at the firewall Ground cable connector Fuel lines Evaporative Emissions (EVAP) canister hoses Wire clamp at right inner fender Negative battery cable at the relay box and right inner fender Positive battery cable Center console Transmission shift lever assembly Transfer case shift lever and rod Exhaust front pipes Stabilizer bar Front and rear driveshafts A/C compressor Power steering pump 6. Attach a hoist to the engine lifting eyes. 7. Remove or disconnect the following:

For complete service labor times, order the Chilton Labor Guide

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TOYOTA AND LEXUS LAND CRUISER ¢ SEQUOIA ¢ LX470

e Transfer case skid plate Left and right motor mounts Transmission mount crossmember

8. Attach a hoist to the engine lifting ‘eyes and raise the powertrain out of the vehicle.

To install: 9. Lower the powertrain into the vehicle.

10. Install or connect the following: Transmission mount crossmember. Tighten the bolts to 37 ft. Ibs. (50 Nm) and the nuts to 55 ft. Ibs. (74 Nm). Transfer case skid plate Left and right motor mounts. Tighten the fasteners to 22 ft. Ibs.

(30 Nm).

1. Before servicing the vehicle, referto the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Timing belt. Refer to the Timing Belt unit repair section. e No. 2 idler pulley

To install: 4. Install or connect the following: Water pump. Use a new gasket and tighten the bolts to 15 ft. Ibs. (21 Nm). Tighten the stud bolt and nut to 13 ft. Ibs. (18 Nm). Water inlet housing assembly. Use a new O-ring and apply sealant as shown. Tighten the bolts to 13 ft. lbs. (18 Nm). e Bypass hose e Radiator hose ¢ No. 2idler pulley ° Timing belt

e Radiator hose ° Bypass hose ¢ Water inlet housing assembly

¢ Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

Water Pump

REMOVAL & INSTALLATION

e Water pump

Power steering pump. Tighten the bolts to 13 ft. Ibs. (17 Nm). A/C compressor. Tighten the bolts to 36 ft. Ibs. (49 Nm). Front driveshaft. Tighten the fasteners to 59 ft. Ibs. (80 Nm). Rear driveshaft. Tighten the fasteners to 78 ft. Ibs. (106 Nm). Stabilizer bar. Tighten the bracket bolts to 13 ft. Ibs. (18 Nm) and the link nuts to 18 ft. Ibs. (25 Nm). Exhaust front pipes Transfer case shift lever and rod Transmission shift lever assembly

Center console Positive battery cable Negative battery cable at the relay box and right inner fender Wire clamp at right inner fender EVAP canister hoses Fuel lines Ground cable connector Engine control wiring harness and grommet at the firewall Heater hoses Alternator harness connectors Power steering vacuum hoses Accelerator cable PCM harness connectors Cooling fan and pulley Accessory drive belt Radiator and fan shroud Radiator hoses Coolant recovery tank Engine under covers Air intake pipe Engine appearance cover Hood Battery and tray

7924SG40

Water inlet housing attaching bolts

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ALG. Resins

11. Fill the crankcase to the correct level.

12. Fill the cooling system. 13. Start the engine and check for leaks.

79248641

Water pump mounting bolts, stud bolts and nut locations

26-5

TOYOTA AND LEXUS

LAND CRUISER © SEQUOIA © LX470

Seal Width 2-3mm

7924SG42

Rear timing belt covers Fuel lines Intake manifold Water inlet housing assembly Front and rear water bypass joints Engine lifting eyes Oil dipstick tube Valve covers Camshafts Cylinder heads with the exhaust manifolds attached. Loosen the bolts in the sequence shown. To install: 5. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows: a. Step 1: 24 ft. Ibs. (32 Nm) b. Step 2: Plus 180 degrees 6. Install or connect the following: e Camshafts e Valve covers Oil dipstick tube Engine lifting eyes Front and rear water bypass joints Water inlet housing assembly Intake manifold Fuel lines Rear timing belt covers Ignition coils

Water inlet housing sealant application &

Accessory drive belt A/C compressor and bracket

Cylinder Head

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4, Remove or disconnect the following: e Battery and tray e Engine appearance cover e Engine under covers e Air intake assembly

Cooling fan and bracket Radiator Idler pulley Front covers Timing belt. Refer to the Timing Belt unit repair section. Camshaft sprockets Camshaft Position (CMP) sensor Power steering pump Exhaust front pipes Transmission dipstick tube Ignition coils

Transmission dipstick tube Exhaust front pipes Power steering pump CMP sensor Camshaft sprockets Timing belt

RH Cylinder Head

RH Cylinder Head

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79248646

79245647

79245643

Cylinder head loosening sequence

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LH Cylinder Head

Front ex, 10 5 3 y

Cylinder head gasket identification

Cylinder head torque sequence

Please visit our web site at www.chiltonsonline.com

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TOvOTA AND Lexus

96-6

LX470 SEQUOIA ©R LAND CRU*ISE

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Spark Plug

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LH Cylinder Head

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Be careful not to damage the brake tube.

e Brake caliper and disc 3. Support the steering knuckle 4. Remove or disconnect the following: ¢ 4 lower ball joint-to-steering knuckle bolts Upper ball joint cotter pin and loosen the nut Upper ball joint from the steering knuckle using tool 09950-40011 Steering knuckle by placing it in a soft-jawed vise Inside oil seal 4 bolts and shift the dust cover towards the hub side (outside) Axle hub from the steering knuckle using tools 09710-30021 and 09950-40011

Be careful not to scratch the speed sensor rotor serrations

¢ Bearing spacer, using a shop press and tools 09950-60010 and 09950-70010 ¢ New inside oil seal, using tool 09527-17011 and a plastic hammer 6. For 4WD, install or connect the following: a. Halfshaft into the axle hub and temporarily tighten the nut ;

Be careful not to damage the oil seal or boot. SS

b. Steering knuckle to the upper control arm. Tighten the nut to 77 ft. Ibs.

(105 Nm). c. New cotter pin. 7. Install or connect the following: e Lower ball joint to the steering

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TOYOTA A

LAND CRUISER » SEGUOK ;a

26-23

@ Cotter Pin

Steering Knuckle with Axle Hub

4wWD: @ Cotter Pin

Lock Cap Grease Cap

Grease Cap

AWD: @ Oil Seal Dust Cover 18 (185, 13)

@ Bearing

Bearing Spacer

é(

:

@ Oil Seal

Steering Knuckle w/ ABS: ABS Speed

Sensor Rotor

N-m (kgf-cm, ft-Ibf) | : Specified torque

@ Snap Ring

Axle Hub

@ Non-reusable part 9308YG13

Exploded view of the front axle hub and related components—Sequoia

For Tune-up, Capacities and Firing orders, see Section 7 of this manual

f

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— AND eLEXUS SER ¢ LX470 SEQUOIA LAND CRUI 2:6- oA TOYOTA ee ae i

- knuckle. Torque the 4 bolts to 59 ft. lbs. (80 Nm). Strut Brake disc and caliper. Torque both caliper bolts to 90 ft. Ibs. (123 Nm).

Brake line clamp to the steering knuckle. Torque the bolt to 21 ft. lbs. (28 Nm). ABS speed sensor. Torque both bolts to 7.1 ft. Ibs. (8.2 Nm). Halfshaft locknut. Torque the nut to 173 ft. Ibs. (235 Nm), by applying the brakes. Lock cap and new cotter pin Grease cap, for 2WD Front wheel 8. Depress the brake pedal several times. 9. Check and/or adjust the front wheel alignment. 10. Check the ABS speed sensor signal. Land Cruiser & LX470

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Brake caliper Grease cap Snapring Hub drive flange Locknut Lockwasher Adjusting nut Outer bearing Wheel hub Disc brake dust shield Wheel speed sensor and harness Outer tie rod end Upper ball joint Lower ball joint Steering knuckle Oil seal, bushing and spindle bearing

|

To install: 3. Coat the spindle bearing and bushing with lithium grease. 4. Fill the spindle cavity with lithium grease. 5. Press the spindle bearing and bushing into the spindle. 6. Install or connect the following: Oil seal Steering knuckle Upper ball joint. Tighten the nut to 81 ft. Ibs. (110 Nm). Lower ball joint. Tighten the nut to 117 ft. Ibs. (159 Nm). Outer tie rod end. Tighten the nut to 91 ft. Ibs. (122 Nm). Wheel speed sensor and harness Disc brake dust shield. Tighten the bolts to 13 ft. Ibs. (18 Nm). Wheel hub Outer bearing Adjusting nut. Adjust the wheel bearings. Lockwasher Locknut. Tighten the nut to 47 ft. lbs. (64 Nm). Hub drive flange. Tighten the nuts to 26 ft. Ibs. (35 Nm). Snapring Grease cap Brake caliper Front wheel

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION Rear

SEQUOIA 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel ¢ Brake drum and gasket

9308SG08

Removing the oil seal, bushing and spindle bearing—Land Cruiser/LX470

a.

sh .

saictins

=

3. Using a dial indicator, check the bearing backlash and the axle shaft deviation. If the bearing backlash exceeds a maximum or 0.028 in. (0.7mm), replace it. If the axle shaft deviation exceeds the maximum of 0.004 in. (0.1mm), replace it. 4, Remove or disconnect the following: Anti-lock Brake System (ABS) speed sensor from the rear axle housing, if equipped ¢ e Brake line from the wheel cylinder, using tool 09023-00100 Parking brake cable 4 backing plate nuts Axle shaft assembly, by pulling it from the axle housing

Be careful not to damage the oil seal.

e O-ring from the rear axle housing e Inner side oil seal using tool 09308-00010 5. If equipped with ABS, perform the ~ following: a. Remove and discard the 4 serration bolt nuts; then, using a hammer, drive the bolts from the backing plate. b. Using a grinder, grind the retainer and sensor rotor surfaces; then, chisel them out. 6. Remove the snapring from the axle shaft. 7. Remove the axle shaft from the backing plate, as follows: a. Position tool 09521-25011 onto the backing plate with the 4 nuts. b. Using a shop press, remove the axle shaft and bearing retainer from the backing plate. 8. Using tool 09308-00010, pull the oil seal from the backing plate. 9. Using a shop press and tools 09223-56010 and 09950-60010, press the bearing from the backing plate. To install: 10. Install or connect the following: e Bearing into the backing plate, ‘ using a shop press and tools 09223-56010 and 09950-60010 e New O-ring to the rear axle housing ¢ New oil seal into the backing plate, using a hammer and tools 0995070010 and 09950-60010 11. Install the axle shaft to the backing plate, as follows: e New outer side seal, lubricate the oil seal lip with multi-purpose grease

TOYOTA ANDL

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LAND CRUISER » SEQUOIA © LXA7B 26-25

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8.0 (82, 71 in.-Ibf)

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Brake Line 15 (155, 11)

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Rear Axle Shaft Assembly w/ ABS:

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@ Bearing © Retainer

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Bearing Case Backing

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@ Oil Seal Sk

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Rear Axle Shaft

N-m (kgf-cm, ft-lbf)

|: Specified torque

@ Non-reusable part 9308YG14

Exploded view of the rear axle—Sequoia

For complete service labor times, order the Chilton Labor Guide

26-26 oo

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TOYOTA AND LEXUS

LAND CRUISER © SEQUOIA ¢ LX470 e Rear wheel. Torque the lug nuts to 81 ft. Ibs. (110 Nm). 15. Bleed the brake system. 16. Check the ABS speed sensor signal.

122.2 + 1.0mm

(4.811 + 0.039 in.)

LAND CRUISER & LX470

9308YG15

Standard length of rear axle ABS speed sensor rotor and bearing retainer— Sequoia

e Backing plate and bearing retainer onto the rear axle shaft e Axle shaft onto the backing plate, by pressing it using a shop press and tool 09316-60011 e New snapring

Be careful not to damage the oil seal.

12. Install or connect the following: e New sensor rotor and new bearing retainer onto the axle shaft, using a shop press and tool 09316-60011 to a Standard length of 4.77—4.85 in. (121.2-123.2mm), if equipped with ABS New inner side oil seal, using a hammer and tools 09950-60020 and 09950-70010 Axle shaft assembly. Torque the bolts to 51 ft. Ibs. (69 Nm).

+k WARNING Be careful not to damage the oil seal. e Parking brake cable e Brake line to the wheel cylinder, using tool 09023-00100. Torque the brake line to 11 ft. Ibs. (15 Nm). e Rear brake assembly e ABS speed sensor to the rear axle housing. Torque it to 7.1 ft. Ibs. (8.0 Nm). 13. Using a dial indicator, check the bearing backlash and the axle shaft deviation. If the bearing backlash exceeds a maximum or 0.028 in. (0.7mm), replace it. If the axle shaft deviation exceeds the maximum of 0.004 in. (0.1mm), replace it. 14. Install or connect the following: ¢ New gasket and brake drum

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Brake caliper and rotor e Parking brake shoes and hardware e Bearing case nuts e Axle shaft and bearing assembly 3. Separate the backing plate from the bearing case by removing the serrated bolts. 4. Grind a flat spot on the wheel speed. sensor rotor and retainer, then split them with a hammer and chisel. 5. Remove the axle snapring. 6. Press the axle bearing case, bearing and retainer off of the axle. 7. Press the axle bearing from the bearing case. 8. Remove or disconnect the following: e Backing plate e Axle housing oil seal e Bearing case oil seal To install: 9. Press the wheel bearing into the bearing case, 10. Install the bearing case to the backing plate with the serrated bolts. 11. Install or connect the following: Bearing case oil seal Axle housing oil seal Axle shaft to backing plate and bearing assembly Bearing retainer Axle snapring Wheel speed sensor rotor and retainer Axle shaft and bearing assembly to the axle housing. Tighten the nuts to 91 ft. Ibs. (123 Nm). Parking brake shoes and hardware Brake caliper and rotor Rear wheel

3. Drain the differential housing oil. 4. Remove the front driveshaft. 5. Remove the companion flange, as follows: e Loosen the staked part of the nut, using a chisel and a hammer ¢ Companion flange nut, using tool 09330-00021 e Companion flange, using tools 09950-30011 and 09954-03010 6. Remove the oil seal and slinger, as follows: ¢ Oil seal, using too! 09308-10010 e Oil slinger To install: 7. Install or connect the following: e Oil slinger ¢ New oil seal, using a hammer and tool 09554-22010 to a depth of 0.153-0.189 in. (4.2-4.8mm). 8. Install the companion flange, as follows: e Companion flange e New nut, lubricated with hypoid gear oil e Torque the nut to 80 ft. Ibs. (108 Nm), using tool 09330-00021. 9. Adjust the drive pinion preload 10. Rotate the drive pinion, using a torque wrench while tightening the flange nut to make sure the bearing preload is 10.4-16.5 inch Ibs. (1.2-1.9 Nm) for a new bearing or 5.2-8.7 inch Ibs. (0.6—1.0 Nm) for a used bearing. Tighten the flange nut to achieve the preload torque readings originally recorded.

ki CAUTION Never loosen the pinion nut to reduce bearing preload. 11. Install or connect the following: e Drive pinion nut, stake it e Front driveshaft. Tighten the fasteners to 54 ft. Ibs. (74 Nm). e Under cover 12. Fill the differential with gear lubricant and check for leaks.

LAND CRUISER & LX470

:

SEQUOIA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Driveshaft ¢ Front wheels e Front brake calipers

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the under cover.

e>The front brake calipers must be removed so that there is no additional drag when measuring pinion bearing preload.

REMOVAL & INSTALLATION Front

LOYOTA AND LEXUS 96.97

LAND CRUISER e SEQUOIA ¢ LX470

7 ,

Companion Flange

Differential

Oil Slinger Bearing

ee M ae a a

N-m (kgf-cm, ft-lbf) |: Specified torque @ Non-reusable part 9308YG16

Exploded view of the Sequoia front differential assembly—Rear differential assembly is similar

while tightening the flange nut to make sure the pinion bearings seat correctly. 7. Take frequent bearing preload torque readings. Tighten the flange nut to achieve the preload torque readings originally recorded. Do not exceed 249 ft. Ibs. (338 Nm) torque when tightening the pinion flange nut.

> CAUTION

9308YG17

Positioning the Sequoia front pinion seal in the differential housing—Rear differential assembly is similar

3. Use an inch Ib. torque wrench and measure the amount of torque required to maintain pinion rotation through several revolutions. 4. Remove or disconnect the following: Pinion flange

Oil seal Oil slinger Pinion bearing and race Oil storage ring Collapsible spacer

To install: ->Use a new collapsible spacer and flange nut for assembly.

5. Install or connect the following: e Collapsible spacer e Oil storage ring e Pinion bearing and race e Pinion seal e Pinion flange. Tighten the nut to 80 ft. Ibs. (108 Nm). 6. Rotate the pinion flange occasionally

Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut. 8. Install or connect the following: e Front brake calipers e Front wheels e Driveshaft. Tighten the fasteners to 59 ft. Ibs. (80 Nm). 9. Fill the differential with gear lubricant and check for leaks. Rear

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

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26-28 TOYOTA AND LEXUS — (EU

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LAND CRUISER

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2. Drain the differential housing oil. 3. Remove the rear driveshaft. 4. Remove the companion flange, as follows: e Loosen the staked part of the nut, using a chisel and a hammer e Companion flange nut, using tool 09330-00021 . e Companion flange, using tools 09950-30011 and 09954-03010 e Oil seal, using tool 09308-10010 To install: 5. Install the new oil seal until it is flush with the housing, using a plastic hammer and tools 09316-12010 and 0964917010 e>Use vinyl tape to connect both oil seal installation tools.

6. Install the companion flange, as follows: e Companion flange e New nut, lubricated with hypoid gear oil e Torque the nut to 109 ft. Ibs. (147 Nm), using too! 09330-00021. 7. Adjust the drive pinion preload 8. Rotate the drive pinion, using a torque wrench while tightening the flange nut to make sure the bearing preload is 11.4-16.7 inch Ibs. (1.3-1.9 Nm) for a new bearing or 4.3-6.9 inch Ibs. (0.5—-0.8 Nm) for a used bearing. Tighten the flange nut to achieve the preload torque readings originally recorded.

+k CAUTION Never loosen the pinion nut to reduce bearing preload. 9. Install or connect the following: e Drive pinion nut, stake it e Rear driveshaft. Tighten the fasteners to 54 ft. Ibs. (74 Nm). 10. Refill the differential with gear lubricant and check for leaks; 3.33 gts. for 2WD or 3.12 gts. for 4WD.

LAND CRUISER & LX470 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Driveshaft e Rear wheels e Rear brake calipers >The rear brake calipers must be removed so that there is no additional drag when measuring pinion bearing preload.

3. Use an inch Ib. torque wrench and measure the amount of torque required to maintain pinion rotation through several revolutions. 4, Remove or disconnect the following: e Pinion flange

e Oil seal e Oil slinger

e Pinion bearing and race e Collapsible spacer To install: >Use a new collapsible spacer and flange nut for assembly.

5. Install or connect the following: ¢ Collapsible spacer e Pinion bearing and race e Pinion seal ¢ Pinion flange. Tighten the nut to 181 ft. Ibs. (245 Nm). 6. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly. 7. Take frequent bearing preload torque ‘readings. Tighten the flange nut to achieve the preload torque readings originally recorded. Do not exceed 326 ft. Ibs. (441 Nm) torque when tightening the pinion flange nut.

:¢ CAUTION Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut. 8. Install or connect the following: e Rear brake calipers e Rear wheels e Driveshaft. Tighten the fasteners to 78 ft. Ibs. (106 Nm). 9. Fill the differential with gear lubricant and check for leaks.

STEERING AND SUSPENSION

2

CAUTION

Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury.

e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. ¢ With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING To avoid personal injury when working on vehicles equipped with an air bag, the negative battery cable must be disconnected and at least 90 seconds must elapse before working on the system. Failure to do so may result in deployment of the air bag.

Power Rack and Pinion Steering Gear

REMOVAL & INSTALLATION Sequoia 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the front wheels in the straight-ahead position. . 3. Remove or disconnect the following: e Engine under cover ¢ Steering wheel pad e Steering wheel e Left and right outer tie-rod ends from the steering knuckles 4. Matchmark the No. 2 intermediate shaft to the steering gear input shaft. 9. Remove or disconnect the following: e Clamp plate

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TOYOTA AND LEXUS 26-29 9F_9Q

LAND CRUISER e SEQUOIA e a 29 (290, 21)

Clamp Plate Pressure Feed Tube

Return Tube

*32 (326, 27)

*32 (326, 27)

| \ |

\ { \

35 (360, 26)

| \ | \

@Cotter Pin

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Bracket

\

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N-m (kgf-cm, ft-lbf) |: Specified torque @Non-reusable part * For use with SST Exploded view of the power rack and pinion steering gear mounting—Sequoia

Timing belt service is covered in Section 3 of this manual

9308YG18

26-30

TOYOTARNDIEXOS = LAND CRUISER © SEQUOIA © LX470

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e Pressure feed and return tubes from the power steering gear, using tool 09631-22020 ° Power steering gear assembly To install: 6. Install or connect the following: ¢ Power steering gear assembly. Torque the set bolt to 123 ft. Ibs. (165 Nm) and the set nut/bolt to 96 ft. Ibs. (91 Nm). e Pressure feed and return tubes to

es ee pe ee e

;

7924SG89

the power steering gear. Torque them to 27 ft. Ibs. (32 Nm), using

tool 09631-22020.

Power rack and pinion steering gear removal—Land Cruiser/LX470

100 (1,020, 74)

‘4

Intermediate Shaft Assembly

Bracket

@ Cotter Pin.

Rat ay

[3a380,25) Grommet

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Return Tube

45 (450, 33) *36 (365, 26)

Tube Clamp

PS Gear Assembly

@ O-Ring

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Pressure Feed Tube

No.2 Engine Under Cover

N-m (kgf-cm, ftlbf) |: Specified torque

No.1 Engine Under Cover

Non-—reusable part * For use with SST

79248690 Exploded view of the rack and pinion steering gear mounting—Land Cruiser/LX470

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2

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Pe

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POS

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TOYOTA AND LEXUS 96-31 :

LAND CRUISER ¢ SEQUOIA ¢ LX470

Le

Clamp plate. Torque the bolt to 21 ft. Ibs. (29 Nm). No. 2 intermediate shaft to the steering gear input shaft e Left and right outer tie-rod ends to the steering knuckles. Torque the nuts to 67 ft. Ibs. (91 Nm). Steering wheel. Torque the nut to 26 ft. Ibs. (35 Nm). ¢ Steering wheel pad e Engine under cover 7. Fill and bleed the power steering system.

8. Check and/or adjust the wheel alignment, as necessary.

Land Cruiser & LX470

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Matchmark the intermediate shaft to the steering gear input shaft. 3. Remove or disconnect the following: e Negative:battery cable e Engine under covers e Outer tie rod ends e Engine oil filter adapter e Intermediate steering shaft e Power steering hoses and bracket Power steering gear To install: 4. Install or connect the following: e Power steering gear. Tighten the fasteners to 74 ft. Ibs. (100 Nm). e Power steering hoses and bracket e |ntermediate steering shaft. Tighten the bolts to 25 ft. Ibs. (34 Nm). e Engine oil filter adapter. Tighten the bolts to 13 ft. Ibs. (18 Nm). e Outer tie rod ends. Tighten the nuts to 90 ft. Ibs. (122 Nm). e Engine under covers e Negative battery cable 5. Fill the power steering fluid reservoir. 6. Check the wheel alignment and adjust as necessary.

2. Support the axle with a jackstand. 3. Remove or disconnect the following: e Front wheel e Shock absorber To install: 4. Install or connect the following: e Shock absorber. Tighten the nut to 51 ft. Ibs. (69 Nm) and the bolt to 100 ft. Ibs. (135 Nm). e Front wheel

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the axle with a jackstand. 3. Remove or disconnect the following: e Rear wheel e Shock absorber

To install: 4. Install or connect the following: e Shock absorber. Tighten the nut to 51 ft. Ibs. (69 Nm) and the bolt to 72 ft. Ibs. (98 Nm). e Rear wheel Land Cruiser & LX470 With Active Height Control

FRONT

CAUTION The vehicle ride height may change suddenly when relieving system pressure. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

%

Front Fender Apron

>

Pressure Hose

\e\—¢ O-ring \21—® Back Up Ring

‘——_e Cal

Cushion

a—

Retainer

—-_

aS—

Cushion

Retainer

Shock Absorber

@ Bushing

Shock Absorber REMOVAL & INSTALLATION Land Cruiser & LX470 Without Active

Height Control

_@ N-m (kgf-cm, ft-bf)

135 (1,400, 101)

|: Specified torque

@ Non-reusable part 7924SG86

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

Exploded view of the front shock absorber mounting—Land Cruiser/LX470 models with Active Height Control (AHC)

Heater Core replacement is covered in Section 2 of this manual

26-32 TOYOTA ANDLEXUS LAND CRUISER ¢ SEQUOIA e LX470 \ Ps

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7e24sG84

Paneviat sistem prassere— ai Cruiser/LX470 with Active Height Control

2. Relieve the Active Height Control (AHC) hydraulic pressure as follows: a. Connect a hose to the contro! actuator bleed screw and place the other end in a container. b. Open the bleed screw. c. When the fluid pressure has dropped and oil stops flowing, close the bleed screw. 3. Remove or disconnect the following: e Front wheel e Inner fender liner ¢ Lower shock absorber mounting bolt

e AHC pressure hose e Upper shock absorber mounting nut e Shock absorber To install: 4. Install or connect the following: e Shock absorber. Tighten the upper nut to 51 ft. Ibs. (68 Nm) and the lower bolt to 101 ft. Ibs. (135 Nm). e AHC pressure hose with new Oring seals. Tighten the bolts to 13 . ff. Ibs. (18 Nm). e Inner fender liner e Front wheel

18 (185, 13)

Pressure Hose

eon @ O-ring eo td Back Up Ring

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wp

68 (700, 51) \

ig ~ Cushion SS

c>—-

Retainer

€&>— Cushion @—

Retainer

€ES5-— Insulator Follow Spring

Shock Absorber

;

@ Bushing

Ea

N-m (kgf-cm, ft-lbf) |: Specified torque @ Non-reusable part 7924SG87

Exploded view of the rear shock absorber mounting—Land Cruiser/LX470 with Active Height Control (AHC)

TOYOTA AND LEXUS 26-33 |

LAND CRUISER ¢ SEQUOIA © LX470 ->Do not let the AHC reservoir run

empty during this procedure.

5. Bleed the AHC system as follows: a. Fill the AHC system reservoir with AHC fluid 08886-01805. b. Start the engine and push N on the vehicle height select switch. c. When the AHC pump stops, turn the engine OFF. d. Open the bleed screw and allow any air in the system to escape. e. Repeat until no air is expelled from the bleed screw. ) 5 Fill the AHC reservoirtothe correct

evel.

REAR

CAUTION The vehicle ride height may change suddenly when relieving system

pressure.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the rear axle with a jack or stands.

3. Relieve the Active Height Contro| (AHC) hydraulic pressure as follows: a. Connect a hose to the control actuator bleed screw and place the other end in a container. b. Open the bleed screw. c. When the fluid pressure has dropped and oil stops flowing, close the bleed screw. 4. Remove or disconnect the following: e Rear wheel e Lower shock absorber mounting bolt e AHC pressure hose e Upper shock absorber mounting nut

e Shock absorber To install: 5. Install or connect the following: e Shock absorber. Tighten the upper nut to 51 ft. Ibs. (68 Nm) and the lower bolt to 72 ft. Ibs. (98 Nm). e AHC pressure hose with new Oring seals. Tighten the bolts to 13 ft. Ibs. (18 Nm). e Rear wheel

b. Start the engine and push N on the vehicle height select switch. c. When the AHC pump stops, turn the engine OFF. d. Open the bleed screw and allow any air in the system to escape. e. Repeat until no air is expelled from the bleed screw. | Fill the AHC reservoir to the correct evel, Sequoia

6. Bleed the AHC system as follows: a. Fill the AHC system reservoir with AHC fluid 08886-01805.

ALL MODELS ~ 1. Before servicing the vehicle, refertothe precautions in the beginning of this section. 2. Support the vehicle at the frame. 3. Support the axle with a floor jack. 4, Remove or disconnect the following: e Rear wheel e Shock absorber ¢ Stabilizer bar brackets e Lateral control rod

¢ Coil spring To install: 5. Install or connect the following: ¢ Coil spring e Lateral control rod. Tighten the axle housing bolt to 181 ft. Ibs. (245 Nm). e Stabilizer bar brackets. Tighten the bolts to 13 ft. Ibs. (18 Nm) e Shock absorber e Rear wheel

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Shock absorber To install: 3. Install or connect the following: e Shock absorber. Tighten the upper nut to 15 ft. Ibs. (20 Nm) and the lower nut/bolt to 64 ft. Ibs. (87 Nm). e Rear wheel. Torque the lug nuts to 81 ft. Ibs. (110 Nm).

Torsion Bars

REMOVAL & INSTALLATION Land Cruiser & LX470

REMOVAL & INSTALLATION Sequoia

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Strut-to-lower control arm nut/bolt and the strut e Strut-to-chassis 3 nuts/bolts and the strut To install: 3. Install or connect the following: e Strut to the chassis. Torque the 3 nuts/bolts to 47 ft. Ibs. (64 Nm). e Strut to the lower control arm. Torque the nut/bolt to 100 ft. Ibs. (135 Nm). e Front wheel

Coil Spring

!

REMOVAL & INSTALLATION

->Do not let the AHC reservoir run empty during this procedure.

Rear

>The front coil springs on the Sequoia are part of the front strut. The Land Cruiser and LX470 employ front torsion bars.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Engine under cover 3. Measure dimension A as shown between the adjustment bolt head and the frame. 4, Loosen the adjusting bolt until all spring tension Is relieved. 5. Measure dimension B as shown between the adjustment bolt head and the frame. 6. Remove or disconnect the following: e Adjustment bolt, swivel and seat e Torsion bar and anchor arm. Separate the anchor arm from the torsion bar. e Torque arm To install: 7. Install or connect the following: e Torque arm. Tighten the fasteners to 166 ft. Ibs. (225 Nm). e Torsion bar and anchor arm. Align the matchmarks. e Adjustment bolt, swivel and seat 8. Check that dimension B is close to the measurement made at disassembly.

Brake service is covered in Section 4 of this manual

.

OTA AND LEXUS |

SEQUOIA ©LX470 — 26-34 A CRUI©SER Anchor Arm Swivel

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Torsion bar mounting exploded view—Land Cruiser/LX470

TOYOTA AND LEXUS LAND CRUISER SEQUOIA © LX470

26-35

9. If installing a new torsion bar, tighten the adjustment bolt until dimension A is as follows: e Left torsion bar: 0.315—-0.984 inches (8—25mm) e Right torsion bar: 0.079-0.709 inches (2-18mm) 10. If installing the original torsion bar, tighten the adjustment bolt until dimension

Front:

A is close to the measurement made at dis9308SG12

Matchmark the torsion bar to the anchor arm and torque arm—Land Cruiser/LX470

Ride height measurements A and B—Land Cruiser/LX470

assembly. 11. Install or connect the following: e Engine under cover e Front wheel 12. Place the vehicle on a flat, level surface and check the vehicle curb height as follows: a. Step 1: Measure dimension A between the spindle center and the ground. b. Step 2: Measure dimension B between the lower control arm front bolt center and the ground. c. Step 3: Turn the adjusting bolt so that A minus B is equal to 2.795 inches (71mm).

Upper Ball Joint REMOVAL & INSTALLATION Land Cruiser & LX470

The upper ball joint is serviced with the upper control arm as an assembly.

Sequoia 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Steering knuckle with the axle hub e Wire and boot e Snapring e Upper ball joint from the steering knuckle, using a deep socket wrench and too! 09050-40011 To install: 3. Install or connect the following: e New upper ball joint to the steering knuckle, using a deep socket and tool 09309-37010 e New snapring 4. Using a torque wrench, inspect the upper ball joint rotation, as follows: a. Flip the ball joint back-and-forth 5 times. 9302SG04

Reference measurements A and B—Land Cruiser/LX470

b. Using a torque wrench, continuously turn the nut 1 turn in 2-4 seconds.

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

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Locl wid

26-36 TOYOTA AND LEXUS

LAND CRUISER ¢ SEQUOIA © LX470

c. Take the reading on the 5th turn; it should be 6-39 inch Ibs. (0.7-4.4 Nm).

Sequoia

5. Install or connect the following:

precautions in the beginning of this section.

If not, replace the upper ball joint.

¢ New boot secured with a wire ¢ Front wheel. Torque the lug nuts to

1. Before servicing the vehicle, refer tothe

Torque the nut to 67 ft. Ibs. (91 Nm).

e Lower ball joint set bolts. Torque

2. Remove or disconnect the following: * Front wheel

81 ft. Ibs. (110 Nm).

the 4 bolts to 59 ft. Ibs. (80 Nm). e Front wheel. Torque the lug nuts to

* 4 lower ball joint set bolts

6. Check and/or adjust the front wheel

81 ft. Ibs. (110 Nm).

* Tie-rod end from the lower ball

alignment.

4. Check and/or adjust the front wheel

joint, using tool 09610-20012

alignment.

e Lower ball joint nut. e Lower ball joint from the lower

5

Lower Ball Joint

|Upper Control Arm

control arm, using tool 09628-

REMOVAL & INSTALLATION Land Cruiser & LX470 ie. ¢

e New cotter pin Re e Tie-rod end to the lower ball joint.

“he

Upper Control Arm

To eth

REMOVAL & INSTALLATION

3. Install or connect the following: e New lower ball joint to the lower ee

Land Cruiser & LX470 ie

control. Torque the bolts to 103 ft.

The lower ball joint is serviced with the

Ibs. (140 Nm).

1. Before servicing the vehicle, refer to the

lower control arm as an assembly.

precautions in the beginning of this section.

Front Fender Apron .

No. 1 Camber Adjust Cam

ABS Speed Sensor Wire Harness

98 (1,000, 72)

6) 9

>.

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