Haynes Dodge & Plymouth Neon Automotive Repair Manual [30034] 1563923696, 9781563923692

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Plymouth Neon 1995 thru 1999 call models

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Dodge & Plymouth Neon Automotive

Repair Manual by Ed Scott and John H Haynes Member of the Guild of Motoring Writers

Models covered: All Dodge and Plymouth Neon models 1995 through 1999 ABCDE FGHI

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California 91820 USA

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Acknowledgements We are grateful to the Chrysler Corporation for providing technical information and certain illustrations. Wiring diagrams originated exclusively for Haynes North America, Inc. by Valley Forge Technical Communications.

© Haynes North America, Inc. 1997, 1998, 1999 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 369 6 Library of Congress Catalog Card Number 99-69836 While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. 97-288

Contents Introductory pages About this manual Introduction to the Neon Vehicle identification numbers

Buying parts Maintenance techniques, tools and working facilities

Booster battery (jump) starting Jacking and towing Automotive chemicals and lubricants Conversion factors

Safety first! Troubleshooting

L2OS 1

ho -— St + - OCO Oro: @OO

Chapter 1 Tune-up and routine maintenance

Chapter 2

PartA

Engines

Chapter 2

1-1

2A-1

PartB

General engine overhaul procedures

2B-1

Chapter 3 Cooling, heating and air conditioning systems

3-1

Chapter 4 Fuel and exhaust systems

4- —_

Chapter 5 Engine electrical systems

5- ast

Chapter 6 Emissions and engine control systems

6- =

Chapter 7A Manual transaxle

TA-

—_

7B-

—_

Chapter 7B Automatic transaxle

Chapter 8 Clutch and driveaxles

8-

_s

9-

—

10-

_

Chapter 9 Brakes

Chapter 10 Suspension and steering systems

Chapter 11 Body

11-1

Chapter 12 Chassis electrical system

12-1

Wiring diagrams

12-20

Index

IND-1

Haynes mechanic, author and photographer with 1995 Dodge Neon

0-5

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal

lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, “see Section 8” means in the same Chapter. References to the left or right side of the vehicle assume you are sitting in the driver’s seat, facing forward. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Dodge and Plymouth Neon The Dodge/Plymouth

Neon is available in four-door sedan and

two-door coupe body styles. The transversely mounted 2.0-liter four-cylinder engine is available in two versions; the standard Single Overhead-Camshaft (SOHC) version is rated at 132 horsepower while the optional Dual OverheadCamshaft (DOHC) version sports 150 horsepower. Both models are equipped with a sequential multi port electronic fuel injection system. The engine transmits power to the front wheels through either a five-speed manual transaxle or a three-speed automatic transaxle via

independent driveaxles. The Neon features an all steel uni-body and independent suspension with MacPherson strut/coil spring suspension used on both the front and rear suspensions. The rack and pinion steering unit is mounted behind the engine with power-assist available as optional equipment. Standard models are equipped with power assisted front disc and rear drum brakes. A power assisted four wheel disc brake system and

an Anti-lock Brake System (ABS) are optional.

0-6

Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly identify the component required.

On the models covered by this manual the engine codes are: Creer esc ice cn onae fens os¥asteees Vacca eartie ottnan cveereamescecesaae 2.0L SOHC Viera ee eee eae coat ese sen Ra rennet eee eae one nae Manes eeeneaers re 2.0L DOHC

Vehicle Identification Number (VIN) This very important identification number is located on a plate attached to the dashboard inside the windshield on the driver's side of the vehicle (see illustration). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was manufactured, the model year and the body style.

Body Code Plate VIN engine and model year codes Two particularly important pieces of information found in the VIN are the engine code and the model year code. Counting from the left, the engine code letter designation is the 8th digit and the model year code designation is the 10th digit.

The Vehicle Identification Number (VIN) is stamped into a metal plate fastened to the dashboard on the driver’s side - it’s visible through the windshield

The Body Code Plate is a stamped metal plate attached to either the radiator support or the right strut tower in the engine compartment (see illustration). It contains more specific information about the manufacturing of the vehicle such as the paint code, trim code and vehicle order number, as well as the VIN.

The Body Code Plate is located on the radiator support

Vehicle identification numbers

MFD BY CHRYSLER CORPORATION

GWR 04112 LB 1866 KG

DATE OF MFR: XX-XX GAWR 2305 LB FRONT 1046 KG

GAWR 1882 LB REAR @854 KG

THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY, BUMPER AND

THEFT PREVENTION STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. VIN: —XXXXXXXXXXXXXXXXX

ANCOR

MDH: XXXXXX XX

TYPE: XXXXXXXXX

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PAINT:XXX VEHICLE MADE IN U.S.A. TRIM:XXXX

The Engine Identification Number is stamped on the left rear of the engine block (SOHC models)

The Vehicle Safety Certification label is affixed to the drivers side door end or post

ENGINE

pentiricarion——>/ LOCATION |

BAR CODE LABEL

The Engine Identification Number is stamped on the rear of the engine block (DOHC models)

Location of the transaxle bar code label

Vehicle Safety Certification label

Transaxle identification numbers

The Vehicle Safety Certification label is attached to the driver’s side door end or post (see illustration). The label contains the name of

The transaxle identification information can be found on a bar code label located on the front of the transaxle (see illustration).

the manufacturer, the month and year of production, the Gross Vehicle

Vehicle Emissions Control Information (VECI) label

Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and the certification statement.

Engine identification numbers The engine identification numbers can be found stamped on a pad on either the left rear of the cylinder block, behind the starter (SOHC engine) or on the rear of the cylinder block (DOHC engine) (see illustrations).

The emissions control information label is found under the hood, normally on the radiator support or the bottom side of the hood. This label contains information on the emissions control equipment installed on the vehicle, as well as tune-up specifications (see Chapter 6).

0-8

Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned parts on an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell

tools and general accessories, have convenient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: \f the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.

used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should be treated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works quite well. After applying the rust penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed

Fasteners

off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and

Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be

removed with a special tool commonly available for this purpose. Most automotive machine shops can perform this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic.

0-9

Maintenance techniques, tools and working facilities aaa.

Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important to be

able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged. All bolts, whether standard or metric, are sized according to diameter, thread pitch and length. For example, a standard 1/2 - 13 x 1 bolt is 1/2 inch in diameter, has 13 threads per inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm

in diameter, has a thread pitch of

1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard

bolt head is measured in inches, while the same dimension on a metric bolt is sized in millimeters (the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt and a metric

wrench should not be used on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to it. The greater the number of slashes, the greater the strength of the bolt. Grades 0 through 5 are commonly used on automobiles. Metric bolts have a property class (grade) number, rather than a slash, molded into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and 10.9 are commonly used on automobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped into one side, while metric nuts are marked with a number. The greater the number of dots, or the higher the number, the greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade.

Grade 8

Grade 1 or 2

Bolt strength marking (standard/SAE/USS; bottom - metric)

Grade

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Metric hex nut strength markings

Metric stud strength markings 00-1 HAYNES

0-10

Maintenance techniques, tools and working facilities

It should be noted that many fasteners, especially Grades 0 through 2, have no distinguishing marks on them. When such is the case, the only way to determine whether it is standard or metric is to measure the thread pitch or compare it to a known fastener of the same size. Standard fasteners are often referred to as SAE, as opposed to metric. However, it should be noted that SAE technically refers to a non-metric fine thread fastener only. Coarse thread non-metric fasten-

Tightening sequences and procedures

ers are referred to as USS sizes.

Chapter. Be sure to follow the torque recommendations closely. For fasteners not assigned a specific torque, a general torque value chart is presented here as a guide. These torque values are for dry (unlubricated) fasteners threaded into steel or cast iron (not aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be applied to it. The figures listed

Since fasteners of the same size (both standard and metric) may have different strength ratings, be sure to reinstall any bolts, studs or nuts removed from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a

strength rating equal to or greater than the original.

Most threaded fasteners should be tightened to a specific torque value (torque is the twisting force applied to a threaded component such as a nut or bolt). Overtightening the fastener can weaken it and cause it to break, while undertightening can cause it to eventually come loose. Bolts, screws and studs, depending on the material they are made of and their thread diameters,

Metric thread sizes NEG piece rel ltr ey) Hs SEO NASB Ieee tiene ike ee EN Une en a MET mee ae Sneek a MEH 2a et oe eake ott ae Nala eee ae cecr eee

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6to9 14 to 28 to 50 to 80 to

9to 12 19 to 28 38 to 54 68 to 96 109 to 154

Pipe thread sizes 11SSS Re Be ee AE ia © Gey eee 1 [MM Say OUP eis LOC RET Sete Fe |

aes nny: 5 ee geeanete

5to8 12to 18 22 to 33 25/1035

7 to 10 17 to 24 30 to 44 34 to 47

6 to9 12 to 14 to 22 to 27 to 40 to 40 to 55 to

9 to 12 17 to 24 19 to 27 30 to 43 37 to 51 55 to 74 55 to 81 75 to 108

oe etait Cae chy od ee anes cat sie es Se Sen 2 Bs

have specific torque values,

many of which are noted in the Specifications at the beginning of each

U.S. thread sizes VARS 20 Veer ce a) Aan ee Mena RS ee B/G =u Oot ae ee cE: GIRO... Ne Been ee eee ed coe Safer MPT ae SIGE Omer eee Bae >———==E=E=

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Dial indicator set

who who comand

Maintenance techniques, tools and working facilities

0-12

Timing light

General purpose puller

Compression gauge with spark plug hole adapter

Hydraulic lifter removal tool

Valve spring compressor

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

Ring removai/installation tool

0-13

Maintenance techniques, tools and working facilities

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ee

Ring compressor

Cylinder hone

Brake hold-down spring tool

Brake cylinder hone

Clutch plate alignment tool

Tap and die set

To help the owner decide which tools are needed to perform the tasks detailed in this manual, the following tool lists are offered: Maintenance and minor repair, Repair/overhaul and Special.

The newcomer to practical mechanics should start off with the maintenance and minor repair tool kit, which is adequate for the simpler jobs performed on a vehicle. Then, as confidence and experience grow, the owner can tackle more difficult tasks, buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and overhaul tool set. Over a period of time, the experienced do-it-yourselfer will assemble a tool set complete enough for most repair and overhaul procedures and will add tools from the special category when it is felt that the expense is justified by the frequency of

use.

Maintenance and minor repair tool kit The tools in this list should be considered the minimum

required

for performance of routine maintenance, servicing and minor repair work. We recommend the purchase of combination wrenches (boxend and open-end combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench. Combination wrench set (1/4-inch to 1 inch or 6 mm to 19 mm) Adjustable wrench, 8 inch Spark plug wrench with rubber insert Spark plug gap adjusting tool Feeler gauge set Brake bleeder wrench Standard screwdriver (5/16-inch x 6 inch) Phillips screwdriver (No. 2 x 6 inch) Combination pliers - 6 inch Hacksaw and assortment of blades

Tire pressure gauge Grease gun

Oil can Fine emery cloth Wire brush Battery post and cable cleaning tool Oil filter wrench Funnel (medium size) Safety goggles Jackstands (2) Drain pan Note: /f basic tune-ups are going to be part of routine maintenance, it will be necessary to purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely necessary for tuning most vehicles properly.

Repair and overhaul tool set These tools are essential for anyone who plans to perform major repairs and are in addition to those in the maintenance and minor repair tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because of their versatility, especially when various extensions and drives are available. We recommend the 1/2-inch drive over the 3/8-inch drive. Although the larger drive is bulky and more expensive, it has the capacity of accepting a very wide range

of large sockets. Ideally, however, the mechanic should have a 3/8inch drive set and a 1/2-inch drive set. Socket set(s) Reversible ratchet Extension - 10 inch Universal joint Torque wrench (same size drive as sockets) Ball peen hammer - 8 ounce Soft-face hammer (plastic/rubber) Standard screwdriver (1/4-inch x 6 inch)

0-14 ns

Maintenance techniques, tools and working facilities SS

SSS

SS

Standard screwdriver (stubby - 5/16-inch) Phillips screwdriver (No. 3 x 8 inch) Phillips screwdriver (stubby - No. 2) Pliers - vise grip Pliers - lineman’s Pliers - needle nose Pliers - snap-ring (internal and external) Cold chisel - 1/2-inch Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch) Steel rule/straightedge - 12 inch

needed, add-on sets, individual tools and a larger tool box can be purchased to expand the tool selection. Building a tool set gradually allows the cost of the tools to be spread over a longer period of time and gives the mechanic the freedom to choose only those tools that will actually be used. Tool stores will often be the only source of some of the special tools that are needed, but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers and sockets, because they won't last very long. The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools.

Allen wrench set (1/8 to 3/8-inch or 4 mm to 10 mm) A selection of files

Good tools are expensive, so it makes sense to treat them with respect. Keep them clean and in usable condition and store them properly when not in use. Always wipe off any dirt, grease or metal chips before putting them away. Never leave tools lying around in the work area. Upon completion of a job, always check closely under the hood for tools that may have been left there so they won’t get lost during a test drive.

Wire brush (large) Jackstands (second set) Jack (scissor or hydraulic type) Note: Another tool which is often useful is an electric drill with a chuck capacity of 3/8-inch and a set of good quality drill bits.

Care and maintenance of tools

Some tools, such as screwdrivers, pliers, wrenches and sockets,

Special tools The tools in this list include those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturer’s instructions. Unless these tools will be used frequently, it is not very economical to purchase many of them. A consideration would be to split the cost and use between yourself and a friend or friends. In addition, most of these tools can be obtained from a tool rental shop on a temporary basis. This list primarily contains only those tools and instruments widely available to the public, and not those special tools produced by the vehicle manufacturer for distribution to dealer service departments. Occasionally, references to the manufacturer’s special tools are included in the text of this manual. Generally, an alternative method of doing the job without the special tool is offered. However, sometimes there is no alternative to their use. Where this is the case, and the tool cannot be purchased or borrowed, the work should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor Piston ring groove cleaning tool Piston ring compressor Piston ring installation tool Cylinder compression gauge

Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge Micrometers and/or dial calipers Hydraulic lifter removal tool Balljoint separator Universal-type puller Impact screwariver Dial indicator set Stroboscopic timing light (inductive pick-up) Hand operated vacuum/pressure pump Tachometer/dwell meter v Universal electrical multimeter Cable hoist

Brake spring removal and installation tools Floor jack

can be hung on a panel mounted on the garage or workshop wall, while others should be kept in a tool box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or impact from other tools. When tools are used with care and stored properly, they will last a very long time. Even with the best of care, though, tools will wear out if used frequenily. When a tool is damaged or worn out, replace it. Subsequent jobs will be safer and more enjoyable if you do.

How to repair damaged threads Sometimes, the internal threads of a nut or bolt hole can become stripped, usually from overtightening. Stripping threads is an all-toocommon occurrence, especially when working with aluminum parts, because aluminum is so soft that it easily strips out. Usually, external or internal threads are only partially stripped. After they’ve been cleaned up with a tap or die, they’ll still work. Some-

times, however, threads are badly damaged. you've got three choices:

When

this happens,

1) Drill and tap the hole to the next suitable oversize and install a larger diameter bolt, screw or stud. 2) Drill and tap the hole to accept a threaded plug, then drill and tap the plug to the original screw size. You can also buy a plug already threaded to the original size. Then you simply drill a hole to the specified size, then run the threaded plug into the hole with a bolt and jam nut. Once the plug is fully seated, remove the jam nut and bolt.

3) The third method uses a patented thread repair kit like Heli-Coil or Slimsert. These easy-to-use kits are designed to repair damaged threads in straight-through holes and blind holes. Both are available as kits which can handle a variety of sizes and thread patterns. Drill the hole, then tap it with the special included tap. Install the Heli-Coil and the hole is back to its original diameter and thread pitch.

Regardless of which method you use, be sure to proceed calmly and carefully. A little impatience or carelessness during one of these relatively simple procedures can ruin your whole day’s work and cost you a bundle if you wreck an expensive part.

Buying tools

Working facilities

For the do-it-yourselfer who is just starting to get involved in vehicle maintenance and repair, there are a number of options available when purchasing tools. If maintenance and minor repair is the extent of the work to be done, the purchase of individual tools is satisfactory. If, on the other hand, extensive work is planned, it would be a good idea to purchase a modest tool set from one of the large retail chain stores. A set can usually be bought at a substantial savings over the individual tool prices, and they often come with a too! box. As additional tools are

Not to be overlooked when discussing tools is the workshop. If anything more than routine maintenance is to be carried out, some sort of suitable work area is essential. It is understood, and appreciated, that many home mechanics do not have a good workshop or garage available, and end up removing an engine or doing major repairs outside. It is recommended, however, that the overhaul or repair be completed under the cover of a roof. A clean, flat workbench or table of comfortable working height is

0-15

Maintenance techniques, tools and working facilities ca

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SP

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an absolute necessity. The workbench should be equipped with a vise that has a jaw opening of at least four inches. As mentioned previously, some clean, dry storage space is also required for tools, as well as the lubricants, fluids, cleaning solvents,

etc. which soon become necessary. Sometimes waste oil and fluids, drained from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, pour the used fluids into large containers, seal them with caps and take them to an authorized disposal site or recycling center. Plastic jugs, such as old antifreeze containers, are ideal for this purpose.

EY

Always keep a supply of old newspapers and clean rags available. Old towels are excellent for mopping up spills. Many mechanics use rolls of paper towels for most work because they are readily available and disposable. To help keep the area under the vehicle clean, a large cardboard box can be cut open and flattened to protect the garage or shop floor. Whenever working over a painted surface, such as when leaning over a fender to service something under the hood, always cover it with an old blanket or bedspread to protect the finish. Vinyl covered pads, made especially for this purpose, are available at auto parts stores.

Booster battery (jump) starting Observe these precautions when using a booster battery to start

Booster battery

Dead Battery

a vehicle: a) Before connecting the booster battery, make sure the ignition switch is in the Off position. b) Turn off the lights, heater and other electrical loads. c) Your eyes should be shielded. Safety goggles are a good idea. d) Make sure the booster battery is the same voltage as the dead one in the vehicle. e) The two vehicles MUST NOT TOUCH each other! f) Make sure the transaxle is in Neutral (manual) or Park (automatic). g) If the booster battery is not a maintenance-free type, remove the vent caps and lay a cloth over the vent holes. Connect the red jumper cable to the positive (+) terminals of each

OO00000

battery (see illustration). Connect one end of the black jumper cable to the negative (-) terminal of the booster battery. The other end of this cable should be con-

nected to a good ground on the vehicle to be started, such as a bolt or

bracket on the body. Start the engine using the booster battery, then, with the engine running at idle speed, disconnect the jumper cables in the reverse order of connection.

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(00-3 HAYNES HAYNES]

Make the booster battery cable connections in the numerical order shown (note that the negative cable of the booster battery is NOT attached to the negative terminal of the dead battery)

0-16

Jacking and towing Jacking Warning: The jack supplied with the vehicle should only be used for changing a tire or placing jackstands under the frame. Never work under the vehicle or start the engine while this jack is being used as the only means of support. The vehicle should be on level ground. Place the shift lever in Park, if you have an automatic, or Reverse if you have a manual transaxle. Block the wheel diagonally opposite the wheel being changed. Set the parking brake. Remove the spare tire and jack from stowage. Remove the wheel cover and trim ring (if so equipped) with the tapered end of the lug nut wrench by inserting and twisting the handle and then prying against the back of the wheel cover. Loosen the wheel lug nuts about 1/4-to1/2 turn each. Place the scissors-type jack under the side of the vehicle and adjust the jack height until it fits in the notch in the vertical rocker panel flange nearest the wheel to be changed. There is a front and rear jacking point on each side of the vehicle (see illustration). Turn the jack handle clockwise until the tire clears the ground. Remove the lug nuts and pull the wheel off. Replace it with the spare. Install the lug nuts with the beveled edges facing in. Tighten them snugly. Don’t attempt to tighten them completely until the vehicle is lowered or it could slip off the jack. Turn the jack handle counterclockwise to lower the vehicle. Remove the jack and tighten the lug nuts in a diagonal pattern. Install the cover (and trim ring, if used) and be sure it’s snapped into place all the way around. Stow the tire, jack and wrench. Unblock the wheels.

don’t exceed 30 mph and the distance is not over 40 miles. Before towing, check the transmission fluid level (see Chapter 1). If the level is below the HOT line on the dipstick, add fluid or use a towing dolly. Caution: Never tow a vehicle with an automatic transaxle from the rear with the front wheels on the ground. When towing a vehicle equipped with a manual transaxle with all four wheels on the ground, be sure to place the shift lever in neutral and release the parking brake. Equipment specifically designed for towing should be used. It should be attached to the main structural members of the vehicle, not

the bumpers or brackets. Safety is a major consideration when towing and all applicable state and local laws must be obeyed. A safety chain system must be used at all times.

Towing As a general rule, the vehicle (drive) wheels off the ground. If they dolly. The ignition key must be in the lock mechanism isn’t strong enough while towing.

should be towed with the front can’t be raised, place them on a ACC position, since the steering to hold the front wheels straight

Vehicles equipped with an automatic transaxle can be towed from the front only with all four wheels on the ground, provided that speeds

The jack fits over the rocker panel flange (there are two jacking points on each side of the vehicle, indicated by a notch in the rocker panel flange)

0-17

Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum, varnish and carbon. Most carburetor cleaners leave a dry-type lubricant film which will not harden or gum up. Because of this film it is not recommended for use on electrical components. Brake system cleaner is used to remove grease and brake fluid from the brake system, where clean surfaces are absolutely necessary. It leaves no residue and often eliminates brake squeal caused by conta-

minants. Electrical cleaner removes oxidation, corrosion and carbon deposits from electrical contacts, restoring full current flow. It can also be used to clean spark plugs, carburetor jets, voltage regulators and other parts where an oil-free surface is desired. Demoisturants remove water and moisture from electrical components such as alternators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive, non-corrosive and non-

flammable. Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and, depending on the type, are rinsed off either with water or solvent.

Lubricants Motor oil is the lubricant formulated for use in engines. It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) from 5 to 80. The recommended weight of the oil depends on the season, temperature and the demands on the engine. Light oil is used in cold climates and under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights from 5W-20 to 20W-S0. Gear oil is designed to be used in differentials, manual transmissions and other areas where high-temperature lubrication is required. Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered, such as for wheel bearings, balljoints, tie-rod ends and universal joints. High-temperature wheel bearing grease is designed to withstand the extreme temperatures encountered by wheel bearings in disc brake equipped vehicles. It usually contains molybdenum disulfide (moly), which is a dry-type lubricant. White grease is a heavy grease for metal-to-metal applications where water is a problem. White grease stays soft under both low and high temperatures (usually from -100 to +190-degrees F), and will not wash off or dilute in the presence of water. Assembly lube is a special extreme pressure lubricant, usually containing moly, used to lubricate high-load parts (such as main and rod bearings and cam lobes) for initial start-up of a new engine. The assembly lube lubricates the parts without being squeezed out or washed away until the engine oiling system begins to function. Silicone lubricants are used to protect rubber, plastic, viny! and

nylon parts. Graphite lubricants are used where oils cannot be used due to contamination problems, such as in locks. The dry graphite will lubricate metal parts while remaining uncontaminated by dirt, water, oil or acids. It is electrically conductive and will not foul electrical contacts in

locks such as the ignition switch. Moly penetrants

loosen and lubricate frozen, rusted and cor-

roded fasteners and prevent future rusting or freezing. Heat-sink grease is a special electrically non-conductive grease

that is used for mounting electronic ignition modules where it is essential that heat is transferred away from the module.

Sealants RTV sealant is one of the most widely used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills surface irregularities, remains flexible, doesn’t shrink, is relatively easy to remove, and is used as a supplementary sealer with almost all low and medium temperature gaskets. , Anaerobic sealant is much like RTV in that it can be used either to seal gaskets or to form gaskets by itself. It remains flexible, is solvent resistant and fills surface imperfections. The difference between an anaerobic sealant and an RTV-type sealant is in the curing. RTV cures when exposed to air, while an anaerobic sealant cures only in the absence of air. This means that an anaerobic sealant cures only after the assembly of parts, sealing them together. Thread and pipe sealant is used for sealing hydraulic and pneumatic fittings and vacuum lines. It is usually made from a Teflon compound, and comes in a spray, a paint-on liquid and as a wrap-around tape.

Chemicals Anti-seize compound prevents seizing, galling, cold welding, rust and corrosion in fasteners. High-temperature ant-seize, usually made with copper and graphite lubricants, is used for exhaust system and exhaust manifold bolts. Anaerobic locking compounds are used to keep fasteners from vibrating or working loose and cure only after installation, in the absence of air. Medium strength locking compound is used for small nuts, bolts and screws that may be removed later. High-strength locking compound is for large nuts, bolts and studs which aren't removed on a regular basis. Oil additives range from viscosity index improvers to chemical treatments that claim to reduce internal engine friction. It should be noted that most oil manufacturers caution against using additives with their oils. Gas additives perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that build up on carburetor, fuel injection and intake parts. They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers. Some additives contain upper cylinder lubricants for valves and piston rings, and others contain chemicals to remove condensation from the gas tank.

Miscellaneous Brake fluid is specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake systems. Care must

be taken so this fluid does not come in contact with painted surfaces or plastics. An opened container should always be resealed to prevent contamination by water or dirt. Weatherstrip adhesive is used to bond weatherstripping around doors, windows and trunk lids. It is sometimes used to attach trim pieces. Undercoating is a petroleum-based, tar-like substance that is designed to protect metal surfaces on the underside of the vehicle from corrosion. It also acts as a sound-deadening agent by insulating the bottom of the vehicle. Waxes and polishes are used to help protect painted and plated surfaces from the weather. Different types of paint may require the use

of different types of wax and polish. Some polishes utilize a chemical or abrasive cleaner to help remove the top layer of oxidized (dull) paint on older vehicles. In recent years many non-wax polishes that contain a wide variety of chemicals such as polymers and silicones have been introduced. These non-wax polishes are usually easier to apply and last longer than conventional waxes and polishes.

0-18

Conversion

factors

Length (distance) Inches (in) Feet (ft) Miles

X X X

25.4 0.305 1.609

=Millimetres (mm) = Metres (m) = Kilometres (km)

X X xX

0.0394 3.281 0.621

= Inches (in) = Feet (ft) = Miles

Volume (capacity) Cubic inches (cu in; in’)

X 16.387

= Cubic centimetres (cc; cm’)

xX

0.061

Imperial pints (Imp pt)

X. 0.568

= Litres (I)

x

1.76

Imperial quarts (Imp qt) Imperial quarts (Imp qt)

X X

=Litres (I) =US quarts (US qt)

x X

0.88 0.833

= Imperial quarts (Imp qt) =Imperial quarts (Imp qt)

1.137 1.201

= Cubic inches (cu in; in’)

= Imperial pints (Imp pt)

US quarts (US qt)

X

0,946

=Litres (I)

X

1.057.

=US quarts (US qt)

Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

X X X

4.546 1.201 3.785

= Litres (I) =US gallons (US gal) =Litres (I)

x X X

0.22 0.833 0.264

= Imperial gallons (Imp gal) =Imperial gallons (Imp gal) =US gallons (US gal)

X X

28.35 0.454

=Grams (g) = Kilograms (kg)

x X

01035 2.205

Ounces (02) =Pounds (Ib)

Ounces-force (ozf; 0z) Pounds-force (Ibf; Ib)

X X

0.278 4.448

= Newtons = Newtons

(N) (N)

x X

= Ounces-force (ozf; oz) = Pounds-force (bf; Ib)

Newtons

X

0.1.

=Kilograms-force (kgf; kg)

X

3.6 0.225 9.81

= Newtons

X

0.070

= Kilograms-force per square

X

14.223

= Pounds-force

Mass (weight) Ounces (oz) Pounds (Ib)

Force (N)

(N)

Pressure Pounds-force

per square inch

(psi; Ibf/in?; Ib/in?)

centimetre (kgf/cm?; kg/cm?)

Pounds-force per square inch

X

0.068

=Atmospheres

(atm)

per square inch

(psi; Ibf/in?; Ib/in?) xX

14.696

= Pounds-force

(psi; Ibf/in?; Ib/in?)

per square inch

(psi; Ibf/in?; Ib/in?)

Pounds-force per square inch

xX

0.069

= Bars

x

14.5

= Pounds-force per square inch

X

6.895

= Kilopascals (kPa)

X

0.145

= Pounds-force per square inch

X

0.01

= Kilograms-force per square

x

98.1

X

0.868

= Pounds-force inches

Xx

8.85

= Pounds-force inches = Pounds-force inches

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?; Ib/in?)

Pounds-force per square inch

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?: Ib/in?)

Kilopascals (kPa)

= Kilopascals (kPa)

centimetre (kgf/cm?; kg/cm?)

Torque (moment of force) Pounds-force

inches

X

1.152

(Ibf in; Ib in) Pounds-force

= Kilograms-force centimetre

(kgf cm; kg cm)

(Ibf in; Ib in)

inches

xX

0.113

=Newton

metres (Nm)

inches

X

0.083

= Pounds-force feet (Ibf ft; Ib ft)

x

12

(Ibf in; Ib in) Pounds-force feet (Ibf ft; Ib ft)

X

0.138

= Kilograms-force metres

X

7.233

Pounds-force feet (Ibf ft; Ib ft)

X

1.356

= Newton

X

0.738

Néwton

X

0.102

= Kilograms-force metres (kgf m; kg m)

X

9.804

X

745.7

=Watts

X

0.0013.

X

1.609

= Kilometres per hour (km/hr; kph) X

0.621

Miles per gallon, Imperial (mpg)

X

0.354

= Kilometres per litre (km/I)

X

2.825

Miles per gallon, US (mpg)

X

0.425

= Kilometres per litre (km/1)

X

2.352

(Ibf in; Ib in) Pounds-force

(Ibf in; Ib in) (Ibf in; Ib in) = Pounds-force feet (Ibf ft; lb ft)

(kgf m; kg m) metres (Nm)

metres (Nm)

=Pounds-force feet (Ibf ft; Ib ft)

=Newton

metres (Nm)

Power Horsepower (hp)

(W)

=Horsepower

(hp)

Velocity (speed) Miles per hour (miles/hr; mph)

=Miles per hour (miles/hr; mph)

Fuel consumption* =Miles per gallon, Imperial (mpg)

=Miles per gallon, US (mpg)

Temperature Degrees Fahrenheit

=

(°C x 1.8) + 32

Degrees Celsius (Degrees Centigrade; °C)

*/t is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (//100km), where mpg (Imperial) x I/100 km = 282 and mpg (US) x 1/100 km = 235

= (°F - 32) x 0.56

0-19

Safety first! Regardless of how enthusiastic you may be about getting on with the job at hand, take the time to ensure that your safety is not jeopardized. A moment’s lack of attention can result in an accident, as can failure to observe certain simple safety precautions. The possibility of an accident will always exist, and the following points should not be considered a comprehensive list of all dangers. Rather, they are intended to make you aware of the risks and to encourage a safety conscious approach to all work you carry out on your vehicle.

Essential DOs and DON’Ts DON’T rely on a jack when working under the vehicle. Always use approved jackstands to support the weight of the vehicle and place them under the recommended lift or support points. DON’T attempt to loosen extremely tight fasteners (i.e. wheel lug nuts) while the vehicle is on a jack - it may fall. DON’T start the engine without first making sure that the transmission is in Neutral (or Park where applicable) and the parking brake is set. DON’T remove the radiator cap from a hot cooling system - let it cool or cover it with a cloth and release the pressure gradually. DON’T attempt to drain the engine oil until you are sure it has cooled to the point that it will not burn you. DON’T touch any part of the engine or exhaust system until it has cooled sufficiently to avoid burns. DON’T siphon toxic liquids such as gasoline, antifreeze and brake fluid by mouth, or allow them to remain on your skin. DON’T inhale brake lining dust - it is potentially hazardous (see Asbestos below). DON’T allow spilled oil or grease to remain on the floor - wipe it up before someone slips on it. DON’T use loose fitting wrenches or other tools which may slip and cause injury. DON’T push on wrenches when loosening or tightening nuts or bolts. Always try to pull the wrench toward you. If the situation calls for pushing the wrench away, push with an open hand to avoid scraped knuckles if the wrench should slip. DON’T attempt to lift a heavy component alone - get someone to help

you. DON’T rush or take unsafe shortcuts to finish a job. DON’T allow children or animals in or around the vehicle while you are working on it. DO

wear

eye protection

when

using power tools such

as a drill,

sander, bench grinder, etc. and when working under a vehicle. DO keep loose clothing and long hair well out of the way of moving parts.

DO make sure that any hoist used has a safe working load rating adequate for the job. DO get someone to check on you periodically when working alone on a vehicle. DO carry out work in a logical sequence and make sure that everything is correctly assembled and tightened. DO keep chemicals and fluids tightly capped and out of the reach of children and pets. DO remember that your vehicle’s safety affects that of yourself and others. If in doubt on any point, get professional advice.

Remember at all times that gasoline is highly flammable. Never smoke or have any kind of open flame around when working on a vehicle. But the risk does not end there. A spark caused by an electrical short circuit, by two metal surfaces contacting each other, or even by static electricity built up in your body under certain conditions, can ignite gasoline vapors, which in a confined space are highly explosive. Do not, under any circumstances, use gasoline for cleaning parts. Use

an approved safety solvent. Always disconnect the battery ground (-) cable at the battery before working on any part of the fuel system or electrical system. Never risk spilling fuel on a hot engine or exhaust component. It is strongly recommended that a fire extinguisher suitable for use on fuel and electrical fires be kept handy in the garage or workshop at all times. Never try to extinguish a fuel or electrical fire with water.

Fumes Certain fumes are highly toxic and can quickly cause unconsciousness and even death if inhaled to any extent. Gasoline vapor falls into this category, as do the vapors from some cleaning solvents. Any draining or pouring of such volatile fluids should be done in a well ventilated area. When using cleaning fluids and solvents, read the instructions on the container carefully. Never use materials from unmarked containers. Never run the engine in an enclosed space, such as a garage. Exhaust fumes contain carbon

monoxide,

which

is extremely poiso-

nous. If you need to run the engine, always do so in the open air, or at least have the rear of the vehicle outside the work area. If you are fortunate enough to have the use of an inspection pit, never drain or pour gasoline and never run the engine while the vehicle is over the pit. The fumes, being heavier than air, will concentrate in the

pit with possibly lethal results.

The battery Never create a spark or allow a bare light bulb near a battery. They normally give off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery ground (-) cable at the battery before working on the fuel or electrical systems. If possible, loosen the filler caps or cover when charging the battery from an external source (this does not apply to sealed or maintenance-free batteries). Do not charge at an excessive rate or the battery may burst. Take care when adding water to a non maintenance-free battery and when carrying a battery. The electrolyte, even when diluted, is very corrosive and should not be allowed to contact clothing or skin. Always wear eye protection when cleaning the battery to prevent the caustic deposits from entering your eyes.

Household current When using an electric power tool, inspection light, etc., which operates on household current, always make sure that the tool is correctly connected to its plug and that, where necessary, it is properly grounded. Do not use such items in damp conditions and, again, do not create a spark or apply excessive heat in the vicinity of fuel or fuel

vapor.

Secondary ignition system voltage

Asbestos Certain friction, insulating, sealing, and other products brake linings, brake bands, clutch linings, torque converters, etc. - may contain asbestos. Extreme care must be taken inhalation of dust from such products, since it is hazardous to in doubt, assume that they do contain asbestos.

Fire

such as gaskets, to avoid health. If

A severe electric shock can result from touching certain parts of the ignition system (such as the spark plug wires) when the engine is

running or being cranked, particularly if components are damp or the insulation is defective. In the case of an electronic ignition system, the secondary system voltage is much higher and could prove fatal.

0-20

Troubleshooting Contents Symptom

Section

E

Engine

Symptom

Section

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Chapter 12

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12-30

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IND-1

Index A

B

About this manual, 0-5 Accelerator cable, replacement, 4-9 Air conditioning and heater blower motor, removal and installation, 3-8

Back-up light switch, check and replacement, 7A-4 Balljoints, check and replacement, 10-7 Battery

control assembly, removal and installation, 3-11

Air conditioning system check and maintenance, 3-12

compressor, removal and installation, 3-13 condenser, removal and installation, 3-14

evaporator and expansion valve, removal and installation, 3-14 receiver and drier, removal and installation, 3-14 Air filter assembly, removal and installation, 4-9 Air filter replacement, 1-21 Airbag passenger, removal and installation, 11-16 system, general information, 12-18

Alignment, wheel, general information, 10-19 Alternator removal and installation, 5-5 Antenna, removal and installation, 12-12 Antifreeze, general information, 3-2 Anti-lock Brake system (ABS), general information, 5-2

Automatic transaxle, 7B-1 through 7B-10 band adjustment, 1-23 diagnosis, general, 7B-1 driveaxle seal replacement, 7B-2 fluid and filter change, 1-22 fluid level check, 1-10 general information and identification, 7B-1 mount, check and replacement, 7B-7 neutral start switch, check, adjustment and replacement, 7B-5 removal and installation, 7B-7

shift cables, removal, installation and adjustment, 7B-3 shift lever, removal and installation, 7B-5 shift/ignition interlock system, description, check and cable replacement, 7B-5 throttle pressure cable, adjustment and replacement, 7B-2 Automotive chemicals and lubricants, 0-17

cables, check and replacement, 5-2

check, maintenance and charging, 1-13 jump starting, 0-15 removal and installation, 5-2 Battery electrolyte, level check, 1-8 Bearings main and connecting rod, inspection and selection, 2B-15 main, oil clearance check, 2B-18 rod bearing installation and oil clearance check, 2B-19 Blower motor, heater and air conditioning

circuit check and component replacement, 3-7 removal and installation, 3-8 Body, 11-1 through 11-24 general information, 11-1 maintenance, 11-1 repair

major damage, 11-3 minor damage, 11-2 Booster battery (jump) starting, 0-15 Brakes, 9-1 through 9-24

Anti-lock Brake system (ABS), general information, 9-2 caliper, removal, overhaul and installation, 9-5 disc, inspection, removal and installation, 9-6 drum, shoes, replacement, 9-8 fluid, level check, 1-8

general information, 9-1 hoses and lines, inspection and replacement, 9-14 light switch, check, replacement and adjustment, 9-22 master cylinder, removal, installation and vacuum seal replacement, 9-12 pads, replacement, 9-2 parking shoes, removal, inspection and installation, 9-16 parking, cable(s) replacement, 9-21 parking, lever and automatic adjuster assembly, removal and installation, 9-20

Index

IND-2 a

power brake booster, general information, removal and installation, 9-15

proportioning valve, description, check and replacement, 9-13 system bleeding, 9-14 system check, 1-18 wheel cylinder, removal, overhaul and installation, 9-12 Bulb

Cooling, heating and air conditioning systems, 3-1 through 3-16 Cowl cover, removal and installation, 11-22

Crankshaft inspection, 2B-14 installation and main bearing oil clearance check, 2B-18 removal, 2B-10 Crankshaft front oil seal, replacement, 2A-11

Crankshaft position sensor, 6-5

replacement, 12-9

Cruise control system, description and check, 12-16 CV joint inspection and driveaxle boot replacement, 8-9

headlight, 12-7 Bumpers, removal and installation, 11-6

Cylinder head cleaning and inspection, 2B-7

Buying parts, 0-8

disassembly, 2B-6

reassembly, 2B-9 removal and installation, 2A-17

C

Cylinder honing, 2B-12

Cable clutch, removal and installation, 8-2 hood, latch, removal and installation, 11-6 parking brake replacement, 5-21 shift, removal, installation and adjustment

D

automatic, 7B-3

manual, 7A-1 throttle pressure, adjustment and replacement, 7B-2 Cable replacement accelerator, 4-9 battery, 5-2

Caliper, disc brake, removal, overhaul and installation, 5-5 Camshaft oil seal, replacement, 2A-11 Camshaft position sensor, 6-7

Camshaft, removal, inspection and installation, 2A-14 Capacities, 1-2 Catalytic converter system, 6-11 Center console, removal and installation,

Dashboard trim panels, removal and installation, 11-15 Defogger rear window

check and repair, 12-15 switch, check and replacement, 12-14 Diagnosis, 0-20 Disc brake caliper, removal, overhaul and installation, 5-5

Disc brake pads, replacement, 5-2 Disc, brake, inspection, removal and installation, 5-6 Door

latch, lock cylinder and outside handle, removal and installation, 11-9 lock system (power), description and check, 12-16 removal and installation, 11-13

11-20

Charging system alternator, removal and installation, 5-5 check. 5-5 general information and precautions

trim panel, removal and installation, 11-8

window glass, removal, installation and adjustment, 11-9 window regulator, removal and installation, 11-11

5-4

Chassis electrical system, 12-1 through 12-30 Chassis lubrication, 1-18

Driveaxle boot check, 1-24

boot, replacement and CV joint inspection, 8-9

Circuit Breakers/Positive Temperature Coefficient (PTC) devices, general information, 12-3

Clutch

cable, removal and installation, 8-2 components, removal, inspection and installation, 8-3 description and check, 8-1 release bearing and lever, removal, inspection and installation, 8-6 start switch, check, replacement and adjustment, 8-7 Clutch and driveaxles, 8-1 through 8-12 Coil spring/strut, replacement, 10-4

Coil, ignition, check and replacement, 5-4 Compression check, 2B-3

general information and inspection, 8-7

removal and installation, 8-8 seal replacement, 7A-6, 7B-2 Drivebelt check, adjustment and replacement, 1-20 Drum brake shoes, replacement, 5-8

E

Electric rear view mirrors, description and check, 12-16 Electrical troubleshooting, general information, 12-2

Compressor, air conditioning, removal and installation, 3-13

Emissions and engine control systems, 6-1 through 6-12

Condenser, air conditioning, removal and installation, 3-14 Control arm, removal, inspection and installation, 10-7 Conversion factors, 0-18

general information, 6-1 Engine, 2A-1 through 2A-24

Coolant, level check, 1-7 Cooling system

block cleaning, 2B-11 inspection, 2B-12

adding refrigerant, 3-12 antifreeze, general information, 3-2 check, 1-14

camshaft oil seal, replacement, 2A-11 camshaft, removal, inspection and installation, 2A-14 cooling fan and circuit, check and component replacement, 3-3

coolant reservoir, removal and installation, 3-5

crankshaft

fan and circuit, check and component replacement, 3-3

radiator, removal and installation, 3-4 servicing (draining, flushing and refilling), 1-24 temperature sending unit, check and replacement, 3-6 thermostat, check and replacement, 3-2 water pump

check, 3-6 replacement, 3-6

inspection, 2B-14

installation and main bearing oil clearance check, 2B-18 removal, 2B-10 front oil seal, replacement, 2A-11 cylinder compression check, 2B-3 cylinder head

cleaning and inspection, 2B-7 disassembly, 2B-6

Index

IND-3

reassembly, 2B-9

general information, 4-1

removal and installation, 2A-17 cylinder honing, 2B-12 electrical systems, general information, 5-1 exhaust manifold, removal and installation, 2A-6 flywheel/driveplate, removal and installation, 2A-22 initial start-up and break-in after overhaul, 2B-21 intake manifold, removal and installation, 2A-5 main and connecting rod bearings, inspection and selection, 2B-15 mounts, check and replacement, 2A-23

lines and fittings, repair and replacement, 4-4 pressure regulator/fuel filter, replacement, 4-12 pressure relief, 4-2 pump, removal and installation, 4-6 pump/fuel pressure, check, 4-2 tank cleaning and repair, 4-6 removal and installation, 4-5 Fuses

oil and filter change, 1-11

general information, 12-2

oil level check, 1-6

Fusible links, general information, 12-3

oil pan, removal and installation, 2A-18 oil pump, removal, inspection and installation, 2A-19 overhaul disassembly sequence, 2B-6

general information, 2B-3 _ Teassembly sequence, 2B-16

piston rings, installation, 2B-16 pistons and connecting rods, inspection, 2B-13

pistons and connecting rods, installation and rod bearing oil

G

General engine overhaul procedures, 2B-1 through 2B-22 Glass, door window, removal, installation and adjustment, 11-9 Glass, quarter, replacement, 11-13 Glovebox, 11-16

Grille, radiator, removal and installation, 11-6

clearance check, 2B-19 pistons and connecting rods, removal, 2B-9 rear main oil seal, replacement, 2A-22

rebuilding alternatives, 2B-5

iL

removal and installation, 2B-4

removal, methods and precautions, 2B-4 repair operations possible with the engine in the vehicle, 2A-3 rocker arm assembly, removal, inspection and installation, 2A-13

timing belt, removal, inspection and installation, 2A-8 Top Dead Center (TDC) for number one piston, locating, 2A-3 vacuum gauge diagnostic checks, 2B-4 valve cover, removal and installation, 2A-4 valve lash adjusters, removal, inspection and installation, 2A-15 valve springs, retainers and seals, replacement, 2A-16

valves, servicing, 2B-9 Engine Coolant Temperature (ECT) sensor, 6-6 Engine electrical systems, 5-1 through 5-8 Evaporative emissions control (EVAP) system, 6-10 Evaporative emissions control system check, 1-26 Evaporator and expansion valve, air conditioning, removal and installation, 3-14 Exhaust Gas Recirculation (EGR) system, 6-9

Exhaust manifold, removal and installation, 2A-6 Exhaust system check, 1-17 servicing and general information, 4-15

Hazard flasher/turn signal, check and replacement, 12-4

Headlight adjustment, 12-8 bulb, replacement, 12-7 housing, removal and installation, 12-8 leveling switch, check and replacement, 12-7 switch, check and replacement, 12-6 Heater and air conditioning blower motor, removal and installation, 3-8 control assembly, removal and installation, 3-11 Heater core, replacement, 3-8 Hinges and locks, maintenance, 11-3 Hood . latch and cable, removal and installation, 11-6 removal, installation and adjustment, 11-3 Horn, check and replacement,

installation, 10-8

F

t

Fault finding, 0-20

Ignition key lock cylinder, replacement, 12-6

Filter replacement

switch, replacement, 12-5 Ignition system check, 5-3

air, 1-21 engine oil, 1-11 fuel, 1-25

Filter, air, assembly, removal and installation, 4-9 Fluid level checks, 1-6 Fluids and lubricants, recommended,

12-13

Hoses and lines (brakes) inspection and replacement, 5-14 Hoses, underhood, check and replacement, 1-15 Hub and bearing assembly (rear), removal and installation, 10-11 Hub, bearing and steering knuckle, removal, inspection and

1-1

Flywheel/driveplate, removal and installation, 2A-22 Front end alignment, general information, 10-19 Fuel and exhaust systems, 4-1 through 4-16 Fuel injection system check, 4-11

general information, 4-10

injectors, check, removal and installation, 4-14

Fuel system check, 1-19 filter replacement, 1-25 fuel level sending unit, check and replacement, 4-7

coil, check and replacement, 5-4 general information and precautions, 5-3 shift interlock, description, check and cable replacement, 7B-5

Information sensors camshaft position sensor, 6-7 crankshaft position sensor, 6-5 Engine Coolant Temperature (ECT) sensor, 6-6 Intake Air Temperature (IAT) sensor, 6-7

knock sensor, 6-8

Manifold Absolute Pressure (MAP) sensor, 6-5 oxygen sensor, 6-4 park/neutral position switch, 6-8 Throttle Position Sensor (TPS), 6-6

Vehicle Speed Sensor (VSS), 6-7

Index

IND-4 a

Oil seal

Information sensors and output actuators, 6-4

camshaft, replacement, 2A-11

Initial start-up and break-in after overhaul, 2B-21

crankshaft, front, replacement, 2A-11

Instrument cluster, removal and installation, 12-13

rear main, replacement, 2A-22

Instrument panel top cover, removal and installation, 11-14

Oil, level check, 1-6

Instrument panel, removal and installation, 11-17

On Board Diagnosis (OBD-II) system, description and trouble

Intake Air Temperature (IAT) sensor, 6-7

code access, 6-2

Intake manifold, removal and installation, 2A-5

Output actuators and information sensors, 6-4 Oxygen sensor, 6-4

Introduction to routine maintenance, 1-6 Introduction to the Dodge and Piymouth Neon, 0-5

J

P

Jacking and towing, 0-16

Pads, disc brake, replacement, 5-2

K

Parking brake cable(s), replacement, 5-21 Parking brake lever and automatic adjuster assembly, removal

Park/Neutral position switch, 6-8

and installation, 5-20

Parking brake shoes, removal, inspection and installation, 5-16 Piston rings, installation, 2B-16 Pistons and connecting rods inspection, 2B-13 installation and rod bearing oil clearance check, 2B-19

Knock sensor, 6-8

L

Latch and trunk lid, removal, installation and adjustment, 11-14 Lateral arms, removal and installation, 10-10 Lock cylinder

general information, 12-3

;

Power door lock system, description and check, 12-16 Power steering fluid, level check, 1-10 pump, removal and installation, 10-16 system bleeding, 10-18

M Main and connecting rod bearings, inspection and selection, 2B-15 Maintenance schedule, 1-5

Power window system, description and check, 12-17

Powertrain Control Module (PCM), replacement, 6-8 Proportioning valve, description, check and replacement, 5-13

Maintenance techniques, tools and working facilities, 0-8 Manifold exhaust, removal and installation, 2A-6 intake, removal and installation, 2A-5 Manifold Absolute Pressure (MAP) sensor, 6-5 Manual transaxle, 7A-1 through 7A-6

Q

Quarter glass, replacement, 11-13

back-up light switch, check and replacement, 7A-4

driveaxle seal replacement, 7A-6 general information, 7A-1 lubricant change, 1-24 lubricant level check, 1-17

R

Radiator grille, removal and installation, 11-6 Radiator, removal and installation, 3-4

overhaul, general information, 7A-6 removal and installation, 7A-4

Radio and speakers, removal and installation, 12-11

shift cables, removal, installation and adjustment, 7A-1

Radio antenna, removal and installation, 12-12

shift lever, removal and installation, 7A-3

Rear main oil seal, replacement, 2A-22 Rear view mirrors, description and check, 12-16 Receiver and drier, removal and installation, 3-14 Recommended lubricants and fluids, 1-1

seal

Relays, general information and testing, 12-4

removal and installation, 11-21

Rocker arm assembly, removal, inspection and installation, 2A-13

Multi-function switch, check and replacement, 12-4

Rotor (brake), inspection, removal and installation, 5-6 Routine maintenance, 1-1 through 1-30 maintenance schedule, 1-5

N Neutral start switch, check, adjustment and replacement,

O

Oil pan, removal and installation, 2A-18 Oil pump,

j

Power brake booster, general information, removal and installation, 5-15

1-1

Master cylinder, removal, installation and vacuum replacement, 5-12 Mirrors electric rear view, description and check, 12-16

;

‘

Positive Temperature Coefficient (PTC)/ Circuit Breakers, devices,

ignition key, replacement, 12-6

Lubricants and fluids, recommended,

Positive Crankcase Ventilation (PCV) valve check and

replacement, 1-26

door lock and outside handle, removal and installation, 11-9 Locks and hinges, maintenance, 11-3

a4 removal, 2B-9 Positive Crankcase Ventilation (PCV) system, 6-9

removal, inspection and installation, 2A-19

7B-5

S Safety first, 0-19 Scheduled maintenance, 1-5 Seat belt check, 1-29 Seats, removal and installation, 11-23

IND-5

Index Sending unit coolant temperature, check and replacement, 3-6 fuel level, check and replacement, 4-7 Shift cables, removal, installation and adjustment

Top Dead Center (TDC) for number one piston, locating, 2A-3 Towing the vehicle, 0-16

automatic, 7B-3 manual, 7A-1 Shift lever, removal and installation

Trailing arms, removal and installation, 10-9 Transaxle automatic

Tires and wheels, general information, 10-18 Tools, 0-11

band adjustment, 1-23 diagnosis, general, 7B-1 driveaxle seal replacement, 7B-2 fluid and filter change, 1-22

automatic, 7B-5 manual, 7A-3 Shift/ignition interlock system, description, check and cable replacement, 7B-5

Spark plug check and replacement, 1-26

fluid level check, 1-10 general information and identification, 7B-1 mount, check and replacement, 7B-7

wire check and replacement, 1-29 Speakers and radio, removal and installation, 12-11 Spindle, removal and installation, 10-11

neutral start switch, check, adjustment and replacement, 7B-5 removal and installation, 7B-7

front, removal and installation, 10-6

shift cables, removal, installation and adjustment, 7B-3 shift lever, removal and installation, 7B-5

rear, removal and installation, 10-8

shift/ignition interlock system, description, check and cable

Stabilizer(sway) bar and bushings

replacement, 7B-5 throttle pressure cable, adjustment and replacement, 7B-2

Starter motor removal and installation, 5-7

manual, 7A-1 through 7A-6

testing in vehicle, 5-6 Starting system, general information and precautions, 5-6

back-up light switch, check and replacement, 7A-4 driveaxle seal replacement, 7A-6 general information, 7A-1

Steering column covers, removal and installation, 11-19

gear, removal and installation, 10-14 knuckle, hub and bearing, removal, inspection and installation, 10-8 power, pump, removal and installation, 10-16 power, system bleeding, 10-18 system, general information, 10-12 tie-rod ends, removal and installation, 10-14 wheel alignment, general information, 10-19 wheel, removal and installation, 10-12 Suspension balljoints, check and replacement, 10-7 control arm, removal, inspection and installation, 10-7 stabilizer(sway) bar and bushings, removal and installation front, 10-6

lubricant change, 1-24 lubricant level check, 1-17 overhaul, general information, 7A-6 removal and installation, 7A-4

shift cables, removal, installation and adjustment, 7A-1 shift lever, removal and installation, 7A-3 Trouble codes, 6-3

Troubleshooting, 0-20 Trunk lid and latch, removal, installation and adjustment, 11-14 Tune-up and routine maintenance, 1-1 through 1-30 Tune-up, general information, 1-6

Turn signal/hazard flasher, check and replacement, 12-4

rear, 10-8

hub and bearing assembly (rear), removal and installation, 10-11 lateral arms, removal and installation, 10-10 strut /coil spring, replacement, 10-4 strut assembly

U Underhood hose check and replacement, 1-15 Upholstery and carpets, maintenance, 11-2

front, removal and installation, 10-3 rear, removal, inspection and installation, 10-9

trailing arms, removal and installation, 10-9 Suspension and steering check, 1-17 Suspension and steering systems, 10-1 through 10-20

Switch brake light, check and adjustment, 9-22 clutch start, check, replacement and adjustment, 8-7

headlight leveling, check and replacement, 12-7 headlight, check and replacement, 12-6 ignition, replacement, 12-5 light, back-up, check and replacement, 7A-4 multi-function, check and replacement, 12-4 neutral start, check, adjustment and replacement, 7B-5 wiper/washer, check and replacement, 12-5

7 Thermostat, check and rep!acement, 3-2 Throttle body, check, removal and installation, 4-12 Throttle Position Sensor (TPS), 6-6 Throttle pressure cable, adjustment and replacement, 7B-2 Tie-rod ends, removal and installation, 10-14 Timing belt, removal, inspection and installation, 2A-8 Tire and tire pressure checks, 1-9 Tire rotation, 1-16

V Vacuum gauge diagnostic checks, 2B-4 Vacuum seal replacement and master cylinder, removal, installation, 5-12 Valve cover, removal and installation, 2A-4 Valve lash adjusters, removal, inspection and installation, 2A-15

Valve springs, retainers and seals, replacement, 2A-16 Valve, proportioning, description, check and replacement, 5-13 Valves

servicing, 2B-9 Vehicle identification numbers, 0-6 Vehicle Speed Sensor (VSS), 6-7 Vinyl trim, maintenance, 11-1

W Water pump check, 3-6 replacement, 3-6 Wheel alignment, general information, 10-19 Wheel cylinder, removal, overhaul and installation, 5-12

Wheels and tires, general information, 10-18

IND-6

ne Window

door, glass, removal, installation and adjustment, 11-9 door, regulator, removal and installation, 11-11

power system, description and check, 12-17 rear defogger check and repair, 12-15 switch, check and replacement, 12-14

Index

EEE!

Windshield and fixed glass, replacement, 11-3

Windshield washer fluid, level check, 1-8 Windshield wiper motor, check and replacement, 12-14

Wiper blade inspection and replacement, 1-16 Wiper/washer switch, check and replacement, 12-5 Wiring diagrams, 12-19

Haynes Automotive

Manuals

NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

HAYNES XTREME CUSTOMIZING 11101 11102 11110 11150 11213 11255 11314 11315 11373

Sport Compact Customizing Sport Compact Performance In-car Entertainment Sport Utility Vehicle Customizing Acura GM Full-size Pick-ups Ford Focus Full-size Ford Pick-ups Honda Civic

24050 24055 24059 24060 24064 24065

ACURA 12020 12021 12050

Integra ‘86 thru '89 & Legend '86 thru '90 Integra '90 thru ’93 & Legend '91 thru '95 Acura TL all models '99 thru ’08

AMC

24070

Jeep CJ - see JEEP (50020)

14020 14025

AUDI 15020 15025 15026

24066

Mid-size modeis '70 thru '83 (Renault) Alliance & Encore 83 thru '87

24071 24072

4000 all models '80 thru '87 5000 all models ’77 thru ’83 5000 all models '84 thru '88

24075 24080 24081

AUSTIN-HEALEY Sprite - see MG Midget (66015)

BMW 18020 18021 18022 18025 18050

19020

19025

Buick Century '97 thru ‘05 Century (front-wheel drive) - see GM (38005) Buick, Oldsmobile & Pontiac Full-size (Front-wheel drive) '85 thru ’05 Buick Electra, LeSabre and Park Avenue; Oldsmobile Delta 88 Royale, Ninety Eight and Regency; Pontiac Bonneville Buick Oldsmobile & Pontiac Full-size

Ninety-eight, Pontiac Bonneville,

Catalina, Grandville, Parisienne Mid-size Regal & Century all rear-drive models with V6, V8 and Turbo '74 thru ’87 Regal - see GENERAL MOTORS (38010) Riviera - see GENERAL MOTORS (38030) Roadmaster - see CHEVROLET (24046) Skyhawk - see GENERAL MOTORS (38015) Skylark - see GM (38020, 38025) Somerset - see GENERAL MOTORS (38025)

CADILLAC 21030

Cadillac Rear Wheel Drive all gasoline models ’70 thru ’93 Cimarron - see GENERAL MOTORS (38015) DeVille - see GM (38031 & 38032) Eldorado - see GM (38030 & 38031) Fleetwood - see GM (38037) Seville - see GM (38030, 38031 & 38032)

CHEVROLET 24010 24015 24016 24017 24020 24024 24027 24032 24040 24041 10305 24045 24046

24047 24048

25015 10310 25020 25025

(Rear wheel drive) '70 thru '90 Buick Estate, Electra, LeSabre, Limited, Oldsmobile Custom Cruiser, Delta 88,

19030

EAGLE

Monte Carlo '95 thru '01 - see LUMINA (24048) Nova all V8 models '69 thru '79 Nova and Geo Prizm '85 thru '92

FIAT

Pick-ups ’67 thru ’87 - Chevrolet & GMC, all V8 & in-line 6 cyl, 2WD & 4WD ’67 thru ’87; Suburbans, Blazers & Jimmys '67 thru '91 Pick-ups ’88 thru ’98 - Chevrolet & GMC, full-size pick-ups '88 thru ’98, C/K Classic '99 &’00, Blazer & Jimmy ’92 thru ’94; Suburban '92 thru ’99; Tahoe & Yukon '95 thru '99 Pick-ups ’99 thru ’06 - Chevrolet Silverado & GMC Sierra '99 thru ’06, Suburban/Tahoe/ Yukon/Yukon XL/Avalanche '00 thru ’06 S-10 & S-15 Pick-ups 82 thru ’93, Blazer & Jimmy '83 thru '94, S-10 & Sonoma Pick-ups '94 thru '04, including Blazer, Jimmy & Hombre Chevrolet TrailBlazer & TrailBlazer EXT, GMC Envoy & Envoy XL, Oldsmobile Bravada ‘02 thru '07 Sprint ’85 thru ’88 & Geo Metro 89 thru ’01 Vans - Chevrolet & GMC ’68 thru '96 Chevrolet Express & GMC Savana Full-size Vans ’96 thru ’07

CHRYSLER 3/5 Series '82 thru ’92 3-Series incl. Z3 models ’92 thru ’98 3-Series, '99 thru '05, Z4 models 320i all 4 cyl models '75 thru ’83 1500 thru 2002 except Turbo '59 thru '77

BUICK 19010

Luv Pick-up all 2WD & 4WD ’72 thru ’82 Malibu ’97 thru ’00 - see GM (38026) Monte Carlo all models ‘70 thru ’88

Astro & GMC Safari Mini-vans 85 thru '05 Camaro V8 all models ’70 thru '81 Camaro all models '82 thru '92 Camaro & Firebird '93 thru '02 Cavalier - see GENERAL MOTORS (38016) Celebrity - see GENERAL MOTORS (38005) Chevelle, Malibu & El Camino ‘69 thru '87 Chevette & Pontiac T1000 ’76 thru '87 Citation - see GENERAL MOTORS (38020) Colorado & GMC Canyon '04 thru '08 Corsica/Beretta all models 87 thru 96 Corvette all V8 models '68 thru '82 Corvette all models '84 thru '96 Chevrolet Engine Overhaul Manual Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons '69 thru ’90 Impala SS & Caprice and Buick Roadmaster '91 thru '96 Impala - see LUMINA (24048) Lumina ’90 thru '94 - see GM (38010) Impala & Monte Carlo all models '06 thru '08 Lumina & Monte Carlo '95 thru '05 Lumina APV - see GM (38035)

eee

ene

ees

seeesreseesesresesea esas

25026 25027

25030 25035 25040

Chrysler Cirrus, Dodge Stratus, Plymouth Breeze '95 thru '00 Chrysler Engine Overhaul Manual Full-size Front-Wheel Drive ‘88 thru '93 K-Cars - see DODGE Aries (30008)

Laser - see DODGE Daytona (30030) Chrysler LHS, Concorde, New Yorker, Dodge Intrepid, Eagle Vision, ’93 thru '97 Chrysler LHS, Concorde, 300M, Dodge Intrepid, ‘98 thru '04 Chrysler 300, Dodge Charger & Magnum '05 thru '07 Chrysler & Plymouth Mid-size front wheel drive '82 thru ’95 Rear-wheel Drive - see Dodge (30050) PT Cruiser all models '01 thru ’03 Chrysler Sebring, Dodge Avenger '95 thru '05 Dodge Stratus '01 thru 05

DATSUN 28005 28007 28009 28012 28014 28018 28020 28022 28025

DODGE 30008 30010 30011 30012 30013

30016 30020 30021 30022 30023 30025 30030 30034 30035 30036 30040 30041 30042 30045 30050 30055 30060 30065

200SX all models ’80 thru ’83

B-210 all models '73 thru '78 210 all models '79 thru ’82

240Z, 280ZX 300ZX 510 &

260Z & 280Z Coupe '70 thru '78 Coupe & 2+2 '79 thru 83 - see NISSAN (72010) PL521 Pick-up ’68 thru '73

510 all models ’78 thru ’81 620 Series Pick-up all models ’73 thru '79 720 Series Pick-up - see NISSAN (72030) 810/Maxima all gasoline models, '77 thru ’84

400 & 600 - see CHRYSLER (25030) Aries & Plymouth Reliant '81 thru '89 Caravan & Plymouth Voyager '84 thru '95 Caravan & Plymouth Voyager ’96 thru '02 Challenger/Plymouth Saporro '78 thru ’83 Caravan, Chrysler Voyager, Town &

Country '03 thru '06 Colt & Plymouth Champ ’78 thru '87 Dakota Pick-ups all models '87 thru '96 Durango '98 & '99, Dakota '97 thru ’99 Dodge Durango models '00 thru '03 Dodge Dakota models '00 thru ’04 Dodge Durango '04 thru '06, Dakota '05 and '06 Dart, Demon,

Plymouth

Barracuda,

Duster & Valiant 6 cyl models '67 thru '76 Daytona & Chrysler Laser '84 thru '89 Intrepid - see CHRYSLER (25025, 25026) Neon all models '95 thru '99 Omni & Plymouth Horizon '78 thru '90 Dodge and Plymouth Neon '00 thru’05 Pick-ups all full-size models '74 thru 93 Pick-ups all full-size models '94 thru '01 Dodge Full-size Pick-ups '02 thru '08 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups '79 thru '93 Dodge/Plymouth/Chrysler RWD ’71 thru ’89 Shadow & Plymouth Sundance '87 thru '94 Spirit & Plymouth Acclaim ‘89 thru '95 Vans - Dodge & Plymouth ‘71 thru ’03

eeceee erasers

esees

sare nsesecre

aescereaca

errr

a

Talon - see MITSUBISHI (68030, 68031) Vision - see CHRYSLER (25025) 34010 34025

FORD 10355 36004 36006 36008 36012 10320 36016 36020 36022 36024 36025 36028 36030 36032 36034 36036 36044 36048 36049 36050 36051 36052 36054 36058 36059 36060 36061 36062 36066 36070 36071 36074 36075 36078 36082 36086 36090 36094 36097

124 Sport Coupe & Spider '68 thru '78 X1/9 all models '74 thru '80 Ford Automatic Transmission Overhaul Aerostar Mini-vans all models '86 thru '97 Contour & Mercury Mystique ‘95 thru '00 Courier Pick-up all models '72 thru ’82 Crown Victoria & Mercury Grand Marquis ‘88 thru '06 Ford Engine Overhaul Manual Escort/Mercury Lynx all models 81 thru '90 Escort/Mercury Tracer ’91 thru '00 Ford Escape & Mazda Tribute '01 thru '07 Explorer & Mazda Navajo '91 thru '01 Ford Explorer & Mercury Mountaineer ‘02 thru ’07 Fairmont & Mercury Zephyr '78 thru '83 Festiva & Aspire '88 thru '97 Fiesta all models '77 thru '80 Focus all models '00 thru ’07 Ford & Mercury Full-size '75 thru '87 Ford & Mercury Mid-size ‘75 thru ’86 Mustang V8 all models '64-1/2 thru '73 Mustang II 4 cyl, V6 & V8 models '74 thru '78 Mustang & Mercury Capri ’79 thru '86 Mustang all models '94 thru '04 Mustang '05 thru '07 Pick-ups & Bronco ’73 thru '79 Pick-ups & Bronco ’80 thru '96 F-150 & Expedition '97 thru '03, F-250 '97 thru ’99 & Lincoln Navigator '98 thru ’02 Super Duty Pick-ups, Excursion '99 thru '06 F-150 full-size '04 thru '06 Pinto & Mercury Bobcat '75 thru ’80 Probe all models ’89 thru ’92 Ranger/Bronco Il gasoline models '83 thru '92 Ranger '93 thru '08 & Mazda Pick-ups '94 thru ’08 Taurus & Mercury Sable '86 thru '95 Taurus & Mercury Sable ’96 thru '05 Tempo & Mercury Topaz '84 thru '94 Thunderbird/Mercury Cougar '83 thru '88 Thunderbird/Mercury Cougar '89 and ’97 Vans all V8 Econoline models 69 thru '91 Vans full size ’92 thru ’05 Windstar Mini-van '95 thru '07

GENERAL 10360 38005 38010

MOTORS

GM Automatic Transmission Overhaul Buick Century, Chevrolet Celebrity, Oldsmobile Cutlass Ciera & Pontiac 6000 all models ’82 thru ’96 Buick Regal, Chevrolet Lumina,

Oldsmobile Cutlass Supreme & Pontiac Grand Prix (FWD) '88 thru '07

38015

Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza & Pontiac J-2000 & Sunbird '82 thru '94

38016

Chevrolet Cavalier & Pontiac Sunfire '95 thru ’04

38017 38020

Chevrolet Cobalt & Pontiac G5 ’05 thru '09 Buick Skylark, Chevrolet Citation,

Olds Omega, Pontiac Phoenix '80 thru '85 38025

38026 38027 38030 38031

38032 38035 38036

GEO 40030

Buick Skylark & Somerset, Oldsmobile Achieva & Calais and Pontiac Grand Am all models '85 thru '98 Chevrolet Malibu, Oids Alero & Cutlass, Pontiac Grand Am '97 thru '03 Chevrolet Malibu '04 thru '07 Cadillac Eldorado, Seville, Oldsmobile Toronado, Buick Riviera '71 thru '85 Cadillac Eldorado & Seville, DeVille, Fleetwood & Olds Toronado, Buick Riviera '86 thru '93

Cadillac DeVille '94 thru '05 & Seville '92 thru '04 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models '90 thru '96 Chevrolet Venture, Olds Silhouette, Pontiac Trans Sport & Montana '97 thru '05 General Motors Full-size Rear-wheel Drive - see BUICK (19025)

Metro - see CHEVROLET Sprint (24075) Prizm - ’85 thru '92 see CHEVY (24060), '93 thru '02 see TOYOTA Corolla (92036) Storm all models '90 thru '93 Tracker - see SUZUKI! Samurai (90010)

(Continued on other side) er

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514 ¢ (805) 498-6703

http://www.haynes.com

Haynes Automotive

Manuals (continued)

NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

GMC

68031 68035 68040

Vans & Pick-ups - see CHEVROLET

NISSAN

HONDA 42010 42011 42012 42013 42014 42015 42020 42021 42022 42023 42024 42025

42026 42035 42037 42040

Accord CVCC all models '76 thru ’83 Accord all models '84 thru '89 Accord all models ‘90 thru ’93 Accord all models ’94 thru ’97 Accord all models ’98 thru ’02 Honda Accord models ’03 thru 07 Civic 1200 all models '73 thru ‘79 Civic 1300 & 1500 CVCC ’80 thru ’83 Civic 1500 CVCC all models '75 thru ’79 Civic all models ’84 thru 91 Civic & del Sol 92 thru ’95 Civic '96 thru ’00, CR-V ’97 thru 01, Acura Integra ’94 thru ’00 Civic '01 thru ’05, CR-V ’02 thru 06 Honda Odyssey all models '99 thru ’04 Honda Pilot 03 thru '07, Acura MDX '01 thru '07 Prelude CVCC all models ’79 thru ’89

HYUNDAI 43010 43015 43050 43055

Elantra all models ’96 thru ’06 Excel & Accent all models ’86 thru ’98 Santa Fe all models ’01 thru ’06 Sonata all models ’99 thru 08

ISUZU 47017 47020

Eclipse 95 thru '05, Eagle Talon ’95 thru ’98 Mitsubishi Galant '94 thru ’03 Pick-up ’83 thru '96 & Montero ’83 thru 93

Hombre - see CHEVROLET S-10 (24071) Rodeo, Amigo & Honda Passport '89 thru ’02

300ZX all models including Turbo ’84 thru ’89 350Z & Infiniti G35 all models ’03 thru ’08 Altima all models ’93 thru ’06 Maxima all models ’85 thru ’92 Maxima all models ’93 thru ’04 Pick-ups ’80 thru 97 Pathfinder ’87 thru ’95

72031 72032 72040

Frontier Pick-up, Xterra, Pathfinder '96 thru ’04 Nissan Frontier & Xterra ’05 thru ’08 Pulsar all models ’83 thru ’86

72050 72051 72060

Quest Sentra Sentra Stanza

Cutlass V6 & V8 gas models ’74 thru ’88 For other OLDSMOBILE titles, see BUICK, CHEVROLET or GENERAL MOTORS listing. For PLYMOUTH

50020

50025 50029

50030 50035

KIA 54070

LEXUS

61030 61035 61036 61040 61041 61042

Cherokee, Comanche & Wagoneer all models ’84 thru ’01 CJ all models '49 thru ’86

Limited

Grand Cherokee all models ’93 thru '04 Grand Wagoneer & Pick-up ‘72 thru 91 Grand Wagoneer 84 thru ’91, Cherokee & Wagoneer '72 thru ’83, Pick-up ’72 thru ’88 Wrangler all models ’87 thru '03 Liberty '02 thru '04

Sephia '94 thru 01, Spectra ’00 thru '04 ES 300 - see TOYOTA Camry (92007) Navigator - see FORD Pick-up (36059) Rear-Wheel Drive all models ’70 thru ’05 GLC Hatchback (rear-wheel drive) '77 thru '83 GLC (front-wheel drive} '81 thru ’85 323 & Protogé '90 thru '00 MX-5 Miata '90 thru ‘97 MPV all models '89 thru '98 Navajo - see Ford Explorer (36024) Pick-ups ’72 thru 93 Pick-ups '94 thru ’00 - see Ford Ranger (36071) RX-7 all models '79 thru '85 RX-7 all models ’86 thru ’91 626 (rear-wheel drive) all modéls’79 thru '82 626/MX-6 (front-wheel drive) '83 thru '92 626, MX-6/Ford Probe '93 thru ’01 123 Series Diesel ’76 thru '85 190 Series four-cyl gas models, ‘84 thru '88 230/250/280 6 cyl sohc models ’68 thru '72

63025

280 123 Series gasoline models ’77 thru ’81

63030

350 & 450 all models

63040

C-Class: C230/C240/C280/C320/C350 '01 thru '07

'71 thru ’80

MERCURY 64200 Villager & Nissan Quest '93 thru '01 All other titles, see FORD Listing.

MG 66010 66015

MGB Roadster & GT Coupe ’62 thru ’80 MG Midget, Austin Healey Sprite '58 thru '80

MITSUBISHI 68020

68030

titles, see BUICK,

PORSCHE 80020 80025 80030 80035

911 914 924 944

except Turbo & Carrera 4 65 thru '89 all 4 cyl models '69 thru '76 all models including Turbo ’76 thru ’82 all models including Turbo ’83 thru ’89

RENAULT Alliance & Encore - see AMC (14020)

SAAB 84010

900 all models including Turbo ’79 thru ’88

SATURN 87010 87011 87020 87040

Saturn Saturn Saturn Saturn

all models '91 thru '02 lon '03 thru ’07 all L-series models '00 thru ’04 VUE ’02 thru ’07

SUBARU 89002 89003

1100, 1300, 1400 & 1600 ’71 thru '79 1600 & 1800 2WD & 4WD’’80 thru '94

89100 89101

Legacy all models ’90 thru ’99 Legacy & Forester ’00 thru ‘06

Cordia, Tredia, Galant, Precis & Mirage ‘83 thru '93 Eclipse, Eagle Talon & Ply. Laser '90 thru '94

90010

Samurai/Sidekick & Geo Tracker '86 thru '01

TOYOTA 92005 92006 92007 92008 92015 92020 92025 92030 92032 92035 92036 92037 92040 92045 92050 92055 92056 92060 92065

Spitfire all models '62 thru ’81 TR7 all models ’75 thru '81

Vw 96008 96009 96016

96017 96018 96020 96023 96030 96035 96040 96045

Beetle & Karmann Ghia ’54 thru ’79 New Beetle '98 thru ’05 Rabbit, Jetta, Scirocco & Pick-up gas

models '75 thru ’92 & Convertible ’80 thru ’92 Golf, GTI & Jetta ’93 thru 98 & Cabrio ‘95 thru ’02 Golf, GTI, Jetta 99 thru ’05 Rabbit, Jetta & Pick-up diesel ’77 thru 84 Passat ’98 thru '05, Audi A4 '96 thru ’01 Transporter 1600 all models ’68 thru ’79 Transporter 1700, 1800 & 2000 '72 thru ’79 Type 3 1500 & 1600 all models ’63 thru '73 Vanagon all air-cooled models ’80 thru ’83

97010 97015

120, 130 Series & 1800 Sports ’61 thru '73 140 Series all models ’66 thru ’74

97020 97040 97050

240 Series all models ’76 thru ’93 740 & 760 Series all models ’82 thru ’88 850 Series all models ’93 thru ’97

TECHBOOK

Camry all models ’83 thru '91 Camry all models ’92 thru '96 Camry, Avalon, Solara, Lexus ES 300 '97 thru ’01 Toyota Camry, Avalon and Solara and Lexus ES 300/330 all models ’02 thru ’06 Celica Rear Wheel Drive '71 thru ’85 Celica Front Wheel Drive ’86 thru '99 Celica Supra all models '79 thru ’92 Corolla all models '75 thru ’79 Corolla all rear wheel drive models ’80 thru '87 Corolla ail front wheel drive models '84 thru ’92 Corolla & Geo Prizm '93 thru '02 Corolla models '03 thru '05 Corolla Tercel all models '80 thru '82 Corona all models '74 thru '82 Cressida all models '78 thru '82 Land Cruiser FJ40, 43, 45, 55 '68 thru '82 Land Cruiser FJ60, 62, 80, FZJ80 '80 thru ’96 Matrix & Pontiac Vibe ’03 thru '08 MR2 all models '85 thru ’87

92070

Pick-up all models '69 thru '78

92075 92076 92077 92078

Pick-up all models Tacoma, 4Runner, Tacoma all models Tundra '00 thru '06

92079 92080 92081 92082

4Runner all models '03 thru ’09 Previa all models '91 thru 95 Prius all models ‘01 thru '08 RAV4 all models '96 thru ’05

'79 thru ’95 & T100 '93 thru '04 '05 thru '09 & Sequoia '01 thru ’06

MANUALS

10205 10206

Automotive Computer Codes OBD-II & Electronic Engine Management

10210

Automotive Emissions Control Manual

10215 10220 10225

Fuel Injection Manual, 1978 thru 1985 Fuel Injection Manual, 1986 thru 1999 Holley Carburetor Manual

10230 10240 10305 10310 10320 10330 10333 10340 10341 10345 10355 10360 10405 10410 10411 10415 10420 10425 10430

Rochester Carburetor Manual Weber/Zenith/Stromberg/SU Carburetors Chevrolet Engine Overhaul Manual Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repair Manual Engine Performance Manual Smail Engine Repair Manual, 5 HP & Less Small Engine Repair Manual, 5.5 - 20 HP Suspension, Steering & Driveline Manual Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Body Repair & Painting Automotive Brake Manual Automotive Anti-lock Brake (ABS) Systems Automotive Detaiing Manua! Automotive Electrical Manual Automotive Heating & Air Conditioning Automotive Reference Manual & Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual ATV Basics Scooters, Automatic Transmission 50cc

10435

SUZUKI

MERCEDES-BENZ 63012 63015 63020

models ’84 thru '88 V8 models except Turbo ’70 thru ’81 all models ‘82 thru ’92 Rear-wheel Drive '70 thru '87

CHEVROLET or GENERAL MOTORS listing.

XJ6 all 6 cyl models ’68 thru ’86 X.J6 all models ’88 thru ’94 XJi2 & XJS all 12 cyl models '72 thru ’85

MAZDA 61010 61011 61015 61016 61020

Fiero all Firebird Firebird Mid-size

For other PONTIAC

LINCOLN 59010

titles, see DODGE listing.

PONTIAC 79008 79018 79019 79040

94007 94010

VOLVO

PLYMOUTH

Trooper & Pick-up ’81 thru ’93

JEEP 50010

- see MERCURY Villager (64200) all models ’82 thru 94 & 200SX all models '95 thru ’04 all models '82 thru 90

OLDSMOBILE

JAGUAR 49010 49011 49015

Tercel all models ’87 thru ’94 2 Toyota Sienna all models '98 thru 06 Highlander & Lexus RX-330 '99 thru ’06

TRIUMPH

72010 72011 72015 72020 72021 72030

73015

92085 92090 92095

10440 10445 10450 10452

to 250cc

SPANISH MANUALS 98903 98904 98905 98910 98913 98915 99040 99041 99042 99055 99075 99077 99088 99091 99095 99100 99106 99110 99118 99125

Reparacién de Carroceria & Pintura Carburadores para los modelos Holley & Rochester Cédigos Automotrices de la Computadora Frenos Automotriz Electricidad Automotriz Inyeccién de Combustible 1986 al 1999 Chevrolet & GMC Camionetas '67 al '87 Chevrolet & GMC Camionetas '88 al '98 Chevrolet & GMC Camionetas Cerradas '68 al '95 Dodge Caravan & Plymouth Voyager '84 al '95 Ford Camionetas y Bronco '80 al '94 Ford Camionetas Cerradas '69 al ’91 Ford Modelos de Tamafio Mediano '75 al '86 Ford Taurus & Mercury Sable '86 al '95 GM Modelos de Tamanho Grande ’70 al '90 GM Modelos de Tamafio Mediano '70 al ’88 Jeep Cherokee, Wagoneer & Comanche *84 al '00 Nissan Camioneta '80 al '96, Pathfinder '87 al '95 Nissan Sentra '82 al ’94 Toyota Camionetas y 4Runner ’79 al '95 Over 100 Haynes motorcycle manuals also available

6-09

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514 © (805) 498-6703 ¢ http://www.haynes.com

Common

spark plug conditions NORMAL Symptoms:

Brown

electrode wear.

to grayish-tan

Correct

color and slight

heat range for engine and

operating conditions. When new spark plugs are Recommendation: installed, replace with plugs of the same heat range.

TOO HOT

WORN Symptoms:

Rounded

electrodes

with a small amount of deposits on the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy.

Recommendation: Plugs been left in the engine too

have

long. Replace with new plugs of the same heat range. Follow the recommended maintenance schedule.

CARBON

PREIGNITION

DEPOSITS

Symptoms: Dry sooty deposits indicate a rich mixture or weak igni-

tion. Causes misfiring, hard starting and hesitation. Recommendation: Make sure the plug has the correct heat range. Check for a clogged air filter or problem in the fuel system or engine management system. Also check for ignition system problems.

ASH DEPOSITS Symptoms:

deposits

valve guide seals to prevent

seep-

age of oil into the combustion chambers. Also try changing gasoline brands.

OIL DEPOSITS valve

Melted electrodes. white, but may be

dirty due to misfiring or flying debris in the combustion chamber. Can lead to engine damage. Recommendation: Check for the correct plug heat range, overadvanced ignition timing, lean fuel mixture, insufficient engine cooling and lack of lubrication.

Symptoms: Insulator has yellowish, glazed appearance. Indicates that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating.

Causes misfiring at high speeds Recommendation: _|nstall new plugs. Consider using a colder plug if driving habits warrant

DETONATION Symptoms:

Insulators

may

be

cracked or chipped. Improper gap setting techniques can also result

Symptoms: Oily coating caused by poor oil control. Oil is leaking worn

Symptoms: Insulators are

HIGH SPEED GLAZING

Light brown

encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfiring and hesitation during acceleration. Recommendation: _ |f excessive deposits accumulate over a short time or low mileage, install new

past

Symptoms: Blistered, white insulator, eroded electrode and absence of deposits. Results in shortened plug life. Recommendation: Check for the correct plug heat range, overadvanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling.

guides

or

piston

rings into the combustion chamber.

Causes hard starting, misfiring and hesitation

Recommendation: mechanical condition

Correct the with neces-

in a fractured insulator tip. Can lead to piston damage Recommendation: Make sure the fuel anti-knock values meet engine requirements.

Use

care

ting the gaps on new lugging the engine

when

plugs.

set-

Avoid

sary repairs and install new plugs.

MECHANICAL Symptoms:

GAP BRIDGING Symptoms: Combustion deposits lodge between the electrodes Heavy deposits accumulate and bridge the electrode gap. The plug ceases to fire, resulting in a dead cylinder. Recommendation: Locate the faulty plug and remove the deposits

from between the electrodes

May

DAMAGE be caused

by a

foreign object in the combustion chamber or the piston striking an

incorrect reach (too long) plug Causes a dead cylinder and could result in piston damage Recommendation: Repair mechanical damage. Remove

the the

foreign object from the engine and or

install the correct reach plug

‘Routinemaintenance :

m Tune-up 5procedures ee a Engine repair — ot Cooling and heating I Air ‘conditioning 2 Fuel Elale exhaust _

Emissions controlis Ignition oe

oe

Brakes Suspension and steering

a Electrical systems —

Wiring diagrams

Chapter 2 PartB

3.0L V6 engine

re)i

linked Kom alUlalelgateis} and illustrations

hs

e Co

.

helps -

identify specific problems

e Written from based on a vehicle teardown using

e Hayods tips give Ce) make the job easier and eliminate the needfor special tools )

for

Bial-mate)anl-maat-veval-lalley x

a C10) (0)¢

e Easy to use

ISBN 1 56392 369 6. 799-1942 ABCDEFGHI

;

3

8345"30034

2