Haynes Dodge Aries and Plymouth Reliant Automotive Repair Manual 5th Edition [5 ed.] 1563922282, 9781563922282

Citation preview

Plymouth 1981 thru 1989 d

aii

Reliari models

Haynes Repair Manual Based on a complete teardown and rebuild

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more complex

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Digitized by the Internet Archive in

2009

http://www.archive.org/details/dodgeariesplymouOOwarr

Dodge Aries

Plymouth Reliant Automotive Repair IVIanual by Larry Warren

and John H Haynes Member of

the Guild of tvlotoring Writers

Models covered: Dodge Aries and Plymouth

All

Reliant

models

1981 through 1989 (9B3

-

30008) (723)

AaXK-AAilOU

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, 861 Lawrence Drive Newbury Park California 91

320

USA

Inc

ABODE

About Its

this

manual overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

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

hope you use the manual

When

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 illustra-

to tackle

work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a the

shop and making the trips to leave and pick 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 it

it

make

Chapter.

References to the vehicle

assume you

left

or right side of the

are sitting

in

Even though we have prepared this manual with extreme care, neither the pub-

tion captions pinpoint the pertinent Section

lisher

and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within

for

nor the author can accept responsibility in, or omissions from, the infor-

any errors mation given.

that Section.

will

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

procedure where the Warning

Acknowledgements

We

are grateful to the Chrysler Corporation for assistance with technical information and certain

©

who

contributed to this project include Robert

Haynes North America,

Inc.

With permission from J H Haynes &

Co

Maddox and Jay

illustra-

Storer.

1996

Ltd

A book

in

the Haynes Automotive Repair Manual Series

Printed

in

the U.S.A.

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.

All rights

ISBN

1

56392 228 2

Library of

Congress Catalog Card Number 96-77662

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.

99-288

the driver's

seat, facing forward.

provides information necessary to properly complete a procedure or information which

tions. Technical writers

neces-

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

the procedure easier to understand.

A Warning

the text,

it's

sary to refer to another Chapter, the refer-

NOTE A Note

in

ence

Using the manual

occurs.

We

Procedures, once described are not normally repeated.

0-3

Contents Introductory pages About this manual

Dodge Aries and Plymouth identification numbers

Introduction to the

Vehicle

Buying parts Maintenance techniques, tools and working Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants Conversion factors Safety first! Troubleshooting

Chapter

1

Tune-up and routine maintenance

Reliant

facilities

0-2 0-4 0-5 0-6 0-6

0-12 0-13 0-14 0-15 0-16 0-17

0-4

Haynes author, mechanic, and photographer with K-car

Introduction to the Dodge Aries and Plymouth Reliant models These models are available in two-door coupe, four-door sedan and station wagon

body

The

styles.

Transversely mounted inline four-cylinder engines, equipped with carburetors or electronic fuel injection are used.

manual or a three-speed automatic transaxle via independent driveaxles.

or five-speed

The engine

drives the front wheels through either a four-

fully

independent front suspension

consists of coil spring/strut units, control arms and a stabilizer bar. The rear suspension uses shocl< absorbers, coil springs, a solid axle with integral trailing arms and a

track bar (Panhard rod).

The

steering gear

is

of the rack-and-pin-

power assist as an option. The braking system is vacuum assisted and features disc brakes at the front and selfadjusting drums at the rear. ion type, with

0-5

Vehicle identification

numbers

4 The Body Code Plate

is

located on the

wheel housing or the upper radiator support (shown) - it provides information about the type of engine, transaxle, paint etc. of the model to which it is attached driver's side of the fireurall, the

The Vehicle Identification Number (VIN) is visible from the outside of the vehicle, through the driver's side of the windshield are

Modifications

unpublicized process

in

a

continuing

and

vehicle manufactur-

ing. Since spare parts manuals and lists are compiled on a numerical basis, the individual

vehicle

numbers are essential component required.

Number

(VIN)

more

illus-

specific information

about the vehicle - type of engine, transaxle, paint, etc. - to which it's attached.

below the EIN on the block. On the 2.6L it is located on the right-rear side of the engine block, adjacent to the exhaust manifold stud (firewall side of the vehicle)

just

engine,

(see illustration).

Engine Identification Number (EIN) On

Transaxle Identification four-cylinder engines, the Engine

Number (EIN) is stamped into a machined boss on the engine block. On 2.2L is stamped into the left and 2.5L engines end of the engine block, just about the

Number (TIN)

Identification

The Vehicle Identification Number (VIN), w/hich appears on the Vehicle Certificate of Title and Registration, is also embossed on a gray plate located on the upper left (driver's dashboard, near the windshield (see illustration). The VIN tells you when and where a vehicle was manufactured, its country of origin, make, type, passenger safety system, line, series, body style, engine side) corner of the

and assembly

plant.

Body Code

Plate

The body code on the

upper radiator support (see

to correctly

identify the

Vehicle Identification

ing or the

tration), provides

Location of the engine identification number on 2.2L and 2.5L engines

left (driver's

which is located firewall, wheel hous-

plate,

side)

Location of the engine identification number on the 2.6L engine

it

transaxle bellhousing (see illustration). On 2.6L engines, the number is on the radiator

side of the of the block, between the core plug and the transaxle end of the block (see illustration).

Engine Serial Number In addition the EIN, a serial number, which is sometimes required when buying replacement parts, is also stamped into the block. On 2.2L and 2.5L engines, it is located

Location of the engine serial number on the 2.6L engine

(TIN)

The Transaxle Identification Number is stamped on a boss located on top of

the transaxle housing (see illustration).

Transaxle Serial

Number

Besides the TIN, the transaxle also has a serial

number which

when buying

you'll

need

to reference

On manual embossed on

transaxle parts.

transaxles, the serial

number

is

a metal tag attached to the front side of the transaxle; on automatic transaxles, the serial number is located on a pad just above the oil

pan

at the rear of the transaxle.

The Transaxle Identification Number (TIN) is stamped into a flat spot on top of the transaxle housing

0-6

Buying parts Replacement parts are available from sources, which generally fall into one of

many

two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these 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 sys-

parts

tems, 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 ters,

oil,

grease,

fil-

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

avail-

able elsewhere (such as major engine parts,

transmission parts, trim pieces,

Warranty information:

If

etc.).

the vehicle

is

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 still

available and,

possible, take the old parts

if

along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques

Most automotive machine shops can perform

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.

this task,

as well as other repair procedures,

such as the repair of threaded holes that have been sthpped out. Flat washers and lockwashers, when

removed from an assembly, should always be replaced exactly as removed. Replace any with new ones. Never use a lockwasher on any soft metal surface (such

damaged washers

as aluminum), thin sheet metal or plastic.

\ /

V

Fasteners 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,

Grade

1

or 2

Grade 8

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

can only be used once. If they are removed, they lose their locking ability and must be replaced with new ones.

Bolt strength

fiber inserts

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, it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners

let

may have

to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If

bly,

it

a bolt or stud breaks

can be

cial tool

drilled

commonly

off in an assemand removed with a spe-

available for this purpose.

Grade

marking (standard/SAE/USS; bottom

-

metric)

Maintenance techniques, tools and working

0-7

facilities

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 inter-

changed. whether standard or methc, are

All bolts,

sized according to diameter, thread pitch and length. For example, a standard bolt

1/2 inch

is

and

inch

is 1

metric bolt

is

in

diameter, has 13 threads per

inch long.

An M12

-

1.75 x 25

mm in diameter, has a thread mm (the distance between 25 mm long. The two bolts are

is

nearly identical,

and

easily confused, but they

are not interchangeable. In addition to the differences

in

diame-

thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the

distance across the

measured

is

in

flats

on a standard

inches, while the

dimension on a metric

bolt

is

sized

in

bolt

same

millime-

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

ters (the

same

is

true for nuts).

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

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

the

bolt.

10.9 are

number, the stronger

Property class numbers 8.8, 9.8 and

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 to property class (grade).

ends according

Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade. It should be noted that many fasteners, through 2, have no disespecially Grades

marks on them. When such is the way to determine whether it is standard or methc is to measure the thread to a known fastener of the pitch or compare

tinguishing

case, the only

it

same

6 to 9 14 to 21

28 to 40 50 to 71 80 to 140

Pipe thread sizes 5 to 8 12 to 18

1/8 1/4

22 to 33 25 to 35

3/8 1/2

U.S. thread sizes 1/4-20 5/16

-

18

5/16-24

ter,

head

Ft-ibs

M-6 M-8 M-10 M-12 M-14

12

pitch of 1.75

threads) and

1/2-13x1

Nm

Metric thread sizes

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 fasteners are referred to as USS sizes. Since fasteners of the same size (both standard and metric) may have different

3/8

-

16

3/8-24 7/16

-

14

7/16-20 1/2

-

13

6 to 9 12 to 18 14 to 20

22 27 40 40 55

to

to to to to

32 38 55 60 80

0-8

Maintenance techniques, tools and working

facilities

Micrometer set ened

in

ponent.

shown

sequence to avoid warping the comTfiis sequence will normally be

in

the appropriate Chapter.

If

a spe-

pattern is not given, the following procedures can be used to prevent warping. Initially, the bolts or nuts should be assembled finger-tight only. Next, they should be tightened one full turn each, in a criss-cross or diagonal pattern. After each one has been tightened one full turn, return to

Dial indicator set

identify the

Hose removal

of

Warning:

two halves with numbered pieces masking tape so they can be easily recon-

nected.

first

one and tighten them

following the

turn,

tighten each of

same

one-half

all

pattern.

them one-quarter

Finally,

turn at a

each fastener has been tightened to To loosen and remove the fasteners, the procedure would be reversed. time

until

the proper torque.

Component disassembly with care and purpose to help ensure

that the parts go back together properly. Always keep track of the sequence in which parts are removed. Make note of special characteristics or marks on parts that can be installed more than one way, such as a grooved thrust washer on a shaft. It is a good idea to lay the disassembled parts out on a clean surface in the order that they were removed. It may also be helpful to make sketches or take instant photos of compo-

nents before removal.

When removing

comSome-

fasteners from a

ponent, keep track of their locations.

times threading a bolt back

in

an assembly. are coated

with a liquid or paste-type gasket sealing

compound

before assembly. Age, heat and pressure can sometimes cause the two parts

to stick together so tightly that they are very difficult to

separate. Often, the assembly can

be loosened by

striking

it

with a soft-face

hammer near the mating surfaces. A regular hammer can be used a block of wood is placed between the hammer and the part. Do not hammer on cast parts or parts that could

or a service station.

Hose removal precautions closely paralgasket removal precautions. Avoid scratching or gouging the surface that the hose mates against or the connection may lel

leak. This is especially true for radiator hoses.

Because of various chemical reactions, the rubber in hoses can bond itself to the metal spigot that the hose fits over. To remove a hose, first loosen the hose clamps that secure it to the spigot. Then, with slip-joint pliers, grab the hose at the clamp and rotate

if

Component disassembly should be done

in

a part, or

washers and nut back on a stud, can prevent mix-ups later. If nuts and bolts cannot be returned to their original locations, they should be kept in a compartmented box or a series of small boxes. A cupcake or muffin tin is ideal for this purpose, since each cavity can hold the bolts and nuts from a particular area (i.e. oil pan bolts, valve cover bolts, engine mount bolts, etc.). A pan of this type is especially helpful when working on assemblies with very small parts, such as the putting the

carburetor, alternator, valve train or interior

dash and trim pieces. The cavities can be marked with paint or tape to identify the contents.

Whenever wiring looms, harnesses or connectors are separated, it is a good idea to

be

easily

damaged. With any

particularly

always recheck to make sure that every fastener has been removed. Avoid using a screwdhver or bar to pry apart an assembly, as they can easily mar the gasket sealing surfaces of the parts, which must remain smooth. If prying is absolutely necessary, use an old broom handle, but stubborn

keep

part,

mind

in

essary

if

the

that extra clean

wood

up

will

be nec-

be soaked with

it

around the spigot. Work

until

it

is

completely

free,

it

back and

then

pull

it

forth

off. Sili-

cone

or other lubricants will ease removal if they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inside of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced with a new one anyway), the rubber can be slit with a knife and the hose peeled

from the spigot.

If

must be done, be is not dam-

this

careful that the metal connection

splinters.

After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can

having the system

first

depressurlzed by a dealer service department

Throughout any vehicle, gaskets are used to seal the mating surfaces between two parts and keep lubricants, fluids, vacuum

Many times these gaskets

is equipped with air do not disconnect any of the

A/C hoses without

Gasket sealing surfaces

or pressure contained

tips

the vehicle

conditioning,

cific

the

If

rust penetrant or

treated with a special chemical to soften

it so can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is

aged. If a hose clamp is broken or damaged, do not reuse it. Wire-type clamps usually weaken with age, so it is a good idea to replace them with screw-type clamps when-

ever a hose

is

removed.

it

recommended because

it

is

usually softer

than the surfaces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire brush, but regardless of the method used, the mating surfaces must be left clean and smooth. If for some reason the gasket surface is gouged, then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components. For most applications, a non-drying (or semi-drying) gasket sealer should be used.

Tools A selection requirement tain

and

for

of good tools is a basic anyone who plans to main-

repair his or her

own

vehicle. For the

owner who has few tools, the initial investment might seem high, but when compared to the spiraling costs of professional auto

maintenance and

repair,

it

is

a wise one.

To help the owner decide which tools are needed to perform the tasks detailed in this

manual, the following tool

lists

are

Maintenance and minor repair, Repair/overhaul and Special. The newcomer to practical mechanics offered:

Maintenance techniques, tools and working

Dial caliper

Compression gauge with spark plug

Hand-operated vacuum

pump

0-9

facilities

Timing

light

Damper/steering wheel puller

General purpose puller

Valve spring compressor

Valve spring compressor

Piston ring groove cleaning tool

Ring removal/installation tool

hole adapter

Hydraulic

lifter

removal tool

Ridge reamer

Maintenance techniques, tools and working

0-10

Cylinder hone

Brake cylinder hone

Clutch plate alignment tool

start

minor repair

of time, the

Bral

e

'C

S E

I c o

« 0)

I (B

O

'5.

:si-

o

E S o>

n 'o

^El E

I ST

c o « IE"

o -CD-**

IB

O

a

_'«-OD_J_

IND-1

Index master

cylinder,

removal and

installation,

9-12

parking brake this manual, 0-2 Accelerator cable, removal and Installation, 4-8 Acknowledgements, 0-2

About

Air aspirator system, 6-11

removal and Installation, 4-8 and heating system, check and maintenance, 3-9 conditioning filter-drier, removal and installation, 3-10

Air cleaner housing, Air conditioning Air

adjustment, 9-14 cables, removal and installation, 9-14 power brake booster, check, removal and installation, 9-14 wheel cylinder, removal, overhaul and installation, 9-11

Bulb replacement, 12-7 Bumpers, removal and installation, 11-6 Buying parts, 0-6

Air filter replacement, 1-21 Air Injection (Al) system, 6-9

Alignment, general information, 10-10 Alternator brushes, replacement, 5-10 removal and installation, 5-9

Camshaft (water pump

Antenna, removal and installation, 12-9 Antifreeze, general information, 3-2 Automatic choke system, 6-8

Automatic Idle Speed (AIS) motor, check and replacement, 6-17 Automatic transaxle, 7B-1 through 7B-4 band adjustment (three-speed models only), 1-31 diagnosis, general, 7B-1 fluid

and

fluid level

change, 1-31 check, 1-10

pulley) oil seal, replacement, 2.6L four-

cylinder engine, 2B-8

Camshaft and hydraulic lash adjusters/rocker arms, removal, inspection and installation, 2.2L and 2.5L four-cylinder engines, 2A-10

Camshaft

oil seal, replacement, 2.2L and 2.5L four-cylinder engines, 2A-9 Camshaft, removal, inspection and installation, 2.6L four-cylinder engine, 2B-9

filter

Carburetor 2.2L engine

general information, 7B-1 neutral start

and back-up

light

switch,

check and replacement, 7B-3

installation, 78-3 check and adjustment, 78-2 throttle pressure cable, adjustment, 7B-2 Automotive chemicals and lubricants, 0-14 Axle assembly, rear, removal and installation, 10-7

removal and shift cable,

adjustments, 4-16 overhaul, 4-12 2.6L engine idle

speed adjustment, 4-21

overhaul, 4-17

choke check and cleaning, 1-23 description and service information, 4-11 removal and installation, 4-11 Carburetor/fuel injection throttle body mounting bolt/nut torque check, 1-24

B

Catalytic converter, 6-23

Balance shaft chain/sprockets, removal, inspection and installation, 2.6L four-cylinder engine, 2B-6 Balance shafts (2.5L engine only), removal and installation, 2C-12 Balljoints, check and replacement, 10-6 Battery

check and replacement, 5-2 check, maintenance and charging, 1-13 cables,

emergency jump starting, 0-13 removal and installation, 5-2 Body, 11-1 through 11-12 general information, 11-1

maintenance, 11-1 repair

major damage, 1 1 -5 minor damage, 11-4 Booster battery (jump) starting, 0-13 Brake system check, 1-27 Brakes, 9-1 through 9-16 brake caliper, removal, overhaul and installation, 9-4 brake disc, inspection, removal and installation, 9-6 brake light switch, check, adjustment and replacement, 9-16 disc brake pads, replacement, 9-2

drum brake shoes, replacement 1981 and 1982 models, 9-7 1983 and later models, 9-9 general information, 9-1

hoses and

lines,

inspection and replacement, 9-13

hydraulic system, bleeding, 9-13

Center console, removal and Charging system

installation,

11-10

check, 5-9 general information and precautions, 5-8 Chassis electrical system, 12-1 through 12-30 Chassis lubrication, 1-16 Circuit breakers, general information, 12-3

Clutch

and installation, 8-3 components, removal, inspection and installation, 8-4 description and check, 8-2 release bearing and release fork, removal and installation, 8-3 Clutch and driveaxles, 8-1 through 8-16 Combustion chamber conditioner application (Canadian leaded fuel models only), 1-15 Compressor, removal and installation, 3-10 Condenser, removal and installation, 3-11 Constant velocity (CV) joint boots, replacement, 8-12 Constant velocity (CV) joints, disassembly, inspection and reassembly, 8-7 Control arm, removal, inspection and installation, 10-5 Conversion factors, 0-15 Coolant reservoir, removal and installation, 3-5 temperature sending unit, check and replacement, 3-6 Cooling system cable, removal

check, 1-25 servicing (draining, flushing

and

refilling),

1-28

IND

1

1

11

Index

IND-2 Cooling, heating and air conditioning systems, 3-1 through 3-12 air conditioning and heating system, check and maintenance, 3-9 air conditioning filter-drier, removal and installation, 3-10 antifreeze, general information, 3-2 compressor, removal and installation, 3-10

condenser, removal and

installation, 3-1

coolant

removal and installation, 3-5 temperature sending unit, check and replacement, 3-6 engine cooling fan and switch, check and replacement, 3-3 evaporator, removal and installation, 3-1 general information, 3-2 heater core, replacement, 3-8 reservoir,

heater/air conditioning

blower motor, circuit check and component replacement, 3-7 control assembly, removal and installation, 3-9 radiator, removal and installation, 3-4 thermostat, check and replacement, 3-2 water pump check, 3-5 replacement, 3-5

Crankshaft front oil seal, replacement 2.2L and 2.5L four-cylinder engines, 2A-10 2.6L four-cylinder engine, 2B-9 Crankshaft inspection, 2C-18 installation and main bearing oil clearance check, 2C-21 removal, 2C-14 Cruise control system, description and check, 12-12 Cylinder compression check, 2C-5 Cylinder head

Engine cooling fan and switch, check and replacement, 3-3 Engine electrical systems, 5-1 through 5-14 alternator brushes, replacement, 5-10 alternator,

removal and

installation,

cables, check and replacement, 5-2

emergency jump starting, 0-13 removal and installation, 5-2 charging system general information and precautions, 5-8 check, 5-9 removal and general information, 5-2

distributor,

installation,

5-6

governor (centrifugal advance) unit (2.6L engine), check and replacement, 5-7 ignition coil, check and replacement, 5-5

system

ignition

check, 5-2 general information, 5-2 pick-up assembly, replacement, 5-7 starter motor assembly, removal and starter motor, in-vehicle check, 5-12

installation,

starter motor/solenoid/gear reduction

5-12

assembly, replacement, 5-13

and precautions, 5-12 (2.6L engine), check and replacement, 5-8

starting system, general information

vacuum advance

unit

voltage regulator, description, 5-12 Engine oil and filter change, 1-11

Engines 2.2L and 2.5L four-cylinder engines, 2A-1 through 2A-20 camshaft and hydraulic lash adjusters/rocker arms, removal, inspection and installation, 2A-10

replacement, 2A-9

cleaning and inspection, 2C-9

camshaft

disassembly, 2C-9

crankshaft front

reassembly, 2C-1 removal and installation 2.2L and 2.5L four-cylinder engines, 2A-14 2.6L four-cylinder engine, 2B-1

cylinder head, removal

Cylinder honing, 2C-16

5-9

battery

oil

seal,

oil

replacement, 2A-10

seal,

and

installation,

flywheel/driveplate, removal

and

2A-14 2A-18

installation,

general information, 2A-3 intake/exhaust manifold, removal and installation, 2A-5 intermediate shaft oil seal, replacement, 2A-9

mounts, check, replacement and adjustment, 2A-19 pan, removal and installation, 2A-16

oil

oil

pump, removal, inspection and installation, 2A-16 main oil seal, replacement, 2A-19

rear

repair operations possible with the engine

Dashboard panels, removal and installation, 11-11 Differential lubricant (1982 and earlier automatic transaxle models only)

installation, 5-6

Door installation,

installation,

2A-6

Top Dead Center (TDC)

for

number one

piston, locating,

2A-3

valve springs, retainers and seals, replacement, 2A-13

removal and

latch, lock cylinder

the vehicle, 2A-3

valve cover, removal and installation, 2A-4

change, 1-30 level check, 1-15 Distributor,

in

timing belt and sprockets, removal, inspection and

and outside handle, removal and

11-8

removal, installation and adjustment, 11-7 trim panel, removal and installation, 11-7

Door window and adjustment, 11-8 and installation, 11-9 Driveaxle boot check, 1-32 glass, removal, installation regulator, removal

installation, 2B-6 camshaft (water pump

pulley)

general information and inspection, 8-5 removal and installation, 8-6

and replacement, 1-19

oil

seal,

replacement, 2B-8

camshaft, removal, inspection and installation, 2B-9 crankshaft front oil seal, replacement, 2B-9 cylinder head, removal and installation, 2B-11 exhaust manifold, removal and installation, 2B-5 flywheel/driveplate, removal and installation, 2B-13 general information, 28-2 intake manifold, removal

Driveaxles

Drivebelt check, adjustment

2.6L four-cylinder engine, 2B-1 through 28-14 balance shaft chain/sprockets, removal, inspection and

and

installation,

28-5

mounts, engine, check, replacement and adjustment, 28-14 oil pan, removal and installation, 28-11 oil

pump, removal, inspection and installation, 28-12 main oil seal, replacement, 28-14

rear

repair operations possible with the engine

in

the vehicle, 28-2

rocker arm assembly, removal, inspection and installation, 2B-4 timing chain/sprockets, removal, inspection and Electrical troubleshooting, general information, 12-1

installation, 2B-7 Top Dead Center (TDC)

Electronic feedback carburetor system, 6-6

valve cover, removal and installation, 28-3

Emissions and engine control systems, 6-1 through 6-24

valve springs, retainers and seals, replacement, 28-5

for

number one

piston, locating,

28-3

6

8

1

1

1

1

IND-3

Index general engine overhaul procedures, 2C-1 through 2C-24

balance shafts (2.5L engine

only),

removal and

installation,

fuel injection

component check and replacement, 4-22

crankshaft

general information, 4-22

2C-18 installation and main bearing oil clearance check, 2C-21 removal, 2C-14 cylinder compression check, 2C-5 cylinder head cleaning and inspection, 2C-9 disassembly, 2C-9 inspection,

sending

fuel level

unit,

check and replacement, 4-7

general information, 4-3 lines

and

fittings,

replacement, 4-5

procedure (fuel-injected models pump, removal and installation, 4-6 pump/fuel pressure, check, 4-3 pressure

relief

only),

4-3

tank

reassembly, 2C-11

cleaning and repair, general information, 4-7 removal and installation, 4-5

2C-16

cylinder honing,

engine block cleaning,

system

check. 4-22

2C-12

Fuel

2C-15 2C-16

inspection.

engine overhaul disassembly sequence, 2C-7

filter

replacement, 1-16

Fuel system check, 1-24 Fuses, general information, 12-2 Fusible links, general information, 12-2

general information, 2C-4

reassembly sequence, 2C-19 engine rebuilding alternatives, 2C-7 engine removal, methods and precautions, 2C-6 engine, removal and installation, 2C-6 general information, 2C-4 start-up and break-in after overhaul, 2C-24 main and connecting rod bearings, inspection, 2C-19 initial

piston rings, installation,

2C-20

pistons and connecting rods

2C-17 and rod bearing oil clearance check, 2C-22 removal, 2C-11 rear main oil seal, installation, 2C-22 vacuum gauge diagnostic checks, 2C-5 inspection, installation

valves, servicing, 2C-1 Evaporative emissions control (EVAP) system, 1-33, 6-18 Evaporator, removal and installation, 3-11 Exhaust Gas Recirculation (EGR) system, 6-21 Exhaust Gas Recirculation (EGR) system check, 1 -22 Exhaust manifold, removal and installation, 2.6L four-cylinder engine, 2B-5 Exhaust system check, 1-25 Exhaust system servicing, general information, 4-25

Gear boots, steering, replacement, 10-8 Gear, steering, removal and installation, 10-8 General engine overhaul procedures, 2C-1 through 2C-24 balance shafts (2.5L engine only), removal and installation, 2C-12 crankshaft, inspection, 2C-18 crankshaft, installation and main beanng oil clearance check, 2C-21 crankshaft, removal, 2C-14 cylinder compression check, 2C-5 cylinder head cleaning and inspection, 2C-9 disassembly, 2C-9 reassembly, 2C-11 cylinder honing, 2C-16 engine block cleaning,

2C-15 2C-16

inspection,

engine overhaul disassembly sequence, 2C-7 general information, 2C-4

reassembly sequence, 2C-19 engine rebuilding alternatives, 2C-7 engine removal, methods and precautions, 2C-6 engine, removal and installation, 2C-6 general information, 2C-4

Fluid level checks, 1-7

start-up and break-in after overhaul, 2C-24 main and connecting rod bearings, inspection, 2C-19 piston rings, installation, 2C-20 pistons and connecting rods inspection, 2C-17 installation and rod bearing oil clearance check, 2C-22 removal, 2C-1 rear main oil seal, installation, 2C-22 vacuum gauge diagnostic checks, 2C-5 valves, servicing, 2C-1 Governor (centrifugal advance) unit (2.6L engine), check and replacement, 5-7 initial

battery electrolyte,

1

-8

engine coolant, 1-8 engine oil, 1-7

power

steering, 1-11

vi/indshield

washer

fluid,

1-8

automatic transaxle fluid level check, 1-10 Flywheel/driveplate, removal and installation 2.2L and 2.5L four-cylinder engines, 2A-1 2.6L four-cylinder engine, 2B-13 Front fender, removal and installation, 11-6 Fuel and exhaust systems, 4-1 through 4-26 accelerator cable, removal and installation, 4-8 air cleaner housing, removal and installation, 4-7 carburetor 2.2L engine adjustments, 4-1 overhaul, 4-12 2.6L engine idle

speed adjustment, 4-21

overhaul, 4-17

descnption and service information, 4-1 removal and installation, 4-11 exhaust system servicing, general information, 4-25

H Headlight

dimmer

switch, check

replacement, 12-6 switch, removal and

and replacement, 12-3

installation,

12-7

Headlights, adjustment, 12-6 inlet air system, 1-24, 6-19 Heater core, replacement, 3-8

Heated

IND

1

IND-4

Index

Heater/air conditioning blower motor, circuit check and component replacement, 3-7 control assembly, removal and installation, 3-9

N Neutral start and back-up light switch, check and

High altitude compensation system, 6-8 Hinges and locks, maintenance, 11-5

replacement, 7B-3

Hood latch

and cable, removal and

installation,

11-6

removal, installation and adjustment, 11-5 Horn, check and replacement, 12-11

and

coil,

filter change, engine, 1-11 pan, removal and installation 2.2L and 2.5L four-cylinder engines, 2A-16 2.6L four-cylinder engine, 2B-1 Oil pump, removal, inspection and installation 2.2L and 2.5L four-cylinder engines, 2A-16 2.6L four-cylinder engine, 2B-12

switch, check

On Board Diagnosis (OBD) system and computer trouble

Oil Oil

Ignition

check and replacement, 5-5 and replacement, 12-5 system

codes, 6-14

check, 5-2 general information, 5-2 timing check and adjustment, 1-29

Information sensors, replacement, 6-15 Initial start-up and break-in after overhaul, 2C-24 Instrument cluster bezel, removal and installation, 11-10 removal and installation, 12-11 Instrument panel, removal and installation, 12-11 Intake manifold, removal and installation, 2.6L four-cylinder

engine, 2B-5 Intake/exhaust manifold, removal and installation, 2.2L and 2.5L four-cylinder engines, 2A-5 Intermediate shaft oil seal, replacement, 2.2L and 2.5L fourcylinder engines, 2A-9 Introduction to the Dodge Aries and Plymouth Reliant models, 0-4

Pick-up assembly, replacement, 5-7 Piston rings, installation, 2C-20 Pistons and connecting rods

2C-17 and rod bearing removal, 2C-11 inspection, installation

Positive Positive

oil

clearance check, 2C-22

Crankcase Ventilation (PCV) system, 6-17 Crankcase Ventilation (PCV) valve check and

replacement, 1-21

Power door lock system, description and check, 12-13 Power seats, description and check, 12-13 Power steering fluid level

check. 1-11

pump, removal and

installation,

10-9

system, bleeding. 10-10 Pulse Air Feeder (PAF) system, 6-10

Jacking and towing, 0-12 Jet Air Control Valve (JACV) system, 6-9

Radiator

grille,

removal and

installation, 11-6

Radiator, removal and installation, 3-4

and adjustment, 11-10 Logic Module and Power Module (1984 through 1987 EFI models), description and replacement, 6-11

Liftgate, removal, installation

Radio and speakers, removal and installation, 12-8 Rear main oil seal installation (during rebuild), 2C-22 replacement

M Main and connecting rod bearings, inspection, 2C-19 Maintenance schedule, 1-5 Maintenance techniques, tools and working facilities, 0-6 Manual transaxle, 7A-1 through 7A-4 general information, 7A-1 lubricant change. 1-30 lubricant level check, 1-14

mount, check and replacement, 7A-3 seal replacement, 7A-3 overhaul, general Information, 7A-4 removal and installation, 7A-3 shift linkage, check and adjustment, 7A-1 speedometer drive pinion, removal and installation, 7A-2 Mikuni carburetor system, 6-7 Mirrors, removal and installation, 11-11 Mounts, engine, check, replacement and adjustment 2.2L and 2.5L four-cylinder engines, 2A-19 2.6L four-cylinder engine, 2B-14

(in

vehicle)

2.2L and 2.5L four-cylinder engines, 2A-19 2.6L four-cylinder engine, 2B-14

Rear shock absorbers and

coil springs,

removal, inspection and

installation, 10-6

Relays, general information, 12-3 Repair operations possible with the engine in the vehicle 2.2L and 2.5L four-cylinder engines, 2A-3 2.6L four-cylinder engine, 2B-2 Rocker arm assembly, removal, inspection and installation, 2.6L four-cylinder engine, 2B-4

oil

first!, 0-16 Seat belt check, 1-33 Seats, removal and installation, 11-12

Safety

Shift

and adjustment, 7B-2 check and adjustment, 7A-1

cable, check linkage,

IND-5

Index Module Engine Controller (SMEC) and information sensors (1988 and later models), description, 6-12 Spark plug check and replacement, 1-17 wire, distributor cap and rotor checl< and replacement, See Single

diagnosis, general, 7B-1 fluid

and

installation,

neutral start

12-11

and installation. 7A-2 Spindle, rear, inspection, removal and installation, 10-7 Stabilizer bar, removal and installation, 10-4 Starter motor assembly, removal and installation, 5-12 Starter motor, in-vehicle check, 5-12 Starter motor/solenoid/gear reduction assembly, replacement, 5-13 Starting system, general information and precautions, 5-12 Steering and suspension check, 1-25 column cover, removal and installation, 11-11

models

only),

1-26

alignment, general information, 10-10

gear boots, replacement, 10-8 gear, removal and installation, 10-8

power steering pump, removal and

installation, 10-9 system, bleeding. 10-10 steering wheel, removal and installation, 10-7 tie-rod ends, removal and installation, 10-8 wheels and tires, general information, 10-10 Steering wheel, removal and installation, 10-7 Strut assembly, removal and installation, 10-3 Strut, replacement, 10-3

stabilizer bar,

removal and

steering knuckle,

installation,

check and

check and adjustment, 7B-2 7B-2 Transaxle, manual, 7A-1 through 7A-4 shift cable,

general information, 7A-1 lubricant change, 1-30 lubricant level check, 1-14

mount, check and replacement, 7A-3 seal replacement. 7A-3

oil

7A-3 check and adjustment, 7A-1 speedometer drive pinion, removal and installation, 7A-2 Troubleshooting, 0-17 Trunk lid, removal, installation and adjustment, 11-10 Tune-up and routine maintenance, 1-1 through 1-34 Tune-up general information, 1-7 Turn signal and hazard flashers, check and replacement, 12-3 Turn signal/hazard warning switch, check and replacement, 12-4 installation,

Underhood hose check and replacement, 1-23 Upholstery and carpets, maintenance, 11-1

10-6

and

switch,

u

Suspension and steering systems, 10-1 through 10-10 Suspension system axle assembly, rear, removal and installation, 10-7 balljoints, check and replacement, 10-6 control arm, removal, inspection and installation, 10-5 shock absorbers (rear) and coil springs, removal, inspection and installation,

light

shift linkage,

Steering system

spindle, rear, inspection, removal

and back-up

throttle pressure cable, adjustment,

removal and

knuckle, hub and bearing, removal, inspection and installation, 10-5 earlier

-31

overhaul, general Information, 7A-4

,

and

1

replacement, 7B-3 removal and installation, 7B-3

drive pinion, removal

shaft seal lubrication (1985

change, check, 1-10

filter

general Information, 7B-1

Speedometer cable, removal

and

fluid level

installation,

10-7

10-4

hub and bearing, removal, inspection and

10-5 assembly, removal and installation, 10-3 strut, replacement, 1 0-3 track bar assembly, removal and installation. 10-7 installation,

strut

Vacuum advance unit (2.6L engine), check and replacement, Vacuum gauge diagnostic checks, 2C-5

5-8

Valve clearance check and adjustment (2.6L engine only), 1-15 Valve cover, removal and installation 2.2L and 2.5L four-cylinder engines, 2A-4 2.6L four-cylinder engine, 28-3

Valve springs, retainers and seals, replacement 2.2L and 2.5L four-cylinder engines, 2A-13 2.6L four-cylinder engine, 2B-5 Valves, servicing, 2C-11 Vehicle identification numbers, 0-5 Vinyl trim, maintenance, 11-1

Voltage regulator, description, 5-12

Thermostat, check and replacement, 3-2 Throttle opener (idle-up) system, 6-9 Throttle pressure cable, adjustment, 7B-2 Tie-rod ends, removal and installation, 10-8 Timing belt and sprockets, removal, inspection and installation, 2.2L and 2.5L four-cylinder engines, 2A-6 Timing chain/sprockets, removal, inspection and installation, 2.6L four-cylinder engine, 2B-7 Tire and tire pressure checks, 1-9 Tire rotation, 1-14

Tools, 0-8

Top Dead Center (TDC)

for number one piston, locating 2.2L and 2.5L four-cylinder engines, 2A-3 2.6L four-cylinder engine, 2B-3

Towing, 0-12 Track bar assembly, removal and installation, 10-7 Transaxle, automatic, 7B-1 through 7B-4 band adjustment (three-speed models only), 1-31

w Water pump check, 3-5 replacement, 3-5

Wheel bearing (rear) check, repack and adjustment, 1-26 Wheelhouse splash shields, removal and installation, 11-12 Wheels and tires, general Information, 10-10 Window defogger, rear, check and repair, 12-13 Window system, power, description and check, 12-12 Windshield and fixed glass, replacement, 11-5 Windshield wiper motor, check and replacement, 12-9 Wiper blade inspection and replacement, 1-12 Wiper/washer switch, check and replacement, 12-5 Wiring diagrams, general Information, 12-14 Working facilities, 0-11

IND

;

,

,

Haynes Automotive Manuals NOTE: New manuals

are

added

to this list

30010 Caravan & Caravan &

ACURA Integra '86 thai '89 Integra 90 thru '93

12020 12021

& Legend & Legend

•3001 1 3001 2

'86 thru '90 '91 thru '95

AMC Jeep CJ

-

30016 30020

see JEEP (50020)

•30021

Concord/Homet/Gremlin/Spirit '70 thru 03 (Renault) Alliance & Encore 63 thru 87

14020 14025

30025

AUDI

30030

15020 4000 15025 5000 5000 1 5026

all all

all

models models models

'80 thnj '87 '77 thru '83

'30034 •30035

'84 thru '88

Healey Sprite

•

see

•30041 '30045

MG Midget (66015)

BMW

30050 30055 30060

3/5 Series "82 thru "92 3 Series including Z3 models "92 thru '98 320i all 4 cyl models "75 thru '83 '77 1 500 thru 2002 except Turbo '59 thnj

•18020 18021

18025 1 8050

•30065

Ply.

Voyager Voyager

•42025

Civic '96 thai '00. CR-V '97 thru 00, Acura Integra '94 thru '00 Passport - see ISUZU Rodeo (47017)

Dodge & Plymouth Neon '95 thru '99 Omni & Plymouth Horizon '78 thai '90

•42040

Prelude

models '74 thru '93 models '94 thru '01 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups '79 thai '93 Dodge/Ply./Chrysler RWD '71 Ihnj 89 Shadow/Plymouth Sundance '87 thru '94 Spirit & Plymouth Acclaim 89 thru '95 Vans - Dodge & Plymouth '71 thai '99 Pick-ups

all

lull-size

all

full-size

Talon

Buick Century "97 thru '02 Century (FWO) - see CM (38005) Buick, Oldsmobile & Pontiac Full-size (Front wheel drive) '85 thru '02 Buick Oldsmobile & Pontiac Full-size

•19010 '19020

19025

34010 34025

'93

-

33031)

CHEVROLET

Expedition

Chevrolet Engine Overhaul Manual Astro & GMC Safari Mini-vans '85 thru 24015 Camaro V8 all models "70 thru '81 24016 Camaro all models '82 thnj '92

10305 '24010

•36060

36062 36066 36070 •36071

GM 138026)

24055 Monte Cario all models '70 thru '88 Monte Cario '95 thru '01 see LUMINA 24059 Nova all V8 models '69 thru '79 24060 Nova/Geo Prizm 85 thru '92 24064 Pick-ups '67 thru '87 Chevrolet & GMC, aJ! V8 & in-line 6 cyl, 2WD & 4WD '67 thru '87; Suburbans. Blazers & Jimmys '67 thru '91 24065 Pick-ups '88 thru '98 Chevrolet & GMC.

36074

-

•36075

-

models '88 thai '98; C/K Classic '99 S 00; Blazer & Jimmy '92 thru '94; Suburban '92 thru '99; Tahoe & Yukon '95 thru '99 *24066 Pick-ups '99 thru '01 - Chevrolet Silverado & GMC Sien-a '99 thru '01 Suburban/TahoeA^ukon/Yukon XL "00 & '01 24070 S-10 & GMC S-15 Pick-ups '82 thm '93 •24071 S-10, Gmc S-15 & Jimmy '94 thru '01 24075 Sprint 85 thai SB, Geo Metro '89 thai 01 24080 Vans - Chevrolet & GMC '68 thnj '96 all full-size

'36010

38015

38020 38025 '38026

-

38030

Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza Pontiac J-2000 & Sunbird '82 thru '94 Chevrolet Cavaller/Pontiac Sunftre 95 thm '00 Buick Skylark. Chevrolet Citation, Olds Omega, Pontiac Phoenix '30 thru '85 Buick Skylark & Somerset, Olds Achieva,

& Pontiac Grand Am '85 thru '98 Chevrolet Malibu, Olds Alero & Cutlass, Pontiac Grand Am '97 thru '00 Cadillac Eldorado & Oldsmobile

•38031

DATSUN

38032 38035 Chevrolet Lumina APV, Oldsmobile '38036

300ZX

-

see

NISSAN

.

•

Metro

-

Prizm

-

see CHEVROLET Sprint (24075) see CHEVROLET (24060) or

TOYOTA (92036) 40030 Storm all models '90 thru '93 Tracker see SUZUKI Samurai -

400 a 600 - see CHRYSLER Aries & Plymouth Reliant

Vans & Pick-ups

-

see

CHEVROLET

Listings

shown

with

updated

42010 Accord CVCC all models '76 thru 4201 1 Accord all models '84 thru '89

(25030) 81 thru 89

an

asterisk

(')

to include later

indicate

'83

RAV4

models "91 thru '95 models '96 thru '02 models '87 thru '94

all

TRIUMPH GLC

94007 Spitfire all models '62 thru 94010 TR7 all models '75 thai '81

(rear wheel drive) '77 thru '83 (front wheel drive) '81 thru "85

'93 thru 01

,

96008 Beetle & Karmann Ghia

& MX-6/Fort Probe

& Nissan Quest

Villager

other

titles,

Beetle '98 thru 00 Rabbit, Jetta, Scirocco, A Pick-up gas models '74 thai '91 & Convertble '80 thai '92 Golf. GTI & Jetta '93 thru '98.

96016 9601 7

'95 thru '98 Golf, GTI, Jetta & Cabrio '98 thru '02 Rabbit, Jetta, Pick-up diesel '77 thru '84 Passat '98 thru '01 Audi A4 '96 thru '01 Transporter 1600 all models '68 thru '79

Cabrio

'96018 91

'93 thru '97

'93 thru '01

FORD listing.

see

'54 thru '79

New

•96009

MERCURY All

'81

vw

63012 123 Series Diesel "76 thru '85 63015 190 Series 4-cyl gas models. '84 thru '88 63020 230, 250 & 280 6 cyl sohc '68 thai '72 63025 280 123 Series gas models "77 thru '81 63030 350 & 450 all models '71 thru '80

96020 96023 96030 96035 96040 96045

,

Transporter 1700, 1800, 2000

'72 thru '79

Type 3 1500 4 1600 '63 thru '73 Vanagon air-cooled models '80 thru

'83

VOLVO 97010 120, 130 Series & 1800 Sports '61 thru '73 97015 140 Series all models '66 thru '74 97020 240 Series all models '76 thru '93 97025 260 Series all models '75 thai '82 97040 740 a 760 Series all models '82 thm '88

TECHBOOK MANUALS MGB Roadster & GT Coupe '62 thru '80 MG Midget & Austin Healey Sprite '58 thru '80

MITSUBISHI 68020 Cordia, Tredia, Galant, Precis & '83 thru '93

Mirage

Eclipse, Eagle Talon

68030

Plymouth Laser 90 •68031

Eclipse '95 thai 01

68040

Pick-up '83 thru

,

&

thai '94 '98

Eagle Talon '95 thru

'96.

Montero

'83 thru '93

NISSAN 300ZX all models incl. Turtx) '84 thai '89 72015 Altima all models '93 thru '01 72020 Maxima all models '85 thru '92 •72021 Maxima all models '93 thru 01 72030 Pick-ups '80 thru '97, Pathfinder '87 thru 7201

Frontier Pick-up '98 thai 01 Xten^ '00 & Pathfinder '96 thru '01 .

'95 '01

Pulsar all models '83 thai 86 Sentra all models '82 thru '94 Sentra & 200SX all models '95 thru '99

Stanza

all

models

'82 It)m '90

OLDSMOBILE Cutlass 74 thru '88 For other OLDSMOBILE titles, see BUICK. CHEVROLET or GM listings.

PLYMOUTH For

PLYMOUTH titles,

see DODGE.

79008 Fiero all models '84 thai '88 7901 8 Rrebird V8 models except Turtx) '70 thru '81 79019 Firebird all models '82 thru '92 79040 Mid-size Rear-wheel Drive '70 thru '87 For other PONTIAC

titles,

BUICK. CHEVROLET or

see

GM listings.

PORSCHE

861 Lawrence Drive,

'95 thru 00.

all

alt

92085 Tercel

91

1

914 924 944

Coupe & Targa models all all

all

'65 thru '89

4 cyl models '69 thru '76 models incl. Turbo '76 thru models incl. Turbo '83 thru

'82 '89

10205 10210 10215 10220 10225 10230 10240 10305 10310 10320 10330 10340 10345 10355 10360 10405 10410 10415 10420 10425 10430 10435 10440 10445 10450

Newbury

Park,

Automotive Computer Codes Automotive Emissions Control Manual Fuel Injection Manual, 1978 thru 1985 Fuel Injection Manual, 1986 thru 1999 Holley Carburetor Manual Rochester Carburetor Manual Weber/Zenfth/Stromberg/SU Carburetor Chevrolet Engine Overhaul Manual Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repair Small Engine Repair Manual Suspension, Steering & Driveline Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Body Repair & Painting Automotive Brake Manual Automotive Detaiing Manual Automotive Eelectrical Manual Automotive Heating & Air Conditioning Automotive Reference Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual ATV Basics

SPANISH MANUALS Reparacibn de Carroceria & PJntura C6dlgos Automotrices de la Computadora Frenos Automotrlz Inyeccion de Combustible 1986 al 1999 Chevrolet & GMC Camionetas '67 al '87 Chevrolet A GMC Camionetas '86 al '98 Chevrolet Camionetas Cerradas '68 al '95 Dodge Caravan/Ply. Voyager '84 al '95 Ford Camionetas y Bronco '80 al '94 Ford Camionetas Cerradas '69 al '91 Ford Modelos de Tamaho Grande '75 al '87 Ford Modelos de Tamaho Medlano 75 al '86 Ford Taurus & Mercury Sable '86 al '95 GM Modelos de Tamai^o Grande '70 al '90 GM Modelos de TamaAo Medlano '70 al '88 991 10 Nissan Camionetas '80 al '96,

98903 98S '5 98910 98915 99040 99041 99042 99055 99075 99077 99083 99088 99091 99095 99100

Pathfinder 67

991 18

'95 '82 al '94

al

Nissan Sentra

99125 Toyota Camionetas

y

4-Runner

'79 al '95

Nearly 100 Haynes motorcycle manuals also available

-

Inc.,

'96

Previa

(36059)

'70 thru "01

MERCEDES-BENZ

80020 80025 80030 80035

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 thai MH2 all models '85 thru '87 Pick-up all models '69 thru '78 Pick-up all models 79 thru '95

Corona

92080 models

all

626

•73015

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 thai '79 Corolla rear wheel drive models '80 thru '87 Corolla front wheel dnve models '84 thru '92 Corolla & Geo Prizm '93 thm 02 Corolla Tercel all models '80 thai '62

'92082

see

6 1 042

72040 72050 72051 72060

'97 thru 01

92015 92020 92025 92030 92032 92035 92036 92040 92045 92050 92055 92056 92065 92070 92075

FORD Pick-up

-

6 1 04 1

•72031

all

4Runner '96 thnj 00. T100 '93 thru '98 Tundra 00 thru '02, Sequoia '01 thru '02

Navajo - see FORD Explorer (36024) Pick-ups '72 thai '93 Pick-ups '94 on - see Ford (36071) RX-7 all models '79 thru '85 RX-7 all models '86 thru '91 626 (rear wheel drive) '79 thru '82 626 & MX-6 (front wheel drive) '83 thai

660 1 66015

models models

all

Tacoma

61015 323 a Proteg6'90thai 00 MX-5 Miata '90 thru 97 61020 MPV all models '89 thru '94

MG

01

'83 thru '91 '92 thru '96

•92076

•61016

64200

"71 thai '79 '80 thru '94

•92078

Rear Wheel Drive

61010 GLC

61035 61 036 61040

& 1600

2WD & 4WD

see 70/0T"A Camry (92007)

MAZDA

61030

thru '99

Camry/Avalon/Solara/Lexus ES 300

model coverage as of this printing. These titles will be periodically consult your Haynes dealer for more information

model years

Haynes North America,

thai '85

models '84 thnj "00 CJ all models '49 thru '86 Grand Cherokee all models '93 thru '00 Grand Wagoneer & Pick-up '72 thnj '91 Wrangler all models '87 thru 00

Navigator

(90010)

GMC HONDA

DODGE

'81 thru '93

Pick-up

LINCOLN

'90 thai '95

GEO

310 all models '78 thru '82 510 & PL521 Pick-up '68 thru '73 510 all models '78 thru '81 620 Series Pick-up all models '73 thnj '79 720 Series Pick-up - NISSAN (72030) 28025 610/Maxima all gas models. '77 thru '84

92005 Camry 92006 Camry

all

ES 300

1

1600 & 1600

'92007

LEXUS

6101

'91

TOYOTA

PONTIAC

(72010)

28016 28018 28020 28022

30008

& Pontiac Trans Sport

Chevrolet Venture, Olds Silhouette, Pontiac Trans Sport & Montana '97 thnj '01 General Motors Full-size Rear-wheel Drive - see BUICK (19025)

200SX

'78

'71 thnj '85, Seville '80 thai '85.

Buick Riviera 79 thai '85 Cadillac Eldorado & Seville '86 thai '91 DeVille & Buick Riviera '86 thru '93. Fleetwood & Olds Toronado 86 thai '92 DeVille '94 thru '02, Seville '92 thru 02 Silhouette

all models '80 thru '83 B-210 all models '73 thru '78 210 all models '78 thaj '82 240Z. 260Z & 280Z Coupe '70 thru 280ZX Coupe & 2*2 '79 Ihai '83

'82 thru '96

Prix front wheel drive '88 thru '02

Toronado

Vision. '93 thru '97

Chrysler LHS, Concorde, 300M, Dodge Intrepid 98 thru 03 Chrysler/Plym. Mid-size '82 thru '95 Rear-wheel Drive - see DODGE (30050) PT Cruiser all models 01 thru '03 Chrysler Sebring/Dodge Avenger '95 thru '02

28005 28007 26009 28012 28014

Celebrity.

Calais

'93

'84 thru '91.

49010 XJ6 all 6 cyl models '68 thru '86 4901 1 XJ6 all models '88 thru '94 49015 XJ12 aXJSall 12 cy! models '72

•59010

models

all

90010 Samurai/Sidekick/Geo Tracker 86 thru

'96 thru '01 models '86 thru '98

Hombre see CHEVROLET S- 10 (24071) Rodeo '91 thru 02, Amlgo '89 thru '02, Honda Passport '95 thru 02

Roadster

Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme & Pontiac

Grand

see DODGE Daylona (30030) Chrysler LHS, Concorde & Nevi/ Yorker,

•25035 '25040

01

Olds Cutlass Clera & Pontiac 6000

•

25030

Probe all models *89 thru '92 Ranger/Bronco II gas models '83 thnj '92 Ford Ranger '93 thru 00 & Mazda Pick-ups '94 thru '00 Taurus & Mercury Sable '86 thru '95 Taurus & Mercury Sable '96 thnj 01 Tempo & Mercury Topaz '84 thru '94 Thunderblrd/Mercury Cougar '83 thai '88 Thunderbird/Mercury Cougar '89 thru '97 Vans all VS Econoltne models '69 thru '91

38005 Buick Century, Chevrolet

•38016

10310 Chrysler Engine Overhaul Manual 25015 Chrysler Cirrus, Dodge Stratus, Plymouth Breeze, 95 thm '98 25020 Full-size Front-Wheel Drive '88 thru K-Cars see DODGE Anes (30008)

'02

GENERAL MOTORS 10360 GM Automatic Transmission Overhaul

CHRYSLER

Eagle

(36059)

Lincoln Navigator 97 thru '02 Super Duty Pick-up, Excursion '97 thru Pinto & Mercury Bobcat '75 thai '80

36078 36082 36086 36090 •36094 Vans full size '92 thru '01 •36097 WIndstar Mini-van '95 thru

-

Intrepid,

FORD Pick-up

Focus all models '00 and '01 Ford & Mercury Full-size '75 thru '87 Granada & Mercury Monarch '75 thru '80 Ford & Mercury Mid-size '75 thru '86 Mustang V8 all models '64-1/2 thai '73 Mustang II 4 cyl, V6 & V8 '74 thru '78 Mustang & Mercury Capri '79 thru '86 36051 Mustang all models '94 thru '00 36054 Pick-ups and Bronco '73 thru '79 36058 Pick-ups and Bronco '60 thru '96 •36059 Pick-ups, Expedition &

-

Dodge

see

36036 36040 36044 36048 36049 36050

-

25025

-

•36034

Citation - see GENERAL MOTORS (38020) 24032 Corsica/Beretta all models '87 thru '96 24040 Corvette all V8 models '68 thru '82 24041 Corvette all models '84 thru '96 24045 Full-size Sedans Capnce. Impala, Biscayne, Bel Air & Wagons '69 thru '90 24046 Impala SS & Caprice and Buick Roadmaster '91 thru '96 Lumina '90 thru '94 see GM (38010) '24048 Lumina & Monte Cario '95 thru 01 Lumina APV see GM (38035) 24050 Luv Pick-up all 2WD S 4WD '72 thru '82

•25026

Festiva (36030)

Explorer & Mazda Navajo '91 thru '01 36028 Fairmont 4 Mercury Zephyr '78 thru "83 36030 Festiva & Aspire '88 thai '97 36032 Fiesta all models '77 thru '80

Cavalier - see GM (38015) Celebrity - see GM (38005)

Laser

FORD

all

JAGUAR

50029 •50030

including Turbo '79 thru "88

1100, 1300, 1400

89002 89003

'79 thnj '89

50010 Cherokee, Comanche & Wagoneer

•36024

'02

24017 Camaro & Firebird '93 Ihni 00 24020 Chevelle, Malibu, El Camino '69 thai 'B7 24024 Chevette A Pontiac T1000 '76 thru '87

Malibu - see

see

-

models

all

Excel & Accent

47020 Trooper

50020

AMC (14020)

SUBARU

-

•50025

900

•87010 Saturn

ISUZU •4701 7

see

SUZUKI

Elantra

Limited

Aspire

'84010

JEEP

36006 Contour/Mercury Mystique '95 thru '00 36008 Courier Pick-up all models '72 thru '82 •36012 Crown Victoria & Mercury Grand Marquis '88 thru '00 36016 Escort/Mercury Lynx '81 thai '90 36020 Escort/Mercury Tracer '91 thnj '00

CADILLAC

models

-

SATURN

'68 thru '78

10355 Ford Automatic Transmission Overhaul 10320 Ford Engine Overhaul Manual 36004 Aerostar Mini-vans '86 thru 97

-

GM (33015. 38030.

124 Sport Coupe & Spider X1/9 all models '74 thru '80

43015

FORD

-

21030 Cadillac Rear Wheel Drive '70 thru Cimarron, Eldorado & Seville see

-

FIAT

(Bear wheel drive) '70 thru '90 Mid-size Regal & Century '74 thru '87 Regal see GENERAL MOTORS (38010) Skyhawk see GM (38030) Skylark - see GM (38020. 38025) Somerset see GENERAL MOTORS (38025)

19030

see MITSUBISHI (68030. 68031) see CHRYSLER (25025)

'

Vision

CVCC all

Encore

Alliance.

SAAB

HYUNDAI •43010

your vehicle,

RENAULT

all models '90 thru '93 all models '94 thai '97 Accord all models 98 and '99 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

•42014

42020 42021 42022 42023 42024

listing for

product information.

42012 Accord 42013 Accord

'84 thru '95 '96 thru '02

EAGLE

BUICK

you do not see a

If

for the latest

Challenger/Plymouth Saporro '78 thru '83 Challenger '67-'76 - see D,4fir (30025) Cott/Plymouth Champ '78 thru '87 Dakota Pick-ups all models 87 thai "96 Durango '98 & 99. Dakota '97 thru '99 Dari, Challenger/Plymouth Barracuda & Valiant 6 cyl models '67 thru '76 Daytona & Chrysler Laser '84 thru '89 Intrepid - see Chrysler (25025. 25026)

30040 Pick-ups

AUSTIN

Ply.

on a periodic basis.

Haynes dealer

consult your local

CA 91320

•

(805) 498-6703

3-03

Common

spark plug conditions NORMAL Symptoms:

Brown to grayish-tan color and slight electrode wear. Correct heat range for engine and operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range.

TOO HOT

WORN Symptoms:

Rounded electrodes with a small amount of deposits on the finng end- Normal color. Causes hard starting in weather and poor

damp fuel

Recommendation:

or

cold

economy. Plugs have

been left in the engine too long. Replace with new plugs of the

same

heat range. Follow the recschedule.

ommended maintenance

Dry sooty deposits mixture or weak igni-

indicate a rich tion.

and

Causes

misfinng. hard starting

hesitation.

Recommendation: (Wake

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

shortened plug

life.

Recommendation: Check

the overadvanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insuffi-

plug

correct

heat

for

range,

cient engine cooling.

Symptoms:

Melted electrodes.

Insulators are 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, over-

advanced

ignition timing, lean fuel mixture, insufficient engine cooling

and

lack of lubncation.

HIGH SPEED GLAZING

Symptoms:

Light brown deposits 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

duhng

Blistered, white insu-

eroded electrode and absence of deposits. Results in lator,

PREIGNITION

CARBON DEPOSITS Symptoms:

Symptoms:

acceleration.

Recommendation:

If excessive deposits accumulate over a short time or low mileage, install new valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gasoline brands.

Symptoms:

Insulator

has yellow-

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. ish,

Recommendation:

Install

new

plugs. Consider using a colder plug if

dnving habits warrant.

DETONATION Insulators may be craci