Haynes General Motors Chevrolet Cavalier & Pontiac Sunfire Automotive Repair Manual [38016] 156392403X, 9781563924033

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General Motors

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Chevrolet Cavalier& maaitclem-leliiila=

1995 thru 2000 £0 All models

Haynes Repair Manual |

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Chevrolet Cavalier & Pontiac Sunfire Automotive Repair Manual by Rob Maddox, Mike Stubblefield and John H Haynes Member of the Guild of Motoring Writers

Models covered: All Chevrolet Cavalier and Pontiac Sunfire models 1995 through 2000

(5D5 - 38016) VN Halmes)

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Pees OMES MEMBER Neeciion Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

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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

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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.

Acknowledgements Wiring diagrams originated exclusively for Haynes North America, Inc. by Valley Forge Technical Information Services.

© Haynes North America, Inc. 1998, 2000 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 photo-. copying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 403 X Library of Congress Catalog Card Number 00-109632 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. 00-256

Contents Introductory pages About this manual Introduction to the Chevrolet Cavalier and Pontiac Sunfire

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Buying parts Vehicle identification numbers

Maintenance techniques, tools and working facilities Booster battery (jump) starting Jacking and towing

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Automotive chemicals and lubricants Conversion factors

Safety first! Troubleshooting

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Chapter 1 Tune-up and routine maintenance

Chapter 2 PartA Overhead valve (OHV) engine

Chapter 2

PartB

Overhead camshaft (OHC) engines

Chapter 2

Part C

General engine overhaul procedures

Chapter 3 Cooling, heating and air conditioning systems

Chapter 4 Fuel and exhaust systems

Chapter 5 Engine electrical systems

5-1

Chapter 6 Emissions and engine control systems

Chapter 7

PartA

Manual transaxle

Chapter 7

6-1

TA-1

PartB

Automatic transaxle

7B-1

*

Chapter 8 Clutch and driveaxles

8-1

Chapter 9 Brakes

9-1

.

Chapter 10 Suspension and steering systems

10-1

Chapter 11 Body

11-1

Chapter 12 Chassis electrical system

Wiring diagrams

12-17

Index

IND-1

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Haynes mechanic, author and photographer with 1997 Chevrolet Cavalier

Introduction to the Chevrolet Cavalier and Pontiac Sunfire The Chevrolet Cavalier and Pontiac Sunfire is available in fourdoor sedan and two-door coupe body styles. These models are available with two engine options. The transversely mounted 2.2-liter four-cylinder, pushrod engine or the 2.3L (1995) or 2.4L (1996 through 1998) engine with Dual OverheadCamshafts (DOHC). 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 or four-speed automatic

transaxle via a pair of driveaxles.

The Cavalier and Sunfire features a steel uni-body and independent suspension with MacPherson strut/coil spring suspension at the front and shock absorbers and coil springs at the rear. 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. All models are equipped with an Anti-lock Brake System (ABS).

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

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: lf the vehicle is still covered under warranty, be sure that any replaceaal paris pur based - segardiess of

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needed for general vehicle maintenance such as oil, grease, filters,

Spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell

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Vehicle identification n 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.

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.

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

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. On the models covered by this manual the engine codes are:

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Sd ee ea 1995 1 ee 1996 WS Ee arecae eae ee ee 1997

The Vehicle Safety Certification label is attached to the edge of the driver’s side door (see illustration). The label contains the name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and the certification statement.

Tire placard The tire placard (label) is attached to the driver’s side door post (see illustration). The label contains the tire label code, the tire sizes (front, rear and spare) tire pressures, tire speed rating, maximum vehicle capacity weight, total seating occupancy and the VIN.

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 (2.2L OHV engine) or on the back of.the timing cover (2.3L and 2.4L OHC engines). 2.2L engine codes are stamped on the rear section of the engine block near the number 4 cylinder spark plug (see illustration).

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2.3L and 1996 and 1997 2.4L engine codes are affixed on the label behind the timing cover (partial laser codes) and also stamped onto the engine block near the oil filter housing and below the starter assembly. 1998 and later 2.4L engine codes are located on the end surface of the cam cover while the VIN derivative is stamped on the bottom of the engine block in front of the transaxle extension.

Transaxle identification numbers The transaxle identification information can be found on a bar

code label located on the front of the transaxle (see illustration).

Vehicle Emissions Control Information (VECI) label 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).

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Safety label is drivers or post

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On the models covered by this manual the model year codes are:

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The Vehicle Certification affixed to the side door end

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The tire placard (label) is affixed to the drivers side door end or post

_* Typical Engine Identification Number location

Location of the transaxle bar code label

0-6

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.

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, 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 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 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 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.

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 x1 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

Grade 1 or 2

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. It should be noted that many fasteners, especially Grades 0 through 2, have no dis-

Grade 5

Grade 8

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

Grade _ Identification

Grade

Hex Nut

Hex Nut

Grade 5

Property

Identification HAH

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Class 9

Hex Nut

Class 10.9

Hex Nut

Property

Grade 8

Class 10 6 Dots

Cla 9.8

Class 8.8

Arabic 10 Metric stud strength markings

Stahdard hex nut strength markings

Metric hex nut strength markings 00-1 HAYNES

Maintenance techniques, tools and working facilities tinguishing 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 fasteners are referred to as USS sizes. 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

Tightening sequences and procedures 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, have specific torque values, many of which are noted in the Specifications at the beginning of each 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)

new one has a strength rating equal to or greater than the original. —————

Metric thread sizes

i

Ft-lbs

Nm

6 to 9 14 to 21 28 to 40 50 to 71 80 to 140

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

5 to 8

7 to 10

12 to 18 22 to 33 25 to 35

17 to 24 30 to 44 34 to 47

6 to9

9 to 12

12 to 18 ee a tor 22 to 32 27 to 38 40 to 55 40 to 60 55 to 80

17 19 30 37 55 55 75

to to to to to to to

24 27 43 51 74 81 108

G L T D

Grade marks (bolt strength) Length (in inches) Thread pitch (number of threads per inch) Nominal diameter (in inches)

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 here are approximate for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners laid out in a pattern, such as cylinder head bolts, oil pan bolts, differential cover bolts, etc., must be loosened or tightened in sequence to avoid warping the component. This sequence will normally be shown in the appropriate Chapter. If a specific 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 the first one and tighten them all one-half turn, following the same pattern. Finally, tighten each of them one-quarter turn at a time until each fastener has been tightened to the proper torque. To loosen and remove the fasteners, the procedure would be reversed.

Component disassembly Component disassembly should be done 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 components before removal. When removing fasteners from a component, keep track of their locations. Sometimes threading a bolt back in a part, or putting the 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 carburetor, alternator, valve train or interior dash and trim pieces. The cavities can be marked with paint or tape to identify the contents.

00-2 HAYNES

Standard (SAE and USS) bolt dimensions/grade marks

0-7

Metric bolt dimensions/grade marks Property class (bolt strength) Length (in millimeters) Thread pitch (distance between threads in millimeters) Oo HrDiameter

Whenever wiring looms, harnesses or connectors are separated, it is a good idea to identify the two halves with numbered pieces of masking tape so they can be easily reconnected.

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

or pressure contained in an assembly.

Maintenance techniques, tools and working facilities

Dial indicator set

Micrometer set

Many times these gaskets 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 if a block of wood is placed between the hammer and the part. Do not hammer on cast parts or parts that could be easily damaged. With any particularly © stubborn part, always recheck to make sure that every fastener has been removed. Avoid using a screwdriver 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 keep in mind that extra clean up will be nec_ essary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated with a special chemical to soften it so it can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is 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.

Hose removal tips Warning: /f the vehicle is equipped with air conditioning, do not disconnect any of the A/C hoses without first having the system depressurized by a dealer service department

or a service station. Hose removal precautions closely parallel gasket removal precautions. Avoid scratching or gouging the surface that the hose mates against or the connection may 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 it around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone 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 this must be done, be careful that the metal connection is not damaged. 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 whenever a hose is removed.

Tools A selection of good tools is a basic requirement for anyone who plans to maintain and 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 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 (box-end and openend 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 1/2inch 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

Maintenance techniques, tools and working facilities

Compression gauge with spark plug hole adapter

Damper/steering wheel puller

Hydraulic lifter removal tool

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

Ring removal/installation tool

0-9

0-10

Maintenance techniques, tools and working facilities

Ring compressor

Cylinder hone

Brake cylinder hone

Clutch plate alignment tool

range of large sockets. Ideally, however, the mechanic should have a 3/8-inch 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) 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) Stee! rule/straightedge - 12 inch Allen wrench set (1/8 to 3/8-inch or 4mm to 10 mm) A selection of files 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.

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

Tap and die set

Balljoint separator — Universal-type puller Impact screwdriver Dial indicator set Stroboscopic timing light (inductive pick-up) Hand operated vacuum/pressure pump Tachometer/dwell meter _ Universal electrical multimeter Cable hoist Brake spring removal and installation tools Floor jack

Buying tools 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 tool box. As additional tools are needed, add-on sets, individual tools and a larger tool box can be purchased to expand the tool selection. Building a tool set gradu-

ally 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,

Maintenance techniques, tools and working facilities 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.

Care and maintenance of tools 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. Some tools, such as screwdrivers, pliers, wrenches and sockets, can be hung ona 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 frequently. 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-too-common 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. Sometimes, however, threads are badly damaged. When this happens, you’ve got three choices: 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 straightthrough 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.

Working facilities 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

0-11

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 com-

fortable working height is 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. 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 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 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 connected 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.

Remote positive terminal

Vehicle with dead battery

Make the booster battery cable connections in.the numerical order shown Booster battery

0-12

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 illustrations). 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 ina 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.

Towing As a general rule, the vehicle should be towed with the front (drive) wheels off the ground. If they can’t be raised, place them on a dolly. The ignition key must be in the ACC position, since the steering lock mechanism isn’t strong enough to hold the front wheels straight while towing. : Vehicles equipped with an automatic transaxle can be towed from the front only with all four wheels on the ground, provided that speeds

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.

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The vehicle is equipped with jacking instructions located in the trunk area

0-13

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.

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

Cleaners

RTV sealant is one of the most widely used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills

Sealants

- 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 contaminants. 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-

surface irregularities, remains flexible, doesn’t shrink, is relatively easy to remove, and is used as a supplementary sealer with almost all low

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.

Chemicals

_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 0 to 50. 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-50. 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 wateris 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, vinyl 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 corroded fasteners and prevent future rusting or freezing. Heat-sink grease is a special electrically non-conductive grease

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.

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.

0-14

Conversion

factors

Length (distance) x x

Inches (in) Feet (ft) Miles

25.4 0.305 1.609

0.0394 3.281 0.621

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

Volume (capacity) 16.387 = Cubic centimetres (cc; cm’)

Cubic inches (cu in; in’) Imperial pints (Imp pt)

Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

. 0.568

= Litres (I)

1.137

=Litres (I)

1.201 0.946 4.546 1.201

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

KK KKKK x 3.785 = Litres (I)

0.061 1.76 0.88 | 0.833 1.057 0.22 0.833 xxxx xKX

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12-24

Chapter 12

Chassis electrical system

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IND-1

Index A About this manual, 0-2 Accelerator cable, removal and installation, 4-7 Air cleaner assembly, removal and installation, 4-7

Booster battery (jump) starting, 0-11 Brakes, 9-1 through 9-14 Anti-lock Brake System (ABS) and Enhanced Traction System

(ETS), general information, 9-2 caliper, removal, overhaul and installation, 9-4 check, 1-16 disc, inspection, removal and installation, 9-6 fluid, check, 1-7 hoses and lines, inspection and replacement, 9-10 hydraulic system, bleeding, 9-11 light switch, check, adjustment and replacement, 9-14 master cylinder, removal and installation, 9-10

Air conditioning system accumulator/drier, removal and installation, 3-13 compressor, removal! and installation, 3-13 condenser, removal and installation, 3-15 evaporator, removal and installation, 3-15 expansion (orifice) tube, removal and installation, 3-16 Air conditioning and heating system, check and maintenance, 3-11 Air filter replacement, 1-18 Air intake plenum, 4-14

pads, replacement, 9-3

parking

Airbag, general information, 12-13 Alignment, front end, general information, 10-14 Alternator, removal and installation, 5-6 Antenna, removal and installation, 12-6 Antifreeze, general information, 3-2 Anti-lock Brake System (ABS) and Enhanced Traction System

(ETS), general information, 9-2 Automatic transaxle, 7B-1 through 7B-8

diagnosis, general, 7B-1 fluid and filter change, 1-22 fluid level check, 1-9 oil seal replacement, 7B-7 Park/Lock system, description, adjustment and cable replacement, 7B-4 Park/Neutral Position (PNP) switch, check and replacement, 7B-6 shift cable, replacement and adjustment, 7B-2 shift lever assembly, removal and installation, 7B-3 Throttle Valve (TV) cable (8T40 transaxle), replacement and adjustment, 7B-4 Automotive chemicals and lubricants, 0-13

cables, replacement, 9-13 brake, adjustment, 9-13 power brake booster, check, removal and installation, 9-12 shoes, replacement, 9-6 Bulb replacement, 12-8 Bumpers, removal and installation, 11-8 Buying parts, 0-4

Cc Camshafts, lifters and housings, removal, inspection and installation, 2B-8 Capacities, engine, 1-2 Catalytic converter, 6-14 Center console, removal and installation, 11-16 Charging system

check, 5-6 general information and precautions, 5-5 Chassis electrical system, 12-1 through 12-28 Chassis lubrication, 1-11 Circuit breakers, general information, 12-2

Clutch Back-up light switch, check and replacement, 7A-2 Balance shaft assembly, removal, inspection and installation, 2B-12 Balljoints, check and replacement, 10-8 Battery cables, check and replacement, 5-2 check, maintenance and charging, 1-12 electrolyte, check, 1-7 jump starting, 0-11 removal and installation, 5-2 Blower motor and circuit, check, 3-8 Blower motor, removal and installation, 3-9 Body, 11-1 through 11-20 damage repair major 11-3 minor, 11-2 maintenance, 11-1

components, removal, inspection and installation, 8-2

description and check, 8-1 hydraulic system, bleeding, 8-4 master cylinder, removal and installation, 8-4 release cylinder and bearing, removal, inspection and installation, 8-4 start switch, check and replacement, 8-4 Clutch and driveaxles, 8-1 through 8-12 Combination switch, removal and installation, 12-3 Control arm, removal and installation, 10-7

Conversion factors, 0-14 Cooling system check, 1-13 coolant temperature gauge sending unit, check and replacement, 3-8 servicing, draining, flushing and refilling, 1-21

IND-2

Index e

s

initial start-up and break-in after overhaul, 2C-26 intake manifold, removal and installation, 2A-4, 2B-4 main and connecting rod bearings, inspection, 2C-21 mounts, check and replacement, 2A-12, 2B-14 oil and filter change, 1-10 oil check, 1-5

Cooling, heating and air conditioning systems, 3-1 through 3-16 Crankshaft front oil seal, replacement, 2A-8, 2B-5 \ inspection, 2C-20 installation and main bearing oil clearance check, 2C-23 removal, 2C-15 sensor, 6-12 Cruise control system, description and check, 12-13 Cylinder compression check, 2C-5 Cylinder head cleaning and inspection, 2C-10 disassembly, 2C-9 reassembly, 2C-12 removal and installation, 2A-6, 2B-11 Cylinder honing, 2C-18

pan, removal and installation, 2A-10, 2B-12

pressure check, 2C-5 pump, removal, inspection and installation, 2A-11, 2B-12 type, 1-1 overhaul disassembly sequence, 2C-9 reassembly sequence, 2C-21

piston rings, installation, 2C-22 pistons and connecting rods inspection, 2C-19 installation and rod bearing oil clearance check, 2C-24

D

removal, 2C-14 rear main oil seal installation, 2C-24 replacement, 2A-11, 2B-13 rebuilding alternatives, 2C-8 removal and installation, 2C-7 removal, methods and precautions, 2C-7 repair operations possible with the engine in the vehicle, 2A-2, 2B-3 rocker arms and pushrods, removal, inspection and installation, 2A-3 timing chain cover, chain and sprockets, removal, inspection and installation, 2A-9

Dashboard trim panels, removal and installation, 11-16

Daytime Running Lights (DRL), general information, 12-10 Diagnosis, 0-16 Diagnosis, automatic transmission, general, 7B-1

Disc brake caliper, removal, overhaul and installation, 9-4 inspection, removal and installation, 9-6 pads, replacement, 9-3 Door handles, lock cylinder and latch, removal and installation,

11-14

removal, installation and adjustment, 11-14

trim panel, removal and installation, 11-12 window glass, removal and installation, 11-15 Driveaxle boot replacement and Constant Velocity (CV) joint overhaul, 8-6 general information and inspection, 8-4 removal and installation, 8-5 Drivebelt check and replacement, 1-15 Drum brake shoes, replacement, 9-6

E Electric side view mirrors, description and check, 12-12 Electrical troubleshooting, general information, 12-1 Emissions and engine control systems, 6-1 through 6-14 Engine balance shaft assembly, removal, inspection and installation, 2B-12 block

housing, removal and installation, 2B-8 timing chain and sprockets, removal, inspection and installation, 2B-6 Top Dead Center (TDC) for number one piston, locating, 2A-2 vacuum gauge diagnostic checks, 2C-6 valve cover, removal and installation, 2A-2 lifters, removal, inspection and installation, 2A-7 servicing, 2C-12 springs, retainers and seals, replacement, 2A-3, 2B-10 Engine Coolant Temperature (ECT) sensor, 6-10 Evaporative Emissions Control (EVAP) System, 6-14 Exhaust Gas Recirculation (EGR) system, 1-19, 6-13 Exhaust manifold, removal and installation, 2A-5, 2B-4 Exhaust system check, 1-17 general information, 4-14

cleaning, 2C-16 inspection, 2C-17 camshafts, lifters and housings, removal, inspection and installation, 2B-8 coolant, check, 1-6 cooling fan and circuit, check and component replacement, 3-3 crankshaft front oil seal, replacement, 2A-8, 2B-5 inspection, 2C-20 installation and main bearing oil clearance check, 2C-23

removal, 2C-15 cylinder compression check, 2C-5 cylinder head cleaning and inspection, 2C-10 disassembly, 2C-9 reassembly, 2C-12 removal and installation, 2A-6, 2B-11 cylinder honing, 2C-18 electrical systems, 5-1 through 5-8 exhaust manifold, removal and installation, 2A-5, 2B-4 flywheel/driveplate, removal and installation, 2A-11

F Fault finding, 0-16 Fender (front), removal and installation, 11-10 Fluid level checks, 1-5 Flywheel/driveplate, removal and installation, 2A-11

Fuel and exhaust systems, 4-1 through 4-14 Fuel system check, 1-20 filter replacement, 1-20 injection system check, 4-8 component check and replacement, 4-10 general information, 4-8 level sending unit, check and replacement, 4-6 lines and fittings, repair and replacement, 4-4 pressure regulator, 4-13 pressure relief procedure, 4-2 pump, removal and installation, 4-6

pump/fuel pressure, check, 4-2

SS

ARTE

tank cleaning and repair, general information, 4-5 removal and installation, 4-5 Fuses, general information, 12-2 Fusibie links, general information, 12-2

Index alg

IND-3 eh

M Main and connecting rod bearings, inspection, 2C-21 Maintenance schedule, 1-4

H

Maintenance techniques, tools and working facilities, 0-6 Manifold Absolute Pressure (MAP) sensor, 6-11 Manual transaxle, 7A-1 through 7A-4 back-up light switch, check and replacement, 7A-2 lubricant change, 1-22 level check, 1-10 overhaul, general information, 7A-3 removal and installation, 7A-2 shift cables, removal and installation, 7A-1 shift control assembly, removal and installation, 7A-2 Mirrors, outside, removal and installation, 11-15

Headlight adjustment, 12-8 bulb, replacement, 12-7 housing, removal and installation, 12-8 Heater and air conditioning control assembly, removal and installation, 3-11

Oil

G General engine overhaul procedures, 2C-1 through 2C-26

Heater core, removal and installation, 3-9

Hinges and locks, maintenance, 11-3 Hood latch and release cable, removal and installation, 11-7 Hood, removal, installation and adjustment, 11-6 Horn, check and replacement, 12-12 Hub and bearing assembly, removal and installation front, 10-8 rear, 10-10

O pan, removal and installation, 2A-10, 2B-12 pressure check, 2C-5 pump, removal, inspection and installation, 2A-11, 2B-12 seal replacement, 7B-7 On Board Diagnostic (OBD) system and trouble codes, 6-2 Overhead camshaft (OHC) engine, 2B-1 through 2B-14 Overhead valve (OHV) engine, 2A-1 through 2A-12 Oxygen sensors, 6-11

p Ignition system

Park/Lock system, description, adjustment and cable

check, 5-3 coil and module, replacement, 5-5 general information, 5-2 switch and key lock cylinder, removal and installation, 12-4 Information sensors crankshaft sensor, 6-12 Engine Coolant Temperature (ECT) sensor, 6-10 general information and testing, 6-7 Intake Air Temperature (IAT) sensor, 6-11 Knock sensor, 6-13 Manifold Absolute Pressure (MAP) sensor, 6-11 Oxygen sensors, 6-11 Throttle Position Sensor (TPS), 6-12 Vehicle Speed Sensor (VSS), 6-12

replacement, 7B-4 Park/Neutral Position (PNP) switch, check and replacement, 7B-6 Parking brake adjustment, 9-13 cables, replacement, 9-13 Piston rings, installation, 2C-22 Pistons and connecting rods inspection, 2C-19 removal, 2C-14

Initial start-up and break-in after overhaul, 2C-26 Instrument cluster, removal and installation, 12-10 Instrument panel, removal and installation, 11-19

Pistons and connecting rods, installation and rod bearing oil clearance check, 2C-24

Positive Crankcase Ventilation (PCV) system, 1-18, 6-14 Power brake booster, check, removal and installation, 9-12 Power steering fluid level check, 1-8 Power window system, description and check, 12-13 Powertrain Control Module (PCM), check and replacement, 6-6

Intake Air Temperature (IAT) sensor, 6-11 Intake manifoid, removal and installation, 2A-4, 2B-4 Intermediate shaft, removal and installation, 8-6

Introduction to the Chevrolet Cavalier and Pontiac Sunfire, 0-4

J Jacking and towing, 0-11

K Knock sensor, 6-13

R Radiator and coolant reservoir, removal and installation, 3-4 Radio and speakers, removal and installation, 12-5 Rear axle beam, removal, inspection and installation, 10-10 Rear main oil seal installation, 2C-24 replacement, 2A-11, 2B-13

Rear window defogger, check and repair, 12-6 Recommended lubricants and fluids, 1-1 Relays, general information, 12-3 Repair operations possible with the engine in the vehicle, 2A-2, 2B-3 Rocker arms and pushrods, removal, inspection and installation, 2A-3

IND-4

Index

Ss Safety first, 0-15 Seat belt check, 1-18, 11-20 removal and installation, 11-20 Shift cable replacement and adjustment, 7B-2 removal and installation, 7A-1 Shift control assembly, removal and installation, 7A-2 Shift lever assembly, removal and installation, 7B-3 Shock absorber and coil spring assembly (rear), removal and installation, 10-9 Spark plug check and replacement, 1-22 type and gap, 1-2 wire check and replacement, 1-20 Stabilizer bar and bushings, removal and installation, 10-2 Starter motor removal and installation, 5-7 testing in vehicle, 5-7 Starter solenoid, removal and installation, 5-7

Starting system, general information and precautions, 5-6 Steering system column covers, removal and installation,

11-16

Park/Lock system, description, adjustment and cable replacement, 7B-4 Park/Neutral Position (PNP) switch, check and replacement, 7B-6 removal and Installation, 7B-7 shift cable, replacement and adjustment, 7B-2 shift lever assembly, removal and installation, 7B-3 Throttle Valve (TV) cable (3T40 transaxle), replacement and adjustment, 7B-4 manual, 7A-1 through 7A-4 back-up light switch, check and replacement, 7A-2 lubricant change, 1-22 lubricant level check, 1-10 overhaul, general information, 7A-3 removal and installation, 7A-2 shift cables, removal and installation, 7A-1 shift control assembly, removal and installation, 7A-2 Trouble codes, 6-4 Troubleshooting, 0-16 Trunk lid latch, striker and lock cylinder, removal and installation, 11-11 removal, installation and adjustment, 11-10 Tune-up and routine maintenance, 1-1 through 1-24 Tune-up general information, 1-5 ! Turn signal/hazard flasher, check and replacement, 12-3

gear boots, replacement, 10-12 removal and installation, 10-12

knuckle and hub, removal and installation, 10-9 suspension and driveaxle boot check, 1-15 system, power bleeding, 10-14 pump, removal and installation, 10-13 wheel, removal and installation, 10-11 Strut and coil spring assembly (front), removal, inspection and installation, 10-4

Strut/shock absorber or coil spring, replacement, 10-5 Suspension and steering systems, 10-1 through 10-14

U Underhood hose check and replacement, 1-14 Upholstery and carpets, maintenance, 11-2

V Vacuum gauge diagnostic checks, 2C-6 Valve cover, removal and installation, 2A-2

+ Thermostat, check and replacement, 3-2 Throttle body mounting nut torque check, 1-17 Throttle Position Sensor (TPS), 6-12 Throttle Valve (TV) cable (3T40 transaxle), replacement and adjustment, 7B-4 Tie-rod ends, removal and installation, 10-11 Timing chain and sprockets, removal, inspection and installation, 2A-9, 2B-6 Tire and tire pressure checks, 1-7

Tire rotation, 1-17 Tools, 0-8 Top Dead Center (TDC) for number one piston, locating, 2A-2 Towing the vehicle, 0-12 Transaxle automatic, 7B-1 through 7B-8 diagnosis, general, 7B-1 fluid and filter change, 1-22 fluid level check, 1-9 mount, check and replacement, 7B-7 oil seal replacement, 7B-7

lifters, removal, inspection and installation, 2A-7 servicing, 2C-12 springs, retainers and seals, replacement, 2A-3, 2B-10 Vehicle identification numbers, 0-5 Vehicle Speed Sensor (VSS), 6-12 Vinyl trim, maintenance, 11-2

W Water pump check, 3-6 removal and installation, 3-6 Wheel cylinder, removal, overhaul and installation, 9-8 Wheels and tires, general information, 10-14

Window regulator, removal and installation, 11-15 Windshield and fixed glass, replacement, 11-6 Windshield washer fluid, check, 1-7 wiper blade inspection and replacement, 1-18 wiper/washer switch, removal and installation, 12-4 wiper motor, check and replacement, 12-11 Wiring diagrams, general information, 12-15

1

Haynes Automotive Manuals NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

ACURA *12020

24048 Integra ’86 thru ’89 & Legend ’86 thru ’90

AMC 14020

Jeep CJ - see JEEP (50020) Mid-size models, Concord, Hornet, Gremlin & Spirit 70 thru ’83

14025

(Renault) Alliance & Encore ’83 thru ’87

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

AUSTIN-HEALEY

BMW *18020 *18021 18025 18035 18050

24059 “24060 24064

*24065

AUDI 15020 15025 15026

24050 *24055

Jimmy ’92 thru ’94; Suburban ’92 thru ’98;

24070 *24071

3/5 Series not including diesel or all-wheel drive models '82 thru '92 3 Series except 325iX models ’92 thru ’97 320i all 4 cyl models '75 thru '83 528i & 530i all models ’75 thru ’80 1500 thru 2002 except Turbo ’59 thru ’77

CHRYSLER 25015 25025 10310 *25020

19030

Buick Oldsmobile & Pontiac Full-size (Rear wheel drive)

Buick Estate '70 thru ’90, Electra’70 thru ’84, LeSabre ’70 thru ’85, Limited ’74 thru ’79 Oldsmobile Custom Cruiser ’70 thru ’90, Delta 88 '70 thru ’85,Ninety-eight ’70 thru ’84 Pontiac Bonneville ’70 thru ’81, Catalina ’70 thru ’81, Grandville *70 thru ’75, Parisienne ’83 thru ’86 Mid-size Regal & Century all rear-drive mode!s 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 ’80 thru ’85 - see GM (38020) Skylark ’86 on - see GM (38025) Somerset - see GENERAL MOTORS (38025)

CADILLAC *21030

Cadillac Rear Wheel Drive all gasoline models ’70 thru ’93 Cimarron - see GENERAL MOTORS (38015) Eldorado - see GENERAL MOTORS (38030) Seville ’80 thru ’85 - see GM (38030)

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

Sprint & Geo Metro ’85 thru 94 Vans - Chevrolet & GMC, V8 & in-line 6 cylinder models ’68 thru ’96

Chrysler Cirrus, Dodge Stratus, Plymouth Breeze ‘95 thru ‘98 Chrysler Concorde, New Yorker & LHS, Dodge Intrepid, Eagle Vision, ‘93 thru ‘97 Chrysler Engine Overhaul Manual Full-size Front-Wheel Drive ’88 thru ’93

K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030) Century (front wheel drive) - see GM (829) Buick, Oldsmobile & Pontiac Full-size (Front wheel drive) all models ’85 thru '98 Buick Electra, LeSabre and Park Avenue;

Astro & GMC Safari Mini-vans ’85 thru ’93 Camaro V8 all models ’70 thru ’81 Camaro all models ’82 thru ’92 Cavalier - see GENERAL MOTORS (38015) Celebrity - see GENERAL MOTORS (38005) Camaro & Firebird ‘93 thru ‘97 Chevelle, Malibu & El Camino ’69 thru ’87 Chevette & Pontiac T1000 '76 thru ’87 Citation - see GENERAL MOTORS (38020) 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 Lumina - see GENERAL MOTORS (38010)

FORD 10355 *36004 *36006 36008 36012 10320 36016 *36020 *36024 36028 36030 36032 36036

Blazer & Jimmy ‘95 thru ‘96

*24075 *24080

Oldsmobile Delta 88 Royale, Ninety Eight and Regency; Pontiac Bonneville

19025

Tahoe & Yukon ’98 S-10 & S-15 Pick-ups ’82 thru ’93, Blazer & Jimmy ’83 thru ’94, S-10 & S-15 Pick-ups ‘94 thru ‘96

Sprite - see MG Midget (66015)

BUICK *19020

Lumina & Monte Carlo ’95 thru ’98 Lumina APV - see GM (38035) Luv Pick-up all 2WD & 4WD ’72 thru ’82 Monte Carlo all models ’70 thru '88 Monte Carlo '95 thru '98 - see LUMINA (24048) Nova all V8 models '69 thru ’79 Nova and Geo Prizm ’85 thru ’92 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, all full-size pick-ups, ’88 thru ’98; Blazer &

*25030

Chrysler & Plymouth Mid-size front wheel drive ’82 thru ’95 Rear-wheel Drive - see Dodge (30050)

DATSUN 28005 28007 28009 28012 28014 28016 28018 28020 28022

28025

200SxX all models ’80 thru ’83 B-210 all models ’73 thru ’78 210 all models ’79 thru ’82

240Z, 260Z & 280Z Coupe ’70 thru ’78 280ZX Coupe & 2+2 ’79 thru ’83 300ZX - see NISSAN (72010) 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 thru ’79 720 Series Pick-up - see NISSAN (72030) 810/Maxima all gasoline models, ’77 thru ’84

DODGE *30008 30010 *30011 30012 30016

*30020 30025 *30030 *30034 *30035 *30040 *30041 *30045 30050 *30055 *30060 *30065

400 & 600 - see CHRYSLER (25030) Aries & Plymouth Reliant ’81 thru ’89 Caravan & Plymouth Voyager Mini-Vans all models ’84 thru ’95 Caravan & Plymouth Voyager Mini-Vans all models ’96 thru ’98 Challenger/Plymouth Saporro ’78 thru ’83 Colt & Plymouth Champ (front wheel drive) all models ’78 thru ’87 Dakota Pick-ups all models ’87 thru ’96 Dart, Demon, Plymouth Barracuda, Duster & Valiant 6 cyl models ’67 thru ’76 Daytona & Chrysler Laser ’84 thru ’89 Intrepid - see CHRYSLER (25025) Neon all models ’95 thru ’97 Omni & Plymouth Horizon '78 thru ’90 Pick-ups all full-size models '74 thru ‘93 Pick-ups all full-size models ‘94 thru ‘96 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups ’79 thru ’93 Dodge/Plymouth/Chrysler rear wheel drive ’71 thru ’89 Shadow & Plymouth Sundance ’87 thru ’94 Spirit & Plymouth Acclaim ’89 thru ’95 Vans - Dodge & Plymouth ’71 thru ’96

36040 36044

Ford Torino,Gran Torino, Elite, Ranchero

pick-up, LTD Il, Mercury Montego, Comet, XR-7 & Lincoln Versailles (’75 thru ’86)

36048 36049 36050 *36051 36054 36058 36059 36062 36066 36070 *36071

36074 *36075 *36078 36082 *36086 36090 *36094 *36097

Talon - see Mitsubishi Eclipse (68030) Vision - see CHRYSLER (25025)

Mustang V8 all models ’64-1/2 thru ’73 Mustang II 4 cyl, V6 & V8 models ’74 thru ’78 Mustang & Mercury Capri all models Mustang, ’79 thru ’93; Capri, ’79 thru ’86 Mustang all models ’94 thru ’97 Pick-ups & Bronco ’73 thru ’79 Pick-ups & Bronco ’80 thru ’96 Pick-ups, Expedition & Mercury Navigator '97 thru ’98 Pinto & Mercury Bobcat ’75 thru ’80 Probe all models ’89 thru ’92

Ranger/Bronco Il gasoline models ’83 thru 92 Ranger ‘93 thru ‘97 & Mazda Pick-ups ‘94 thru ‘97 Taurus & Mercury Sable ’86 thru 95 Taurus & Mercury Sable ’96 thru ’98 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-’95 Windstar Mini-van '95-’98

GENERAL MOTORS *10360 *38005 *38010

*38015 *38016 38020 38025

38030

*38035

EAGLE

Ford Automatic Transmission Overhaul Aerostar Mini-vans all models ’86 thru ’96 Contour & Mercury Mystique ’95 thru ’98 Courier Pick-up all models ’72 thru ’82 Crown Victoria & Mercury Grand Marquis ’88 thru ’96 Ford Engine Overhaul Manual Escort/Mercury Lynx all models ’81 thru 90 Escort/Mercury Tracer 91 thru ’96 Explorer & Mazda Navajo ’91 thru ’95 Fairmont & Mercury Zephyr ’78 thru ’83 Festiva & Aspire ’88 thru ’97 Fiesta all models '77 thru ’80 Ford & Mercury Full-size, Ford LTD & Mercury Marquis (75 thru ’82); Ford Custom 500,Country Squire, Crown Victoria & Mercury Colony Park ('75 thru ’87); Ford LTD Crown Victoria & Mercury Gran Marquis (’83 thru ’87) Granada & Mercury Monarch ’75 thru ’80 Ford & Mercury Mid-size, Ford Thunderbird & Mercury Cougar (’75 thru ’82); Ford LTD & Mercury Marquis (’83 thru ’86);

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 front-wheel drive models ’88 thru ’95 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza & Pontiac J-2000 & Sunbird ‘82 thru ’94 Chevrolet Cavalier & Pontiac Sunfire ’95 thru ’98 Buick Skylark, Chevrolet Citation, Olds Omega, Pontiac Phoenix ’80 thru ’85 Buick Skylark & Somerset, Oldsmobile Achieva & Calais and Pontiac Grand Am all models ’85 thru ’95 Cadillac Eldorado ’71 thru ’85, Seville ’80 thru ’85, Oldsmobile Toronado '71 thru ’85 & Buick Riviera ’79 thru ’85 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models '90 thru ’95 General Motors Full-size

Rear-wheel Drive - see BUICK (19025)

FIAT 34010 34025

124 Sport Coupe & Spider ’68 thru ’78 X1/9 all models ’74 thru ’80

(Continued on other side)

be periodically updated to include later model years - consult your * Listings shown with an asterisk (“) indicate model coverage as of this printing. These titles will Haynes dealer for more information.

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

A,

S&

NN

Haynes Automotive Manuals (continued)

aumes

STS

®

NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

GE (o}

*40030 :

Safari - see CHEVROLET ASTRO (24010) Vans & Pick-ups - see CHEVROLET

HONDA 42011 42012 42013 42020 42021 42022 42023 *42024 *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 ’95 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 Prelude CVCC all models ’79 thru 89

Hombre - see CHEVROLET S-10 (24071) Rodeo ’91 thru ’97; Amigo ’89 thru ’94;

72010 *72015 *72020 *72030 72040 *72050 *72051 *72060

‘ 300ZX all models including Turbo ’84 thru ’89 Altima all models ’93 thru ’97 Maxima all models ’85 thru ’91 Pick-ups ’80 thru ’96 Pathfinder ’87 thru 95 Pulsar all models ’83 thru ’86 Sentra all models ’82 thru ’94 Sentra & 200SX all models ’95 thru 98 Stanza all models ’82 thru ’90

*73015

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

50020 *50025 50029

*50030

79008 79018 79019

Fiero all models ’84 thru ’88 Firebird V8 models except Turbo ’70 thru ’81 Firebird all models ’82 thru ’92 For other PONTIAC titles, see BUICK,

CHEVROLET or GENERAL MOTORS listing.

*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

SAAB

Grand Wagoneer ’84 thru ’91, Cherokee &

*84010

Wagoneer ’72 thru ’83, Pick-up *72 thru ’88 Wrangler all models ’87 thru ’95

GLC Hatchback (rear wheel drive) ’77 thru ’83 GLC (front wheel drive) ’81 thru ’85 323 & Protogé ’90 thru ’97

*61016 *61020

MX-5 Miata 90 thru ’97 MPV all models ’89 thru 94 Navajo - see Ford Explorer (36024) Pick-ups ’72 thru ’93 Pick-ups '94 thru ’96 - see Ford Ranger (36071) RX-7 all models ’79 thru ’85 RX-7 all models ’86 thru ’91 626 (rear wheel drive) all models ’79 thru ’82 626/MX-6 (front wheel drive) ’83 thru ’91

MERCEDES-BENZ 63012

*63015 63020 63025 63030

Alliance & Encore - see AMC (14020)

900 all models including Turbo ’79 thru ’88

SATURN 87010

Navigator - see FORD Pick-up (36059) Rear Wheel Drive all models ’70 thru ’96

61010 61011 *61015

61035 *61036 61040 *61041

RENAULT

Cherokee, Comanche & Wagoneer Limited all models ’84 thru ’96 CJ all models ’49 thru ’86 Grand Cherokee all models ’93 thru 98 Grand Wagoneer & Pick-up ’72 thru ’91

MAZDA

61030

Vw 96008 96012 *96016 96017 96020 96030 96035

96040 96045

Beetle & Karmann Ghia ’54 thru ’79 Dasher all gasoline models ’74 thru ’81 Rabbit, Jetta, Scirocco, & Pick-up gas models ’74 thru 91 & Convertible ’80 thru 92 Golf & Jetta all models ’93 thru ’97 Rabbit, Jetta & Pick-up diesel ’77 thru '84 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 *97020 97025 *97040

120, 140 240 260 740

130 Series & 1800 Sports ’61 thru ’73 Series all models ’66 thru ’74 Series all models ’76 thru 93 Series all models ’75 thru ’82 & 760 Series all models ’82 thru ’88

TECHBOOK

PORSCHE

XJ6 all 6 cyl models ’68 thru ’86 XJ6 all models ’88 thru ’94 XJ12 & XJS all 12 cyl models ’72 thru ’85

LINCOLN 59010

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

For PLYMOUTH titles, see DODGE listing.

JEEP *50010

94007 94010

VOLVO

OLDSMOBILE

Trooper & Pick-up, all gasoline models Pick-up, ’81 thru ’93; Trooper, ’84 thru ’91

JAGUAR *49010 *49011 *49015

Tredia, Galant, Precis & ’83 thru ’93 Eagle Talon & Ply. Laser ’90 thru 94 ’83 thru ‘96 & Montero ’83 thru ’93

PONTIAC

Honda Passport ’95 thru ’97

*47020

*68030 *68040

Excel all models ’86 thru ’94

ISUZU *47017

Cordia, Mirage Eclipse, Pick-up

PLYMOUTH

HYUNDAI *43015

*68020

NISSAN

GMC

42010

TRIUMPH

MITSUBISHI Metro - see CHEVROLET Sprint (24075) Prizm - ’85 thru ’92 see CHEVY (24060), 93 thru ’96 see TOYOTA Corolla (92036) Storm all models ’90 thru ‘93 Tracker - see SUZUKI Samurai (90010)

123 Series Diesel ’76 thru ‘85

190 Series four-cyl gas models, ’84 thru ’88 230/250/280 6 cyl sohc models ’68 thru ’72 280 123 Series gasoline models ’77 thru ’81

350 & 450 all models ’71 thru ’80

MERCURY See FORD Listing.

MG 66010

MGB Roadster & GT Coupe ’62 thru ’80

66015

MG Midget, Austin Healey Sprite ’58 thru ’80

Saturn all models ’91 thru ’96

SUBARU 89002 1100,,1300, 1400 & 1600 '71 thru ’79 *89003 1600 & 1800 2WD & 4WD ’80 thru ’94 SUZUKI *90010

Samurai/Sidekick & Geo Tracker '86 thru ’96

TOYOTA 92005 92006 92015 *92020 92025 92030 92032 92035 *92036 92040 92045 92050 92055 92056 *92065

Camry all models ’83 thru ’91 Camry all models ’92 thru ’96 Celica Rear Wheel Drive ’71 thru ’85 Celica Front Wheel Drive ’86 thru ’93 Celica Supra all models ’79 thru ’92 Corolla all models ’75 thru '79 Corolla all rear wheel drive models ’80 thru ’87 Corolla all front wheel drive models ’84 thru ’92 Corolla & Geo Prizm ’93 thru ’97 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 MR2 all models ’85 thru ’87

92070 *92075 *92076

Pick-up all models ’69 thru '78 Pick-up all models ’79 thru ’95 Tacoma 95 thru 98, 4Runner '96 thru 98,

MANUALS

10205 10210

Automotive Computer Codes Automotive Emissions Control Manual

10215 10220 10225 10230 10240 10305 10310 10320 10330 10340

Fuel Injection Manual, 1978 thru 1985 Fuel Injection Manual, 1986 thru 1996 Holley Carburetor Manual 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 Small Engine Repair Manual

10345 10355 10360 10405 10410 10415 10420 10425 10430 10435 10440 10445 10450

Suspension, Steering & Driveline Manual 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 Manual & Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual

ATV Basics

SPANISH MANUALS 98903 98905 98910 98915 99040 99041

. 99042 99055 99075 99077 99083 99088 99091 99095 99100 99110 99118 99125

Reparacién de Carroceria & Pintura Coédigos Automotrices de la Computadora Frenos Automotriz Inyeccién de Combustible 1986 al 1994 Chevrolet & GMC Camionetas ’67 al '87 Incluye Suburban, Blazer & Jimmy 67 al ’91 Chevrolet & GMC Camionetas '88 al '95 Incluye Suburban ’92 al ’95, Blazer & Jimmy ’92 al ’94, Tahoe y Yukon ’95 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 Grande ‘75 al ‘87 Ford Modelos de Tamajio Mediano ‘75 al ‘86 Ford Taurus & Mercury Sable ’86 al ’95 GM Modelos de Tamajio Grande ‘70 al ‘90 GM Modelos de Tamajfio Mediano ‘70 al ‘88 Nissan Camionetas ‘80 al ‘96, Pathfinder ‘87 al ‘95 Nissan Sentra ‘82 al ‘94 Toyota Camionetas y 4Runner ’79 al 95

& T100 ’93 thru ’98

*92080 92085

Previa all models ’91 thru ’95 Tercel all models ’87 thru ’94

-* Listings shown with an asterisk (“) indicate model coverage as of this printing. These titles will be periodically updated to include later model years - consult your Haynes dealer for more information.

Over 100 Haynes motorcycle manuals

also available

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

5-98

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 firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Recommendation: Plugs have been left in the engine too long. Replace with new plugs of the same heat range. Follow the recommended maintenance schedule.

CARBON

Symptoms: Blistered, white insulator, eroded electrode and absence of deposits. Results in shortened plug life. Recommendation: Check for the correct plug heat range, over-

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

€ient engine cooling.

PREIGNITION

DEPOSITS

Symptoms: Dry sooty deposits indicate a rich mixture or weak ignition. 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.

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, overadvanced ignition timing, lean fuel mixture, insufficient engine cooling and lack of lubrication.

ASH DEPOSITS

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

Symptoms: Insulator has yellowish, glazed appearance. Indicates that combustion chamber temper-

during acceleration. Recommendation: _ |f excessive deposits

time

accumulate

or low

mileage,

over a short

install

new

valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gasoline brands.

OIL DEPOSITS Symptoms: Oily coating caused by poor oil control. Oil is leaking past worn valve guides or piston rings into the combustion chamber. Causes hard starting, misfiring and hesitation. Recommendation: Correct the mechanical condition with necessary repairs and install new plugs.

atures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating. Causes misfiring at high speeds. Recommendation: Install 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

in a fractured insulator tip. Can lead to piston damage. Recommendation: Make sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid

lugging the engine.

MECHANICAL DAMAGE 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.

Symptoms: May 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 the mechanical damage. Remove ‘the foreign object from the engine and/or install the correct reach plug.

ae mal ies

oc ‘Tune-up procedures

state liavemes) ex=ls

erereliiateneUureRatetiite PNimere)areliaceyariare Fuel and exhaust slaltsxs) a (0)alswere) aitge)|

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Electrical systems A iTatate melts (ele-laats

Chapter 2 PartB

Engine

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