Haynes Dodge Pick-Ups 2009 thru 2012 Automotive Repair Manual [30043] 1620920077, 9781620920077

Citation preview

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Power window system - 2009 2500/3500 models

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Chapter 12

12-51

Chassis electrical system HOT W/ RUN/ ACCESSORY RELAY ENERGIZED

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Chapter 12

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Chassis electrical system HOT AT ALL TIMES

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Chapter 12 Chassis electrical system

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IND-1

index

A About this manual, 0-5 Accelerator Pedal Position (APP) sensor, replacement, 6-16 Acknowledgements, 0-2 Air conditioning

and heating system, check and maintenance, 3-11 compressor, removal and installation, 3-13 condenser, removal and installation, 3-13 expansion valve, removal and installation, 3-14 pressure switch, replacement, 3-14 Air filter housing, removal and installation diesel engine, 4B-7 gasoline engines, 4A-8 Air filter replacement, 1-24 Air heater and relay, diesel engines, replacement, 4B-6 Airbag system, general information, 12-17 Alternator, removal and installation, 5-7 Antenna and cable, removal and installation, 12-8 Antifreeze, general information, 3-2 Anti-lock Brake System (ABS), general information, 9-2 Automatic transmission Brake Transmission Shift Interlock (BTSI) system, description, check and adjustment, 7B-4 diagnosis, general, 7B-2 extension housing oil seal, replacement, 7A-2 fluid and filter change, 1-28 level check, 1-12 type, 1-2 mount, check and replacement, 7B-5 oil cooler, removal and installation, 7B-4 overhaul, general information, 7B-7 removal and installation, 7B-5 shift cable, check, adjustment and replacement, 7B-3 Automotive chemicals and lubricants, 0-18 Axle assembly, front (4€WD models), removal and installation, 8-15 Axle assembly, rear general information, 8-11 removal and installation, 8-11 Axleshaft, rear bearing (semi-floating axle), replacement, 8-14 oil seal (semi-floating axle), replacement, 8-13 removal and installation, 8-11

Back-up light switch, check and replacement, 7A-2 Balljoints, replacement, 5-10

Battery cables, check and replacement, 5-4 check and replacement, 5-2 check, maintenance and charging, 1-16 Blower motor resistor and blower motor, replacement, 3-9 Body repair major damage, 11-3 minor damage, 11-2 Body, maintenance, 11-1 Booster battery (jump) starting, 0-17 Brake Anti-lock Brake System (ABS), general information, 9-2

caliper, removal and installation, 9-5 disc, inspection, removal and installation, 9-5 fluid change, 1-24 level check, 1-11

type, 1-2 general information, 9-2 hose check, 1-19 hoses and lines, inspection and replacement, 9-7 hydraulic brake booster (diesel engine), removal and installation, 9-11 hydraulic system, bleeding, 9-8 light switch, removal and installation, 9-12 master cylinder, removal and installation, 9-6 pads, replacement, 9-3 parking brake adjustment, 9-12 shoes, replacement, 9-8 power brake booster (gasoline engines), check, removal and installation, 9-7

system check, 1-20 Brake Transmission Shift Interlock (BTSI) system, description, check and adjustment, 7B-4 Bulb replacement, 12-12 Bumpers, removal and installation, 11-7 Buying parts, 0-7

C Cable replacement antenna, 12-8 battery, 5-4 hood release, 11-6 shift, automatic transmission, 7B-3 Caliper, disc brake, removal and installation, 9-5 Camshaft and lifters, Hemi engine, removal, inspection and installation, 2B-11

IND-2

Index

Camshaft and tappets, diesel engine, removal, inspection and installation, 2C-5

Camshaft Position (CMP) sensor, replacement, 6-16 Camshafts, 3.7L V6 and 4.7L V8 engines, removal, inspection and installation, 2A-11 Capacities, fluids and lubricants, 1-2 Carpets, maintenance, 11-2

Crankshaft Position (CKP) sensor, replacement, 6-17 Crankshaft pulley/vibration damper, removal and installation 3.7L V6 and 4.7L V8 engines, 2A-15 diesel engine, 2C-5 Hemi engine, 2B-7

Crankshaft, removal and installation, 2D-14

Carrier plate, door, removal and installation, 11-10

Cruise control system, general information, 12-15

Catalytic converter, general description, check and

Cylinder compression check, 2D-4 Cylinder head(s), removal and installation 3.7L V6 and 4.7L V8 engines, 2A-14 diesel engine, 2C-8 Hemi engine, 2B-10

replacement, 6-23

Center support bearing, driveshaft, removal and installation, 8-7 Charging system alternator, removal and installation, 5-7 check, 5-7

general information and precautions, 5-7 Chassis electrical system, 12-1 Chassis grease type, 1-2 Chemicals and lubricants, 0-18 Circuit breakers, general information, 12-3 Closed Crankcase Ventilation (CCV) filter replacement (diesel engine), 1-28 Clutch components, removal, inspection and installation, 8-3

description and check, 8-3 fluid level check, 1-11

type, 1-2 hydraulic release system, removal and installation, 8-3 pedal position switch, check and replacement, 8-6 pilot bearing, inspection and replacement, 8-5 release bearing, removal, inspection and installation, 8-5 Coil spring, removal and installation front, 5-8 rear, 5-13

Coil, ignition, check and replacement, 5-6 Compressor, air conditioning, removal and installation, 3-13 Condenser, air conditioning, removal and installation, 3-13 Console, removal and installation, 11-18

Control arm, front, removal and installation lower, 5-9 upper, 5-9 Conversion factors, 0-19 Coolant general information, 3-2

level check, 1-11 reservoir, removal and installation, 3-5 temperature sending unit, check and replacement, 3-9 type, 1-2

Coolant Temperature (ECT) sensor, replacement, 6-18 Cooling system check, 1-19 servicing (draining, flushing and refilling), 1-29 Cowl cover, removal and installation, 11-19 Crankshaft front oil seal, replacement 3.7L V6 and 4.7L V8 engines, 2A-15 diesel engine, 2C-5 Hemi engine, 2B-7

D Dashboard trim panels, removal and installation, 11-14 Daytime Running Lights (DRL), general information, 12-17 Defogger, rear window, check and repair, 12-8 Diagnosis, 0-22 Diagnostic Trouble Codes (DTCs), obtaining and clearing, 6-4 Diesel engine, in-vehicle repair procedures camshaft and tappets, removal, inspection and installation, 2C-5 crankshaft front oil seal and gear housing cover, replacement, 2C-5 cylinder head, removal, inspection and installation, 2C-8 engine mounts, check and replacement, 2C-12

exhaust manifold, removal and installation, 2C-5 flywheel/driveplate, removal and installation, 2C-11 intake manifold, removal and installation, 2C-4 oil pan, removal and installation, 2C-11 oil pressure relief valve, replacement, 2C-11 oil pump, removal and installation, 2C-10 rear main oil seal, replacement, 2C-12 repair operations possible with the engine in the vehicle, 2C-3 rocker arms and pushrods, removal, inspection,- -— — installation and adjustment, 2C-4 Top Dead Center (TDC) for number 1 piston, locating, 2C-3 valve cover, removal and installation, 2C-3 Differential lubricant change, 1-27 level check, 1-24 type, 1-2 pinion oil seal, replacement, 8-14 Disc brake caliper, removal and installation, 9-5 disc, inspection, removal and installation, 9-5 pads, replacement, 9-3 Door ae carrier plate, latch, handles and lock cylinder, removal —

and installation, 11-10

—a

IND-3

Index eennnn nnn nncrere ene reennrcecee screenees

eeec

eases

ec

SS

a

removal, installation and adjustment, 11-10 trim panels, removal and installation, 11-8 window glass regulator, removal and installation, 11-12 removal and installation, 11-12 Driveaxle (4WD models with independent front suspension) boot check, 1-19 replacement, 8-8 front oil seal, removal and installation, 8-15 removal and installation, 8-8 Drivebelt check and replacement, 1-21 Driveshaft(s) center support bearing, removal and installation, 8-7 general information, 8-6 lubrication, front (2500/3500 4WD), 1-16 removal and installation, 8-6 universal joints general information and check, 8-7 replacement, 8-7

E EGR valve and EGR cooler cleaning (diesel engine), 1-27 Electric shift motor, transfer case, replacement, 7C-2 Electric side view mirrors, general information, 12-15

Electrical troubleshooting, general information, 12-1 Emissions and engine control systems, 6-1 Engine and emissions control systems, general information, 6-1 Engine Coolant Temperature (ECT) sensor, replacement, 6-18

Engine coolant, level check, 1-11 Engine electrical systems, 5-1 Engine mounts, check and replacement

3.7L V6 and 4.7L V8 engines, 2A-18 diesel engine, 2C-12 Hemi engine, 2B-14 Engine oil and oil filter change, 1-14 level check, 1-10 type and viscosity, 1-1 Engine overhaul disassembly sequence, 2D-8 reassembly sequence, 2D-18 Engine rebuilding alternatives, 2D-6 Engine removal, methods and precautions, 2D-6 Engine, general overhaul procedures crankshaft, removal and installation, 2D-14 cylinder compression check, 2D-4 engine overhaul disassembly sequence, 2D-8 reassembly sequence, 2D-18 engine rebuilding alternatives, 2D-6 engine removal, methods and precautions, 2D-6

SSA

2ST

SI

SESS SPSS

ATS

SA

PS

RS

GS

RN

engine, removal and installation, 2D-7 initial start-up and break-in after overhaul, 2D-18 oil pressure check, 2D-4 pistons and connecting rods, removal and installation, 2D-9 vacuum gauge diagnostic checks, 2D-5 Engine, in-vehicle repair procedures 3.7L V6 and 4.7L V8 engines camshafts, removal, inspection and installation, 2A-11 crankshaft front oil seal, replacement, 2A-15 crankshaft pulley/vibration damper, removal and installation, 2A-15 cylinder head, removal and installation, 2A-14

exhaust manifold, removal and installation, 2A-13 flywheel/driveplate, removal and installation, 2A-18 intake manifold, removal and installation, 2A-13 mounts, check and replacement, 2A-18 oil pan, removal and installation, 2A-16 oil pump, removal, inspection and installation, 2A-16 rear main oil seal, replacement, 2A-18 repair operations possible with the engine in the vehicle, 2A-4 rocker arms and hydraulic lash adjusters, removal, inspection and installation, 2A-5 timing chain and sprockets, removal, inspection and installation, 2A-6

Top Dead Center (TDC) for number 1 piston, locating, 2A-4

valve covers, removal and installation, 2A-5 5.7L V8 (Hemi) engine camshaft and lifters, removal, inspection and

installation, 2B-11 cylinder heads, removal and installation, 2B-10

engine mounts, check and replacement, 2B-14 exhaust manifolds, removal and installation, 2B-6 flywheel/driveplate, removal and installation, 2B-14 intake manifold, removal and installation, 2B-5 oil pan, removal and installation, 2B-13 oil pump, removal and installation, 2B-14 rear main oil seal, replacement, 2B-14 repair operations possible with the engine in the vehicle, 2B-3

rocker arms and pushrods, removal, inspection and installation, 2B-4

timing chain cover and sprockets, removal, inspection and installation, 2B-8

Top Dead Center (TDC) for number 1 piston, locating, 2B-3 valve covers, removal and installation, 2B-3

vibration damper and front oil seal, removal and installation, 2B-7 Diesel engine camshaft and tappets, removal, inspection and installation, 2C-5 crankshaft front oil seal and gear housing cover, replacement, 2C-5 cylinder head, removal, inspection and installation, 2C-8 engine mounts, check and replacement, 2C-12

IND-4

Index

exhaust manifold, removal and installation, 2C-5

flywheel/driveplate, removal and installation, 2C-11 intake manifold, removal and installation, 2C-4 oil pan, removal and installation, 2C-11

oil pressure relief valve, replacement, 2C-11 oil pump, removal and installation, 2C-10 rear main oil seal, replacement, 2C-12 repair operations possible with the engine in the vehicle, 2C-3 rocker arms and pushrods, removal, inspection, installation and adjustment, 2C-4

Top Dead Center (TDC) for number 1 piston, locating, 2C-3 valve cover, removal and installation, 2C-3 Engine, removal and installation, 2D-7

Engine-mounted and radiator-mounted cooling fans, check and component replacement, 3-4 Evaporative emissions control (EVAP) system, general description and component replacement, 6-24 Exhaust Gas Recirculation (EGR) system, description and component replacement, 6-26 Exhaust manifold(s), removal and installation 3.7L V6 and 4.7L V8 engines, 2A-13 diesel engine, 2C-5 Hemi engine, 2B-6 Exhaust system check, 1-19 servicing, general information, 4A-11

Expansion valve, air conditioning, removal and installation, 3-14 Extension housing oil seal, replacement, 7A-2

Fans, engine cooling, check and component replacement, 3-4 Fault finding, 0-22 Fender, removal and installation, 11-8 Filter replacement automatic transmission, 1-28 CCV (diesel engine), 1-28 engine air, 1-24 engine oil, 1-14 fuel (diesel engine), 1-23 Firing order, 1-3 Fluid level checks, 1-10 automatic transmission, 1-12 brake fluid, 1-11 clutch fluid, 1-11

differential, 1-24 engine coolant, 1-11 engine oil, 1-10

manual transmission, 1-24 power steering, 1-12 transfer case, 1-24

windshield washer, 1-12

Fluids and lubricants capacities, 1-2 recommended, 1-1 Flywheel/driveplate, removal and installation 3.7L V6 and 4.7L V8 engines, 2A-18 diesel engine, 2C-11 Hemi engine, 2B-14 Fraction/decimal/millimeter equivalents, 0-20 Front axle assembly (4WD models), removal and installation, 8-15 Front driveaxle oil seal (independent front suspension), removal and installation, 8-15

Front hub bearing assembly and axleshaft (solid axle), removal and installation, 8-16 Fuel filter draining and replacement (diesel engine), 1-23 Fuel Control Actuator (FCA), diesel engine, replacement, 4B-4 heater, filter housing and heater relay, diesel engine, replacement, 4B-5 injection system check, 4A-9 general information, 4A-8 pump, diesel engine, removal and installation, 4B-4 injectors, diesel engines, check and replacement, 4B-5 lines and fittings diesel engine, general information, 4B-3 repair and replacement, 4A-3 pressure relief procedure (gasoline engines), 4A-2 pump and fuel level sending unit module, removal and installation (gasoline engines), 4A-7 pump/pressure, check (gasoline engines), 4A-2 rail and injectors, gasoline engines, removal and installation, 4A-9 system check, 1-22 system priming, diesel engine, 4B-3 tank cleaning and repair, general information, 4A-7 removal and installation, 4A-6 transfer pump, diesel engine, check and replacement, 4B-3 = Fuel and exhaust systems diesel engine, 4B-1 gasoline engines, 4A-1 Fuses, general information, 12-3

G General engine overhaul procedures, 2D-1

crankshaft, removal and installation, 2D-14 cylinder compression check, 2D-4 engine overhaul disassembly sequence, 2D-8 reassembly sequence, 2D-18 engine rebuilding alternatives, 2D-6 engine removal, methods and precautions, 2D-6 engine, removal and installation, 2D-7

=

Index initial start-up and break-in after overhaul, 2D-18 oil pressure check, 2D-4 pistons and connecting rods, removal and installation, 2D-9 vacuum gauge diagnostic checks, 2D-5 Grille, radiator, removal and installation, 11-6

H Headlight adjustment, 12-10 bulb, replacement, 12-9 housing, removal and installation, 12-10 switch, replacement, 12-5 Heater core, removal and installation, 3-10 Heater/air conditioning control assembly, removal and installation, 3-10 Heating and air conditioning system, check and maintenance, 3-11 Hemi engine, in-vehicle repair procedures camshaft and lifters, removal, inspection and installation, 2B-11 cylinder heads, removal and installation, 2B-10 engine mounts, check and replacement, 2B-14 exhaust manifolds, removal and installation, 2B-6 flywheel/driveplate, removal and installation, 2B-14 intake manifold, removal and installation, 2B-5 oil pan, removal and installation, 2B-13 oil pump, removal and installation, 2B-14 rear main oil seal, replacement, 2B-14 repair operations possible with the engine in the vehicle, 2B-3 rocker arms and pushrods, removal, inspection and installation, 2B-4 timing chain cover and sprockets, removal, inspection and installation, 2B-8 Top Dead Center (TDC) for number 1 piston, locating, 2B-3 valve covers, removal and installation, 2B-3 vibration damper and front oil seal, removal and installation, 2B-7 Hinges and locks, maintenance, 11-3 Hood latch and release cable, removal and installation, 11-6 removal, installation and adjustment, 11-3 support struts, removal and installation, 11-3 Horn, replacement, 12-15 Hub and bearing assembly, independent front suspension, removal and installation, 5-11 Hub and bearing, removal and installation front, solid axle, 8-16 independent front suspension, 5-11 Hydraulic brake booster (diesel engine), removal and installation, 9-11

Hydraulic release system, clutch, removal and installation, 8-3

IND-5

Ignition switch and key lock cylinder, replacement, 12-5 Ignition system check, 5-5 coil, check and replacement, 5-6 general information, 5-4 Initial start-up and break-in after overhaul, 2D-18 Injectors, fuel, removal and installation diesel engine, 4B-5 gasoline engines, 4A-9 Input Shaft Speed (ISS) and Output Shaft Speed (OSS) sensors, replacement, 6-19 Instrument cluster, removal and installation, 12-5 panel, removal and installation, 11-18 Intake Air Temperature (IAT) sensor, replacement, 6-19 Intake manifold, air heater and air heater relay, diesel engines, replacement, 4B-6 Intake manifold, removal and installation 3.7L V6 and 4.7L V8 engines, 2A-13 diesel engine, 2C-4 Hemi engine, 2B-5 Intercooler, diesel engine, removal and installation, 4B-9 Introduction, 0-5

J Jacking and towing, 0-16 Jump starting, 0-17

K Key lock cylinder and latch, door, removal and installation, 11-10 ignition, replacement, 12-5 Knock sensor(s), replacement, 6-20

L Leaf spring, removal and installation, 5-12 Lower control arm, front, removal and installation, 5-9 Lubricants and chemicals, 0-18 Lubricants and fluids capacities, 1-2 recommended, 1-1

IND-6 Mi Maintenance schedule, 1-8 routine, 1-1 techniques, tools and working facilities, 0-10

Manifold Absolute Pressure (MAP) sensor, replacement, 6-21 Manual transmission back-up light switch, check and replacement, 7A-2 extension housing oil seal, replacement, 7A-2 lubricant change, 1-27 level check, 1-24 type, 1-2 overhaul, general information, 7A-4 removal and installation, 7A-3 shift lever, removal and installation, 7A-2 Master cylinder, brake, removal and installation, 9-6 Mirrors electric side view, general information, 12-15 removal and installation, 11-13 Multi-function switch, replacement, 12-4

Index Parts, replacement, buying, 0-7 Pilot bearing, clutch, inspection and replacement, 8-5 Pinion oil seal, replacement, 8-14 Pistons and connecting rods, removal and installation, 2D-9

Positive Crankcase Ventilation (PCV) system general description and check, 6-25 valve replacement (gasoline engines), 1-28 Power brake booster (gasoline engines), check, removal and installation, 9-7 Power door lock system, general information, 12-16 Power seats, general information, 12-16 Power steering fluid level check, 1-12 replacement, 1-30 type, 1-2 pump, removal and installation, 5-18 system, bleeding, 5-18 Power window system, general information, 12-15 Powertrain Control Module (PCM), removal and installation, 6-23 Pressure switch, air conditioning, removal and installation, 3-14

O Oil Change Required light, resetting, 1-15 Oil cooler, automatic transmission, removal and

installation, 7B-4

Oil pan, removal and installation

3.7L V6 and 4.7L V8 engines, 2A-16

diesel engine, 2C-11 Hemi engine, 2B-13 Oil pressure check, 2D-4 Oil pressure relief valve, diesel engine, replacement, 2C-11 Oil pump, removal and installation 3.7L V6 and 4.7L V8 engines, 2A-16

Hise engine ‘2C-10 , H ngine, 2B-14

Oil sey eal

laveahchaaaeto

type and viscosity, 1-1

R i

Radiator

grille, removal and installation, 11-6 removal and installation, 3-6 Radio and speakers, removal and installation, 12-6 Rear axle assembly, removal and installation, 8-11

Real exteabatt , , bearing (semi-floating axle), replacement, 8-14 oil seal (semi-floating axle), replacement, 8-13

removal and installation, 8-11 Rear main oil seal, , replacement

—

3.7L V6 and 4.7L V8 engines, 2A-18

diesel engine, 2C-12 Hemi engine, 2B-14

f

On-Board Diagnostic (OBD) system and Diagnostic Trouble Codes (DTCs), 6-2

Rear wheel hub bearing and grease seal (full-floating axle), removal, installation and adjustment, 8-13

Output Shaft Speed (OSS) and Input Shaft Speed (ISS)

ear window defogger, check and repair, 12-8

sensors, replacement, 6-19

Recall information, 0-8 :

replacement, 6-22

Relays, general information and testing, 12-4 Release bearing, clutch, removal, inspection and installation, 8-5 Repair operations possible with the engine

Oxygen sensors, general description and

Pads, disc brake, replacement, 9-3

Parking brake

adjustment, 9-12

chobs replacement 9-8

ee

Recommended lubricants and fluids, 1-

in the vehicle

aye indypls ices. pal le me

diesel engingsetr

Hemi engine, 2B-3

Replacement parts, buying, 0-7

sibs

IND-7

Index Rocker arms and hydraulic lash adjusters, 3.7L V6 and 4.7L V8 engines, removal, inspection and installation, 2A-5 Rocker arms and pushrods, removal, inspection and installation diesel engine, 2C-4 Hemi engine, 2B-4 Rotating the tires, 1-18 Rotor, brake, inspection, removal and installation, 9-5 Routine maintenance schedule, 1-8

S Safety first!, 0-21 Safety recall information, 0-8 Scheduled maintenance, 1-1

Seat belt check, 1-18 Seats, removal and installation, 11-19 Shift cable, automatic transmission, check, adjustment and replacement, 7B-3 lever, manual transmission, removal and installation, 7A-2 linkage adjustment, transfer case (manual shift models), 7C-2 range selector switch, transfer case (electric shift models), replacement, 7C-2 Shock absorber, removal and installation front, 5-7 rear, 5-12 Spare tire, installing, 0-16 Spark plug replacement, 1-25 torque, 1-3 type and gap, 1-2 wire replacement, 1-26 Speakers, removal and installation, 12-6 Stabilizer bar, removal and installation front, 5-7 rear, 5-13 Starter motor and circuit, check, 5-8 removal and installation, 5-9 Starting system, general description and precautions, 5-8

Steering column, removal and installation, 5-15 column covers, removal and installation, 11-18 gear boots, removal and installation, 5-17 gear, removal and installation, 5-17 knuckle, removal and installation, 5-12 linkage, removal and installation, 5-15 wheel, removal and installation, 5-14 Stop light switch, removal and installation, 9-12 Suspension and steering systems, 5-1

Suspension arms, removal and installation front, link/coil suspension, 5-8 rear, 5-13 Suspension, steering and driveaxle boot check, 1-19

+ Tailgate latch and handle, removal and installation, 11-13 removal and installation, 11-13 Thermostat, check and replacement, 3-2 Throttle body, gasoline engines, removal and installation, 4A-9 Tie-rod end lubrication (diesel models), 1-16 replacement independent front suspension, 10-15 link/coil front suspension, 10-16 Timing chain and sprockets, removal, inspection and installation 3.7L V6 and 4.7L V8 engines, 2A-6 Hemi engine, removal, inspection and installation, 2B-8 Tire and tire pressure checks, 1-13 rotation, 1-18 spare, installing, 0-16 Tools and working facilities, 0-10 Top Dead Center (TDC) for number 1 piston, locating 3.7L V6 and 4.7L V8 engines, 2A-4

diesel engine, 2C-3 Hemi engine, 2B-3 Torque specifications cylinder head bolts 3.7L V6 and 4.7L V8 engines, 2A-3 diesel engine, 2C-2 Hemi engine, 2B-2 spark plugs, 1-3 thermostat housing bolts, 3-1 water pump bolts, 3-1 wheel lug nuts, 1-3 Other torque specifications can be found in the Chapter that deals with the component being serviced Towing, 0-16 Transfer case electric shift motor, replacement, 7C-2 lubricant change, 1-27

level check, 1-24 type, 1-2 oil seals, replacement, 7C-2 overhaul, general information, 7C-3 removal and installation, 7C-3

shift linkage adjustment (manual shift models), 7C-2 range selector switch (electric shift models), replacement, 7C-2

IND-8 Transmission, automatic Brake Transmission Shift Interlock (BTSI) system, description, check and adjustment, 7B-4 diagnosis, general, 7B-2 extension housing oil seal, replacement, 7A-2 fluid and filter change, 1-28 level check, 1-12 type, 1-2 mount, check and replacement, 7B-5 oil cooler, removal and installation, 7B-4 overhaul, general information, 7B-7 removal and installation, 7B-5 shift cable, check, adjustment and replacement, 7B-3 Transmission, manual back-up light switch, check and replacement, 7A-2 extension housing oil seal, replacement, 7A-2 lubricant change, 1-27 level check, 1-24 type, 1-2 overhaul, general information, 7A-4 removal and installation, 7A-3 shift lever, removal and installation, 7A-2 Trim panels, removal and installation dashboard, 11-14 door, 11-8 Trouble codes, obtaining and clearing, 6-4 Troubleshooting, 0-22 Tune-up and routine maintenance, 1-1 general information, 1-10 Turbocharger description and inspection, 4B-7 remvoal and installation, 4B-7

U Underhood hose check and replacement, 1-18 Universal joints general information and check, 8-7 replacement, 8-7 Upholstery, maintenance, 11-2 Upper control arm, front, removal and installation, 5-9

V V6 (3.7L) and V8 (4.7L) engines, in-vehicle repair precedures camshafts, removal, inspection and installation, 2A-11 crankshaft front oil seal, replacement, 2A-15

Index crankshaft pulley/vibration damper, removal and installation, 2A-15 cylinder head, removal and installation, 2A-14 exhaust manifold, removal and installation, 2A-13 flywheel/driveplate, removal and installation, 2A-18 intake manifold, removal and installation, 2A-13 mounts, check and replacement, 2A-18 oil pan, removal and installation, 2A-16 oil pump, removal, inspection and installation, 2A-16 rear main oil seal, replacement, 2A-18 repair operations possible with the engine in the vehicle, 2A-4 rocker arms and hydraulic lash adjusters, removal, inspection and installation, 2A-5 timing chain and sprockets, removal, inspection and installation, 2A-6 Top Dead Center (TDC) for number 1 piston, locating, 2A-4 valve covers, removal and installation, 2A-5 Vacuum gauge diagnostic checks, 2D-5 Valve cover(s), removal and installation 3.7L V6 and 4.7L V8 engines, 2A-5 diesel engine, 2C-3 Hemi engine, 2B-3 Vehicle identification numbers, 0-6 Vibration damper, removal and installation 3.7L V6 and 4.7L V8 engines, 2A-15 diesel engine, 2C-5 Hemi engine, 2B-7 Vinyl trim, maintenance, 11-2

W Water pump check, 3-7 removal and installation, 3-8 Wheel alignment, general information, 5-18 Wheels and tires, general information, 5-18

Window glass, door, removal and installation, 11-12 Window regulator, removal and installation, 11-12 Windshield and fixed glass, replacement, 11-3 washer fluid, level check, 1-12 wiper blade inspection and replacement, 1-16 wiper motor, check and replacement, 12-5 Wiring diagrams, general information, 12-18 Working facilities, 0-10

Haynes Automotive

Manuals

NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information. ACURA 12020 12021

12050

Integra ’86 thru '89 & Legend ’86 thru 90 Integra ’90 thru ’93 & Legend '91 thru ’95 Integra '94 thru '00 - see HONDA Civic (42025) MDX ’01 thru '07 - see HONDA Pilot (42037) Acura TL all models '99 thru 08

AMC 14020 14025

Jeep CJ - see JEEP (50020) Mid-size models '70 thru ’83 (Renault) Alliance & Encore '83 thru '87

AUDI 15020 15025 15026 15030

4000 5000 5000 Audi Audi

all all all A4 A4

models models models ’96 thru ‘02 thru

’80 thru ’87 '77 thru ’83 '84 thru ’88 '01 - see VW Passat (96023) ‘08

24066 24067 24070

Pick-ups '99 thru ’06 - Chevrolet & GMC Chevrolet Silverado & GMC Sierra ‘07 thru ‘12 S-10 & S-15 Pick-ups '82 thru 93, Blazer & Jimmy ’83 thru ’94, S-10 & Sonoma Pick-ups ’94 thru '04, including Blazer, Jimmy & Hombre Chevrolet TrailBlazer, GMC Envoy & Oldsmobile Bravada ’02 thru ’09 Sprint '85 thru ’88 & Geo Metro ’89 thru ’01 Vans - Chevrolet & GMC ’68 thru '96 Chevrolet Express & GMC Savana Full-size Vans ’96 thru ’10

24071 24072 24075 24080 24081

CHRYSLER 10310 25015

Chrysler Engine Overhaul Manual Chrysler Cirrus, Dodge Stratus, Plymouth Breeze '95 thru ’00 Full-size Front-Wheel Drive '88 thru 93 K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030) Chrysler LHS, Concorde, New Yorker, Dodge Intrepid, Eagle Vision, ’93 thru ’97

25020

AUSTIN-HEALEY 25025

Sprite - see MG Midget (66015)

BMW

25026

18020

3/5 Series ’82 thru ’92

18021

3-Series incl. Z3 models '92 thru ’98

18022 18023

3-Series incl. Z4 models ’99 thru '05 3-Series ‘06 thru ‘10

18025

320i all 4 cyl models '75 thru '83

18050

1500 thru 2002 except Turbo '59 thru ’77

25030

BUICK 19010 19020

19025

19030

Buick Century ’97 thru ’05 Century (front-wheel drive) - see GM (38005) Buick, Oldsmobile & Pontiac Full-size (Front-wheel drive) '85 thru '05 Buick Electra, LeSabre and Park Avenue; Oldsmobile Delta 88 Royale, Ninety Eight and Regency; Pontiac Bonneville Buick, Oldsmobile & Pontiac Full-size (Rear wheel drive) '70 thru ’90 Buick Estate, Electra, LeSabre, Limited, Oldsmobile Custom Cruiser, Delta 88, Ninety-eight, Pontiac Bonneville, Catalina, Grandville, Parisienne Mid-size Regal & Century all rear-drive models with V6, V8 and Turbo ’74 thru ’87 Regal - see GENERAL MOTORS (38010) Riviera - see GENERAL MOTORS (38030) Roadmaster - see CHEVROLET (24046) Skyhawk - see GENERAL MOTORS (38015) Skylark - see GM (38020, 38025) Somerset - see GENERAL MOTORS (38025)

CADILLAC 21015 21030

CTS & CTS-V ‘03 thru ‘12 Cadillac Rear Wheel Drive ’70 thru ’93 Cimarron - see GENERAL MOTORS (38015) DeVille - see GM (38031 & 38032) Eldorado - see GM (38030 & 38031) Fleetwood - see GM (38031) Seville - see GM (38030, 38031 & 38032)

10305 24010 24015 24016 24017 24020

24024 24027 24032 24040 24041 24045 24046

24047 24048 24050 24055 24059 24060

24064 24065 LS

Chevrolet Engine Overhaul Manual Astro & GMC Safari Mini-vans '85 thru ’05 Camaro V8 alli models '70 thru ’81 Camaro all models ’82 thru '92 Camaro & Firebird '93 thru '02 Cavalier - see GENERAL MOTORS (38016) Celebrity - see GENERAL MOTORS (38005) Chevelle, Malibu & El Camino ’69 thru ’87 Chevette & Pontiac T1000 '76 thru '87 Citation - see GENERAL MOTORS (38020) Colorado & GMC Canyon ’04 thru '10 Corsica/Beretta all models '87 thru '96 Corvette all V8 models ’68 thru '82 Corvette all models ’84 thru '96 Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons ’69 thru ’90 Impala SS & Caprice and Buick Roadmaster ’91 thru ’96 Impala '00 thru ’05 - see LUMINA (24048) Impala & Monte Carlo all models ’06 thru '11 Lumina ’90 thru '94 - see GM (38010) Lumina & Monte Carlo '95 thru '05 Lumina APV - see GM (38035) Luv Pick-up all 2WD & 4WD ’72 thru '82 Malibu '97 thru ’00 - see GM (38026) Monte Carlo all models ’70 thru ’88 Monte Carlo '95 thru '01 - see LUMINA (24048) Nova all V8 models 69 thru '79 Nova and Geo Prizm ’85 thru '92 Pick-ups ’67 thru '87 - Chevrolet & GMC Pick-ups ’88 thru '98 - Chevrolet & GMC

SS

Chrysler & Plymouth Mid-size front wheel drive ’82 thru ’95 Rear-wheel Drive - see Dodge (30050) PT Cruiser ali models ’01 thru 10 Chrysler Sebring '95 thru 06, Dodge Stratus ‘01 thru '06, Dodge Avenger ’95 thru '00

25035 25040

DATSUN 28005 28007 28009 28012 28014

200SX 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) 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

28018 28020 28022 28025

DODGE 30008 30010 30011 30012 30013 30016 30020 30021 30022 30023 30025

A

A

Neon all models '95 thru ’99 Omni & Plymouth Horizon ’78 thru '90 Dodge and Plymouth Neon ’00 thru ’05 Pick-ups all full-size models '74 thru ’93 Pick-ups all full-size models '94 thru '01 Pick-ups full-size models 02 thru ’08 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups '79 thru '93 Dodge/Plymouth/Chrysler RWD ’71 thru ’89 Shadow & Plymouth Sundance ’87 thru ’94 Spirit & Plymouth Acclaim ’89 thru ’95 Vans - Dodge & Plymouth '71 thru ’03

30050 30055 30060 30065

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

FIAT 34010 34025 FORD 10320 10355 11500 36004 36006 36008 36012 36016 36020

10360 38005 38010

38016 38017 38020 38025

38026 38027 38030

38031 38032 38035 38036

Mustang Mustang Mustang Mustang

V8 all models ’64-1/2 thru ’73 Il 4 cyl, V6 & V8 models ’74 thru ’78 & Mercury Capri ’79 thru ’93 all models '94 thru '04

Mustang ’05 thru 10 Pick-ups & Bronco ’73 thru ’79 Pick-ups & Bronco '80 thru ’96

F-150 & Expedition '97 thru '09, thru ’99 & Lincoln Navigator ’98 Super Duty Pick-ups, Excursion F-150 full-size '04 thru '10 Pinto & Mercury Bobcat ’75 thru

F-250 97 thru ’09 '99 thru '10 ’80

Probe all models ’89 thru ’92

Probe '93 thru ’97 - see MAZDA 626 (61042) Ranger/Bronco Il gasoline models ’83 thru ’92 Ranger '93 thru 10 & Mazda Pick-ups ’94 thru '09 Taurus & Mercury Sable ’86 thru ’95

Taurus & Mercury Sable ’96 thru ’05 Tempo & Mercury Topaz ’84 thru '94 Thunderbird/Mercury Cougar ’83 thru ’88 Thunderbird/Mercury Cougar '89 thru '97 Vans all V8 Econoline models 69 thru ’91 Vans full size ’92 thru ’10 Windstar Mini-van ’95 thru ’07

GM Automatic Transmission Overhaul Buick Century, Chevrolet Celebrity, Oldsmobile Cutlass Ciera & Pontiac 6000 all models '82 thru ’96 Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme & Pontiac Grand Prix (FWD) ’88 thru ’07 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza & Pontiac J-2000 & Sunbird ’82 thru '94 Chevrolet Cavalier & Pontiac Sunfire '95 thru ’05 Chevrolet Cobalt & Pontiac G5 ’05 thru ’11 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 ’98 Chevrolet Malibu, Olds Alero & Cutlass, Pontiac Grand Am '97 thru ’03 Chevrolet Malibu ’04 thru 10 Cadillac Eldorado, Seville, Oldsmobile

Toronado, Buick Riviera '71 thru '85 Cadillac Eldorado & Seville, DeVille, Fleetwood & Olds Toronado, Buick Riviera '86 thru 93 Cadillac DeVille '94 thru '05 & Seville '92 thru ’04 Cadillac DTS ’06 thru '10 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models '90 thru ’96 Chevrolet Venture, Olds Silhouette, Pontiac Trans Sport & Montana '97 thru '05 General Motors Full-size

38040

38070 GEO 40030

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

Escape & Mazda Tribute ’01 thru '11 Explorer & Mazda Navajo ’91 thru ’01 Explorer/Mercury Mountaineer ’02 thru '10 Fairmont & Mercury Zephyr '78 thru '83 Festiva & Aspire ’88 thru '97 Fiesta all models '77 thru ’80 Focus all models ’00 thru '11 Ford & Mercury Full-size ‘75 thru '87 Ford & Mercury Mid-size ’75 thru ’86 Fusion & Mercury Milan ‘06 thru ‘10

GENERAL MOTORS

38015

Durango ’98 & ’99, Dakota '97 thru ’99 Durango ’00 thru '03 Dakota '00 thru ’04 Durango '04 thru '09, Dakota '05 thru '11 Dart, Demon, Plymouth Barracuda, Duster & Valiant 6 cyl models ’67 thru ’76 Daytona & Chrysler Laser ’84 thru ’89 Intrepid - see CHRYSLER (25025, 25026)

30034 30035 30036 30040 30041 30042 30045

36070 36071 36074 36075 36078 36082 36086 36090 36094 36097

400 & 600 - see CHRYSLER (25030) Aries & Plymouth Reliant '81 thru '’89 Caravan & Plymouth Voyager ’84 thru '95 Caravan & Plymouth Voyager ’96 thru ’02 Challenger/Plymouth Saporro '78 thru '83 Caravan, Chrysler Voyager, Town & Country '03 thru ’07 Colt & Plymouth Champ '78 thru ’87 Dakota Pick-ups all models '87 thru '96

30030

CHEVROLET

36060 36061 36062 36066

Chrysler LHS, Concorde, 300M, Dodge Intrepid, ’98 thru '04 Chrysler 300, Dodge Charger & Magnum '05 thru ’09

25027

36022 36024 36025 36028 36030 36032 36034 36036 36044 36045 36048 36049 36050 36051 36052 36054 36058 36059

GMC

Rear-wheel Drive - see BUICK (19025) Chevrolet Equinox ‘05 thru ‘09 Pontiac Torrent ‘06 thru ‘09 Chevrolet HHR ‘06 thru ‘11 Metro - see CHEVROLET Sprint (24075) Prizm - ’85 thru '92 see CHEVY (24060), 93 thru '02 see TOYOTA Corolla (92036) Storm all models '90 thru '93 Tracker - see SUZUKI Samurai (90010) Vans & Pick-ups - see CHEVROLET

HONDA Ford Engine Overhaul Manual Ford Automatic Transmission Overhaul Mustang '64-1/2 thru '70 Restoration Guide Aerostar Mini-vans all models ’86 thru '97 Contour & Mercury Mystique '95 thru ’00 Courier Pick-up all models '72 thru '82 Crown Victoria & Mercury Grand Marquis '88 thru '10 Escort/Mercury Lynx all models '81 thru ’90 Escort/Mercury Tracer '91 thru '02 IF

A

SESE

PS

SSS

SES

ES

42010 42011 42012 42013 42014 42015 42020 42021 42022

Sr Se ee eee

Accord CVCC all models ’76 thru ’83 Accord all models '84 thru '89 Accord all models '90 thru '93 Accord all models '94 thru ’97 Accord all models '98 thru ’02 Accord '03 thru '07 Civic 1200 all models '73 thru '79 Civic 1300 & 1500 CVCC '80 thru '83 Civic 1500 CVCC all models '75 thru '79

(Continued on other side) SS

ee

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

Haynes Automotive Manuals (continued) NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information. NISSAN 42023 42024 42025

42026 42035

42037 42040

Civic Civic Civic Acura Civic

all models '84 thru '91 & del Sol ’92 thru ’95 '96 thru ’00, CR-V '97 thru '01, Integra '94 thru '00 '01 thru '10, CR-V '02 thru '09 Odyssey all models '99 thru 10 Passport - see [SUZU Rodeo (47017) Honda Pilot '03 thru '07, Acura MDX '01 thru '07 Prelude CVCC all models ’79 thru ’89

HYUNDAI 43010 43015

Elantra all models ’96 thru 10 Excel & Accent all models '86 thru 09

43050 43055

Santa Fe all models ’01 thru ’06 Sonata all models ’99 thru ’08

INFINITI G35 '03 thru '08 - see NISSAN 350Z (72011) ISUZU 47017 47020

Hombre - see CHEVROLET S-10 (24071) Rodeo, Amigo & Honda Passport '89 thru '02 Trooper & Pick-up '81 thru ’93

JAGUAR 49010 49011 49015

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

JEEP 50010

50030

Cherokee, Comanche & Wagoneer Limited all models '84 thru ’01 CJ all models ’49 thru ’86 Grand Cherokee all models '93 thru '04 Grand Cherokee '05 thru ’09 Grand Wagoneer & Pick-up ’72 thru '91 Grand Wagoneer ’84 thru ’91, Cherokee & Wagoneer ’72 thru ’83, Pick-up ’72 thru ’88 Wrangler all models '87 thru ’11

50035

Liberty '02 thru ’07

50020 50025 50026 50029

KIA

TRIUMPH

72010 72011 72015 72016 72020 72021 72025 72030

300ZX all models including Turbo '84 thru ’89 350Z & Infiniti G35 all models ’03 thru '08 Altima all models '93 thru ’06 Altima ‘07 thru ‘10 Maxima all models ’85 thru '92 Maxima all models ’93 thru ’04 Murano ‘03 thru ‘10 Pick-ups ’80 thru ’97 Pathfinder ’87 thru ’95

72031

Frontier Pick-up, Xterra, Pathfinder '96 thru '04

72032 72040

Frontier & Xterra ’05 thru ‘11 Pulsar all models ’83 thru ’86 Quest - see MERCURY Villager (64200)

72050

Sentra all models ’82 thru ’94

72051 72060 72070

Sentra & 200SX all models '95 thru '06 Stanza all models ’82 thru '90 Titan pick-ups ‘04 thru ‘10 Armada ‘05 thru ‘10

OLDSMOBILE 73015

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

PLYMOUTH For PLYMOUTH titles, see DODGE listing.

PONTIAC 79008 79018

Fiero all models ’84 thru ’88 Firebird V8 models except Turbo ’70 thru ’81

79019 79025

Firebird all models ’82 thru '92 G6 all models ‘05 thru ‘09

79040

Mid-size Rear-wheel Drive ’70 thru ’87

Vibe ’03 thru ’11 - see TOYOTA Matrix (92060) For other PONTIAC titles, see BUICK, CHEVROLET or GENERAL MOTORS listing.

PORSCHE 80020 80025 80030 80035

911 914 924 944

RENAULT

54050

Optima ‘01 thru ‘10

54070

Sephia '94 thru ’01, Spectra '00 thru ’09, Sportage '05 thru '10

SAAB

ES 300/330 - see TOYOTA Camry (92007) (92008) RX 330 - see TOYOTA Highlander (92095)

SATURN

LEXUS

LINCOLN 59010

Navigator - see FORD Pick-up (36059) Rear-Wheel Drive all models ’70 thru 10

MAZDA 61010 61011 61012 61015 61016 61020

61030 61035 61036 61040 61041

61042 61043

GLC Hatchback (rear-wheel drive) '77 thru ’83 GLC (front-wheel drive) ’81 thru ’85 Mazda3 ‘04 thru ‘11 323 & Protogé '90 thru 03 MX-5 Miata '90 thru '09 MPV all models ’89 thru '98 Navajo - see Ford Explorer (36024) Pick-ups '72 thru '93 Pick-ups '94 thru '00 - see Ford Ranger (36071) RX-7 all models '79 thru ’85 RX-7 all models '86 thru ’91 626 (rear-wheel drive) all models '79 thru ’82 626/MX-6 (front-wheel drive) '83 thru ’92 626, MX-6/Ford Probe ’93 thru '02 Mazda6 ‘03 thru ‘11

MERCEDES-BENZ 63012 63015 63020 63025 63030 63040

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

MERCURY 64200

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

MG 66010 66015

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

MINI 67020 Mini ‘02 thru ‘11 MITSUBISHI 68020 68030 68031 68035 68040

Cordia, Tredia, Galant, Precis & Mirage '83 thru '93 Eclipse, Eagle Talon & Ply. Laser '90 thru '94 Eclipse ’95 thru '05, Eagle Talon 95 thru '98 Galant ’94 thru '10 Pick-up ’83 thru '96 & Montero '83 thru '93

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

Alliance & Encore - see AMC (14020) 84010

900 all models including Turbo ’79 thru ’88

87010 87011 87020

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

87040

Saturn VUE '02 thru '07

SUBARU 89002 89003 89100 89101

1100, 1300, 1400 & 1600 '71 thru’79 1600 & 1800 2WD & 4WD 'S80 thru '94 Legacy all models '90 thru ’99 Legacy & Forester ’00 thru ’06

SUZUKI 90010

Samurai/Sidekick & Geo Tracker '86 thru '01

TOYOTA 92005 92006 92007 92008

92009 92015 92020 92025

92030 92032 92035

92036 92037 92040 92045 92050

92055 92056 92060 92065 92070

92075 92076 92077 92078 92079 92080 92081

92082 92085 92090 92095

Camry all models '83 thru '91 Camry all models ’92 thru '96 Camry, Avalon, Solara, Lexus ES 300 '97 thru '01 Toyota Camry, Avalon and Solara and Lexus ES 300/330 all models ’02 thru ’06 Camry ‘07 thru ‘11 Celica Rear Wheel Drive '71 thru '’85 Celica Front Wheel Drive ’86 thru ’99 Celica Supra all models '79 thru ’92 Corolla all models '75 thru '79 Corolla all rear wheel drive models.’80 thru ’87 Corolla all front wheel drive models '84 thru ’92 Corolla & Geo Prizm '93 thru 02 Corolla models '03 thru 11 Corolla Tercel all models ’80 thru ’82 Corona all models '74 thru ’82 Cressida all models '78 thru ’82 Land Cruiser FJ40, 43, 45, 55 ’68 thru ’82 Land Cruiser FJ60, 62, 80, FZJ80 '80 thru '96 Matrix & Pontiac Vibe ’03 thru '11 MR2 all models ’85 thru ’87 Pick-up all models ’69 thru ’78 Pick-up all models ’79 thru '95 Tacoma, 4Runner, & T100 '93 thru '04 Tacoma all models '05 thru '09 Tundra ’00 thru ’06 & Sequoia 01 thru ’07 4Runner all models '03 thru '09 Previa all models '91 thru ’95 Prius all models ’01 thru '08 RAV4 all models '96 thru ’10 Tercel all models ’87 thru '94 Sienna all models '98 thru '09 Highlander & Lexus RX-330 '99 thru '07

94007 94010

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

VW 96008

Beetle & Karmann Ghia '54 thru '79

96009

96016

New Beetle '98 thru '11 Rabbit, Jetta, Scirocco & Pick-up gas models ’75 thru '92 & Convertible '’80 thru ’92

96017 96018 96019

Golf, GTI & Jetta ’93 thru 98, Cabrio '95 thru '02 Golf, GTI, Jetta '99 thru ’05 Jetta, Rabbit, GTI & Golf ‘05 thru ‘11

96020

Rabbit, Jetta & Pick-up diesel '77 thru ’84

96023

Passat ’98 thru ’05, Audi A4 ’96 thru ’01

96030

Transporter 1600 all models ’68 thru ’79

96035 96040 96045

Transporter 1700, 1800 & 2000 '72 thru ’79 Type 3 1500 & 1600 all models ’63 thru '73 Vanagon all air-cooled models '80 thru ’83

VOLVO 97010 97015 97020

120, 130 Series & 1800 Sports ’61 thru '73 140 Series all models 66 thru ’74 240 Series all models '76 thru '93

97040

740 & 760 Series all models '82 thru ’88

97050

850 Series all models '93 thru ’97

TECHBOOK

MANUALS

10205 10206 10210

Automotive Computer Codes OBD-II & Electronic Engine Management Automotive Emissions Control Manual

10215 10220

Fuel Injection Manual '78 thru ’85 Fuel Injection Manual ’86 thru '99

10225

Holley Carburetor Manual

10230

Rochester Carburetor Manual

10240 10305

Weber/Zenith/Stromberg/SU Carburetors Chevrolet Engine Overhaul Manual

10310 10320 10330

Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repair Manual

10333 10340

Engine Performance Manual Small Engine Repair Manual, 5 HP & Less

10341

Small Engine Repair Manual, 5.5 - 20 HP

10345

Suspension, Steering & Driveline Manual

10355 10360

Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul

10405 10410 10411

Automotive Body Repair & Painting Automotive Brake Manual

10415 10420 10425 10430 10435 10440 10445 10450 10452

Automotive Anti-lock Brake (ABS) Systems Automotive Detaiing Manual Automotive Electrical Manual Automotive Heating & Air Conditioning Automotive Reference Manual & Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual ATV Basics Scooters 50cc to 250cc

SPANISH MANUALS 98903 98904

98905 98906 98910 98913 98915

99040 99041 99042 99043 99048 99055 99075

99076 99077 99088 99089 99091

99095 99100 99106

Reparacién de Carroceria & Pintura Manual de Carburador Modelos Holley & Rochester ¢ Cédigos Automotrices de taComputadora OBD-Il & Sistemas de Control Electrénico del Motor Frenos Automotriz

Electricidad Automotriz Inyeccién de Combustible '86 al 99 Chevrolet & GMC Camionetas ’67 al '87 Chevrolet & GMC Camionetas ’88 al '98 Chevrolet & GMC Camionetas Cerradas '68 al ’95 Chevrolet/GMC Camionetas ‘94 al ‘04 Chevrolet/GMC Camionetas ‘99 al ‘06 Dodge Caravan & Plymouth Voyager '84 al '95 Ford Camionetas y Bronco '80 al '94 Ford F-150 ‘97 al ‘09 Ford Camionetas Cerradas '69 al '91 Ford Modelos de Tamafio Mediano ’75 al '86 Ford Camionetas Ranger ‘93 al ‘10 Ford Taurus & Mercury Sable '86 al '95 GM Modelos de Tamafio Grande ’70 al '90 GM Modelos de Tamajfio Mediano '70 al 88 =f Cherokee, Wagoneer & Comanche ’84 al 00

"99110 Nissan Camioneta '80al'96, Pathfinder '87al'95 99118 99125

Nissan Sentra ’82 al ’94 Toyota Camionetas y 4Runner ’79 al '95

also available

7-12

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

Common

spark plug conditions NORMAL Symptoms: Brown 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

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.

ASH DEPOSITS 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 during acceleration. Recommendation: lf excessive deposits accumulate over a short time or low mileage, install new valve guide seals to prevent seep-

age 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.

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

PREIGNITION 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.

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

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.

this

side ni:

n lan

f

g = Routine maintenance

. srribpe Up procedures 4 5 Engine repair |

MID-CONTINENT PUBLIC LIBRARY - QU

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