Haynes Ford Festiva & Aspire Automotive Repair Manual 1563922878, 9781563922879

Citation preview

Oem Kemble @©HAYNES 1998

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/tordfestivaaspirOO0OkibI -@

Ford Festiva & Aspire Automotive

Repair Manual

by Jeff Kibler and John H Haynes Member of the Guild of Motoring Writers

Models covered:

All Ford Festiva and Aspire models 1988 through 1997

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SO SN

LZ SN Haimes Ss

SS

l

INTERIOR LIGHTS yBLU/WHTsf SYSTEM BLU/WHT BLU

5

BLU/YEL pace!

O6C/ EG

BLK HEATER

CONTROL

UNIT

Typical 1994 and later heating system

[- — — “| POWERTRAIN | CONTROL Lj MODULE (PCM)

12-42

Chapter 12

HOT

Chassis electrical system

IN ACC

OR

RUN

tei DeaBea ae FUSE | § CIGAR FUSE | PANEL 1¢ 15A | |

|

{be

ee se ee

a}

BLK/YEL

REMOTE CONTROL MIRROR SWITCH

MIRROR SELECTOR SWITCH

BLU/|

ays

LT GRN/

BRN

BLK

LT GRN|

BRNata

BRN

LT GRN/

reo |. Eth

(OR

BRN

BLU/RED)

(OR

BLU/RED)}

BRN

BRN

wit

UP/DOWN

LEFT REMOTE CONTROL POWER MIRROR

BRN/

BLK

BRN

(OR

LT GRN/RED)

BRN

BRN/ UP/DOWN MOTOR

RIGHT REMOTE CONTROL POWER MIRROR

Typical 1993 and earlier power mirror system

Chapter 12

HOT IN RUN OR ACC

Chassis electrical system

HOT AT ALL TIMES Erle eho ete ie ewe Ppoeglevn syhattey INTERIOR PANE! FUSE ; 10A faery a nS ROE ee WHT/ RED

INTERIOR LIGHTS SYSTEM oS

WHT / RED

BLU/ YEL

GRN/} RED

GRN/

BLU/

ORG

LEFT REAR SPEAKER

GRN/

YEL

LEFT FRONT SPEAKER

Typical audio system

BLU/| WHT

RED BLK

BLU/

BLK

RIGHT REAR SPEAKER

12-43

12-44

Chapter 12

Chassis electrical system

BLU

W/_ INTERVAL WIPER

BLU

® WASHER PUMP

;

BLU

BLU/] WHT

BLU/ RED

BLU/ ORG

a

ue

WINDSHIELD

ie

SWITCH

BLK

Typical 1993 and earlier windshield wiper and washer system

Chapter 12

12-45

Chassis electrical system

HOT IN RUN (give: pier |Pa

FUSE 2-SPEED

FUSE

ls SARE TELE TERED (eT.SAREE

oie Sana

Leyes De

A ee

FUNCTION

ISWITCH

WASHER

WINDSHIELD

|

SWITCH

WIPER

SWITCH

WIPER/WASHER

|

ON

| |

ee

ee

a

ee

es

es)

NCA

BLU/WHT |BLU/RED| BLU/BLK reas

BLU ZORS

WINDSHIELD WASHER seal

|

WINDSHIELD WIPER MOTOR

(MI

“|

PARK

HOT Ses IN RUN

ig

ire

enios minaret? IN Wie nd

WIPER 20A

DASH FUSE |BOX

NERS Ureke seats

FUSE

INTERVAL

oS ee

WIPER/WASHER

YS

7 MULTI|FUNCTION

WINDSHIELD , SWITCH WASHER SWITCH

ey Ee eee ON

|

| | | Sy

BLU /WHT / i

a

ay

AN ly

ea

BLU/RED] BLU/BLK / i / | HIGH

Af

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WINDSHIELD WIPER es Re

Se

SS

NCA

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ai

BLU/ORG WINDSHIELD pa |WASHER (M) |PUMP

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12 Typical 1994 and later windshield wiper and washer system

12-46

Chapter 12

HOT

Chassis electrical system

IN RUN

REAR WIPER IEUSE

PE RTINA

BLU/ORG

BLU/ORG

BLU/ORG =

(M)

WIPER

REAR

MOTOR

WASHER

PUMP

=

GRN/ BLU OR GRN/

OR

BLK

BLK BLU

REAR SWITCH |WASHER

WIPER

WASHER | WIPER

Ses

SWITCH

HOT IN RUN_

RSRIEY

REAR WIPER MOTOR REAR ii) WASHER PUMP

PARK RUN

BLU/YEL

BLK /BLU

NCA page

eae beors aig orate ees Sumit

eM hye org aes |

MULTI| FUNCTION j witcH

Typical rear windshield wiper and washer system

IND-1

Index A

Body, 11-1 through 11-18 damage repair

About this manual, 0-5 Accelerator cable, removal, installation and adjustment, 4-8 Antenna, removal and installation, 12-13 Air cleaner assembly, removal and installation, 4-8 Air conditioning and heating system, check and maintenance, 3-12

_

major, 11-5 minor, 11-4

maintenance, 11-1

Booster battery (jump) starting, 0-14 Brakes, 9-1 through 9-20 booster, check, removal and installation, 9-16 caliper, removal, overhaul and installation, 9-4

Air conditioning system compressor, removal and installation, 3-15 condenser removal and installation, 3-16

check, 1-19 disc, inspection, removal and installation, 9-6

fluid, check, 1-8 general information, 9-2 hoses and lines, inspection and replacement, 9-15 hydraulic system, bleeding, 9-16 light switch, check, adjustment and replacement, 9-20 master cylinder, removal, overhaul and installation, 9-13 pads (front), replacement, 9-3 parking adjustment, 9-18

evaporator and expansion valve, removal and installation, 3-17 receiver/drier, removal and installation, 3-14 Air filter replacement, 1-25

Air inlet plenum, 4-13 Airbag system, general information, 12-17 Airflow sensor/intake air temperature sensor, 6-11

Alternator, removal and installation, 5-7 Antifreeze, general information, 3-2

Anti-lock Brake System (ABS), general information, 9-2 Automatic transaxle, 7B-1 through 7B-8 diagnosis, general, 7B-2 fluid and filter change, 1-29 fluid level check, 1-12

intermediate band, adjustment, 7B-7 park/neutral start switch, check and replacement, 7B-5 removal and installation, 7B-7 shift cable, removal, installation and adjustment, 7B-4 shift lever, removal and installation, 7B-2 shift-lock system, description, check and cable replacement, 7B-6 Automotive chemicals and lubricants, 0-16 Axle beam (rear), removal, inspection and installation, 10-7

Back-up light switch, check and replacement, 7A-2 Balljoints, check and replacement, 10-6 Battery cables, check and replacement, 5-2

electrolyte, check, 1-8 jump starting, 0-14 removal and installation, 5-2 Blower motor and circuit, check and component replacement, 3-7

cables, replacement, 9-18 pedal, adjustment, 9-19 shoes (rear), replacement, 9-7 wheel cylinder, removal, overhaul and installation, 9-12 Bulb replacement, 12-10 Bumpers, removal and installation, 11-7

Bushings and stabilizer bar, removal and installation, 10-5 Buying parts, 0-7

Cc Camshaft oil seal, replacement, 2A-8 Camshaft Position Sensor (CMP), 6-13 Camshaft, removal, inspection, and installation, 2A-10 Capacities, 1-2 Carburetor diagnosis, overhaul and adjustment, 4-9 feedback system, 6-16 removal and installation, 4-10 Carpets and upholstery, maintenance, 11-1 Catalytic converter, 6-17 Center console, removal and installation, 11-14

IND

IND-2 Charging system check, 5-7 generai information and precautions, 5-6

Chassis electrical system, 12-1 through 12-46 Clearing codes, 6-8 Clutch and driveaxles, 8-1 through 8-12 Clutch cable, replacement, 8-2 components, removal, inspection and installation, 8-2

description and check, 8-2 pedal height and freeplay, check and adjustment, 1-15 release bearing and lever, removal, inspection and installation, 8-4 start switch, check and replacement, 8-6

Clutch Pedal Position switch (manual transaxle), 6-13 Coil spring or strut/shock absorber, replacement, 10-4

Coil spring/shock absorber (rear), removal, inspection and installation, 10-7

Combination switch check, 12-4

removal and installation, 12-4

Compression check, 2B-4 Control arm, removal, inspection and installation, 10-5 Conversion factors, 0-17

Cooling system check, 1-16 coolant temperature

gauge sending unit, check and replacement, 3-6 sensor, 6-9 servicing (draining, flushing and refilling), 1-26 Cooling, heating and air conditioning system, 3-1 through 3-18 Crankshaft front oil seal, replacement, 2A-16

inspection, 2B-14 installation and main bearing oil clearance check, 2B-16 removal, 2B-10

Crankshaft Position Sensor (CKP), 6-13 Cylinder head cleaning and inspection, 2B-7 disassembly, 2B-7 reassembly, 2B-9 removal and installation, 2A-13 Cylinder honing, 2B-12

D Dashboard trim panels, removal and installation, 11-15

Daytime Running Lights (DRL), general information, 12-12 Deceleration Control system, 6-3 Diagnosis, 0-19

Diagnostic tool information, 6-4 Disc brake caliper, removal, overhaul and installation, 9-4 pads (front), replacement, 9-3 Distributor, removal and installation, 5-5 Door

latch, lock cylinder and handle, removal and installation, 11-11 trim panel, removal and installation, 11-9 window glass, removal and installation, 11-12

removal, installation and adjustment, 11-10 Driveaxle boot check, 1-28 replacement, 8-8 removal and installation, 8-7 general information and inspection, 8-6 Drivebelt check, adjustment and replacement, 1-20 Drum brake shoes, replacement, 9-7 Early Fuel Evaporation (EFE) system, 6-2

Index EGR gas temperature sensor, 6-13 Electric pump (fuel-injected engines), 4-3 Electric side view mirrors, description and check, 12-16 Electrical troubleshooting, general information, 12-1 Electronic Control Module (ECM), removal and installation, 6-14 Electronic Fuel Injection (EFI) system, check, 4-11 component check and replacement, 4-12 general information, 4-11

Emissions and engine control systems, 6-1 through 6-18 Engines, 2A-1 through 2A-18

block cleaning, 2B-11 inspection, 2B-12 camshaft oil seal, replacement, 2A-8 removal, inspection, and installation, 2A-10 compression check, 2B-4 coolant, check, 1-7

cooling fan and circuit, check and component replacement, 3-3 crankshaft front oil seal, replacement, 2A-16

inspection, 2B-14 installation and main bearing oil clearance check, 2B-16 removal, 2B-10 cylinder head cleaning and inspection, 2B-7 disassembly, 2B-7 reassembly, 2B-9 removal and installation, 2A-13

cylinder honing, 2B-12 electrical systems, 5-1 through 5-8 exhaust manifold, removal and installation, 2A-5

flywheel/driveplate, removal and installation, 2A-16 initial start-up and break-in after overhaul, 2B-20 intake manifold, removal and installation, 2A-4 main and connecting rod bearings, inspection and selection, 2B-14 mounts, check and replacement, 2A-17

oil and oil filter change, 1-10 oil check, 1-6 pan, removal and installation, 2A-14 pressure check, 2B-3

pump, removal, inspection and installation, 2A-14 type, 1-1 overhaul disassembly sequence, 2B-6 reassembly sequence, 2B-15 piston rings, installation, 2B-16

pistons/connecting rods inspection, 2B-13 installation and rod bearing oil clearance check, 2B-19 removal, 2B-9 rear main oil seal installation, 2B-18 replacement, 2A-17

rebuilding alternatives, 2B-6 removal and installation, 2B-5 removal, methods and precautions, 2B-4 repair operations possible with the engine in the vehicle, 2A-2 rocker arm assembly and lash adjusters, removal, inspection and installation, 2A-9

timing belt and sprockets, removal, inspection and installation, 2A-6

Top Dead Center (TDC), locating, 2A-3 vacuum gauge diagnostic check, 2B-3 valve cover, removal and installation, 2A-4 servicing, 2B-9 springs, retainers and seals, replacement, 2A-11

IND-3

Index Evaporative Emission Control (EVAP) system, 1-26, 6-14 Exhaust Gas Recirculation (EGR) system, 6-15 Exhaust manifold, removal and installation, 2A-5 Exhaust system check, 1-28 general information, 4-15

cE Fault finding, 0-19 Feedback carburetor system, 6-16 Fluid level checks, 1-6 Flywheel/driveplate, removal and installation, 2A-16 Front fender, removal and installation, 11-7 Fuel and exhaust systems, 4-1 through 4-16 Fuel system check, 1-28 filter replacement, 1-31 level sending unit, check and replacement, 4-7 lines and fittings, inspection and replacement, 4-5 pressure regulator, 4-13 pressure relief procedure, fuel-injected models, 4-2 pump electric (fuel-injected engines), 4-3 mechanical (carbureted engines), 4-3 pump, removal and installation, 4-6 pump/fuel pressure, check, 4-3 tank cleaning and repair, general information, 4-6 removal and installation, 4-5 Fuses, general information, 12-2 Fusible links, general information, 12-3

control module, replacement, 5-5 general information and precautions, 5-2

key lock cylinder, removal and installation, 12-8 switch, check and replacement, 12-6

timing, check and adjustment, 5-6 Information sensors, 6-7, 6-9 Airflow sensor/intake air temperature sensor, 6-11 Camshaft Position Sensor (CMP), 1996 and later, 6-13 Clutch Pedal Position switch (manual transaxle), 6-13 Coolant temperature sensor, 6-9 Crankshaft Position Sensor (CKP), external module ignition systems, 6-13 EGR gas temperature sensor, 6-13

Intake Air Temperature (IAT) sensor, 6-12 Mass Airflow (MAF) sensor, 6-12

Neutral Start switch (automatic transmission), 6-14 Oxygen sensor, 6-10 Power steering pressure switch, 6-13 Throttle Position Sensor (TPS), 6-11

Vehicle Speed Sensor (VSS), 6-13 Initial start-up and break-in after overhaul, 2B-20 Instrument cluster, removal and installation, 12-13 Instrument panel, removal and installation, 11-15

Intake Air Temperature (IAT) sensor, 6-12 Intake manifold, removal and installation, 2A-4 Intermediate band, adjustment, 7B-7 Introduction to the Ford Festiva and Aspire, 0-5

J Jacking and towing, 0-15

L

G General engine overhaul procedures, 2B-1 through 2B-20

Liftgate support strut, replacement, 11-9 removal, installation and adjustment, 11-8

H Handle, door latch and lock cylinder, removal and installation, 11-11

Headlight adjustment, 12-9 bulb, replacement, 12-8 housing, removal and installation, 12-9

Heated Air Inlet (HAI) system, 6-3 Heater and air conditioning control assembly, removal, installation, check and adjustment, 3-10 Heater core, replacement, 3-9

M Main and connecting rod bearings, inspection and selection, 2B-14 Maintenance schedule, 1-5

techniques, tools and working facilities, 0-7 Manual transaxle, 7A-1 through 7A-6 back-up light switch, check and replacement, 7A-2 lubricant change, 1-32

High-Altitude Compensation (HAC) system, 6-4

level check, 1-20 mount, check and replacement, 7A-4 oil seal, replacement, 7A-3 overhaul, general information, 7A-6 removal and installation, 7A-4 shift lever, removal and installation, 7A-2

Hinges and locks, maintenance, 11-5 Hood release latch and cable, removal and installation, 11-6

removal, installation and adjustment, 11-5 Horn, check and replacement, 12-14 Hub and bearing assembly (front), removal and installation, 10-6

Mass Airflow (MAF) sensor, 6-12 Master cylinder, removal, overhaul and installation, 9-13 Mechanical pump (carbureted engines), 4-3 Mirror, outside (manual), removal and installation, 11-13

Idle speed check and adjustment, 1-17 Idle speed control-bypass air (ISC-BPA), 4-13 Ignition system, 1-2 check, 5-3 coil, check and replacement, 5-4

N Neutral Start switch (automatic transmission), 6-14 Neutral/park start switch, check and replacement, 7B-5

IND-4

Index

O OBD general information, 6-5 Oil pan, removal and installation, 2A-14 pressure check, 2B-3 pump, removal, inspection and installation, 2A-14 seal, replacement, 7A-3

On-Board Diagnostic (OBD) System and trouble codes, 6-4 Output actuators, 6-8 Outside mirror (manual), removal and installation, 11-13 Oxygen sensor, 6-10

Shift cable, removal, installation and adjustment, 7B-4 Shift lever, removal and installation, 7A-2, 7B-2 Shift-lock system, description, check and cable replacement, 7B-6 Shock absorber/coil spring (rear), removal, inspection and installation, 10-7 Spark plug check and replacement, 1-22 wire, distributor cap and rotor check and replacement, 1-23 Stabilizer bar and bushings, removal and installation, 10-5 Starter motor in-vehicle testing, 5-8 removal and installation, 5-8 Starting system, general information and precautions, 5-8 Steering and suspension check, 1-27 Steering system column covers, removal and installation, 11-14

p Park/neutral start switch, check and replacement, 7B-5

gear boots, replacement, 10-9

Parking brake adjustment, 9-18 cables, replacement, 9-18 Pilot bearing, inspection and replacement, 8-5 Piston rings, installation, 2B-16 Pistons/connecting rods inspection, 2B-13 installation and rod bearing oil clearance check, 2B-19 removal, 2B-9 Positive Crankcase Ventilation (PCV) system, 6-15

gear, removal and installation, 10-10

valve and hose check and replacement, 1-26 Power brake booster, check, removal and installation, 9-16 Power steering system

bleeding, 10-11 fluid level check, 1-11 pressure switch, 6-13

pump, removal and installation, 10-11 Pulse Air system, 6-2

R Radiator and coolant reservoir, removal and installation, 3-5 Radiator grille, removal and installation, 11-6 Radio and speakers, removal and installation, 12-12 Rear main oil seal installation, 2B-18 replacement, 2A-17

Rear quarter window, replacement (1993 and earlier), 11-12 Rear wheel bearing check, repack and adjustment, 1-30 Rear window defogger switch, check and replacement, 12-15 check and repair, 12-16 Recommended lubricants and fluids, 1-1 Relays, general information and testing, 12-3 Release bearing and lever, clutch, removal, inspection and installation, 8-4 Repair operations possible with the engine in the vehicle, 2A-2 Rocker arm assembly and lash adjusters, removal, inspection and installation, 2A-9

S

+ Thermostat, check and replacement, 3-2 Throttle body, 4-12 Throttle Position Sensor (TPS), 4-12, 6-11 Tie-rod ends, removal and installation, 10-9 Timing belt and sprockets, removal, inspection and installation, 2A-6 Tire and tire pressure checks, 1-8 Tire rotation, 1-15 Tires and wheels, general information, 10-11 Tools, 0-10 Top Dead Center (TDC), locating, 2A-3 Towing the vehicle, 0-15 Transaxle

automatic, 7B-1 through 7B-8 diagnosis, general, 7B-2 fluid and filter change, 1-29 fluid level check, 1-12 intermediate band, adjustment, 7B-7 park/neutral start switch, check and replacement, 7B-5 removal and installation, 7B-7

shift cable, removal, installation and adjustment, 7B-4 shift lever, removal and installation, 7B-2 shift-lock system, description, check and cable replacement, 7B-6 manual back-up light switch, check and replacement, 7A-2

lubricant change, 1-32 lubricant level check, 1-20 mount, check and replacement, 7A-4 oil seal, replacement, 7A-3 . overhaul, general information, 7A-6 removal and installation, 7A-4 shift lever, removal and installation, 7A-2

Trouble codes, 6-4

Safety first, 0-18 Seat belts, check, 11-18 removal and installation,

knuckle and hub, removal and installation, 10-6 wheel, removal and installation, 10-8 Strut assembly (front), removal, inspection and installation, 10-3 Strut/shock absorber or spring assembly, replacement, 10-4 Suspension and steering systems, 10-1 through 10-12

Troubleshooting, 0-19

Tune-up and routine maintenance, 1-1 through 1-32 11-17

Tune-up, general information, 1-6 Turn signal/hazard flashers, check and replacement, 12-3

IND-5

Index

U

W

Underhood hose check and replacement, 1-16 Upholstery and carpets, maintenance, 11-1

Water pump check, 3-6 removal and installation, 3-6 Wheel

V Vacuum gauge diagnostic check, 2B-3 Valve clearance check and adjustment (carbureted engines), 1-18 cover, removal and installation, 2A-4 servicing, 2B-9 springs, retainers and seals, replacement, 2A-11 Vehicle identification numbers, 0-6 Vehicle Speed Sensor (VSS), 6-13 Vinyl trim, maintenance, 11-1

alignment, general information, 10-12 cylinder, removal, overhaul and installation, 9-12 rear, bearing check, repack and adjustment, 1-30 Wheels and tires, general information, 10-11 Window regulator, removal and installation, 11-12 Windshield and fixed glass, replacement, 11-5

Windshield wiper blade inspection and replacement, 1-13 Windshield/window washer fluid, check, 1-7 Wiper motor, check and replacement, 12-14

Wiring diagrams, 12-18

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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 “1776

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

934

Jeep CJ - see JEEP (412) Mid-size models, Concord, Hornet, Gremlin & Spirit ’70 thru ’83 (Renault) Alliance & Encore ’83 thru ’87

AUDI 615 428 1117

Nova all V8 models ’69 thru ’79 Nova and Geo Prizm all front wheel drive models, ’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

420

AMC 694

241 *{642

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

*1664

Pick-ups ’88 thru ’95 - Chevrolet & GMC, all full-size pick-ups, ’88 thru ’95; Blazer & Jimmy ’92 thru ’94; Suburban ’92 thru ’95; Tahoe & Yukon ’95

831 *24071 *1727 *345

S-10 & GMC S-15 Pick-ups ’82 thru ’93 S-10 & GMC S-15 Pick-ups ‘94 thru ‘96 Sprint & Geo Metro ’85 thru ’94 Vans - Chevrolet & GMC, V8 & in-line 6 cylinder models ’68 thru ’96

CHRYSLER

AUSTIN-HEALEY Sprite - see MG Midget (265)

BMW *2020 276

632 240

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

BUICK Century (front wheel drive) - see GM (829)

*1627

1551

Buick, Oldsmobile & Pontiac Full-size (Front wheel drive) all models ’85 thru ’95

Buick Electra, LeSabre and Park Avenue; Oldsmobile Delta 88 Royale, Ninety Eight and Regency; Pontiac Bonneville 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,

25025

Chrysler Concorde, New Yorker & LHS, Dodge Intrepid, Eagle Vision, ‘93 thru ‘96 Chrysler Engine Overhaul Manual Full-size Front-Wheel Drive ’88 thru ’93 K-Cars - see DODGE Aries (723) Laser - see DODGE Daytona (1140) Chrysler & Plymouth Mid-size front wheel drive ’82 thru ’95

2114 *2058

*1337

Rear-wheel Drive - see Dodge (2098)

Parisienne ’83 thru ’86 Mid-size Regal & Century all rear-drive models with V6, V8 and Turbo ’74 thru ’87 Regal - see GENERAL MOTORS (1671)

Riviera - see GENERAL MOTORS (38030) Skyhawk - see GENERAL MOTORS (766) Skylark ’80 thru ’85 - see GM (38020) Skylark ’86 on - see GM (1420) Somerset - see GENERAL MOTORS (1420)

647 228 525 206 563 679 123 430 372 277

200SX all models ’80 thru ’83 8B - 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 (1137) 310 all models ’78 thru ’82 510 & PL521 Pick-up ’68 thru ’73 510 all models ’78 thru ’81 610 all models ’72 thru ’76 620 Series Pick-up all models ’73 thru ’79 720 Series Pick-up - see NISSAN (771)

376

*751

Cadillac Rear Wheel Drive all gasoline models '70 thru ’93 Cimarron - see GENERAL MOTORS (766) Eldorado - see GENERAL MOTORS (38030) Seville ’80 thru ’85 - see GM (38030)

CHEVROLET "1477 554 866

Astro & Camaro Camaro Cavalier

GMC Safari Mini-vans ’85 thru ’93 V8 all models '70 thru ’81 all models ’82 thru ’92 - see GENERAL MOTORS (766)

Celebrity - see GENERAL MOTORS (829) Camaro & Firebird ‘93 thru ‘96

625

Chevelle, Malibu & El Camino all V6 &

449 550

V8 models ’69 thru ’87 Chevette & Pontiac T1000 ’76 thru ’87 Citation all models ’80 thru ’85

810/Maxima all gasoline models, '77 thru ’84

Stanza - see NISSAN (981)

DODGE *723 1231 699

*1668 234

704

Corvette all V8 models ’68 thru ’82 Corvette all models 84 thru ’91 Chevrolet Engine Overhaul Manual Full-size Sedans Caprice, Impala, Biscayne,

319

Bel Air & Wagons ’69 thru ’90 Lumina - see GENERAL MOTORS (1671) Lumina APV - see GENERAL MOTORS (2035) Luv Pick-up all 2WD & 4WD ’72 thru ’82

626

Monte Carlo all models ’70 thru ’88

400 & 600 - see CHRYSLER Mia-size (1337) Aries & Plymouth Reliant ’81 thru ’89 Caravan & Plymouth Voyager Mini-Vans all models ’84 thru ’95 Challenger/Plymouth Saporro ’78 thru ’83

Challenger ’67-’76 - see DODGE Dart (234) Colt & Plymouth Champ (front wheel drive) all models ’78 thru ’87

*30034 *545

Dakota Pick-ups all models ’87 thru ’96 Dart, Challenger/Plymouth Barracuda & Valiant 6 cyl models ’67 thru ’76 Daytona & Chrysler Laser ’84 thru ’89 Intrepid - see CHRYSLER (25025) Neon all models ’94 thru ’97 Omni & Plymouth Horizon ’78 thru ’90

*912 *30041

Pick-ups all full-size models ’74 thru ’93 Pick-ups all full-size models ‘94 thru ‘96

*1140

*556 2098 *1726 “1779 *349

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 V8 & 6 cyl models ’71 thru ’96

“1671

*766 38020 1420 38030

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,

Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models '90 thru ’95 General Motors Full-size Rear-wheel Drive - see BUICK (1551)

GEO

094

124 Sport Coupe & Spider ’68 thru ’78

GMC

273

X1/9 all models ’74 thru ’80

FORD

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 Buick Skylark, Chevrolet Citation,

Oldsmobile Toronado ’71 thru ’85 & Buick Riviera ’79 thru ’85

*2035

*2039

10355 *1476

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 &

Seville ’80 thru ’85,

Talon - see Mitsubishi Eclipse (2097) Vision - see CHRYSLER (25025)

FIAT

Pick-ups & Bronco ’73 thru '79 Pick-ups & Bronco ’80 thru ’96 Pinto & Mercury Bobcat ’75 thru ’80 Probe all models ’89 thru ’92 Ranger/Bronco Il gasoline models ’83 thru ’92 Ranger ‘93 thru ‘96 & Mazda Pick-ups ‘94 thru ‘96 Taurus & Mercury Sable ’86 thru ’95 Tempo & Mercury Topaz all gasoline models ’84 thru ’94 Thunderbird/Mercury Cougar ’83 thru ’88 Thunderbird/Mercury Cougar ’89 and ’96 Vans all V8 Econoline models ’69 thru ’91 Vans full size ’92-’95

GENERAL MOTORS *10360 *829

EAGLE

Corsica/Beretta all models ’87 thru ’96 274

788

Pulsar - see NISSAN (876) Sentra - see NISSAN (982)

610

CADILLAC

Mustang, ’79 thru ’93; Capri, ’79 thru ’86 Mustang all models ’94 thru ’97

DATSUN

Catalina ’70 thru ’81, Grandville ’70 thru ’75, 627

773

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 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 all in-line, 6 cyl & V8 models ’75 thru ’80 Ford & Mercury Mid-size, Ford Thunderbird & Mercury Cougar (’75 thru ’82); Ford LTD & Mercury Marquis (’83 thru ’86); Ford Torino,Gran Torino, Elite, Ranchero pick-up, LTD II, Mercury Montego, Comet, XR-7 & Lincoln Versailles (’75 thru ’86) Mustang II 4 cyl, V6 & V8 models ’74 thru ’78 Mustang V8 all models ’64-1/2 thru ’73 Mustang & Mercury Capri all models

Metro - see CHEVROLET Sprint (1727) Prizm - ’85 thru ’92 see CHEVY Nova (1642), 93 thru '96 see TOYOTA Corolla (1642) Storm all models 90 thru ’93 Tracker - see SUZUKI Samurai (1626)

Safari - see CHEVROLET ASTRO (1477) Vans & Pick-ups - see CHEVROLET (420, 831, 345, 1664 & 24071)

Ford Automatic Trans. Overhaul Aerostar Mini-vans all models ’86 thru 96

(Continued on other side)

* 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.

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

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. HONDA 351 1221 2067 42013 160 633 297 1227

OLDSMOBILE 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

*601

*658

FWD (1551), RWD (1627) Delta 88 Royale - see BUICK RWD (1551) Firenza - see GENERAL MOTORS (766) Ninety-eight Regency - see BUICK Full-size

Excel all models ’86 thru 94

RWD (1551), FWD (1627) Ninety-eight Regency Brougham - see BUICK Full-size RWD (1551) Omega - see GENERAL MOTORS (38020) Silhouette - see GENERAL MOTORS (2035) Toronado - see GENERAL MOTORS (38030)

ISUZU *1641

Trooper & Pick-up, all gasoline models Pick-up, ’81 thru ’93; Trooper, ’84 thru ’91 Hombre - see CHEVROLET S-10 (24071)

JAGUAR *242 *49011 *478

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

PEUGEOT 663

Laser - see MITSUBISHI Eclipse (2097) For other PLYMOUTH titles, see DODGE.

*4553

412 50025 50029

Cherokee, Comanche & Wagoneer Limited all models ’84 thru ’96 CJall models ’49 thru ’86 Grand Cherokee all models ’93 thru ’95 Grand Wagoneer & Pick-up ’72 thru ’91

“1777

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

PONTIAC T1000 - see CHEVROLET Chevette (449)

J-2000 - see GENERAL MOTORS (766) 6000 - see GENERAL MOTORS (829)

Grand Wagoneer ’84 thru ’91, Cherokee &

LINCOLN 2117

Rear Wheel Drive all models ’70 thru ’96

1232 555__—«“ 867

MAZDA

267 460 *1419

626 (rear wheel drive) all models ’79 thru ’82 626/MX-6 (front wheel drive) ’83 thru ’91 GLC Hatchback (rear wheel drive) ’77 thru ’83 GLC (front wheel drive) ’81 thru ’85 MPV all models ’89 thru ’94 Navajo - see Ford Explorer (2021) = 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

MERCEDES-BENZ *1643 346 983 698 697

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 Diesel 123 Series ’76 thru ’85

MERCURY See FORD Listing

MG 111 265

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

MITSUBISHI *1669

Cordia, Tredia, Galant, Precis & Mirage ’83 thru ’93 Eclipse, Eagle Talon & Plymouth Laser ’90 thru ’94 Pick-up ’83 thru '96 & Montero ’83 thru ’93

*2097 *2022

Bonneville - see Buick FWD (1627), RWD (1551) Bonneville Brougham - see Buick (1551) Catalina - see Buick Full-size (1551) Fiero all models ’84 thru ’88 Firebird V8 models except Turbo ’70 thru ’81 ‘Firebird all models ’82 thru ’92 Firebird '93 thru ’96 - see CHEVY Camaro (24017) Full-size Front Wheel Drive - see BUICK, Oldsmobile, Pontiac Full-size FWD (1627) Full-size Rear Wheel Drive - see BUICK Oldsmobile, Pontiac Full-size RWD (1551)

Grand Am Grand Prix Grandville Parisienne

PORSCHE *264 239 397 *4027

911 914 924 944

141

5 Le Car all models ’76 thru ’83 Alliance & Encore - see AMC (934)

SAAB 247 *980

99 all models including Turbo ’69 thru ’80 900 all models including Turbo ’79 thru ’88

SATURN 2083

Saturn all models ’91 thru ’96

SUBARU 237 1100, 1300, 1400 & 1600 71 thru ’79 *681 1600 & 1800 2WD & 4WD ’80 thru ’89 SUZUKI Samurai/Sidekick &Geo Tracker ’86 thru ’96

*72015

Altima all models ’93 thru ’97 Maxima all models ’85 thru ’91

1023 92006 935

1139 361

*92036 636 360 532 313

304 *656 2106

Corolla all rear wheel drive models ’80 thru ’87 Corolla all front wheel drive models ’84 thru ’92 Corolla & Geo Prizm ’93 thru ’96 Corolla Tercel all models ’80 thru ’82 Corona all models ’74 thru ’82 Cressida all models ’78 thru ’82 Land Cruiser all models ’68 thru ’82 MR2 all models ’85 thru ’87 ~=Pick-up all models ’69 thru ’78 ~~Pick-up all models ’79 thru ’95 Previa all models ’91 thru ’95 = Tercel all models '87 thru ’94

TRIUMPH 113 322

- 159 238 96017 *884 451 082 226 084 1029

Camry Camry Celica Celica Celica Corolla

all models ’83 thru ’91 ail models ’92 thru ’95 Rear Wheel Drive ’71 thru ’85 Front Wheel Drive ’86 thru ’93

Supra all models ’79 thru ’92

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

Beetle & Karmann Ghia ’54 thru ’79 Dasher all gasoline models ’74 thru ’81 Golf & Jetta all models ’93 thru ’97 Rabbit, Jetta, Scirocco, & Pick-up gas models ’74 thru ’91 & Convertible ’80 thru ’92 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

VOLVO 203 129 *270 400

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

MANUALS

1667 482 2111 2069 2068

Automotive Computer Codes Automotive Emissions Control Manual Fuel Injection Manual, 1978 thru 1985 Fuel Injection Manual, 1986 thru 1996 Holley Carburetor Manual Rochester Carburetor Manual

10240 1762

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

1763 1736 1666 10355 10360 1479 2112 2113 1654 1480 2109 2107 10440 2110 10450

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

*1341

Sentra all models ’82 thru ’94 Stanza all models ’82 thru ’90

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

RENAULT

TOYOTA

*982 *981

- see BUICK Full-size (1551) - see BUICK Full-size (1551) (38020)

Sunbird - see GENERAL MOTORS (766) Trans Sport - see GENERAL MOTORS (2035)

3002ZX all models including Turbo ’84 thru ’89

*771 ~~‘Pick-ups ’80 thru ’96 Pathfinder ’87 thru ’95 876 Pulsar all models ’83 thru ’86

- see GENERAL MOTORS (1420) - see GENERAL MOTORS (1671)

Phoenix - see GENERAL MOTORS

*4626

NISSAN 1137

:

961 1025

504 all diesel models ’74 thru ’83

PLYMOUTH

JEEP

648 *1082 370 757 *2047

- see GENERAL MOTORS (1420) - see CHEVROLET S-10 (831) see GENERAL MOTORS (1420) Cruiser - see BUICK RWD (1551) V6 & V8 gas models ’74 thru ’88 Ciera - see GENERAL MOTORS (829)

Cutlass Supreme - see GM (1671) Delta 88 - see BUICK Full-size RWD (1551) Delta 88 Brougham - see BUICK Full-size

HYUNDAI *1552

Achieva Bravada Calais Custom Cutlass Cutlass

99055 99075 99077 99083 99088 99095 99118 99125

Reparacién de Carroceria & Pintura Céddigos 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 Tamaiio Grande ‘75 al ‘87 Ford Modelos de Tamafio Mediano ‘75 al ‘86 GM Modelos de Tamajio Grande ‘70 al ‘90 Nissan Sentra ‘82 al ‘94 Toyota Camionetas y 4-Runner ’79 al 95

all models ’75 thru ’79

* 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 ¢ (805) 498-6703

' 5-97

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

= TOO HOT

WORN Symptoms: Rounded electrodes with a small amount of deposits on

the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Recommendation: Plugs 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: _ |f excessive deposits accumulate over a short time or low mileage, install new valve guide seais 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.

Symptoms:

Blistered, white insu-

lator, 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 temperatures 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: |nsulators 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.

Every manual based on a complete teardown and rebuild

Fa ie \

Models covered by this manual: aro)ge a -S-) 4c: Wem blotomatalgelele|a matches) Ford Aspire - 1994 through 1997

Haynes Manuals Explain Best: e e

Step-by-step procedures linked tg Written from “hands-on” experig

¢

Quick and easy troubleshooti

e ¢

Detailed wiring diagrams Color spark plug diagnosis &

eds of easy-to-follow photos Tele mexeyen]eareyg me cele)ky