Haynes Ford Mustang 2005 thru 2007 Automotive Repair Manual 156392661X, 9781563926617

Citation preview

Haynes Repair Manual Based on a complete teardown

and rebuild

Includes essential information for today’s more complex vehicles

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JUN 11 2009

Ford

Mustang

Automotive Repair Manual — by Mike Stubblefield and John H Haynes Member of the Guild of Motoring Writers

Models covered: Ford Mustang models 2005 through 2007 Does not include information specific to Shelby GT500 Cobra models SR

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ASSSCIATION. EMBER 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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Acknowledgements Technical writers who contributed to this project include John Wegmann, Rob Maddox and Joe L. Hamilton. Wiring diagrams provided exclusively for Haynes North America, Inc by Valley Forge Technical Information Services.

© Haynes North America, Inc. 2007 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted

in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN-13: 978-1-56392-661-7 ISBN-10: 1-56392-661-X Library of Congress Control Number 2007920605 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. "Ford" and the Ford logo are registered trademarks of Ford Motor Company. Ford Motor Company is not a sponsor or affiliate of Haynes Publishing Group or Haynes North America, Inc. and is not a contributor to the content of this manual. 07-288

3 1223 08666 5891

Contents Introductory pages About this manual Introduction Vehicle identification numbers Recall information Buying parts Maintenance techniques, tools and working facilities Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants Conversion factors Fraction/decimal/millimeter equivalents Safety first! ’ Troubleshooting

é

0-5 0-5 0-6 0-7 0-8 0-8 0-15 0-16 0-17 0-18 0-19 0-20 0-21

Chapter 1 Tune-up and routine maintenance

1-1

Chapter 2 PartA 4.0L V6 engine

2A-1

Chapter 2 Part B 4.6L V8 engine

2B-1

Chapter 2 Part C General engine overhaul procedures

2C-1

Chapter 3 Cooling, heating and air conditioning systems

3-1

Chapter 4

y

Fuel and exhaust systems

4-1

Chapter 5 Engine electrical systems

5-1

Chapter 6 Emissions and engine control systems

6-1

Chapter 7 PartA Manual transmission

g

TA-1

Chapter 7 Part B Automatic transmission

7B-1

Chapter 8 Clutch and drivetrain

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

12-1

Wiring diagrams Index

i

:

12-19 IND-1

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0-4

Haynes mechanic with a 2005 Mustang GT

About this manual Its purpose

costs. An added benefit is the sense of satis-

_ 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 heip 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

faction 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 Sec-

tion 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.

2

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

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

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

Introduction The Ford Mustang is available in twodoor sport coupe or convertible body styles and have a conventional front engine/rearwheel drive layout. The available engines on the models covered by this manual are: a Single Over-Head Cam two-valves per cylinder (SOHC-2V) 4.0L V6, and a Dual Over-Head Cam three-valves”

per cylinder (DOHC-3V) 4.6L V8. All models use an electronically controlled Sequential Multiport Fuel Injection (SFI) system.

Power from the engine is transferred through either a five- or six-speed manual or four speed automatic transmission and a driveshaft to the differential which is mounted in the solid rear axle assembly. Axles inside the assembly carry power from the differential to the rear wheels. Suspension is independent in the front, utilizing MacPherson struts and control arms. The rear suspension features coil springs and shock absorbers.

The steering gear is a power assisted rack-and-pinion type that is mounted to the front of the engine crossmember with rubber insulators. The brakes are disc at the front and the

rear with vacuum assist as standard equipment. An Anti-lock Brake System (ABS) is available as an option on base models, and is standard equipment on GT models.

Vehicle identification numbers Modifications

are

a continuing

and

unpublicized process in vehicle manufacturing. Since spare parts lists and manuals are

compiled on a numerical basis, the individual vehicle numbers are necessary to correctly identify the component required.

Vehicle Identification Number

(VIN) This very important identification number is stamped 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.

Vehicle Certification Label

Automatic transmission

The Vehicle Certification Label is attached to the driver’s side door pillar (see illustration). Information on this label includes the name of the manufacturer, the month and year of production, as well as information on the options with which it is equipped. This label is especially useful for matching the color and type of paint for repair work.

identification number

Engine identification number Labels containing the engine code, engine number and build date can be found on the valve cover. The engine number is also stamped onto a machined pad on the external surface of the engine block.

The automatic transmission ID number is affixed to a label on the right side of the case (see illustration).

Manual transmission identification number The manual transmission ID number is stamped on a tag which is bolted to the driver’s side of the bellhousing.

Vehicle Emissions Control Information label. This label is found in the engine compartment. See Chapter 6 for more information on this label.

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 letter designation is the 10th digit. On the models covered by this manual the engine codes are:

Nessie: 4.0L SOHC V6 El Absence 4.6L DOHC V8

The VIN number is visible through the windshield on the driver’s side

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

Dy nitccvovaceneset oss 2005 Ore ko tnatnyey 2006 Hiistes aura can vact sons 2007

The vehicle certification label is affixed the to the

The automatic transmission identification tag is located on the

driver’s side door pillar

right side of the transmission

Recall information Vehicle recalis are carried out by the manufacturer in the rare event of a possible

safety-related defect. The vehicle’s registered owner is contacted at the address on file at the Department of Motor Vehicles and given the details of the recall. Remedial work is carried out free of charge at a dealer service department.

Recall date

Aug 7, 2006

Oct 16, 2006

If you are the new owner of a used vehicle which was subject to a recall and you want to be sure that the work has been carried out, it's best to contact a dealer service department and ask about your individual vehicle you'll need to furnish them your Vehicle Identification Number (VIN). The table below is based on informa-

Recall campaign number

06E071000

06E089000

tion provided by the National Highway Traffic Safety Administration (NHTSA), the body which oversees vehicle recalls in the United States. The recall database is updated constantly. For the latest information on vehicle recalls, check the NHTSA website. at www.nhtsa.gov, or call the NHTSA hotline at

1-888-327-4236.

Model(s) affected

2005/2006 Mustang GT

Certain aftermarket Roush branded front struts as a stand alone component, part no. 401297, and Roush branded front struts as a suspension kit, part no. 401296, sold for use on 2005 and 2006 Ford Mustang GT vehicles. The front stabilizer bar attachment bracket on the front strut can separate from the strut housing due to inconsistent welding. This could result in a clunking noise and or poor handling in extreme or emergency maneuvers. It could also damage the tire sidewall, resulting in deflation and loss of control of the vehicle

2005/2006/2007 Mustang

Certain aftermarket Eibach branded front struts only, part no. 35101.8001, and Eibach branded front struts as suspension kits, part nos. 35101.840, 35101.680, 35101.780, 35100.680, 35100.780, 4.10135.680, and 4.10035.780, sold for use on 2005 through 2007 Ford Mustang vehicles. The front stabilizer bar attachment bracket on the front strut can separate from the strut housing due to inconsistent welding. This could result in a clunking noise and or poor handling in extreme or emergency maneuvers. It could also damage the tire sidewall; resulting in deflation and loss of control of the vehicle

Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is

as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such

as clutch components,

exhaust systems,

brake parts, tune-up parts, etc. These stores often supply new or reconditioned parts on

an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general accessories, have convenient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are

unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: \f the vehicle is still covered under warranty, be sure that any replacement parts purchased regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

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

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 undam-

aged 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 x 1 bolt is 1/2 inch in diameter, has 13 threads per inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm in diameter, has a thread pitch of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, . thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard bolt head is measured in inches, while the same dimension on a metric bolt is sized in millimeters ‘

0-9

Maintenance techniques, tools and working facilities

(the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt and a metric wrench should not be used

on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to it. The greater the number of slashes, the greater the strength of the bolt. Grades 0 through 5 are commonly used on automobiles. Metric bolts

have a property class (grade) number, rather than a slash, molded into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and 10.9 are commonly used on automobiles.

Strength markings can also be used to distinguish standard nuts. Many standard into one side, while with a number. The

hex nuts from metric hex nuts have dots stamped metric nuts are marked 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 distinguishing marks on them. When such is the case, the only way to determine whether it is . standard or metric is to measure the thread

pitch or compare it to a known fastener of the same size. Standard fasteners are often referred to as SAE, as opposed to metric. However, it | should be noted that SAE technically refers to a non-metric fine thread fastener only. Coarse thread non-metric fasteners are referred to as USS sizes. Since fasteners of the same size (both

standard

and

Grade i or 2

metric) may

Grade 5

have different

strength ratings, be sure to reinstall any bolts,

studs or nuts removed from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a strength rating equal to or greater than the original.

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

Grade 8

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

Grade

Identification

Grade

_ Identification :F cine the

Hex Nut Grade 5

Hex Nut

Pro

Gloss 8.

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Arabic 9

Hex Nut Grade 8

a Nut fe]

Class 10

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Class 10.9

Class 9.8

Class 8.8

Arabic 10

Standard hex nut strength markings

Metric hex nut strength markings

Metric stud strength markings 00-1 HAYNES

0-10

Maintenance techniques, tools and working facilities

specific torque, a general torque value chart is presented here as a guide. These torque values are for dry (unlubricated) fasteners threaded into steel or cast iron (not alumi-

num). 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

been tightened one full turn, returnto the first

cover bolts, etc., must be loosened or tight-

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. j

ened 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 crisscross or diagonal pattern. After each one has

Component disassembly Component disassembly should be done. with care and purpose to help ensure that

Metric thread sizes as es enti il US ia aaah ROP 1 OsBlahSee eGR ES, ree YTS eA Ue ek YR re ne 8S Bie ED AMER aE (SeGe aS pe oe ee COND Lee Shire 7 Bae atiSehr NRMP reaMeO: aLea

Ft-Ibs 6 to 9 14 to 21 28 to 40 50 to 71 80 to 140

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

Pipe thread sizes se Ha ea EN Oe reel) MCR ODS Ea aM re tL Seber shee reercect ireCnepten oaraoa ere mer TE cc RRA PEAS see hf ERAe ser COE re 8 WYgineOe aieAkar oie Ect gt Demo ae

5 to 8 12 to 18 22 to 33 25 to 35

7 to 10 17 to 24 30 to 44

U.S. thread sizes AAS 20% eee ce Ee eee Bis GN ee ase OAT... aici, a eee BI 24 iss cones och Mea ae SIG OG ee ean hePea SiG OA eo ae see Ee ears PENG AA ee ene Mech Se hol he TAG BOO eee op aot ns, a oe PDS ee ieee cake at

6 to 9 12 to 18 14 to 20 22 to 32 27 to 38 40 to 55 40 to 60 55 to 80

9 to 12 17 to 24 19 to 27

34 to 47

30 to 43

37 to 51 55 to 74 55 to 81

75 to 108

>

00-2 HAYNES

Standard (SAE and USS) bolt dimensions/grade marks

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

Metric bolt dimensions/grade marks Property class (bolt strength) Length (in millimeters) Thread pitch (distance between threads in millimeters) O4xrv Diameter

Maintenance techniques, tools and working facilities

Micrometer set

Dial indicator set

the parts go back together properly. Always not hammer on cast parts or parts that could keep track of the sequence in which parts be easily damaged. With any particularly stubare removed. Make note of special characterborn part, always recheck to make sure that istics or marks on parts that can be installed every fastener has been removed. more than one way, such as a grooved thrust Avoid using a screwdriver or bar to pry washer on a shaft. It is a good idea to lay the apart an assembly, as they can easily mar the disassembled parts out on a clean surface in gasket sealing surfaces of the parts, which the order that they were removed. It may also must remain smooth. If prying is absolutely be helpful to make sketches or take instant necessary, use an old broom handle, but keep photos of components before removal. in mind that extra clean up will be necessary if When removing fasteners from a compothe wood splinters. nent, keep track of their locations. Sometimes ~ After the parts are separated, the old threading a bolt back in a part, or putting the gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket washers and nut back on a stud, can prevent mix-ups later. If nuts and bolts cannot be material can be soaked with rust penetrant returned to their original locations, they should or treated with a special chemical to soften it so it can be easily scraped off. Caution: be kept in a compartmented box or a series of Never use gasket removal solutioris or caussmall boxes. A cupcake or muffin tin is ideal tic chemicals on plastic or other composite for this purpose, since each cavity can hold components. A scraper can be fashioned from the bolts and nuts from a particular area (i.e. a piece of copper tubing by flattening and oil pan bolts, valve cover bolts, engine mount sharpening one end. Copper is recommended bolts, etc.). A pan of this type is especially because it is usually softer than the surfaces helpful when working on assemblies with very to be scraped, which reduces the chance small parts, such as the carburetor, alternator, of gouging the part. Some gaskets can be valve train or interior dash and trim pieces. removed with a wire brush, but regardless of The cavities can be marked with paint or tape the method used, the mating surfaces must to identify the contents. be left clean and smooth. If for some reason Whenever wiring looms, harnesses or the gasket surface is gouged, then a gasket connectors are separated, it is a good idea to sealer thick enough to fill scratches will have identify the two halves with numbered pieces to be used during reassembly of the compoof masking tape so they can be easily reconnents. For most applications, a non-drying (or nected. semi-drying) gasket sealer should be used.

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. 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

0-11

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 ahose 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.

Compression gauge with spark plug hole adapter

:

Hydraulic lifter removal tool

Valve spring compressor

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

Ring removail/installation tool

0-13

Brake hold-down spring tool

Ring compressor

Torque angle gauge

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 open-

end combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench.

Combination wrench set (1/4-inch to. 1 inch or 6 mm to. 19 mm) Adjustable wrench, 8 inch Spark plug wrench with rubber insert Spark plug gap adjusting tool Feeler gauge set

_ Brake bleeder wrench Standard screwdriver (5/16-inch x 6 inch) Phillips screwdriver (No. 2 x 6 inch) Combination pliers - 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush Battery post and cable cleaning tool Oil filter wrench Funnel (medium size) Safety goggles Jackstands (2) Drain pan

Clutch plate alignment tool

Note: /f basic tune-ups are going to be part of routine maintenance, it will be necessary to purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely necessary for tuning most vehicles properly.

Repair and overhaul tool set These tools are essential for anyone who

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

Tap and die set Standard screwdriver (stubby -

5/16-inch) Phillips screwdriver (No. 3 x 8 inch) Phillips screwdriver (stubby - No. 2)

Pliers - vise grip Pliers - lineman’s Pliers - needle nose Pliers - snap-ring (internal and external) Cold chisel - 1/2-inch Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch) Steel rule/straightedge - 12 inch Allen wrench set (1/8 to 3/8-inch or 4 mm 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,

0-14 SS

Maintenance techniques, tools and working facilities SS

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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

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.

without the special tool is offered. However, sometimes there is no alternative to their use.

clean and in usable condition and store them-

Where this is the case, and the tool cannot be purchased or borrowed, the work should be turned over to the dealer service department or an automotive repair shop.

Valve spring compressor Piston ring groove cleaning tool Piston ring compressor Piston ring installation tool Cylinder compression gauge Cylinder ridge reamer

Cylinder surfacing hone Cylinder bore gauge Micrometers and/or dial calipers Hydraulic lifter removal tool Balljoint separator Universal-type puller Impact 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 gradually allows the cost of the tools to be spread over a longer period of time and gives the mechanic the freedom to

choose only those tools that will actually be used. Tool stores will often be the only source of some of the special tools that are needed,

Care and maintenance of tools Good tools are expensive, so it makes sense to treat them with respect. Keep 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 on a panel mounted on the garage or workshop wall, while others should be kept in a tool box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or impact from other tools. When tools are used with care and stored properly, they will last a very long time. Even with the best of care, though, tools will wear out if used 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-toocommon occurrence, especially when working with aluminum parts, because aluminum is so soft that it easily strips out. Usually, external or internal threads are only partially stripped. After they’ve been cleaned up with a tap or die, they'll still work. Sometimes, however, threads are badly damaged. When this happens, you’ve got three choices: i 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 origi-

nal 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

PS

easy-to-use kits are designed to repair damaged threads in.straight-through holes and blind holes. Both are available as kits which can handle a variety of sizes and thread patterns. Drill the hole,

then tap it with the special included tap. _ Install the Heli-Coil and the hole is back to:its original diameter and thread pitch. Regardless of which method you use, be sure to proceed calmly and carefully. A little impatience or carelessness during one of these relatively simple procedures can ruin your whole day’s work and cost you a bundle if you wreck an expensive part.

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 many home mechanics do not have a good workshop or garage available, and end up removing an engine or doing major repairs outside. It is recommended, however, that the overhaul or repair be completed under the cover of a roof. A clean, flat workbench or table of comfortable working height is 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.

0-15

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 transmission. 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-to-1/2 turn each.

E:

_ 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

the vehicle is lowered or it could slip off the jack. Turn the jack handle counterclockwise to lower the vehicle. Remove the jack and tighten the lug nuts in a diagonal pattern.

Install the cover (and trim ring, if used) and be sure it’s snapped into place all the way around. Stow the tire, jack and wrench. Unblock the wheels.

Towing As a general rule, the vehicle should be towed with the rear wheels off the ground. If they can't be raised, either place them on a dolly or disconnect the driveshaft from the differential. When a vehicle is towed with the rear wheels raised, the steering wheel must be clamped in the straight ahead position with a special device designed for use during, towing. The ignition key must be in the OFF position, since the steering lock mechanism isn't strong enough to hold the front wheels straight while towing.

Vehicles equipped with an automatic transmission can be towed from the front only with all four wheels on the ground, provided that speeds don’t exceed 35 mph and the distance is not over 50 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. Release the parking brake, put the transmission in Neutral and place the ignition key in the OFF position. There’s no distance limitation when towing with either the rear wheels off the ground or the driveshaft disconnected, but don’t exceed 50 mph. 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. Remember that power steering and power brakes will not work with

the engine off.

side of the vehicle (see illustration). Turn the jack handle clockwise until the tire clears the ground. Remove the lug nuts and pull the wheel off. Replace it with the spare. Install the lug nuts with the bevele edges facing in. Tighten them snugly. Don't attempt to tighten them completely until

Place the jack so it engages the notch in the rocker panel nearest the wheel to be raised

0-16

Booster battery (jump) starting Observe the following precautions when using a booster battery to start a vehicle:

Dead battery

Booster battery

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 transmission 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 one jumper lead between the positive (+) terminals of the two batteries (see illustration). Connect the other jumper lead first to the negative (-) terminal of the booster battery, then to a good engine ground on the vehicle to be started.Attach the lead at least 18 inches from the battery, if possible. Make sure the that the jumper leads will not contact the fan, drivebelt or other moving parts of the engine. 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.

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

0-17

Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning sol-

temperatures encountered by wheel bearings in disc brake equipped vehicles. It usually contains molybdenum disulfide (moly), which is a dry-type lubricant. White grease is\a heavy grease for ’ metal-to-metal applications where water is a problem. White grease stays soft under both low and high temperatures (usually from -100 to +190-degrees F), and will not wash off or dilute in the presence of water. Assembly lube is a special extreme pressure lubricant, usually containing moly, used to lubricate high-load parts (such as

vents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum, varnish and car-

bon. 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.

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

Brake system cleaner is used to remove brake dust, 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 alter- nators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive and non-corrosive. 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.

cannot be used due to contamination

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

Sealants __RTV sealant is one of the most widely

Lubricants

used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills surface irregularities, remains flexible, doesn’t shrink, is relatively easy to remove, and is used as a supplementary sealer with almost all low and medium temperature gaskets. Anaerobic sealant is much like RTV in that it can be used either to seal gaskets or to form gaskets by itself. It remains flexible,

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

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.

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,

prob-

lems, 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

such

as for

wheel bearings, balljoints, tie-rod ends and universal joints. : High-temperature wheel bearing grease is designed to withstand the extreme

°

Chemicals Anti-seize compound

prevents seiz-

ing, 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. Highstrength 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.

Ae

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

0-18

Conversion

factors

Length (distance) Inches (in)

X

Feet (ft) Miles

X X

25.4 0.305 1.609

Volume (capacity)

=Millimeters (mm) = Meters (m) = Kilometers (km)

X

0.0394

X xX

3.281 0.621

=Inches (in)

=Feet (ft) =Miles

.

Cubic inches (cu in; in?)

X 16.387 = Cubic centimeters (cc; cm’)

X

0.061

= Cubic inches (cu in; in*)

Imperial pints (Imp pt) Imperial quarts (Imp qt)

xX 0.568 X .1.137

= Liters (I) =Liters (I)

x x

1.76 0.88

= 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) K

X X X X X

1.201

=US quarts (US qt)

0.946 4.546 1.201

= Liters (I) = Liters (I) =US gallons (US gal)

3.785

= Liters (I)

X X x X X

0.833 1.057 0.22 0.833 0.264

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

X X

28.35 0.454

=Grams (g) = Kilograms (kg)

X xX

0.035 2.205

=Ounces (oz) =Pounds (!b)

X 0.278 xX 4.448 xX 0.1.

=Newtons (N) = Newtons (N) =Kilograms-force (kgf; kg)

x X X

3.6 0.225 9.81

= Ounces-force (ozf; 02) = Pounds-force (Ibf; Ib) = Newtons (N)

X

= Kilograms-force per square

X

14,223

= Pounds-force per square inch

xX

14.696

= Pounds-force per square inch

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

Force Ounces-force (ozf; oz) Pounds-force (Ibf; Ib) Newtons (N)

Pressure Pounds-force per square inch

0.070

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

centimeter (kgf/cm?; kg/cm?) © X

0.068

=Atmospheres

' Pounds-force per square inch

X

0.069

= Bars

x

14.5

= Pounds-force per square inch

X

6.895

=Kilopascals (kPa)

X

0.145

= Pounds-force per square inch

X

0.01

=Kilograms-force per square

x

98.1

X

0.868

= Pounds-force inches

= Pounds-force inches

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

(atm)

(psi; Ibf/in?; |b/in?)

Pounds-force per square inch

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

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

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

Pounds-force per square inch

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

(psi; Ibf/in; {b/in?)

Kilopascals (kPa)

= Kilopascals (kPa)

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

Torque (moment of force) Pounds-force inches

X

1.152

(Ibf in; Ib in)

= Kilograms-force centimeter

(kgf cm; kg cm)

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

(Ibf in; Ib in)

X

0.113

=Newton meters (Nm)

X

8.85

X

0.083

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

X

12

X

0.138

= Kilograms-force meters

xX

7.233

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

(kgf m; kg m) Pounds-force feet (Ibf ft; Ib ft) Newton meters (Nm)

X X

1.356 0.102

=Newton meters (Nm) = Kilograms-force meters (kgf m; kg m)

xX X

0.738 9.804

= Pounds-force feet (Ibf ft; Ib ft) =Newton meters (Nm)

X X

3.377 25.4

= Kilopascals (kPa) = Millimeters mercury (mm Hg)

X X

0.2961 0.0394

=Inches mercury =Inches mercury

X

745.7

=Watts (W)

X

0.0013

= Horsepower (hp)

Vacuum Inches mercury (in. Hg) Inches mercury (in. Hg)

Power Horsepower (hp)

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

xX. 1.609

= Kilometers per hour (km/hr; kph) x

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12-24

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Air conditioning and engine cooling systems - V8 models (2 of 2)

h

12-25

Chapter 12 Chassis electrical system HOT RUN OR fetes sah | |

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ILLUMINATION

Cruise control system (2005 and 2006 models)

12-26

Chapter 12

Chassis electrical system

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|

12-27

‘Chapter 12 Chassis electrical system

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Warning light system

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12-38

Chapter 12

Chassis electrical system

HOT AT ALL TIMES BUSSED | al ELECTRICAL FUSE | CENTER (BEC) | 56 |

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IND-1

Index A About this manual, 0-5 Accelerator Pedal Positicn Sensors (APPS), replacement, 6-14 _ Accumulator, air conditioning, removal and installation, 3-11 - Acknowledgements, 0-2 Air conditioning accumulator, removal and installation, 3-11 and heating system, check and maintenance, 3-8 compressor, removal and installation, 3-10 condenser, removal and installation, 3-11 control assembly, removal and installation, 3-7 cycling switch, dual function pressure switch and air conditioning pressure transducer, replacement, 3-12 expansion (orifice) tube, replacement, 3-12 Air filter replacement, 1-18 Air intake duct and filter housing, removal and installation, 4-9 Airbag system, general information and precautions, 12-17 Alignment, wheel, general information, 10-16 Alternator, removal and installation, 5-6 _ Antenna and cables, replacement, 12-10 Antifreeze, general information, 3-2 Anti-lock Brake System (ABS), general information, 9-2 Automatic transmission, 7B-1 through 7B-6 Brake Transmission Shift Interlock (BTSI) system, description, check and replacement, 7B-3 diagnosis, general, 7B-1 fluid change, 1-24 type, 1-1 fluid cooler, removal and installation, 7B-4

general information, 7B-1 — mount, check and replacement, 7A-2 overhaul, general information, 7B-6 removal and installation, 7B-4 shift cable, check, replacement and adjustment, 7B-2

lever, removal and installation, 7B-2 transmission fluid cooler, removal and installation, 7B-4

Automotive chemicals and lubricants, 0-17 Axleshaft

bearing, replacement, 8-8 oil seal, replacement, 8-8 removal and installation, 8-7

Balljoints, check and replacement, 10-6 Battery cables, check and replacement, 5-4 check and replacement, 5-2 check, maintenance and charging, 1-13 precautions and disconnection, 5-1 Blower motor resistor and blower motor, replacement, 3-7 Body repair major damage, 11-3 minor damage, 11-2

Body, 11-1 through 11-18 Body, maintenance, 11-1 Booster battery (jump) starting, 0-16 Brakes, 9-1 through 9-12 © Anti-lock Brake System (ABS), general information, 9-2 caliper, removal and installation, 9-7 disc, inspection, removal and installation, 9-7

fluid change, 1-19

level check, 1-9 type, 1-1 general information, 9-2 hoses and lines, inspection and replacement, 9-10 hydraulic system, bleeding, 9-11 light switch, replacement, 9-12 master cylinder, removal and installation, 9-9 pads, replacement, 9-2 parking brake cable, adjustment, 9-12 power brake booster, check, removal and installation, 9-12 system check, 1-16 Brake Transmission Shift Interlock (BTSI) system, description, check and replacement, 7B-3

IND-2 Bulb replacement, 12-13 Bumper covers, removal and installation, 11-6

Index Cooling, heating and air conditioning systems, 3-1 through 3-14

Buying parts, 0-8

Cowl cover, removal and installation, 11-17

C

Crankshaft Position (CKP) sensor, replacement, 6-15 Crankshaft pulley and front oil seal, removal and installation V6 engine, 2A-10

Cable replacement antenna, 12-10

battery, 5-4 hood release, 11-6 Caliper, disc brake, removal and installation, 9-7 Camshaft position (CMP) sensor, replacement, 6-15 Camshafts, removal, inspection and installation V6 engine, 2A-13 V8 engine, 2B-11 Capacities, fluids and lubricants, 1-2 Catalytic converters, description, check and replacement, 6-20 Center console, removal and installation, 11-13 Charge Motion Control Valve (CMCV) (V8 — removal and installation, 6-19

Charging system alternator, removal and installation, 5-6 check, 5-6 general information and precautions, 5-6 Chassis electrical system, 12-1 through 12-18 Chemicals and lubricants, 0-17 Circuit breakers, general information, 12-4 Clutch components, removal, inspection and installation, 8-2 description and check, 8-1 fluid level check, 1-9 type, 1-1 hydraulic system, bleeding, 8-2 master cylinder, removal and installation, 8-2 pedal position (CPP) switch, replacement, 8-4 release bearing, removal, inspection and installation, 8-2 cylinder, removal and installation, 8-2 Clutch and driveline, 8-1 through 8-10 Coil spring, rear, removal and installation, 10-8 Coil, ignition check, 1-23 replacement, 5-5 Common engine overhaul terms, 2C-18 Compressor, air conditioning, removal and installation, 3-10 Condenser, air conditioning, removal and installation, 3-11 Control arm, front, removal and installation, 10-6 Conversion factors, 0-18 Coolant expansion tank, removal and installation, 3-4

V8 engine, 2B-5 Crankshaft, removal and installation, 2C-14

- Cruise control system, general information, 12-16 Cycling switch, air conditioning, , replacement, 3-12 Cylinder compression check, 2C-3 Cylinder Head Temperature (CHT) rhea replacement, 6-15 Cylinder head, removal and installation V6 engine, 2A-7 : V8 engine, 2B-13

D Dashboard trim panels, removal and installation, 11-14 Daytime Running Lights (DRL), general information, 12-17 Defogger, rear window, check and repair, 12-15 Diagnosis, 0-21 Diagnostic Trouble Codes (DTCs), accessing, 6-2 Differential lubricant change, 1-20 level check, 1-10 type, 1-1

pinion oil seal, replacement, 8-6 Disc brake caliper, removal and installation, 9-7 disc, inspection, removal and installation, 9-7 pads, replacement, 9-2 Door latch, lock cylinder and handle, removal and installation,. 11-12 removal, installation and adjustment, 11-11 trim panels, removal and installation, 11-10 — window glass regulator, removal and installation, 11-12

window glass, removal and installation, 11-12 Drivebelt check and replacement, 1-19 tensioner, replacement, 1-20 Driveshaft inspection, 8-4 removal and installation, 8-5 universal joints, replacement, 8-5 Dual function pressure switch, air conditioning, replacement, 3-12

general information, 3-2 level check, 1-8 temperature indicator, check, 3-7 type, 1-1

Cooling system check, 1-14

general information, 3-2 servicing (draining, flushing and refilling), 1-23

E Electric side view mirrors, general information, 12-16 Electrical troubleshooting, general information, 12-1 Emissions and engine control systems, 6-1 through 6-24 Engine and emissions control systems, general information, 6-1

IND-3

Index a

SS

I,

a

Engine Coolant Temperature (ECT) sensor, replacement, 6-16 _Engine coolant, level check, 1-8 _ Engine cooling fan, check and replacement, 3-3 _ Engine electrical systems, 5-1 through 5-10 _ Engine, general overhaul procedures, 2C-1 through 2C-20 crankshaft, removal and installation, 2C-14 cylinder compression check, 2C-3 engine overhaul disassembly sequence, 2C-8 reassembly sequence, 2C-17 terms, 2C-18 . engine rebuilding alternatives, 2C-5 engine removal, methods and precautions, 2C-5 engine, removal and installation, 2C-6 general information, 2C-2 initial start-up and break-in after overhaul, 2C-17 jackshaft and balance shaft (V6 models), removal,

_

inspection and installation, 2C-8 _ oil pressure check, 2C-3 pistons and connecting rods, removal and installation, 2C-9 vacuum gauge diagnostic checks, 2C-4 Engine, in-vehicle repair procedures V6 engine, 2A-1 through 2A-18 camshafts, removal, inspection and installation, 2A-13 crankshaft pulley and front oil seal, removal and installation, 2A-10 cylinder heads, removal and installation, 2A-7

engine mounts, check and replacement, 2A-16 exhaust manifold, removal and installation, 2A-6 flywheel/driveplate, removal and installation, 2A-16 intake manifold, removal and installation, 2A-6 jackshaft and balance shaft, removal, inspection and installation, 2C-8 oil pan, removal and installation, 2A-14 oil pump, removal, inspection and installation, 2A-15

powertrain mounts, check and replacement, 2A-16 rear main oil seal, replacement, 2A-16 repair operations possible with the engine in the vehicle, 2A-3 rocker arms and lash adjusters, removal, inspection and installation, 2A-4 timing chains and sprockets, removal, inspection and installation, 2A-11 Top Dead Center (TDC) for number 1 piston, locating, 2A-3 valve covers, removal and installation, 2A-4 V8 engine, 2B-1 through 2B-18 camshafts, removal, inspection and installation, 2B-11 crankshaft front oil seal, removal and installation, 2B-5

cylinder heads, removal and installation, 2B-13 engine mounts, check and replacement, 2B-17 exhaust manifold, removal and installation, 2B-4 flywheel/driveplate, removal and installation, 2B-16 intake manifold, removal and installation, 2B-4 oil pan, removal and installation, 2B-15 oil pump, removal, inspection and installation, 2B- 15 powertrain mounts, check and replacement, 2B-17 rear main oil seal, replacement, 2B-16 repair operations possible with the engine in the vehicle, 2B-2

SS

SS

BS

I

BG

DE

EEE

OETE

rocker arms and valve lash adjusters, removal, inspection and installation, 2B-10 timing chain and sprockets, removal, inspection and installation, 2B-7 timing chain cover, removal and installation, 2B-6

Top Dead Center (TDC) for number 1 piston, locating, 2B-2 valve covers, removal and installation, 2B-3 Variable Camshaft Timing (VCT) system, general information and component checks, 2B-11 Engine mounts, check and replacement V6 engine, 2A-16 V8 engine, 2B-17 Engine oil and filter change, 1-11 level check, 1-7

type and viscosity, 1-1

Engine overhaul disassembly sequence, 2C-8 reassembly sequence, 2C-17 terms, 2C-18

Engine rebuilding alternatives, 2C-5 Engine removal, methods and precautions, 2C-5

Engine, removal and installation, 2C-6 Evaporative Emission Control (EVAP) system, description and component replacement, 6-21 Exhaust Gas Recirculation (EGR) system, description oe component replacement, 6-22 Exhaust manifold, removal and installation V6 engine, 2A-6 V8 engine, 2B-4

Exhaust system check, 1-18

servicing, general information, 4-13 Expansion (orifice) tube, air conditioning, replacement, 3-12 Expansion tank, coolant, removal and installation, 3-4

IF Fan, engine cooling, check and replacement, 3-3 Fault finding, 0-21 Fender, front, removal and installation, 11-8

Filter housing, engine air, removal and installation, 4-9 Filter replacement engine air, 1-18 engine oil, 1-11 fuel, 1-19

Firing order, 1-2 Fluid level checks, 1-7 automatic transmission, 1-24 brake fluid, 1-9 clutch fluid, 1-9 differential, 1-10 engine coolant, 1-8 engine oil, 1-7 manual transmission, 1-9 power steering, 1-9 windshield washer, 1-9

IND-4

~ Index

Fluids and lubricants Capacities, 1-2 recommended, 1-1 Flywheel/driveplate, removal and installation V6 engine, 2A-16 V8 engine, 2B-16 Fraction/decimal/millimeter equivalents, 0-19 Front end alignment, general information, 10-16

Front hub and bearing, removal and installation, 10-6 Fuel filter replacement, 1-19 injection system, check, 4-10 level sensor, removal and installation, 4-7 lines and fittings, general information, 4-3 pressure relief procedure, 4-2 pump module, removal and installation, 4-6 pump/fuel pressure, check, 4-2 rail and injectors, removal and installation, 4-12 Sequential Multiport Fuel Injection (SFI) system, general information, 4-10 system check, 1-17 tank cleaning and repair, 4-9 removal and installation, 4-8 Fuel and exhaust systems, 4-1 through 4-14 Fuel Pump Driver Module (FPDM), replacement, 6-19

Fuel Rail Pressure and Temperature (FRPT) sensor, replacement, 6-16 Fuses and fusible links, general information, 12-3

Heater/air conditioning control assembly, removal and installation, 3-7 Heating and air conditioning system, check and maintenance, 3-8 Hinges and locks, maintenance, 11-3 Hood release latch and cable, removal and installation, 11-6 removal, installation and adjustment, 11-3 Horn, replacement, 12-12 Hub and bearing, removal and installation, 10-6

Ignition system check, 5-5 coil check, 1-23 coil(s), replacement, 5-5 general information and precautions, 5-4 switch and key lock cylinder, replacement, 12-6 Information sensors, description, 6-2 Initial start-up and break-in after overhaul, 2C-17 Instrument cluster, removal and installation, 12-7 panel switches, replacement, 12-7 panel, removal and installation, 11-15 Intake Air Temperature (IAT) sensor, replacement, 6-16 Intake manifold, removal and installation V6 engine, 2A-6 V8 engine, 2B-4 Interior ventilation filter replacement, 1-18

G Gear, steering, removal and installation, 10-13 General engine overhaul procedures, 2C-1 through 2C-20 -_ crankshaft, removal and installation, 2C-14

cylinder compression check, 2C-3 engine overhaul disassembly sequence, 2C-8 reassembly sequence, 2C-17 terms, 2C-18 engine rebuilding alternatives, 2C-5 engine removal, methods and precautions, 2C-5

engine, removal and installation, 2C-6 general information, 2C-2 initial start-up and break-in after overhaul, 2C-17 jackshaft and balance shaft (V6 models), removal, inspection and installation, 2C-8 oil pressure check, 2C-3 pistons and connecting rods, removal and installation, 2C-9 vacuum gauge diagnostic checks, 2C-4 Glossary of engine overhaul terms, 2C-18

J Jacking and towing, 0-15 Jackshaft and balance shaft (V6 models), removal, inspection and installation, 2C-8 Jump starting, 0-16

K Key lock cylinder, ignition switch, replacement, 12-6 Knock sensor, replacement, 6-16

L Lubricants and chemicals, 0-17 Lubricants and fluids capacities, 1-2 recommended, 1-1

H Headlights adjustment, 12-11 bulb, replacement, 12-11 housing, replacement, 12-12 Heater core, replacement, 3-7

Maintenance routine, 1-1 through 1-26 schedule, 1-6 techniques, tools and working facilities, 0-8

ee Se

IND-5

Index Manual transmission, 7A-1 through 7A-4 general information, 7A-1 lubricant change, 1-20 level check, 1-9 type, 1-1 mount, check and replacement, 7A-2 oil seal, replacement, 7A-1 overhaul, general information, 7A-3 ’ removal and installation, 7A-2 shift lever, removal and installation, 7A-1

Mass Air Flow (MAF) sensor, replacement, 6-16 _ Master cylinder, removal and installation brake, 9-9 clutch, 8-2 _ Mirrors, electric side view, general information, 12-16

R Radiator, removal and installation, 3-4 Radio and speakers, removal and installation, 12-9 Rear axle assembly, removal and installation, 8-9 Rear main oil seal, replacement V6 engine, 2A-16 V8 engine, 2B-16 ‘

:

Rear support braces (convertibles only), removal and installation, 10-10 Rear trim panels, removal and installation, 11-17

Rear window defogger, check and repair, 12-15 Recall information, 0-7 Recommended lubricants and fluids, 1-1

Relays, general information and testing, 12-4 Release bearing, clutch, removal, inspection and

. Mirrors, removal and installation, 11-13

installation, 8-2 Release cylinder, clutch, removal and installation, 8-2 Repair operations possible with the engine in the vehicle

: O

V8 engine, 2B-2 Replacement parts, buying, 0-8 Rocker arms and lash adjusters, removal, inspection and

V6 engine, 2A-3 _ Oil pan, removal and installation

_

V6 engine, 2A-14

installation

V8 engine, 2B-15

V6 engine, 2A-4

' Oil pressure check, 2C-3 _ Oil pump, removal, inspection and installation V6 engine, 2A-15 V8 engine, 2B-15 - Oil, engine, level check, 1-7 On-Board Diagnostic (OBD) system and trouble codes, 6-2

Orifice tube, air conditioning, replacement, 3-12 _ Output actuators, description, 6-4 _ Oxygen sensors, general description and replacement, 6-17

V8 engine, 2B-70

Rotating the tires, 1-12 Rotor, brake, inspection, removal and installation, 9-7

Routine maintenance schedule, 1-6 Routine maintenance, 1-1 through 1-26

S Safety first!, 0-20

Safety recall information, 0-7 Scheduled maintenance, 1-1 through 1-26

P

_ Pads, disc brake, replacement, 9-2 Panhard rod, removal and installation, 10-9 _ Parking brake cable, adjustment, 9-12 _ Parts, replacement, buying, 0-8 _ Pistons and connecting rods, removal and installation, 2C-9_ Positive Crankcase Ventilation (PCV) system, 1-24, 6-23 _ Power brake booster, check, removal and installation, 9-12 ~ Power door lock system, general information, 12-17 - Power steering fluid level check, 1-9 type, 1-1 pump, removal and installation, 10-15 system, bleeding, 10-16 - Power window system, general information, 12-16 Powertrain Control Module (PCM), removal and

_ . installation, 6-18 Powertrain mounts, check and replacement

V6 engine, 2A-16 V8 engine, 2B-17 Pressure transducer, air conditioning, replacement, 3-12

Seat belt check, 1-15 Seats, removai and installation, 11-17

Sequential Multiport Fuel Injection (SFI) system, general

information, 4-10 ; Shift cable, automatic transmission, check, replacement and adjustment, 7B-2 lever, removal and installation automatic transmission, 7B-2 manual transmission, 7A-1 Shock absorber, rear, removal and installation, 10-8 Sideview mirrors, removal and installation, 11-13

Slave cylinder, clutch, removal and installation, 8-2 Spare tire, installing, 0-15

Spark plug check and replacement, 1-21 torque, 1-2 type and gap, 1-2 . wire check and replacement (V6 engines), 1-25 Speakers, removal and installation, 12-9 Stabilizer bar bushings and links, removal and installation front, 10-5 rear, 10-7

Starter motor and circuit, in-vehicle check, 5-7 removal and installation, 5-8

.

IND-6 Se

Index PS

SSP

PS

SSP

Starting system, general information and precautions, 5-7 Steering column covers, removal and installation, 11-14 switches, replacement, 12-5 removal and installation, 10-14 gear boots, replacement, 10-13

gear, removal and installation, 10-13 knuckle, removal and installation, 10-7 wheel, removal and installation, 10-14 Steering and suspension check, 1-17

Stop light switch, replacement, 9-12 Strut assembly, removal, inspection and installation, 10-4

Strut/coil spring assembly, replacement, 10-4 Support braces, rear (convertibles only), removal and installation, 10-10

- Suspension and steering systems, 10-1 through 10-18 Suspension arms, lateral stiffener and Panhard rod (rear), removal and installation, 10-9 Switches, instrument panel, replacement, 12-7

T Temperature sensor, replacement cylinder head (V8 models), 6-15 engine coolant (V6 models), 6-16 Tensioner, drivebelt, replacement, 1-20 Thermostat, check and replacement, 3-2 Throttle body, removal and installation, 4-11 Tie-rod ends, removal and installation, 10-12 Timing chain cover, V8 engine, removal and installation, 2B-6 Timing chains and sprockets, removal, inspection and installation V6 engine, 2A-11 V8 engine, 2B-7 Tire and tire pressure checks, 1-10 Tire rotation, 1-12 Tire, spare, installing, 0-15 ~ Tools and working facilities, 0-8 Top Dead Center (TDC) for number 1 piston, locating V6 engine, 2A-3 V8 engine, 2B-2 Torque specifications brake caliper mounting bolts, 9-1 cylinder head bolts V6 engine, 2A-2 V8 engine, 2B-1 engine oil drain plug, 1-2 spark plugs, 1-2 thermostat housing bolts, 3-1 water pump bolts, 3-1 wheel lug nuts, 1-2

Other torque specifications can be found in the chapter that deals with the component being serviced

Towing, 0-15 Transmission, automatic, 7B-1 through 7B-6 Brake Transmission Shift Interlock (BTSI) system, description, check and replacement, 7B-3 diagnosis, general, 7B-1

SRE

SS

SSE

SS

fluid change, 1-24 type, 1-1 fluid cooler, removal and installation, 7B-4 general information, 7B-1 . mount, check and replacement, 7A-2 overhaul, general information, 7B-6 removal and installation, 7B-4 shift cable, check, replacement and adjustment, 7B-2 lever, removal and installation, 7B-2 transmission fluid cooler, removal and installation, 7B-4 Transmission, manual, 7A-1 through 7A-4 general information, 7A-1 lubricant change, 1-20 level check, 1-9 type, 1-1 mount, check and replacement, 7A-2 oil seal, replacement, 7A-1 overhaul, general information, 7A-3 removal and installation, 7A-2 shift lever, removal and installation, 7A-1 Transmission Range (TR) sensor, replacement, 6-18 Transmission speed sensors, replacement, 6-18 Trim panels, removal and installation dashboard, 11-14 door, 11-10 rear, 11-17 Trouble codes, accessing, 6-2 Troubleshooting, 0-21 Trunk lid latch and lock cylinder, removal and installation, 11-9 removal, installation and adjustment, 11-9 support struts, removal and installation, 11-9 Tune-up and routine maintenance, 1-1 through 1-26 Tune-up general information, 1-7

U Underhood hose check and replacement, 1-15 Universal joints, replacement, 8-5 Upholstery and carpets, maintenance, 11-2

V V6 engine, 2A-1 through 2A-18 camshafts, removal, inspection and installation, 2A-13 crankshaft pulley and front oil seal, removal and installation, 2A-10

cylinder heads, removal and installation, 2A-7 engine mounts, check and replacement, 2A-16 exhaust manifold, removal and installation, 2A-6 flywheel/driveplate, removal and installation, 2A-16 intake manifold, removal and installation, 2A-6 jackshaft and balance shaft (V6 models), removal, inspection and installation, 2C-8 oil pan, removal and installation, 2A-14 oil pump, removal, inspection and installation, 2A-15

Index SS

b

SS

a

AES

powertrain mounts, check and replacement, 2A-16 rear main oil seal, replacement, 2A-16 repair operations possible with the engine in the vehicle, 2A-3 rocker arms and lash adjusters, removal, inspection and installation, 2A-4 timing chains and sprockets, removal, inspection and installation, 2A-11 Top Dead Center (TDC) for number 1 piston, locating, 2A-3 valve covers, removal and installation, 2A-4

A

IND-7 SS

aS

SE

SS

a ST

tN

SO

PS

Da

CTS SETS

Vacuum gauge diagnostic checks, 2C-4 Valve covers, removal and installation V6 engine, 2A-4

V8 engine, 2B-3 Variable Camshaft Timing (VCT) system (V8 engine) general information and component checks, 2B-11 oil control solenoid, replacement, 6-19 Vehicie identification numbers, 0-6 Vinyl trim, maintenance, 11-1

gV8 engine, 2B-1 through 2B-18 e

camshafts, removal, inspection and installation, 2B-11 crankshaft front oil seal, removal and installation, 2B-5 cylinder heads, removal and installation, 2B-13 engine mounts, check and replacement, 2B-17 exhaust manifold, removal and installation, 2B-4

flywheel/driveplate, removal and installation, 2B-16 intake manifold, removal and installation, 2B-4 oil pan, removal and installation, 2B-15 oil pump, removal, inspection and installation, 2B-15 powertrain mounts, check and replacement, 2B-17 rear main oil seal, replacement, 2B-16 repair operations possible with the engine in the vehicle, 2B-2 rocker arms and valve lash adjusters, removal, inspection

and installation, 2B-10 timing chain and sprockets, removal, inspection and installation, 2B-7 timing chain cover, removal and installation, 2B-6 Top Dead Center (TDC) for number 1 piston, locating, 2B-2 valve covers, removal and installation, 2B-3 Variable Camshaft Timing (VCT) system, general information and component checks, 2B-11

WwW Water pump check, 3-6

replacement, 3-6 Wheel alignment, general information, 10-16 Wheel bearings, front, replacement, 10-6 Wheels and tires, general information, 10-16 Window glass regulator, removal and installation, 11-12 Window glass, door, removal and installation, 11-12

Windshield and fixed glass, replacement, 11-3 washer fluid, level check, 1-9 wiper blade inspection and replacement, 1-13 wiper motor, replacement, 12-8 Wiring diagrams, general information, 12-18 Working facilities, 0-8

Haynes Automotive Manuals NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information. HAYNES XTREME CUSTOMIZING 11101 11102 11110 11150 11213 11255 11314 11315 11373

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

24050

Luv Pick-up all 2WD & 4WD ’72 thru ’82

24055

Malibu ’97 thru ’00 - see GM (38026) Monte Carlo all models ’70 thru ’88 Monte Carlo ’95 thru 01 - see LUMINA (24048)

24059 24060 24064

Nova ali V8 models ’69 thru ’79 Nova and Geo Prizm ’85 thru ’92 Pick-ups ’67 thru ’87 - Chevrolet

24065

ACURA 12020 12021

Integra '86 thru 89 & Legend ’86 thru ’90 Integra ’90 thru ’93 & Legend '91 thru ’95 24066

AMC 14020

Jeep CJ - see JEEP (50020) Mid-size models ’70 thru ’83

14025

(Renault) Alliance & Encore ’83 thru ’87

AUDI

|

15020

4000 all models ’80 thru ’87

15025 15026

5000 all models ’77 thru ’83 5000 all models ’84 thru '88

AUSTIN-HEALEY Sprite - see MG Midget (66015)

BMW 18020 18021 18022 18025 18050

: 3/5 Series not including diesel or all-wheel drive models ’82 thru ’92 3-Series incl. Z3 models ’92 thru ’98 3-Series, E46 chassis ’99 thru ’05, Z4 mcdels ’03 thru ’05 320i all 4 cyl models ’75 thru ’83 1500 thru 2002 except Turbo ’59 thru ’77

24070 24071 24072

Bravada '02 thru ’06

24075 24080 24081

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) Buick Estate ’70 thru ’90, Electra’70 thru ’84,

10310 25020

25030

DATSUN

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

Astro & GMC Safari Mini-vans ’85 thru ’03

24015 24016

Camaro V8 all models ’70 thru ’81 Camaro all models ’82 thru 92

24017 -

Camaro & Firebird ’93 thru ’02 Cavalier - see GENERAL MOTORS (38016) Celebrity - see GENERAL MOTORS (38005)

24020 24024

Chevelle, Malibu & El Camino ’69 thru ’87 Chevette & Pontiac T1000 ’76 thru ’87

24048

25027

Pontiac Bonneville ’70 thru ’81, Catalina ’70 thru ’81, Grandville ’70 thru ’75, Parisienne ’83 thru ’86 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)

24010

24046

25026

K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030) Chrysler LHS, Concorde, New Yorker, Dodge Intrepid, Eagle Vision, ’93 thru ’97 Chrysler LHS, Concorde, 300M, Dodge Intrepid, ’98 thru ’03 Chrysler 300, Dodge Charger & Magnum 05 thru ’07 Chrysler & Plymouth Mid-size front wheel drive ’82 thru ’95 Rear-wheei Drive - see Dodge (30050) PT Cruiser all models ’01 thru ’03 Chrysler Sebring, Dodge Avenger ’95 thru ’05 Dodge Stratus '01 thru 05

25035 25040

CHEVROLET

24027 24032 24040 24041 10305. 24045

25025

Cirrus, Dodge Stratus, Plymouth Breeze ’95 thru ’00 Chrysler Engine Overhaul Manual Full-size Front-Wheel Drive ’88 thru ’93

LeSabre ’70 thru ’85, Limited ’74 thru ’79 Oldsmobile Custom Cruiser ’70 thru 90, Delta 88 ’70 thru ’85,Ninety-eight ’70 thru ’84

CADILLAC 21030

Sprint ’85 thru ’88 & Geo Metro ’89 thru ’01 Vans - Chevrolet & GMC ’68 thru ’96 Chevrolet Express & GMC Savana Full-size Vans ’96 thru ’05

CHRYSLER 25015 Chrysler

BUICK 19010

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

Citation - see GENERAL MOTORS (38020) Colorado & GMC Canyon ’04 thru ’06 Corsica/Beretta all models ’87 thru ’96 | Corvette all V8 models ’68 thru ’82 Corvette all models '84 thru ’96 Chevrolet Engine Overhaul Manual Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons ’69 thru ’90 Impala SS & Caprice and Buick Roadmaster ’91 thru ’96 Impala - see LUMINA (24048) Lumina ’90 thru ’94 - see GM (38010) Lumina & Monte Carlo ’95 thru ’05 Lumina APV - see GM (38035)

28005 28007 28009 28012 28014 28018 28020 28022 28025

DODGE 30008 30010 30011 30012 30013 30016 30020 30021 30022 30023 30025 30030

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

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

FIAT 34010 34025

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

36074 36075 36078 36082 36086 36090 36094 36097

Intrepid - see CHRYSLER (25025, 25026)

30034 30035 30036 30040 30041 30042 30045

Neon all models 95 thru ’99 Omni & Plymouth Horizon ’78 thru ’90 Dodge and Plymouth Neon ’00 thru’05 Pick-ups all full-size models ’74 thru ‘93 Pick-ups all full-size models ’94 thru ’01 Dodge Full-size Pick-ups ’02 thru ‘05 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups ‘79 thru '93

30050 30055 30060 30065

Dodge/Plymouth/Chrysier RWD ’71 thru ’89 Shadow & Plymouth Sundance ’87 thru ’94 Spirit & Plymouth Acclaim ’89 thru ’95 Vans - Dodge & Plymouth ’71 thru 03

Ford Automatic Transmission Overhaul Aerostar Mini-vans all models ’86 thru ’97 Contour & Mercury Mystique ’95 thru ’00 Courier Pick-up all models ’72 thru ’82 Crown Victoria & Mercury Grand Marquis ’88 thru ’06 : Ford Engine Overhaul Manual Escort/Mercury Lynx all models ’81 thru ’90 Escort/Mercury Tracer ’91 thru ’00 Ford Escape & Mazda Tribute ’01 thru ’03 Explorer & Mazda Navajo ’91 thru ’01 Ford Explorer & Mercury Mountaineer ’02 thru ’06 Fairmont & Mercury Zephyr ’78 thru ’83 Festiva & Aspire ’88 thru ’97 Fiesta all models ’77 thru ‘80 Focus all models ’00 thru ’05 Ford & Mercury Full-size ’75 thru ’87 Ford & Mercury Mid-size '75 thru ’86 Mustang V8 all models *64-1/2 thru ’73

Mustang Il 4 cyl, V6 & V8. models ’74 thru ’78 Mustang Mustang, Mustang Mustang Pick-ups Pick-ups

& Mercury Capri all models ’79 thru ’93; Capri, ’79 thru ’86 all models ’94 thru ’04

’05 thru ’07 & Bronco ’73 thru ’79 & Bronco ’80 thru ’96 F-150 & Expedition ’97 thru ’03, F-250 ’97 thru ’99 & Lincoin Navigator ’98 thru ’02 Super Duty Pick-ups, Excursion ’99 thru '06 F-150 full-size ’04 thru ’06 Pinto & Mercury Bobcat ’75 thru ’80 Probe all models ’89 thru ’92 Ranger/Bronco Il gasoline models ’83 thru ’92 Ranger '93 thru ’05 & Mazda Pick-ups ‘94 thru ’05 Taurus & Mercury Sable ’86 thru ’95 Taurus & Mercury Sable ’96 thru ’05 Tempo & Mercury Topaz ’84 thru ’94 Thunderbird/Mercury Cougar ’83 thru 88 Thunderbird/Mercury Cougar ’89 and ‘97

Vans all V8 Econoline models ’69 thru ’91 Vans full size ’92 thru ’05 Windstar Mini-van '95 thru ’03

GENERAL MOTORS 10360 38005 38010

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 ’05 38015

400 & 600 - see CHRYSLER (25030) Aries & Plymouth Reliant ’81 thru ’89 Caravan & Plymouth Voyager ’84 thru ’95 Caravan & Plymouth Voyager ’96 thru ’02 Challenger/Plymouth Saporro ’78 thru ’83 Caravan, Chrysler Voyager, Town & Country '03 thru ’06 Colt & Plymouth Champ ’78 thru ’87 Dakota Pick-ups ali models ’87 thru ’96 Durango ’98 & ’99, Dakota ’97 thru ‘99 Dodge Durango models ’00 thru ’03 Dodge Dakota models ’00 thru ’04 Dodge Durango '04 thru ’06, Dakota '05 and ’06 Dart, Demon, Plymouth Barracuda, Duster & Valiant 6 cyl models ’67 thru ’76 Daytona & Chrysler Laser ’84 thru ’89

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

Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza &

Pontiac J-2000 & Sunbird ’82 thru '94 38016

38017 38020 38025

Chevrolet Cavalier & Pontiac Sunfire ’95 thru ’04 ‘Chevrolet Cobalt & Pontiac G5 ’05 thru '07

Buick Skylark, Chevrolet Citation, Olds Omega, Pontiac Phoenix ’80 thru ‘85 Buick Skylark & Somerset,

Oldsmobile Achieva & Calais and 38026 38027 38030

Pontiac Grand Am all models ’85 thru ’98 Chevrolet Malibu, Olds Alero & Cutlass, Pontiac Grand Am ’97 thru ’03 Chevrolet Malibu ’04 thru ’07 Cadillac Eldorado ’71 thru ’85,

Seville ’80 thru ’85, Oldsmobile Toronado '71 thru '85, Buick Riviera ’79 thru ’85 Cadillac Eldorado & Seville ’86 thru ’91, DeVille '86 thru ’93, Fleetwood & Olds Toronado '86 thru ’92, Buick Riviera ’86 thru ’93 38032 - Cadillac DeVille '94 thru 05 & Seville ’92 thru '04 38035 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models ’90 thru ’96 38036 Chevrolet Venture, Olds Silhouette, Pontiac Trans Sport & Montana ’97 thru ’05 General Motors Full-size Rear-wheel Drive - see BUICK (19025)

38031

GEO

Metro - see CHEVROLET Sprint (24075) Prizm - '85 thru ’92 see CHEVY (24060), 93 thru ’02 see TOYOTA Corolla (92036)

(Continued on other side)

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

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. 40030

GMC

Storm all models ’90 thru ’93 Tracker - see SUZUKI Samurai (90010)

68030 68031 68035

Eclipse, Eagle Talon & Ply. Laser ’90 thru ’94 Eclipse '95 thru ’01, Eagle Talon ’95 thru ’98 Mitsubishi Galant '94 thru ’03

Vans & Pick-ups - see CHEVROLET

68040

Pick-up ’83 thru ’96 & Montero ’83 thru ’93

NISSAN

HONDA 42010 42011 42012 42013 42014

Accord Accord Accord Accord Accord

CVCC all all models all models all models all models

models ’76 thru ’83 ’84 thru '89 ’90 thru ’93 ’94 thru ’97 ’98 thru 02

42015

Honda Accord models ’03 thru ’05

42020

Civic 1200 all models ’73 thru ’79

42021 42022 42023 42024 42025 42026

Civic 1300 & 1500 CVCC ’80 thru ’83 Civic 1500 CVCC all models ’75 thru '79 Civic all models ’84 thru ’91 Civic & del Sol ’92 thru ’95 Civic ’96 thru 00, CR-V ’97 thru ’01, Acura Integra '94 thru ’00 Civic ’01 thru ’04, CR-V 02 thru ’04

42035 42037 42040

Honda Odyssey all models ’99 thru ’04 Honda Pilot ’03 thru 07, Acura MDX '01 thru '07 Prelude CVCC ali models ’79 thru ’89

72010 72015 72020 72021 72030 72031

300ZX all models including Turbo ’84 thru ’89 Altima all models ’93 thru ’04 Maxima all models ’85 thru ’92 Maxima all models ’93 thru ’04 Pick-ups ’80 thru ’97 Pathfinder ’87 thru 95 Frontier Pick-up '98 thru '04, Xterra ’00 thru

72040

04, Pathfinder ’96 thru ’04 Pulsar all models ’83 thru ’86

72050 72051 72060

Sentra all models ’82 thru ’94 Sentra & 200SX all models ’95 thru ’04 Stanza all models ’82 thru ’90

Quest - see MERCURY Villager (64200)

OLDSMOBILE 73015

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

HYUNDAI

PLYMOUTH

43010 43015

PONTIAC

Elantra all models '96 thru ’01 Excel & Accent all models ’86 thru ’98

ISUZU Hombre - see CHEVROLET S-10 (24071) Rodeo ’91 thru 02; Amigo ’89 thru 94 and ’98 thru '02; Honda Passport ’95 thru ’02 Trooper & Pick-up ’81 thru 93

47017 47020

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 Wagoneer & Pick-up ’72 thru ’91 Grand Wagoneer ’84 thru ’91, Cherokee & Wagoneer ’72 thru ’83, Pick-up ’72 thru ’88 Wrangler all models ’87 thru ’03

50035

Liberty ’02 thru ’04

50020 50025 50029

KIA 54070

Sephia ’94 thru ’01, Spectra ’00 thru '04

LEXUS

ES 300 - see TOYOTA Camry (92007) -

LINCOLN Navigator - see FORD Pick-up (36059) Rear-Wheel Drive all models ’70 thru ’05

59010

61015 61016 61020 _ 61030 61035 61036 61040 61041 61042

GLC Hatchback (rear-wheel drive) ’77 thru83 GLC (front-wheel drive) ’81 thru ’85 323 & Protogé ’90 thru ’00 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 ’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 ’93 thru ’01, MX-6/Ford Probe ’93 thru ’01

MERCEDES-BENZ 63012

123 Series Diesel ’76 thru ’85

63015 63020

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

63025

280 123 Series gasoline models ’77 thru ’81

63030

350 & 450 all models ’71 thru ’80

MERCURY 64200

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

MG 66010

MGB Roadster & GT Coupe ’62 thru ’80

66015

MG Midget, Austin Healey Sprite ’58 thru ’80

MITSUBISHI 68020

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

79019

Firebird all models ’82 thru ’92

79040

Mid-size Rear-wheel Drive ’70 thru ’87 For other PONTIAC titles, see BUICK,

CHEVROLET or GENERAL MOTORS listing.

PORSCHE 80020 80025 80030 80035

Cordia, Tredia, Galant, Precis & Mirage ’83 thru ’93

911 914 924 944

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

RENAULT Alliance & Encore - see AMC (14020)

SAAB 84010

900 all models including Turbo ’79 thru ’88

SATURN 87010 87011 87020

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

SUBARU 89002 89003 89100 89101

1100, 1300, 1400 & 1600 ’71 thru ’79 1600 & 1800 2WD & 4WD’80 thru ’94 Legacy all models ’90 thru ’99 Legacy & Forester ’00 thru ’06

SUZUKI Samurai/Sidekick & Geo Tracker ’86 thru ’01

TOYOTA 92005

Camry all models ’83 thru ’91

92006 92007 92008

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 ’05 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 ’05 Corolla Tercel all models ’80 thru ’82 Corona all models ’74 thru ’82 Cressida all models ’78 thru ’82 Land Cruiser FJ40, 43, 45, 55 ’68 thru ’82 Land Cruiser FJ60, 62, 80, FZJ80 ’80 thru ’96 MR2 all models ’85 thru ’87 Pick-up all models ’69 thru ’78 Pick-up all models ’79 thru ’95 Tacoma 95 thru ’04, 4Runner ’96 thru 02, & T100 '93 thru ’98 Tundra ’00 thru ’05 & Sequoia ’01 thru ’05 Previa all models ’91 thru ’95

92015 92020 92025 92030 92032 92035 92036 92037 92040 92045 92050 92055 92056 92065 92070 92075 92076

92078 92080 92081 92082 92085

92090 92095

94007 94010

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

VW 96008 96009 96016

Beetle & Karmann Ghia ’54 thru ’79 New Beetle ’98 thru ’05 Rabbit, Jetta, Scirocco & Pick-up gas models ’75 thru ’92 & Convertible ’80 thru ’92 Golf, GTI & Jetta 93 thru ’98 & Cabrio ’95 thru ’98 Golf, GTI, Jetta & Cabrio ’99 thru ’02 Rabbit, Jetta & Pick-up diesel ’77 thru ’84

96017 96018 96020 96023 96030 96035 96040 96045

Passat ’98 thru ’01, Audi A4 ’96 thru ’01 Transporter 1600 all models ’68 thru ’79 Transporter 1700, 1800 & 2000 ’72 thru ’79 Type 3 1500 & 1600 all models ’63 thru ’73 Vanagon all air-cooled models ’80 thru ’83

VOLVO 97010 97015 97020 97040 97050

120, 140 240 740 850

130 Series & 1800 Sports ’61 thru ’73 Series all models ’66 thru ’74 Series all models ’76 thru 93 & 760 Series all models ’82 thru ’88 Series all models ’93 thru ’97

TECHBOOK MANUALS

79008 79018

90010

MAZDA 61010 ‘61011

For PLYMOUTH titles, see DODGE listing.

TRIUMPH

Prius all models ’01 thru ’08 RAV4 all models ’96 thru ’05 Tercel all models ’87 thru ’94 Toyota Sienna all models '98 thru '02 Highlander & Lexus RX-330 ’99 thru ’06

10205 10206 10210 10215 10220 10225 10230 10240 10305 10310 10320 10330 10333 10340 10341 10345 10355 10360 10405 10410 10411 10415 10420 10425 10430 10435 10440 10445 10450 10452

Automotive Computer Codes OBD-II & Electronic Engine Management Systems Automotive Emissions Control Manual Fuel Injection Manual, 1978 thru 1985 Fuel Injection Manual, 1986 thru 1999 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 Building Engine Power Manual Small Engine Repair Manual, 5 HP & Léss Small Engine Repair Manual, 5.5 - 20 HP Suspension, Steering & Driveline Manual Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Body Repair & Painting Automotive Brake Manual Automotive Anti-lock Brake (ABS) Systems Automotive Detaiing Manual Automotive Electrical Manual Automotive Heating & Air Conditioning

Automotive Reference Manual & Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual ATV Basics Scooters, Automatic Transmission 50cc to 250cc

SPANISH MANUALS 98903 98904 98905 98910 $8913 98915 99040

99041 99042 99055 99075 99077 99088 99091 99095 99100 99106

Reparaci6n de Carroceria & Pintura Carburadores para los modelos Holley & Rochester Cédigos Automotrices de la Computadora Frenos Automotriz Electricidad Automotriz Inyeccién de Combustible 1986 al 1999 Chevrolet & GMC Camionetas ’67 al ’87 Incluye Suburban, Blazer & Jimmy ’67 al ’91 Chevrolet & GMC Camionetas ’88 al ’98 Incluye Suburban ’92 al ’98, Blazer &

Jimmy ’92 al ’94, Tahoe y Yukon ’95 al ’98 Chevrolet & GMC Camionetas Cerradas ’68 al ’95 Dodge Caravan & Plymouth Voyager ’84 al’95

Ford Camionetas y Bronco ’80 al ’94 Ford Camionetas Cerradas ’69 al ’91 Ford Modelos de Tamafio Mediano ’75 al '86 Ford Taurus & Mercury Sable ’86 al ’95 GM Modelos de Tamajio Grande ’70 al ’90

GM Modelos de Tamafio Mediano ’70 al ’88 Jeep Cherokee, Wagoneer & Comanche * 784 al ’00 Nissan Camioneta ’80 al ’96, Pathfinder ’87 al '95 Nissan Sentra ’82 al ’94 Toyota Camionetas y 4Runner ’79 al ’95 Over 100 Haynes motorcycle manuals also available

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

10-07

—

Common spark plug conditions 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.

Pua 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: 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

air filter or

problem

in the

fuel

correct

plug

heat

range,

over-

advanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling.

PREIGNITION

DEPOSITS

for a clogged

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

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 seals to prevent seep-

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:

\nsulator has yellow-

ish, glazed appearance.

Indicates

that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits

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

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

DETONATION

OIL DEPOSITS

Symptoms: Insulators may be cracked or chipped. Improper gap setting techniques can also result

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

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:

lodge

Combustion

between

the

deposits

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.

Inside this manual: L Maceleliiaromant-liaicsar-laver-) m@ Tune-up procedures

m@ Engine repair | MOrore) Tale p-laremar-r-lil are) L_Wallaeesarelitfelaliare| @ Fuel and exhaust m= Emissions control

L Blefaliareya m= Brakes

| RslUryey-lalyrolam-laremcicci-1alare| m Electrical systems | A iTatale melte\elestaarss

Chapter 2 PartB

3.0L V6 engine

O-Ring i

Distributor rive Adaptor

9.5b An exploded view of the distributor drive adapter assembly

9.52 To remove the distributor drive adapter, remove the distributor hold-down hut (upper arrow), remove the distributor and remove the three adapter retaining bolts (arrows)

e Complete troubleshooting section helps re (=\ah duaves)ef>\eq) (em@)¢0)@)(=\eais 5 To replace the seal on the front camshaft, it's agood idea to replace the O-

prevent damaging thepin. 8 _If you replaced the front cam seal, rein-

tions). Note: /f you ramove the adapter, skip the following Steps describing on-vehicle seal

the pulley with the deep recess must face the

St ak ra agsureude ube pop Ca (see Chapter 5) and the adapter (see Illustrathe R or F mark faces out! The side of

replacement. Pry out the old seal, install a

new seal with the adapter on the bench, reattach the adapter, tighten the bolts securely, and install the distributor.

6

If you're replacing a rear seal or you do

not

want

to remove

the distributor

drive

adapter, drill a couple of small holes in the old seal, thread a pair of sheetmetal screws Into the holes, then carefully remove the old

oil seal with a screwdriver and a claw hammer (see Illustration). Don't nick or scratch

the camshaft in the process.

couple of small holés In thé old seal,

thread a pair of sheetmetal screws into the holes and pry'the seal out with a ug’

Serewdriver and a claw hammer

Step-by-step procedures linked to hundreds of easy-to-follow photos and illustrations

7 There are several ways to install the new seal. Fabricate a seal installation tool as described in Section 8 or use a very large socket with an Inside diameter large enough to clear the nose of the camshaft and carefully drive the seal Into place (see Iilustrations). Remove the sprocket positioning pin from the nose of the cam, if necessary, to

engine, which means the shallow recess must face out. 10 Use your sprocket holding tool to tighten the bolt to the torque in this Chapter's Specifications. 11 Installation of the remaining components is the reverse of removal 10

Rocker arm and hydraulic valve

lash adjusters - check, removal, Inspection, and Installation

Check Refer to illustration 10.1 1 Check the hydraulic lash adjusters tor freeplay by inserting a small wire through the air bleed hole in the rocker arm while lightly pushing the check ball down (see Iilustration).

e Written from hands-on experience based on a vehicle teardown using commonly available tools ®:

=

Haynes tips give valuable short cuts to laats\.¢omdalowm(elom=r-ts)(-1ar-lale me)ilanliareiccmial=mal=\-ve| ice) ans)@\=(e1 =| cele)(3) LaCo)Cex Or TU dCelitme-lilem idaom ale)aatomaaicveiatclalle

Ec laallile Miele

Color spark plug diagnosis 9.7a You can press a new seal into place with a section of pipe and a bolt of the proper size and thread pitch (don’t let the camshaft tun as the bolt Is tightened)

9.7b As a last resort, you can also drive a cam seal into place with a hammer and a large socket, but make sure you don't damage the sprocket positioning pin on the end of the camshaft

10.1. When performing the freeplay test, make sure the adjuster that’s being tested has the corresponding camshaft lobe pointing away from the rocker arm (closed valve)

sxe Ks \VMKOMUIXom [ale l=) ISBN-13: 978-1-56392-661-7

Models covered by this manual: lo)com(Ul) \ elale mpalete (=)33 2005 thru 2007

9"781563"926617

ISBN 1 56392 661 X 799-3182

ABCDEFGHIJKLMNOPQRS

Does not include information specific to SY41-110)" ChKol0/0 Ore) oe Witlele(=15 0

38345

36052