Haynes Ford Ranger & Mazda B-Series Pick-Ups Automotive Repair Manual 1563923203, 9781563923203

Citation preview

RANGER pick-ups 1993 thru 1997

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27.8 An exploded view of the manual locking hub and wheel bearings (4WD models)

1 2 3

Grease seal Wheel bearing cup Brake disc

4 5 6

Inner locknut Washer Axleshaft spacer(s)

7 8 9

Hub Retainer washer Snap-ring

10 17 12

Outer locknut Outer wheel bearing Inner wheel bearing

13

Dust seal

14

Wheel spindle

FOUR-PRONG SPINDLE NUT SPANNER WRENCH

AXLE SHAFT SPACER

27.10 A four-

pronged socket is 27.9 Remove the snap-ring, then the axleshaft spacer(s)

required to remove the outer locknut; the nut is very tight, so don’t use makeshift tools

Chapter

1 Tune-up and routine maintenance

LOCKWASHER

27.16 Align the pin in the locknut with one of the holes in the lockwasher; if necessary, adjust the locknut position slightly to align the pin with a hole

most auto parts stores (see illustration). Note: This nut is very tight. Don’t try to remove it with a makeshift tool. 11. Remove the inner wheel bearing locknut with the spanner wrench. Be sure the notch in the wrench is positioned over the locknut pin. 12 Perform Steps 9 through 20 of Section 26 to repack the bearings. Be sure to use the type of grease listed in this Chapter’s Specifications. 13 Install the inner locknut on the spindle and tighten it to the specified torque (Step 1

in this Chapter’s Specifications). 14 Spin the brake disc several turns in each direction to seat the bearings. 15 Loosen the inner locknut 1/4-turn, then retighten it to the specified torque (Step 3 in this Chapter’s Specifications). 16 Install the lockwasher and align the locknut pin with one of the holes in the lockwasher (see illustration). If necessary, turn the inner locknut slightly to align the hole and pin. 17 Install the outer locknut and tighten it to the specified torque (Step 4 in this Chapter’s Specifications). 18 Lubricate the needle bearing spacer and needle bearing (if equipped) with the same grease used for the wheel bearings. Install them on the spindle.

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27.21 To remove the internal components from a manual locking hub, insert a small screwdriver behind the retaining ring and work it gently out of its groove - DO NOT remove the screw from the plastic dial 19 Install the axleshaft spacer. 20 Install the snap-ring on the spindle. 21 Remove the lock ring that secures the inner components in the locking hub (see illustration). Caution: Don’t remove the screw from the plastic dial. 22 Remove the internal assembly, spring and clutch gear. Lubricate the components with the specified grease. 23 Reassemble the hub and install the lock ring. 24 Install the locking hub on the wheel studs and secure it with the retainer washers. Proceed to Step 35.

Automatic locking hubs Refer to illustrations 27.25a, 27.25b, 27.26,

27.278, 21.21Dy 2(21C, 2028, 2130) 27332} 27.33b and 27.34 25 Using snap-ring pliers, carefully expand the snap-ring just enough to remove it from the end of the spindle shaft (see illustrations). Note: /f you don’t have snap-ring pliers, carefully pry the snap-ring off with a screwdriver. Hold a finger against the snapring as shown in the illustration so the snapring doesn’t fly off.

26 Remove the axleshaft spacer(s) (see illustration). 27 Carefully pull the plastic cam assembly from the wheel bearing adjusting nut (see illustration). Caution: Don’t pry the cam off or you may damage it. If it’s hard to remove, try turning it as you pull. Pull off the two plastic thrust spacers and remove the locking key with a magnet (see illustrations). Note: The thrust spacers are thin and flexible, with a tendency to cock sideways and jam on the spindle. Hook your fingernails behind the spacers and pull evenly at two or more points. If necessary, rotate the adjusting nut slightly to relieve pressure on the locking key. 28 Remove the wheel bearing adjusting nut from the spindle. It may be loose enough to turn with fingers. If not, use a 2-3/8 inch hex socket (see illustration). Caution: Be sure to remove the locking key before you remove the nut or the spindle threads will be damaged. Note: The socket may be 3/4-inch drive. If so, an adapter can be used so the socket can be turned with a 1/2-inch drive tool. 29 Perform

Steps 9 through 20 of Section 26 to repack the wheel bearings. Be sure to use the correct grease (listed in this Chapter’s Specifications). 30 Install the wheel bearing adjusting nut (see illustration). While spinning the brake disc, tighten the nut to the specified torque (Step 1 in this Chapter’s Specifications). 31. Loosen the nut 1/4-turn. 32 Retighten the nut to the final torque (Step 3 in this Chapter’s Specifications). 33 Line up the center of the spindle keyway slot with the closest slot in the wheel bearing adjusting nut (see illustration). If necessary, tighten the adjusting nut so the next slot aligns with the keyway slot. Be sure the slots line up exactly. a) Install the locking key in the keyway slot, under the adjusting nut. Don’t force the key in or it will be damaged. If it is difficult to insert, make sure the slots are lined up exactly.

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27.25a An exploded view of the automatic locking hub and wheel bearings (4WD models)

1 2 3 4

Wheel spindle Grease seal Wheel bearing cup Brake disc

5 6 7 8

Adjusting nut Thrust spacers Retainer Axleshaft spacer

9 10 11.

Hub Retainer washer Axleshaft spacers (later models)

12 13 14 15

Locking key Outer wheel bearing ‘Inner wheel bearing Dust seal

Chapter 1

Tune-up and routine maintenance

27.25b The snap-ring can be lifted off with a screwdriver if snap-ring pliers aren’t available - hold the center of the snap-ring with a finger as

27.27a

1-33

Remove the cam from the spindle

shown so it doesn’t fly off

rN 27.27c Remove the locking key (arrow) with a magnet - don’t try to unscrew the nut before removing the key 27.27b

27.28 On automatic locking hubs, loosen the wheel bearing adjusting nut with a 2-3/8 inch hex locknut wrench

Remove the two plastic thrust spacers

b) Install the two thrust spacers (see illustration 27.27b). c) Line up the key in the fixed cam with the keyway slot in the spindle, then push the cam on over the adjusting nut (see illus-

tration). d) Install the axleshaft spacer. e) Install the snap-ring on the end of the spindle.

34 Line up the three legs on the automatic locking hub with the pockets in the cam (see illustration), then install the locking hub and secure it with the retainer washers.

27.30

Install the wheel bearing adjusting nut

27.33a The adjusting nut has internal slots - line up one of them with the keyway slot

All models 35 Install the wheel and lug nuts. Lower the vehicle and tighten the lug nuts to the torque listed in this Chapter’s Specifications. 36 Check the endplay of the wheel on the spindle and measure the amount of torque required to turn the hub. Compare your findings with this Chapter’s Specifications. If the measurements are incorrect, readjust the wheel bearings.

28

1

Windshield wiper blade check and replacement (every 12,000 miles or 12 months, whichever comes first) Road film can

build up on the wiper

27.33b Position the cam over the wheel bearing adjusting nut - use extreme care to align the key accurately with the slot in the spindle

27.34 Align the legs in the automatic locking hub with the pockets on the cam when installing the hub

1-34

Chapter 1 Tune-up and routine maintenance Ee INSERT SCREWDRIVER 1/8 INCH (3.2mm) OR LESS PAST THE EDGE

FRAME

PRESS DOWN AND IN SCREWDRIVER ELEMENT

28.5a

Squeeze the retaining lever...

blades and affect their efficiency, so they should be washed regularly with a mild detergent solution.

Check 2 The windshield wiper and blade assembly should be inspected periodically. Even if you don’t use your wipers, the sun and elements will dry out the rubber portions, causing them to crack and break apart. If inspection reveals

hardened

or cracked

rubber,

replace the wiper blades. If inspection reveals nothing unusual, wet the windshield, turn the wipers on, allow them to cycle several times,

then shut them off. An uneven wiper pattern across the glass or streaks over clean glass indicate that the blades should be replaced. 3 The operation of the wiper mechanism can loosen the fasteners, so they should be checked and tightened, as necessary, at the same time the wiper blades are checked (see Chapter 12 for further information regarding the wiper mechanism).

Wiper blade replacement Refer to illustrations 28.5a and 28.5b 4 Park the wiper blades in a convenient position to be worked on. To do this, run the wipers, then turn the ignition key to Off when the wiper blades reach the desired position. 5 Lift the blade slightly from the windshield. Squeeze the retaining lever to release the blade (see illustration), unhook the wiper arm from the blade (see illustration) and take the blade off. Caution: Do not press too hard on the spring lock or it will be distorted. 6 Slide the new blade onto the wiper arm hook until the blade locks. Make sure the spring lock secures the blade to the pin.

Wiper element replacement Refer to illustrations 28.7 and 28.10 7 Insert a screwdriver blade between the wiper blade and element (see illustration). Twist the screwdriver clockwise while pressing in and down to separate the element from the end retaining claw. 8 Slide the element out of the remaining retaining claws. 9 Starting at either end of the blade, slide a new element into the second retaining claw (not the one closest to the end of the blade). Slide it through the other retaining claws until

28.5b ... push the wiper blade down the arm to disengage the hook and separate the blade from the arm it reaches the end of the blade. 10 Bend the element and slide it back into the claw at the end of the blade (see illustration).

29

28.7 To remove a wiper element, pry it out of the retaining claw at either

end of the blade

ELEMENT

Cooling system servicing

(draining, flushing and refilling) (every 24,000 miles or 24 months, whichever comes first) Refer to illustration 29.4 Warning: Do not allow antifreeze to come in contact with your skin or painted surfaces of the vehicle. Rinse off spills immediately with plenty of water. Antifreeze is highly toxic if ingested. Never leave antifreeze lying around in an open container or in puddles on the floor; children and pets are attracted by it’s sweet smell and may drink it. Check with local authorities about disposing of used antifreeze. Many communities have collection centers which will see that antifreeze is disposed of safely. 1 Periodically, the cooling system should be drained, flushed and refilled to replenish the antifreeze mixture and prevent formation of rust and corrosion, which can impair the performance of the cooling system and Cause engine damage. When the cooling system is serviced, all hoses and the radiator cap should be checked and replaced if nec-

RETAINING CLAW 28.10

To install an element, slide it into

three of the retaining claws, then bend it back and slide it into the retaining claw at the end of the blade

6 Replace any damaged clamps or hoses (see Chapter 3 for detailed replacement procedures).

Flushing 7 Once the system is completely drained, flush the radiator with fresh water from a garden hose until the water runs clear at the drain. The flushing action of the water will remove sediments from the radiator but will not remove rust and scale from the engine and cooling tube surfaces. 8 These deposits can be removed by the chemical action of a cleaner such as Ford

essary.

Draining 2 Apply the parking brake and block the wheels. If the vehicle has just been driven, wait several hours to allow the engine to coo! down before beginning this procedure. 3 Once the engine is completely cool, remove the radiator cap. 4 Move a large container under the radiator drain to catch the coolant (see illustration). Attach a 3/8-inch diameter hose to the drain fitting to direct the coolant into the container, then open the drain fitting (a pair of pliers may be required to turn it). 5 While the coolant is draining, check the condition of the radiator hoses, heater hoses and clamps (see Section 22 if necessary).

29.4 The radiator drain is located on the bottom of the radiator; connect a length of rubber hose to the drain and let it hang into the drain pan

Chapter 1

30.2a Loosen the clamp (arrow) and disconnect the air outlet tube and hose (4.0L engine shown)

Tune-up and routine maintenance

30.2b

Unplug the electrical connector for the Mass Air Flow sensor (4.0L engine shown)

30.2c Label and disconnect the vacuum lines at the rear of the cover, remove the cover retaining screws and slide the cover

sideways out of the retaining tab slots (4.0L engine shown)

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30.9 On 1995 and later models, unsnap the clip...

Premium Cooling System Flush, or equivalent. Follow the procedure outlined in the manufacturer’s instructions. If the radiator is severely corroded, damaged or leaking, it should be removed (see Chapter 3) and taken to a radiator repair shop.; 9 The heater core should be back-flushed whenever the cooling system is flushed. To do this, disconnect the heater return hose

from the thermostat housing or engine. Slide a female garden hose fitting into the heater hose and secure it with a clamp. This will allow you to attach a garden hose securely. 10 Attach the end of a garden hose to the fitting you installed in the heater hose. 11. Disconnect the heater inlet hose and position it to act as a drain. 12 Turn the water on and off several times to create a surging action through the heater core. Then turn the water on full force and allow it to run for approximately five minutes. 13 Turn off the water and disconnect the garden hose from the female fitting. Remove the fitting from the heater return hose, then reconnect the hoses to the engine. 14 Remove the overflow hose from the coolant recovery reservoir. Drain the reservoir and flush it with clean water, then reconnect the hose.

Refilling 15

Close and tighten the radiator drain.

Install and tighten the block drain plug(s). 16 Place the heater temperature control in the maximum heat position. 17 Slowly add new coolant (a 50/50 mixture of water and antifreeze) to the radiator until it is full. Add coolant to the reservoir up to the lower mark. 18 Leave the radiator cap off and run the engine in a well-ventilated area until the thermostat opens (coolant will begin flowing through the radiator and the upper radiator hose will become hot). 19 Turn the engine off and let it cool. Add more coolant mixture to bring the coolant level back up to the lip on the radiator filler neck. 20 Squeeze the upper radiator hose to expel air, then add more coolant mixture if necessary. Replace the radiator cap. 21 Start the engine, allow it to reach normal operating temperature and check for leaks.

30

Air filter replacement (every 30,000 miles or 30 months, whichever comes first)

should

be replaced

at least every 30,000

miles, even if it looks clean.

1993 and 1994 models Refer to illustrations 30.2a, 30.2b, 30.2c and

30.3 2 Disconnect the PCV hose from the air outlet tube, then disconnect the air outlet tube from the air cleaner cover. Disconnect the electrical connector from the Mass Air Flow (MAF) sensor. Label and disconnect the vacuum lines at the rear of the cover (see illustrations).

3 Remove the cover retaining screws. Disengage the cover tabs from the slots and lift off the cover (see illustration). 4 Lift the element out of the housing. 5 Wipe the inside of the air cleaner housing with a clean cloth. 6

Place the new air filter element

in the

housing. If the element is marked TOP be sure the marked side faces up. if Reinstall the cover and install the screws. 8 Connect the electrical connector, vacuum lines, air outlet tube and PCV hose.

1995 and later models 1 If the vehicle is driven in dust, the filter should be checked every 3,000 miles and replaced if it’s dirty. In any case, the filter

Refer to illustrations 30.9 and 30.10 9 Unsnap the cover retaining clip (see illustration).

Chapter 1

Tune-up and routine maintenance

Oe

= ity pay e =2 NOL

30.10

... remove the cover and pull the element out

10 Detach the cover and pull out the element (see illustration). 11 Wipe the inside of the air cleaner housing with a clean cloth. 12 Place the new air filter element in the housing. 13 Reinstall the cover and secure the clip.

31

Fuel filter replacement (every 30,000 miles or 30 months, whichever comes first)

Refer to illustration 31.1 Warning: Gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don’t smoke or allow open flames or bare light bulbs near the work area, and don’t work in a garage where a natural gas-type appliance (such as a water heater or a clothes dryer) with a pilot light is present. Since gasoline is carcinogenic, wear latex gloves when there’s a possibility of being exposed to fuel, and, if you spill any fuel on your skin, rinse it off immediately with soap and water. Mop up any spills immediately and do not store fuel-soaked rags where they could ignite. When you perform any kind

31.1 The inline fuel filter is mounted in the left frame rail; make sure the fuel line fittings are clean before disconnecting them (see Chapter 4 for disconnection procedures)

of work on the fuel system, wear safety glasses and have a Class B type fire extinguisher on hand. 1 The fuel filter is mounted within the left frame rail (see illustration). Ford states that replacement of the fuel filter at 30,000 miles is recommended, but not required, for California vehicles. 2 Obtain a new fuel filter before starting. Warning: Be sure the new filter is specifically designed for your engine. Fuel injection system filters are built to withstand high pressure, and as a result, often cost more than filters meant for use in carbureted systems. Filters meant for carbureted systems may burst due to the high pressure. Also, be sure the new filter includes replacement hairpin clips (if used). Ford recommends against reusing the clips. Warning: Before removing the fuel filter, the fuel system pressure must be relieved. See Chapter 4. 3 Position the front end of the vehicle higher than the rear to prevent fuel siphoning. Remove the gas cap, then reinstall it after relieving the fuel system pressure. 4 Inspect the hose fittings at both ends of the filter to see if they’re clean. If more than a light coating of dust is present, clean the fit-

tings before proceeding. 5 Disconnect the push-connect fittings from the filter (see Chapter 4). 6 Note which way the arrow on the filter is pointing - the new filter must be installed the same way. Loosen the clamp screw and detach the filter from the bracket. 7 Install the new filter in the bracket with the arrow pointing in the right direction and tighten the clamp screw securely. 8 Carefully connect each fuel line to the filter (see Chapter 4). 9 Start the engine and check for fuel leaks.

32

Driveshaft and driveaxlie yoke lubrication (4€WD models) (every 30,000 miles or 30 months, whichever comes first)

on

At the specified intervals, the slip yokes the driveshafts and the right front

driveaxle

should

be

lubricated

(see

this

Chapter’s Specifications for the correct lubricant). This requires removal of the driveshafts and driveaxle (see Chapter 8 for the procedures).

2A-1

Chapter 2 PartA 2.3L four-cylinder engine Contents Section Auxiliary shaft (1993 and 1994 models) - removal, inspection SIMCOE AN ATHOM se sotonssnceves-n Me tecoscedascesea’asavas ecco ato. Camshaft - removal, inspection and installation ..........0..cccccceeeeeees

Section Front oiliseals:replacement :ai2Ae ees. ee

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Engine ollrandiilterchanigek, aia ake tghtc cs. See Chapter 1 Engine overhaul - general information .................:c0008 See Chapter 2D Engine - removal and installation...............ccc:ccccceeseeeee See Chapter 2D Exhaust manifold - removal and installation .............c:ccc:cccseeeeeeees 11 Flywheel/driveplate - removal and installation ............::cc:ccccseeeeees 1k)

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Chapter 12

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Ignition system circuit (1995-on)

Vacuum controlled by the speed control amplifie.. Servo motor moves the throttle

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Controls speed control operations by applying vacuum to the speed control servo motor through the modulating valve. The speed control module receives VSS signals to calculate proper amount of vacuum to apply to the servo to maintain vehicle set speed.

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Chapter 12

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A small gear-driven permanent magnet signal generator mounted on transmission. Generates signal that is proportional to vehicle speed and sends to system components.

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A combined module and stepper motor which receives inputs from various switches and VSS Maintains vehicle speed by controlling throttle linkage position through an actuator cable.

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Limits speed of Blower Motorso that it operates

12

at LO, MED LO and MED HI speeds.

Heater circuit (without air conditioner) (1993 and 1994 models)

Chassis electrical system

Chapter 12

12-42 HOT a ALL TIMES

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bed

| PANEL

sowen! COMPARTMENT {

oe

{

|

ee

364

SS

eS 12V (RUN)

& BK/LG

————4

Rl

{

BLOWER

t

MOTOR

t { t

ceca

|

es cies cs cae fs ee coe es cect ees eee ees /fem me ame come es cee eis aes, ee es ms ee

371]

PK/W C161 7] BLOWER

() 4

| When energized

directs voltage and

MOTOR

current to the blower motor.

C161

aE

261 § O/BK $114

a8)

“

260 ffR/O

261 O/BK

HOIes

Allows driver to select

Ce) C135M C135F

LO, MED LO, MED HI, § or HI Blower Motor

INSTRUMENT

ead

ILLUMINATION 235 # R/BK

280 8)R/C

C233

fe Provides three levels

. bee

of resistance

—

to control the! speed of the blower

.

752

C134M

YA

eaical

C234 | 3 ASSEMBLY 5

C134F

4 | —_

=

Ps

oe eek

aaa

motor.

LG/w :

res rir Y

as

57 § BK

I

260

R/O

57 g BK

pes

R/O

INSTRUMENT

i

ILLUMINATION

|

@ Gi03 Heater circuit (without air conditioner) (1995-on)

HOT WITH MAIN LIGHT SWITCH IN PARK OR HEAD

HOT IN RUN

7) FUSE

7777 EUSE | PANEL bial bbs [

\ t

eke

BuO.

181

r

[5% 4 |panes 19

}LB/R

Forces air through front A/C-Heater registers.

Pitas

42V (RUN)

261 || O/BK

12V

(WITH MAIN LIGHT SWITCH IN PARK OR HEAD)

Limits speed of Blower Motorso

be Becta at LO, and

MED

HI

Allows driver to select

LO, MEDLO, MED HI, or HI Blower Motor speed.

speeds.

Heater/air conditioner circuit (1993 and 1994 models; part 1 of 2)

ne Pp

1

R/Y|

RY

(START

(B00) ) SWITCH

C210

640

R $240 OSjo 640 aoaa CI36E C136M ae

a

a

a

em

LOCK BRAKE

SYSTEM (RABS)

| mopuLe

ed

monitors

wheel speed with a sensor mounted on rear axle for an impending rear wheel lockup |,

condition during braking. RABS Module will modulate hydraulic pressure to rear brake cylinders

to inhibit

RABS

rear

wheel

Module

ie

3

has

lockup.

| |

§ [-

self—test =

—

‘

q

i

Closes with low fluid level.

SURES }

I eo I

applied to RABS module |,°” I Eas disabling it and lamp will i

ry

When

a

closed,

ground

illuminate.

;

is

beary

519

LG/BK

Avariable reluctance sensor and toothed speed indicator ring are used to determine wheel speed. As ring teeth pass by reluctance sensor, a sine wave signal is generated and sent to RABS mod-

519 |} LG/BK

ee

Bis

LCE

i 519

ce

ule. The frequency of the

LG/BK

sine wave is directly proportional to rotational wheel

e

519 |) LG/BK —_—-

—

sae

519 f} LG/BK

519 [LG/BK

iva! |) | i RR a

| ee DUMP

euteut.

es

BABS CONNECTOR TEST a eee. Uk fd Re I ee ee

:

4

SOLENGIO BUMP SOLENOID Solin

one

tee ee

ge

ISOLATION

STATE Sure

as ge :

ee)

DJFF SPEED

BEAR

:ANTI-LOCK

;

:

WARNE RESET NPUT | (RABS)

C238 | ad te 664 ¥ Y/LG

© s204

599 ffPK/LG

535 ffLB/R

664 PACT

ta.

-

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C201F -

una. =

2

C201M LB/R

ql

PF ff fF ff fF —7 | 7

Peete

ed

ay

@ S118 1 Sh!

@ cio1

Contains solenoid control valves that modulate brake fluid level pressure to the rear wheels. Controlled by the

RABS module

ER

Rear Anti-lock Brake System (RABS) (1996 model shown; others similar; part 2 of 2)

12

Chapter 12 Chassis electrical system 12-46 nT {5

3%

{

15A,

Pies

Directs power to 4WABS system related components.

BRAKE

154

iBOX #3

42V (BRAKE ON/OFF SWITCH CLOSED)

-

ey . RELAY COIL (~) Levee {

(aWABS) — J MAIN RELAY 4|

(eee ee

5118

ache eateps gaunt

| enon recep

eee ae ee

2

ox

EERE

~~~

535 & LB/R

§

47

836 |)O/W ee

or]

=———

C1007F

—

Y

2

O/BK

cack C201M

be engaged

Provides 4WABS Module with deceleration G—Force information. 4WABS Module uses this information to select anti-lock control depending upon road conditions as well as providing necessary information) for Ans fo 2 perfonmlin AWD.

8878

aoe

TO S132 BK

|| BRAKE ANTI-LOCK

——

886 |)O/BK

‘

|

| Re

=

Monitors the Brake On/ |e Off Switch and system speed sensors to determine when the 4WABS system should

l

ET

5102 LG

é g Switch#2 G-SwiTcH#1 G-swirch status See ees |(4WABS) q

@ sias

1

Signals 4WABS Module that braking condition is 4 about to occur.

BOO SWITCH FEED

Soup state

a)

57

I |

a

:

599

57)

511 imo

ENGINE CONTROLS

Mi2vpun)

Palast

=!

system

LG/R

511

LB/PK i

eile | ANTI-LOCK

|

c2i0 YT.

oe

wa WHEEL meRELAY

| Fuse

Era

10

12V (RUN)

4WABS

HOT AT ALL TIMES

HOT IN RUN

HOT AT ALL TIMES

olo/w

en 599

BMPK/LG

=

274

& BK/W

— x

18 ———

S

ace ACCELERATION SENSOR

4-Wheel Anti-lock Brake System (4WABS) (part 1 of 3)

aWABS TO 4WABS Hie wiABS

RELAY | COMPARTMENT conen

DIODE

&

2003

534 |} Y/LG 12V

4WHEELANTI.

499 ) GY/BK 510 {} T/R

498

—.

When energized, directs voltage to 4WABS pump motor.

SYSTEM (4WABS) MODULE

Contains 3 sets ofsolenoid control valves. Provides brake fluid level pressure as controlled by 4WABS control module.

2

aNo

When energized, pumps high pressure fluid into master cylinder causing brake pedal to be forced up. Pump motor speed sensor also provides feedback signal to 4WABS module. Bs ee es es Ee ee

Gio@ 48

BELAY

4-Wheel Anti-lock Brake System (4WABS) (part 2 of 3)

Chapter 12

12-47

Chassis electrical system

A variable reluctance sensor and toothed speed indicator ring used to determine wheel speed. Asring teeth pass by reluctance sensor, a pulsing voltage signalisgenerated and sent to 4WABS module, Voltage pulses are directly proportional to rotational

HOT IN START OR RUN

4WABS

esol] rv

516}

Y/BK

521} S14

T/0

Y/R

Avariable reluctance sensor and toothed speed indicator ring used to determine axle speed. As

ring teeth pass by reluctance sensor, a pulsing voltage signalis generated and sent to 4WABS module. Voltage pulses are directly proportionalto rotational axle speed.

519%

LG/BK

C1010

REAR AXLE SENSOR

4-Wheel Anti-lock Brake System (4WABS) (part 3 of 3)

HOT AT ALL TIMES

Directs current to sound high and low pitch horns.

Rene |

1 i

meen enon | SPEED suP | CONTROL RING SPEED CONTROL HORN

DB 12

12V

(WITH HORN SWITCH

DEPRESSED)

(WITH HORN SWITCH C1021

LEFT

©1020

C188

DEPRESSED)

RIGHT

Horn wiring diagram (1993 and 1994 models)

a

12

12-48 SS

Chapter 12 Chassis electrical system eS ————E—E———eeee——

ES

HOT WITH MAIN LIGHT SWITCH IN PARK OR HEAD

HOT AT ALL TIMES

FT

7

FUSE

{3° | PANEL by35) tL—d

19 | La/A @ $212 12v

tr

MULTI-FUNCTION

tacts close and current|

WITH MAIN LIGHT

SWiFGH iN PARK

OR HEAD

+19 N LER

flows through heating

40

{ SWITCH

|

566 § DG

**

When depressed, con-| element to ground.

|

CIGAR | HGHTER

——

*

as

POWER DISTRIBUTION

WITH LIGHT ONLY

GROUP

ov Ww C271 57 &# BK

@ $201 aye | BK

@ G201 Cigarette lighter wiring diagram (1993 and 1994 models)

| scheme’

po. H

spatretrems-e tmentamnninemaien tacit ameter

eee

eee AoneR

a | a60 nyie

| ENGINE

j COMPARTMENT Y j FUSEIRELABOX

:

20A.

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| PANEL

.

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|

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ers ame

4

{

|

|

|

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LB

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ENGINE

power | COMPARTMENT

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sire C134M

pel

C135M

rv

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CIGAR

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C134F

Se

efyic

# BK/PK

iavk C235 i AUXILIARY : POWER SOCKET

LIGHTER

Sen

REMOTE

Vice

CONTROL

12V (RELAY)

ene

LOCK SYSTEM

aren

C125 contro: |WHEEL | ASSEMBLY

When depressed, con» tacts close and current flows through heating element to ground. |slountenieeemntenntente

Horn and cigarette lighter wiring diagram (1995-on)

ENERGIZED)

1

fil ne PITCH HORN ioe

Chapter 12

Chassis electrical system

12-49

Allows driverto selectwasher, LO. | HI or Interval wiper functions.

INTERVAL ADJUST (VARIABLE RESISTOR)

GOVERNOR

(WIPER/WASHER)

ELECTRONIC SWITCH

C208

Receives signal from multi-function switch to control wiper and washer

941)

B/W

motor functions

C1011

ee

WINDSHIELD

| When Pump

[S]—

C1011

activated sprays

the

washer

solvent onto windshield

57 § BK

Wf ov

C208

© s203

@ S201

57 ! BK

57 1 BK

I

I

a

G202

£

G201

:

. Operates at LO or HI speeds and contains a switch that allows the wiper motor to perform-parking operations.

Windshield wipers and washers wiring diagram (1993 and 1994 models)

HOT IN ACC OR RUN

dota amenaae eat evoeea NTT

|

$143

Receives input from

GEM to operate wipers

"6 |FUSE

ff

at desired speed.

et ae

a

s

Windshield wipers and washers wiring diagram (1995-on; part 1 of 2)

{(cT™)

Chapter 12

12-50

Chassis electrical system HOT IN ACC OR RUN

6848

PK/Y

3598

GY/R

680 § LB/O

W/ ELECTRONIC SHIFT CONTROL ONLY

Controlled through GEM. Energized when multi-function switch for wash is activated.

WINDSHIELD _

Windshield wipers and washers wiring diagram (1995-on; part 2 of 2)

—

IND-1

index A

Axle assembly, removal and installation

front (4WD models), 8-13

About this manual, 0-2 Acknowledgements, 0-2 Air cleaner housing, removal and installation, 4-6 Air conditioning system accumulator, removal and installation, 3-11 check and maintenance, 3-9

rear, 8-10

Axleshaft and joint assemblies (front), removal, component replacement and installation, 8-14 Axleshafts, bearings and oil seals (rear), removal and installation, 8-11

compressor, removal and installation, 3-10 condenser, removal and installation, 3-11 evaporator, replacement, 3-12 Air filter replacement, 1-35

Airbag, general information, 12-21 Alternator, removal and installation, 5-10 Antifreeze/coolant, general information, 3-2 Anti-lock Brake System (ABS) brake control module, 9-6 diagnosis and repair, 9-6 exciter ring, 9-5 Four-wheel Anti-lock Brake System (4WABS), 9-5 general information, 9-3

Rear-wheel Anti-lock Brake System (RABS), 9-3 relays, 9-6 speed sensor, 9-5 wheel sensors, 9-5 Automatic transmission, 7B-1 through 7B-6

diagnosis, general, 7B-1 extension housing oil seal, replacement, 7B-3 fluid and filter change, 1-12 level check/change, 1-12 general information, 7B-1 kickdown cable adjustment, 7B-3 replacement, 7B-3 mount, check and replacement, 7B-6

neutral start switch, removal, installation and adjustment, 7B-5 removal and installation, 7B-4 shift cable adjustment, 7B-2 replacement, 7B-2

shift linkage lubrication, 1-21 vacuum diaphragm, removal and installation, 7B-5 Automotive chemicals and lubricants, 0-14 Axle

arm, pivot pivot rear,

front, removal and installation, 10-8 bracket, removal and installation, 10-10 bushing, removal and installation, 10-9 description and check, 8-9

B Balljoints, removal and installation, 10-5 Battery cables, check and replacement, 5-2

check, maintenance and charging, 1-16 removal and installation, 5-2 Body, 11-1 through 11-14 general information, 11-1 maintenance, 11-1

repair major damage, 11-5 minor damage, 11-4 Booster battery (jump) starting, 0-13 Brake light switch, removal and installation, 9-20 Brake On/Off (BOO) switch, 6-13 Brakes, 9-1 through 9-20 Anti-lock Brake System (ABS), general information, 9-3 brake control module, 9-6 brake disc, inspection, removal and installation, 9-10 caliper, removal, overhaul and installation, 9-8 general information, 9-2

hoses and lines, inspection and replacement, 9-16 hydraulic system, bleeding, 9-17 master cylinder, removal, overhaul and installation, 9-15 pads, replacement, 9-6 parking adjustment, 9-18 cables, replacement, 9-18 power brake booster, check, removal, installation and adjustment, 9-18 shoes (rear), replacement, 9-10 system check, 1-28 wheel cylinder, removal, overhaul and installation, 9-14 Bulb replacement, 12-14 Bumper and valance, front, removal and installation, 11-9 rear, removal and installation, 11-10 Buying parts, 0-6

IND

IND-2

Camshaft position sensor, 6-11 lifters and bearings, inspection and replacement, 2D-18 Catalytic converter, 6-18 Center bearing, replacement, 8-9 Charging system check, 5-9

Index

Diagnostic systems, general information, 6-2 Diagnostic Trouble Codes (EEC-IV, 1993 and 1994 models), 6-5 Differential lubricant level check and change, 1-23 Distributor removal and installation, 5-4 stator assembly, check and replacement, 5-5 Door

general information and precautions, 5-8 Chassis electrical system, 12-1 through 12-50 Chassis lubrication, 1-22

hinge, removal and installation, 11-6

Circuit breakers, general information, 12-7

lock system, power, description and check, 12-21 trim panel and watershield, removal and installation, 11-8

Clutch and drivetrain, 8-1 through 8-16 Clutch clutch/starter interlock switch, removal and installation, 8-6 components, removal, inspection and installation, 8-3

hydraulic line quick-disconnect fittings, general information, 8-4 hydraulic system, bleeding, 8-6 master cylinder and reservoir, removal and installation, 8-5 pedal, removal and installation, 8-6

latch striker, removal, installation and adjustment, 11-6 lock cylinder, removal and installation, 11-7

removal, installation and alignment, 11-6

window glass, front, replacement and adjustment, 11-8 window regulator, front, replacement, 11-9 Drag link, removal and installation, 10-15 Drivebelt check, adjustment and replacement, 1-14 Driveshaft and driveaxle yoke lubrication (4WD models), 1-36 and universal joints, description and check, 8-7 removal and installation, 8-7

release bearing, removal, inspection and installation, 8-5 release cylinder, removal and installation, 8-5

description and check, 8-2 Coil spring, removal and installation, 10-7 Connecting rod, steering, removal and installation, 10-15

Connectors, general information, 12-2 Console, removal and installation, 11-11 Conversion factors, 0-15 Coolant reservoir, removal and installation, 3-5

temperature sending unit, check and replacement, 3-5 Cooling and heating systems antifreeze/coolant, general information, 3-2

coolant reservoir, removal and installation, 3-5 coolant temperature sending unit, check and replacement, 3-5 cooling fan and viscous clutch, inspection, removal and installation, 3-4

heater and air conditioning control assembly, removal and installation, 3-7 blower motor and circuit, check and replacement, 3-8 control cables, check and adjustment, 3-7 core, replacement, 3-8 general information, 3-6 radiator, removal and installation, 3-3 system check, 1-26 servicing, 1-34 thermostat, check and replacement, 3-2

water pump, check and replacement, 3-6 Cooling, heating and air conditioning systems, 3-1 through 3-12 Crankshaft position sensor, 5-4, 6-13 inspection, 2D-17

installation and main bearing oil clearance check, 2D-20 removal, 2D-13 Cruise control system, description and check, 12-21 Cylinder compression check, 2D-7 head cleaning and inspection, 2D-10 disassembly, 2D-10 reassembly, 2D-12 removal and installation 2.3L four-cylinder engine, 2A-9 3.0L V6 engine, 2B-7 4.0L V6 engine, 2C-9

honing, 2D-15

E Electrical troubleshooting, general information, 12-1 Electronic Engine Control (EEC-IV, EEC-V) system and trouble codes, 6-2

Electronic shift control module, removal and installation, 7C-3 removal and installation, 7C-2 Emissions control systems, 6-1 through 6-18 catalytic converter, 6-18

diagnostic systems, general information, 6-2 Electronic Engine Control (EEC-IV, EEC-V) system and trouble codes, 6-2 Evaporative Emissions Control System (EECS), 6-15 Exhaust Gas Recirculation (EGR) system, 6-14 general information, 6-1 information sensors, 6-7 inlet air temperature control system (1993 and 1994 models), 6-17 Positive Crankcase Ventilation (PCV) system, 6-16 Powertrain Control Module (PCM), 6-7 Engine 2.3L four-cylinder engine auxiliary shaft (1993 and 1994 models), removal, inspection and installation, 2A-7 camshaft, removal, inspection and installation, 2A-6 cylinder head, removal and installation, 2A-9 exhaust manifold, removal and installation, 2A-8

flywheel/driveplate, removal and installation, 2A-11 front oil seals, replacement, 2A-7 general.information, 2A-2 intake manifold, removal and installation, 2A-8 mounts, removal and installation, 2A-12 oil pan, removal and installation, 2A-10 oil pump, removal and installation, 2A-10 rear main oil seal, replacement, 2A-12

repair operations possible with the engine in the vehicle, 2A-2 timing belt, removal and installation, 2A-4 Top Dead Center (TDC) for number one piston, locating, 2A-2 valve cover, removal and installation, 2A-3 valve train components, removal and installation, 2A-3 3.0L V6 engine, 2B-1 through 2B-12 camshaft, removal, inspection and installation, 2B-11 crankshaft front oil seal, replacement, 2B-8 cylinder heads, removal and installation, 2B-7

IND-3

Index SS SSS SSS SSS SSS SSS

exhaust manifolds, removal and installation, 2B-6 general information, 2B-2 intake manifold, removal and installation, 2B-5 mounts, removal and installation, 2B-12 oil pan, removal and installation, 2B-11 oil pump and pick-up, removal and installation, 2B-12 rear main oil seal, replacement, 2B-12 repair operations possible with the engine in the vehicle, 2B-2 rocker arms and pushrods, removal, inspection and installation, 2B-3 timing chain and sprockets, check, removal and installation, 2B-9

timing chain cover, removal and installation, 2B-8 Top Dead Center (TDC) for number one piston, locating, 2B-2 valve covers, removal and installation, 2B-3 valve lifters, removal, inspection and installation, 2B-10 valve springs, retainers and seals, replacement, 2B-4 4.0L V6 engine, 2C-1 through 2C-18

2WD models, 7A-4 4WD models, 7B-3

Fender, front, removal and installation, 11-11

Ss

lS

SSS

Fluid level checks, 1-7 brake and clutch fluid, 1-8 engine coolant, 1-8 engine oil, 1-7 windshield washer fluid, 1-9

Four wheel Anti-lock Brake System (4WABS), 9-5 Front end alignment, general information, 10-20 Front hub lock, spindle bearing and wheel bearing maintenance (4WD models), 1-31 Fuel and exhaust systems, 4-1 through 4-12 Fuel filter replacement, 1-36 Fuel system accelerator cable, removal and installation, 4-7 check, 1-25

electronic fuel injection system, component check and replacement, 4-8 electronic fuel injection system, general checks, 4-8 fuel

camshaft, removal, inspection and installation, 2C-14

crankshaft oil seals replacement, 2C-17 pulley and front oil seal, removal and installation, 2C-10 cylinder heads, removal and installation, 2C-9 exhaust manifolds, removal and installation, 2C-8 flywheel/driveplate, removal and installation, 2C-17 general information, 2C-2 intake manifold, removal and installation, 2C-7 mounts, check and replacement, 2C-18 oil pan and baffle, removal and installation, 2C-15 oil pump, removal and installation, 2C-16 repair operations possible with the engine in the vehicle, 2C-2 rocker arms and pushrods, removal, inspection and installation, 2C-5 timing chain and sprockets, inspection, removal and installation, 2C-11 timing chain cover, removal and installation, 2C-11 Top Dead Center (TDC) for number one piston, locating, 2C-2 valve covers, removal and installation, 2C-3 valve lifters, removal, inspection and installation, 2C-13 valve springs, retainers and seals, replacement, 2C-6 general overhaul procedures block cleaning, 2D-14 inspection, 2D-14 general information, 2D-6 oil and filter change, 1-10 overhaul disassembly sequence, 2D-9 general information, 2D-6 reassembly sequence, 2D-19 rebuilding alternatives, 2D-7 removal, methods and precautions, 2D-7 removal and installation, 2D-8 Engine Coolant Temperature (ECT) sensor, 6-7 Engine electrical systems, 5-1 through 5-12 Evaporative Emissions Control System (EECS), 6-15 Exciter ring, 9-5 Exhaust Gas Recirculation (EGR) system, 6-14 Exhaust system air cleaner housing, removal and installation, 4-6 check, 1-26 service, general information, 4-12 Extension housing oil seal, replacement

SSS

level sending unit, check and replacement, 4-6 lines and fittings, general information, 4-2

pressure relief procedure, 4-2 pump, removal and installation, 4-5

pump/fuel pressure, check, 4-4 tank cleaning and repair, 4-5 removal and installation, 4-4 Fuses, general information, 12-2 Fusible links, general information, 12-7

G Gauges, replacement, 12-18 General engine overhaul procedures, 2D-1 through 2D-24 Glove box, removal and installation, 11-14

H Headlight adjusting, 12-13 bulb and housing, replacement, 12-13 switch, replacement, 12-12 Heater and air conditioning control assembly, removal and installation, 3-7 blower motor and circuit, check and replacement, 3-8 control cables, check and adjustment, 3-7 core, replacement, 3-8 general information, 3-6 Hinges and locks, maintenance, 11-5

Hood latch control cable, removal and installation, 11-5 removal, installation and adjustment, 11-5 Horn, check and replacement, 12-11

Idle Air Control (IAC) solenoid, 6-11 Ignition coil, check, removal and installation, 5-3 module, check, removal and installation, 5-6 switch/key lock cylinder, check and replacement, 12-8 system check, 5-2 general information, 5-2 timing procedure, 5-8

am IND

IND-4

Index

a

Information sensors, 6-7

Brake On/Off (BOO) switch, 6-13 camshaft position sensor, 6-11 crankshaft position sensor, 6-13

Engine Coolant Temperature (ECT) sensor, 6-7 Idle Air Control (IAC) solenoid, 6-11 Intake Air Temperature (IAT) Sensor, 6-10 Mass Airflow Sensor (MAF), 6-9 oxygen sensor, 6-7 power steering pressure switch, 6-11 Throttle Position Sensor (TPS), 6-8

Vehicle Speed Sensor (VSS), 6-9 Initial start-up and break-in after overhaul, 2D-23 Inlet air temperature control system (1993 and 1994 models), 6-17 Inner door handle and latch assembly, removal and installation, 11-7 Instrument cluster bezel, removal and installation, 11-12 cluster, removal and installation, 12-17

Instrument panel, removal and installation, 11-13 intake Air Temperature (IAT) Sensor, 6-10

Introduction to the Ford Ranger/Mazda B-series pick-ups, 1-7

O Outer door handle, removal and installation, 11-7 Output shaft oil seal, front, removal and installation, 7C-3 Oxygen sensor, 6-7

p Parking brake adjustment, 9-18 cables, replacement, 9-18 check, 1-29 Pilot bearing, inspection and replacement, 8-4 Piston rings, installation, 2D-19

Pistons/connecting rods inspection, 2D-16 installation and rod bearing oil clearance check, 2D-21 removal, 2D-12

Positive Crankcase Ventilation (PCV) system, 6-16 Power brake booster, check, removal, installation and adjustment, 9-18 Power steering fluid level check, 1-11

J

line quick-disconnect fittings, 10-18 pressure switch, 6-11 pump, removal and installation, 10-17

Jacking and towing, 0-12

system, bleeding, 10-19

Powertrain Control Module (PCM), 6-7

K Kickdown cable adjustment, 7B-3 replacement, 7B-3

E

R Radiator grille, removal and installation, 11-10 removal and installation, 3-3 Radio antenna, removal and installation, 12-16

Leaf Spring, removal and installation, 10-12 Linkage adjustment, manual shift transfer case, 7C-1

removal and installation, 12-15 Radius arm insulators, replacement, 10-8 removal and installation, 10-8

Rear Wheel Anti-lock Brake System (RABS), 9-3

M Main and connecting rod bearings, inspection, 2D-17 Maintenance schedule, 1-6 Maintenance techniques, tools and working facilities, 0-6 Manual transmission, 7A-1 through 7A-4 extension housing oil seal (2WD models), replacement, 7A-4 general information, 7A-2 lubricant level check and change, 1-23 removal and installation, 7A-3 shift lever, removal and installation, 7A-2 speedometer pinion gear and seal, removal and installation, 7A-3 transmission overhaul, general information, 7A-4 Mass Airflow Sensor (MAF), 6-9 Master cylinder, removal, overhaul and installation, 9-15

Mirrors exterior, removal and installation, 11-14

power, check, removal and installation, 12-20

N Neutral start switch, removal, installation and adjustment, 7B-5

S Safety checks, 1-10 Safety first!, 0-16 Seat belt check, 11-14 Seats, removal and installation, 11-14 Shift cable adjustment, 7B-2 replacement, 7B-2 Shift lever, removal and installation, 7A-2 Shock absorbers, inspection, removal and installation front, 10-3 rear, 10-12 Slip yoke (right) and stub shaft assembly, carrier, carrier oil seals

and bearings, removal and installation, 8-15 Spark plugs, wires, distributor cap and rotor check and replacement, 1-17 Speakers, removal and installation, 12-16 Speed sensor, 9-5 Speedometer cable, replacement, 12-19

pinion gear and seal, removal and installation, 7A-3

Index

IND-5

NN

Stabilizer bar front, removal and installation, 10-11 bar, rear, removal and installation, 10-12

Transfer case, 7C-1 through 7C-6 electronic shift control module, removal and installation, 7C-3

Starter motor and circuit, in-vehicle check, 5-11 removal and installation, 5-12

removal and installation, 7C-2 front output shaft oil seal, removal and installation, 7C-3

general information, 7C-1 linkage adjustment, manual shift transfer case, 7C-1 lubricant level check and change, 1-24

relay, removal and installation, 5-12

Starting system, general information, 5-11

overhaul, general information, 7C-5 rear output shaft oil seal, removal and installation, 7C-3

Steering system and suspension check, 1-27 column cover and shroud, removal and installation, 11-12 column switches, replacement, 12-8 connecting rod, removal and installation, 10-15

drag link, removal and installation, 10-15 front end alignment, general information, 10-20 gear, removal and installation, 10-16 general information, 10-13 power steering line quick disconnect fittings, 10-18 pump, removal and installation, 10-17 system, bleeding, 10-19 steering gear, removal and installation, 10-16 steering wheel, removal and installation, 10-14 tie-rod ends, removal and installation, 10-16 wheel, removal and installation, 10-14 wheels and tires, general information, 10-19 Suspension and steering systems, 10-1 through 10-20

Suspension system axle arm, front, removal and installation, 10-8 pivot bracket, removal and installation, 10-10 pivot bushing, removal and installation, 10-9 balljoints, removal and installation, 10-5 coil spring, removal and installation, 10-7 leaf spring, removal and installation, 10-12

removal and installation, 7C-4 shift lever, removal and installation, 7C-2 Transmission mount, check and replacement, 7A-2 Transmission overhaul, general information, 7A-4

Troubleshooting, 0-17 Tune-up and routine maintenance, 1-1 through 1-36

general information, 1-7 Turn signal/hazard flasher relay, replacement, 12-8

U Underhood hose check and replacement, 1-13 Universal joints, replacement, 8-8 Upholstery and carpets, maintenance, 11-4

V Vacuum diaphragm, removal and installation, 7B-5 Valves, servicing, 2D-12 Vehicle identification numbers, 0-5

Vehicle Speed Sensor (VSS), 6-9 Vinyl trim, maintenance, 11-1

Voltage regulator/alternator brushes, replacement, 5-11

radius arm insulators, replacement, 10-8 removal and installation, 10-8 shock absorbers front, inspection, removal and installation, 10-3 rear, inspection, removal and installation, 10-12

stabilizer bar front, removal and installation, 10-11 rear, removal and installation, 10-12 wheel spindle, front, removal and installation, 10-4

+: Thermostat, check and replacement, 3-2

Throttle Position Sensor (TPS), 6-8 Tie-rod ends, removal and installation, 10-16 Tire and tire pressure checks, 1-9 Tire rotation, 1-13 Tools, 0-8

W Water pump, check and replacement, 3-6 Wheel bearing (front) check, repack and adjustment (2WD models), 1-29 cylinder, removal, overhaul and installation, 9-14 sensors, 9-5 spindle, front, removal and installation, 10-4 Wheels and tires, general information, 10-19 Window, power system, description and check, 12-19

Windshield and fixed glass, removal and installation, 11-11 wiper arm, removal and installation, 12-11 blade check and replacement, 1-33 motor, removal and installation, 12-11 Wiring diagrams, general information, 12-22 Working facilities, 0-11

ee pe

ShSSN =

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

Integra '86 thru '89 & Legend '86 thru '90

*12020

AMC Jeep CJ - see JEEP (50020) Concord/Homet/Gremlin/Spirit '70 thru '83 (Renault) Alliance & Encore '83 thru '87

14020 14025

15020 15025 15026

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

*30030

AUSTIN Healey Sprite - see MG Midget (66015)

BMW 3/5 Series '82 thru '92

“18020 *18021 18025 18035 18050

3 Series except 325iX models '92 thru '97

320i all 4 cyl models ’75 thru '83 528i & 530i all models ’75 thru '80 1500 thru 2002 except Turbo ’59 thru '77

BUICK Century (FWD) - see GM (38005) *19020

*30008 30010 *30011 30012

30016 *30020 30025

AUDI

*30034 *30035 30040 *30041 *30045

30050 *30055 *30060 *30065

19025

19030

CADILLAC Cadillac Rear Wheel Drive ’70 thru ’93

*21030

Cimarron, Eldorado & Seville - see

GM (38015, 38030)

Chevrolet Engine Overhaul Manual Astro & GMC Safari Mini-vans '85 thru '93 Camaro V8 all models '70 thru '81 Camaro all models '82 thru ’92 Cavalier - see GM (38015) Celebrity - see GM (38005) Camaro & Firebird ‘93 thru ‘97

24017 24020 24024

34010 34025 10355 10320 *36004 *36006 36008 36012 36016 *36020 *36024 36028 36030 36032 36036

36040 36044

*24070 24071 *24075 *24080

CHRYS 10310 *25015

LER Chrysler Engine Overhaul Manual Chrysler Cirrus, Dodge Stratus,

*38010

*25020

Full-size Front-Wheel Drive '88 thru '93 K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030)

24048 24050 24055 24059 *24060 24064 *24065

Plymouth Breeze, ‘95 thru ‘98

25025

Chrysler LHS, Concorde & New Yorker, Dodge Intrepid, Eagle Vision, ‘93 thru ‘97 Chrysler/Plym. Mid-size ’82 thru '95 Rear-wheel Drive - see DODGE (30050)

*25030

DATSUN

28016 28018 28020 28022

28025

200SxX all models '80 thru '83 B-210 all models '73 thru '78 210 all models '78 thru '82 240Z, 260Z & 280Z Coupe '70 thru ’78 280ZX Coupe & 2+2 '79 thru '83 300ZX - see NISSAN (72010) 310 all models '78 thru '82 510 & PL521 Pick-up ’68 thru '73 510 all models '78 thru '81 620 Series Pick-up all models '73 thru '79 720 Series Pick-up - NISSAN (72030) 810/Maxima all gas models, '77 thru ’84

Vans & Pick-ups - see CHEVROLET

HONDA 42010 42011 42012 *42013 42020 42021 42022 42023 42024 *42040

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

Ford LTD Crown Victoria & Mercury Gran Marquis (’83 thru ’87) Granada & Mercury Monarch '75 thru ’80 Ford & Mercury Mid-size, Ford Thunderbird & Mercury Cougar ('75 thru *82); Ford LTD & Mercury Marquis (83 thru ’86); Ford Torino,Gran Torino, Elite, Ranchero

36048 36049 36050 *36051 36054 *36058 *36059

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

pick-up, LTD II, Mercury Montego, Comet, XR-7 & Lincoln Versailles ('75 thru '86) Mustang V8 all models '64-1/2 thru '73 Mustang Il 4 cyl, V6 & V8 '74 thru '78 Mustang & Mercury Capri incl. Turbo Mustang, ’79 thru ’93; Capri, 79 thru ’86 Mustang all models '94 thru '97 Pick-ups and Bronco '73 thru '79

Pick-ups and Bronco ’80 thru '96 Pick-ups, Expedition & Lincoln Navigator '97 thru '98 Pinto & Mercury Bobcat '75 thru ’80 Probe all models '89 thru '92 Ranger/Bronco Il gas models '83 thru '92 Ford Ranger ‘93 thru ‘97 & Mazda Pick-ups ‘94 thru ‘97 Taurus & Mercury Sable ’86 thru '95 Taurus & Mercury Sable '96 thru '98 Tempo & Mercury Topaz '84 thru '94 Thunderbird/Mercury Cougar '83 thru '88 Thunderbird/Mercury Cougar '89 and '97 Vans all V8 Econoline models '69 thru '91 Vans full size '92 thru '95 Windstar Mini-van '95 thru '98

GENERAL MOTORS *10360 *38005

*38015 "38016 38020 38025 38030 "38035

GM Automatic Transmission Overhaul Buick Century, Chevrolet Celebrity, Olds Cutlass Ciera & Pontiac 6000 all models '82 thru '96 Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme & Pontiac Grand Prix front wheel drive '88 thru '95 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza Pontiac J-2000 & Sunbird '82 thru '94 Chevrolet Cavalier & Pontiac Sunfire '95 thru '98 Buick Skylark, Chevrolet Citation, Olds Omega, Pontiac Phoenix '80 thru '85

Buick Skylark & Somerset, Olds Achieva, Calais & Pontiac Grand Am '85 thru '95 Cadillac Eldorado & Oldsmobile Toronado '71 thru '85, Seville '80 thru '85, Buick Riviera '79 thru '85 Chevrolet Lumina APV, Oldsmobile Silhouette & Pontiac Trans Sport '90 thru '95 General Motors Full-size Rear-wheel Drive - see BUICK (19025)

GEO

*40030

Metro - see CHEVROLET Sprint (24075) Prizm - see CHEVROLET (24060) or TOYOTA (92036) Storm all models '90 thru '93 Tracker - see SUZUKI Samurai (90010)

all models ’86 thru '94

ISUZU *47017

Hombre - see CHEVROLET S-10 (24071) Rodeo '91 thru '97, Amigo ’89 thru '94, Honda Passport '95 thru '97 Trooper ’84 thru ’91, Pick-up '81 thru '93

JAGUAR *49010 “49011 *49015

50020 *50025 *50029 *50030

61030 61035 *61036 61040 *61041

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

323 & Protegé ’90 thru ’97 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 on - see Ford (36071) RX-7 all models '79 thru '85 RX-7 all models '86 thru ‘91 626 (rear wheel drive) '79 thru ’82

626 & MX-6 (front wheel drive) '83 thru '91

123 Series Diesel '76 thru '85 190 Series 4-cyl gas models, '84 thru '88 280 123 Series gas models '77 thru '81 350 & 450 all models '71 thru '80 See FORD Listing MGB Roadster & GT Coupe '62 thru 80 MG Midget & Austin Healey Sprite Roadster '58 thru '80

MITSUBISHI *68020 *68030

Cordia, Tredia, Galant, Precis &° Mirage ’83 thru '93 Eclipse, Eagle Talon &

Plymouth Laser '90 thru '94 *68040

Pick-up 83 thru '96, Montero '83 thru '93

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

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

OLDSMOBILE *73015

Cutlass '74 thru '88 For other OLDSMOBILE titles, see BUICK, CHEVROLET or GENERAL MOTORS listing.

PLYMOUTH For PLYMOUTH titles, see DODGE.

PONTIAC 79008 79018 79019

Fiero all models '84 thru '88 Firebird V8 models except Turbo '70 thru '81 Firebird all models '82 thru '92 For other PONTIAC titles, see BUICK, CHEVROLET or GENERAL MOTORS listing.

SUZUKI *90010 Samurai/Sidekick/Geo Tracker '86 thru '96 TOYOTA 92005

*92006 92015 *92020 92025

92030 92032 *92035 *92036 92040 92045 92050 92055

*92080 92085

Camry all models '83 thru "91

Camry all models '92 thru ’96 Celica Rear Wheel Drive '71 thru '85 Celica Front Wheel Drive '86 thru '93 Celica Supra all models '79 thru '92

Corolla all models '75 thru '79 Corolla rear wheel drive models '80 thru '87 Corolla front whee! drive models ’84 thru 92 Corolla & Geo Prizm '93 thru ’97 Corolla Tercel all models ‘80 thru '82 Corona all models '74 thru "82 Cressida all models '78 thru ‘82 Land Cruiser Series FJ40, 43, 45 & 55 "68 thru '82 Land Cruiser Series FJ60, 62, 80 & FZJ80 '68 thru '82 MR2 all models ’85 thru ’87 Pick-up all models '69 thru '78 Pick-up all models '79 thru "95 Tacoma '95 thru '98,

4Runner '96 thru '98, T100 '93 thru '98 Previa all models '91 thru "95 Tercel all models '87 thru '94

94007

Spitfire all models '62 thru '81

94010

TR7 all models '75 thru ’81

Vw 96008 96012 *96016 “96017 96020 96030 96035 96040 96045

Beetle & Karmann Ghia '54 thru '79 Dasher all gasoline models '74 thru '81 Rabbit, Jetta, Scirocco, & Pick-up gas models '74 thru "91 & Convertible '80 thru "92 Golf & Jetta ‘93 thru '97 Rabbit, Jetta, Pick-up diesel '77 thru '84 Transporter 1600 ali models '68 thru ‘79 Transporter 1700, 1800, 2000 '72 thru "79 Type3 1500 & 1600 ’63 thru '73 Vanagon air-cooled models ’80 thru '83

VOLVO 97010 97015 *97020 97025 *97040

120, 130 Series & 1800 Sports '61 thru '73

140 240 260 740

Series Series Series & 760

all models '66 thru '74 all models '76 thru "93 all models '75 thru '82 Series all models '82 thru '88

911 914 924 944

TECHBOOK 10205 10210 10215 10220 10225 10230 10240

MANUALS

Automotive Computer Codes Automotive Emissions Control Manual Fuel Injection Manual, 1978 thru 1985 Fuel Injection Manual, 1986 thru 1996 Holley Carburetor Manual Rochester Carburetor Manual Weber/Zenith/Stromberg/SU Carburetor Chevrolet Engine Overhaul Manual Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repair Small Engine Repair Manual Suspension, Steering & Driveline

:

Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Body Repair & Painting Automotive Brake Manual Automotive Detaiing Manual Automotive Eelectrical Manual Automotive Heating & Air Conditioning Automotive Reference Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual

ATV Basics

SPANISH MANUALS Reparacién de Carroceria & Pintura Cédigos Automotrices de la Computadora Frenos Automotriz ; Inyeccién de Combustible 1986 al 1994 Chevrolet & GMC Cami Chevrolet & GMC Cami

"67 al 87 "88 al '95

Chevrolet Camionetas Cerradas ‘68 al ‘95 Dodge Caravan/Ply. Voyager '84 al '95 Ford Camionetas y Bronco '80 al '94 Ford Camionetas Cerradas ‘69 al ‘91 Ford Modelos de Tamafio Grande ‘87

Ford Modelos de Tamafo Mediano ‘75al ‘86 Ford Taurus & Mercury Sable ‘75 al ‘86

GM Modelos de Tamafio Grande ‘70al ‘90

GM Modelos de Tamafio Mediano ‘70al‘88

PORSCHE *80020 80025 80030 *80035

1100, 1300, 1400 & 1600 '71 thru '79 1600 & 1800 2WD & 4WD ’80 thru '94

230, 250 & 280 6 cyl sohc ’68 thru '72

MERCURY

MG 66010 66015

89002 *89003

TRIUMPH

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

MERCEDES-BENZ 63012 *63015 63020 63025 63030

Saturn all models '91 thru '96

SUBARU

"92065 92070 *92075 *92076

& Wagoneer

MAZDA 61010 61011 “61015 "61016 “61020

*87010

Cherokee, Comanche

Limited all models '84 thru '96 CJ all models '49 thru '86 Grand Cherokee all models '93 thru '98 Grand Wagoneer & Pick-up '72 thru '91 Wrangler all models ’87 thru '95

900 including Turbo '79 thru ’88

SATURN

*92056

LINCOLN 59010

SAAB *84010

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

Ford Automatic Transmission Overhaul Ford Engine Overhaul Manual Aerostar Mini-vans '86 thru '96 Aspire - see FORD Festiva (36030) Contour/Mercury Mystique '95 thru '98 Courier Pick-up all models '72 thru '82 Crown Victoria & Mercury Grand Marquis ‘88 thru '96 Escort/Mercury Lynx '81 thru ’90 Escort/Mercury Tracer '91 thru ’96 Expedition - see FORD Pick-up (36059) Explorer & Mazda Navajo '91 thru '95 Fairmont & Mercury Zephyr ’78 thru '83 Festiva & Aspire '88 thru '97 Fiesta all models '77 thru '80 Ford & Mercury Full-size, Ford LTD & Mercury Marquis (75 thru ’82); Ford Custom 500,Country Squire, Crown

Accord CVCC all models '76 thru '83 Accord all models '84 thru '89 Accord all models ’90 thru '93 Accord all models 94 thru '95 Civic 1200 all models '73 thru '79 Civic 1300 & 1500 CVCC '80 thru '83 Civic 1500 CVCC all models '75 thru '79 Civic all models '84 thru ’91 Civic & del Sol '92 thru '95 Passport - see /SUZU Rodeo (47017) Prelude CVCC all models '79 thru ’89

HYUNDAI *43015 Excel

Victoria & Mercury Colony Park (75 thru '87);

36062 36066 *36070 *36071

24046

Safari - see CHEVROLET ASTRO (24010)

*47020

FORD

Chevelle, Malibu, El Camino '69 thru '87 Chevette & Pontiac T1000 '76 thru '87 Citation - see GENERAL MOTORS (38020) Corsica/Beretta all models '87 thru '96 Corvette all V8 models '68 thru 82 Corvette all models ’84 thru '96 Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons ’69 thru '90 Impala SS & Caprice and Buick Roadmaster ’91 thru '96 Lumina ’90 thru ’94 - see GM (38010) Lumina & Monte Carlo ‘95 thru ’98 Lumina APV - see GM (38038) Luv Pick-up all 2WD & 4WD '72 thru ’82 Monte Carlo all models '70 thru '88 Monte Carlo ’95 thru ’98 - see LUMINA Nova all V8 models '69 thru '79 Nova/Geo Prizm '85 thru ’92 Pick-ups '67 thru ’87 - Chevrolet & GMC, all V8 & in-line 6 cyl, 2WD & 4WD '67 thru ’87; Suburbans, Blazers & Jimmys ’67 thru ’91 Pick-ups ’88 thru ’98 - Chevrolet & GMC, all full-size models ’88 thru '98; Blazer & Jimmy ’92 thru '94; Suburban '92 thru '98; Tahoe & Yukon ’95 thru ’98 S-10 & GMC S-15 Pick-ups ’82 thru '93 S-10, Gme S-15 & Jimmy ‘94 thru ‘96 Sprint & Geo Metro ’85 thru ’94 Vans - Chevrolet & GMC ’68 thru ’96

*24032 24040 *24041 24045

Omni & Plymouth Horizon '78 thru '90 Pick-ups all full-size models '74 thru '93 Pick-ups all full-size models '94 thru '96 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups '79 thru '93 Dodge/Ply./Chrysler RWD '71 thru '89 Shadow/Plymouth Sundance ’87 thru '94 Spirit & Plymouth Acclaim '89 thru '95 Vans - Dodge & Plymouth '71 thru '96

FIAT

CHEVROLET 10305 *24010 24015 24016

& Valiant 6 cyl models '67 thru '76 Daytona & Chrysler Laser '84 thru 89 Intrepid - see Chrysler (25025) Dodge & Plymouth Neon ’95 thru '97

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

(Front wheel drive) '85 thru ’98 Oldsmobile Delta 88 Royale, Ninety Eight and Regency; Pontiac Bonneville Buick Oldsmobile & Pontiac Full-size (Rear wheel drive) Buick Estate ’70 thru ’90, Electra’70 thru '84, LeSabre '70 thru '85, Limited ’74 thru '79 Oldsmobile Custom Cruiser 70 thru '90, Delta 88 '70 thru ’85,Ninety-eight '70 thru ’84 Pontiac Bonneville '70 thru ’81, Catalina ’70 thru ’81, Grandville '70 thru ’75, Parisienne '83 thru '86 Mid-size Regal & Century ’74 thru ’87 Regal - see GENERAL MOTORS (38010) Skyhawk - see GM (38030) Skylark - see GM (38020, 38025) Somerset - see GENERAL MOTORS (38025)

400 & 600 - see CHRYSLER (25030) Aries & Plymouth Reliant '81 thru '89 Caravan & Ply. Voyager '84 thru '95 Caravan & Ply. Voyager '96 thru '98 Challenger/Plymouth Saporro '78 thru '83 Challenger ’67-'76 - see DART (30025) Colt/Plymouth Champ '78 thru '87 Dakota Pick-ups all models '87 thru '96 Dart, Challenger/Plymouth Barracuda

EAGLE

Buick, Oldsmobile & Pontiac Full-size Buick Electra, LeSabre and Park Avenue;

28005 28007 28009 28012 28014

GMC

DODGE

ACURA

Coupe & Targa all 4 cyl models all models incl. all models incl.

models '65 thru '89 '69 thru '76 Turbo '76 thru '82 Turbo '83 thru '89

Nissan Camionetas ‘80 al ‘96,

Pathfinder ‘87 al ‘95

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

RENAULT Alliance, Encore - see AMC (14020)

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

Nearly 100 Haynes motorcycle manuals also available

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

5-98

:

Common

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

TOO HOT

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

CARBON

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

OIL DEPOSITS Oily coating

correct plug heat range, overadvanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and _ insufficient engine cooling.

PREIGNITION

DEPOSITS

Symptoms: Dry sooty deposits indicate a rich mixture or weak ignition. Causes misfiring, hard starting and hesitation. Recommendation: Make sure the plug has the correct heat range. Check for a clogged air filter or problem in the fuel system or engine management system. Also check for ignition system problems.

Symptoms:

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

caused

by poor oil control. Oil is leaking past worn valve guides or piston rings into the combustion chamber.

Causes hard starting, misfiring and hesitation. Recommendation: Correct the mechanical condition with necessary repairs and install new plugs.

Symptoms: Melted electrodes. Insulators are white, but may be

dirty due to misfiring or flying debris in the combustion chamber. Can lead to engine damage. Recommendation: Check for the correct plug heat range, overadvanced ignition timing, lean fuel mixture, insufficient engine cooling and lack of lubrication.

HIGH SPEED GLAZING Symptoms: Insulator has yellowish, glazed appearance. Indicates that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating. Causes misfiring at high speeds. Recommendation: _ Install new plugs. Consider using a colder plug if driving habits warrant.

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

in a fractured insulator tip. Can lead to piston damage. Recommendation: Make sure the fuel anti-knock values meet engine

requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine.

MECHANICAL DAMAGE GAP BRIDGING Symptoms: Combustion deposits lodge between the electrodes. Heavy deposits accumulate and bridge the electrode gap. The plug

ceases to fire, resulting in a dead cylinder. Recommendation: Locate the faulty plug and remove the deposits from between the electrodes.

Symptoms: May be caused by a foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could result in piston damage. Recommendation: Repair the mechanical damage. Remove the foreign object from the engine and/or install the correct reach plug.

Every manual based on a complete teardown and rebuild! —

PN iMac valcelele|smbcloyaate)gemat-lalel-)ael(e1. Git) os-m-lare| 1994 through 1997 Mazda B2300, B3000 and B4000 pick-ups 2WD and 4WD

Step-by-step procedures linked to hundreds of easy-to-follow photos Written from “hands-on” experience . .. using common tools Quick and easy troubleshooting sections Detailed wiring diagrams LOf0) [oYayof-]a.@o)(Ele MelFle]pleaky

itions plug cond n spark Chapter 12 Chai

ABCDE

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SO0( 1

3

———————

ISBN 1 56392 320 3.