Haynes Jeep Grand Cherokee 1993 thru 2000 Automotive Repair Manual 1563923947, 9781563923944

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Jeep |

Grand

Cherokee Automotive Repair Manual by Larry Warren and John H Haynes Member of the Guild of Motoring Writers

Models covered: All Jeep Grand Cherokee models 1993 through 2000

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yet ARSScimion MEMBER 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 We are grateful to the DaimlerChrysler Corporation for assis-

tance with technical information and certain illustrations. Tech_ nical writers who contributed to this project include Eric Godfrey, Bob Henderson, Rob Maddox, Mike Stubblefield, Jay Storer and Jeff Kibler. eee ee (oye Nai ae oe

©

Haynes North America, Inc. 2000

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With permission from J.H. Haynes & Co. Ltd.

form or by any means, electronic or mechanical, including photoin any copying, recording or by any information storage or retrieval system,

ut permission in writing from the copyright holder.

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Introductory pages About this manual Introduction to the Jeep Grand Cherokee Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting Jacking and towing Automotive chemicals and lubricants Conversion factors Safety first! Troubleshooting

0-5 0-5 0-6 0-8 0-8 0-14 0-14 0-15 0-16 0-17 0-18

Chapter 1 Tune-up and routine maintenance

Chapter2

1-1

PartA

Six-cylinder engine

Chapter2

2A-1

PartB

5.2L and 5.9L V8 engines

Chapter 2

2B-1

PartC

4.7L V8 engine

Chapter 2

2C-1

PartD

General engine overhaul procedures

2D-1

Chapter 3 Cooling, heating and air conditioning systems

3-1

Chapter 4 Fuel and exhaust systems

4-1

Chapter 5

i

Engine electrical systems

5-1

&

Chapter 6 Emissions and engine control systems

Chapter 7

6-1

PartA

Manual transmission

Chapter7

7TA-1

PartB

-

Automatic transmission

Chapter 7

7B-1

Part C

Transfer case

7C-1

Chapter 8 Clutch and drivetrain

Chapter 9 Brakes

8-1

c 9-1

Chapter 10 Suspension and steering systems

10-1

Chapter 11 Body

: 11-4 zs

Chapter 12 Chassis electrical system

Wiring diagrams Index

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About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you

choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs,

doing it yourself may be quicker than arranging an appointment to get the vehicle into a

shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop

must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within

that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the refer-

ence 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 pub-

lisher nor the author can accept responsibility for any errors in, or omissions from, the infor-

mation given.

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

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

WARNING 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 to the Jeep Grand Cherokee Chassis layout is conventional, with the engine mounted at the front and the power being transmitted through either a manual or automatic transmission to a driveshaft and solid rear axle on 2WD models. On 4WD

models a transfer case transmits power to

he front axle by way of a driveshaft. Trans-

missions used are a five-speed overdrive manual and four-speed overdrive automatic. The suspension on these models features solid axles with coil springs and control arms front and rear. 2WD vehicles use a

beam-type front axle while 4WD vehicles use a live-axle,

similar

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axle assembly. All models

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with power

assisted front disc and either drum or disc rear brakes. An Anti-lock Braking System (ABS) is used on all models.

0-6

Vehicle identification numbers VIN engine and model year

Vehicle identification numbers Modifications

are

a

continuing

and

unpublicized process in vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are necessary to correctly identify the component required.

Vehicle Identification Number:

(VIN)

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

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 character and the model year code letter designation is the 10th character (see illustration).

ones Vices Li feaise Ngee

the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was manufactured, engine type, the model year and the body style.

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1J/4G2Z258S8RC000001 Engine code (8th digit)

Model year code

(10th digit)

The engine code is the 8th character of the VIN number; the model code is the 10th character

inline six-cylinder engine V8 engine V8 engine V8 engine

On models covered by this manual model year codes are:

This very important identification number is located on a plate attached to the left side dashboard just inside the windshield (see illustration). The VIN also appears on

4.0L 5.2L 5.9L 4.7L

The Vehicle Certification label (VC label is attached to the rear of the left (driver’s side)

VIEW_IN DIRECTION OF ARROW V CHILD PROTECTION DOOR LOCK

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DOOR DIRECTION VIEW_IN EOE ARROW ARROW X

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—11MM_—_ TRANSFER CASE

CHILD PROTECTION 5

DOOR LOCK

WINDOW DECAL

IN CIRCLE VIEW (LEFT SIDE SHOWN}

SHIFT PATTERN VIEW IN DIRECTIO OF ARROW Z

The Vehicle Identification Number (VIN), Vehicle Certification and other label locations

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1993 1994 1995 1996 1997 1998 999 2000

Vehicle Certification Label

BODY CODE

EXPORT DECAL

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Vehicle identification numbers SS)

\ TRANSMISSION ID. PLATE NO. 3 CYLINDER

FT MACHINED SmeA SURFACE Six-cylinder engine ID number location

Manual transmission identification number location

1993 model automatic transmission identification plate location

door. The upper half of the label contains the name

of the manufacturer,

the month

and

year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and the certification statement. The VC label also contains the VIN number, which is used for warranty identification

of the vehicle, and provides such information as manufacturer, type of restraint system, body type, engine, transmission, model year and vehicle serial number.

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Engine identification numbers On six-cylinder engines, build date information can be found stamped on a machined pad located on the right side of the cylinder

block between the number 2 and 3 cylinders (see illustration). On 5.2L/5.9L V8 engines, the serial number is stamped on a machined pad on the left front corner of the cylinder block. On 4.7L V8 engines, the serial number is

PART NUMBER

BUILD

SERIAL

DATE

NUMBER

1994 and later model automatic transmission identification number location

Transfer case identification plate

located on the right front side of the engine block.

Axle identification numbers

Manual transmission identification number

On both front and rear axles the identification number is located on a tag attached to the differential cover (see illustration).

Vehicle Emissions Control Information (VECI) label This label is found under the hood, usually on the radiator support (See Chapter 6).

The manual transmission identification number and serial numbers can be found on

a tag on the side of the transmission case near the drain plug (see illustration).

DIFFERENTIAL COVER

Automatic transmission identification numbers

AXLE MODEL

PUSH-IN FILL PLUG

On 1993 models, a plate with the automatic transmission serial number, build date

and other rear side 1994 and stamped above the

Axle identification tag location

information is attached to the right of the case (see illustration). On later models, the information is on the left side of the case, just fluid pan gasket (see illustration).

Transfer case identification number The transfer case identification plate is

____ attached to the left rear side of the case (see illustration).

LIMITED SLIP TAG

IDENTIFICATION TAG

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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 sys-

tems, brake parts, tune-up parts, etc. These

stores often supply new

or reconditioned

unique to the vehicle and not generally available elsewhere (Such as major engine parts, transmission parts, trim pieces, etc.).

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

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.

vehicle maintenance such as oil, grease, fil-

ters, 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

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

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.

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

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

Grade 5

Grade 1 or 2

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

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

Grade

identification Cd

Grade

Grade

Hex Nut Property Class 9

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cial tool commonly available for this purpose. hine shops can perform ou. _

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Standard hex nut

strength markings

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at tool stores.

If a bolt or stud breaks off in an assembly, it can be drilled and removed with a spe-

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Arabic 9

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GradeB8

identification

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Class

Class

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8.8

Arabic 10

Metric hex nut

strength markings

Metric stud strength markings

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Maintenance techniques, tools and working facilities Fastener sizes For a number

of reasons,

automobile

manufacturers are making wider and wider

Metric thread sizes

use of metric fasteners. Therefore, it is impor-

tant to be able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged.

Ft-Ibs

Nm

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

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

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

7 to 10 17 to 24 30 to 44 34 to 47

6 to 9 12to 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 30 to 43 37 to 51 55 to 74 55 to 81 75 to 108

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 (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

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(grade) number, rather than a slash, molded

into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and 10.9 are commonly used on automobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped into one side, while metric nuts are marked with a number. The greater the number of dots, or the higher the number, the greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade. It should be noted that many fasteners, especially Grades 0 through 2, have no 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 metric) may have different

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Standard (SAE and USS) bolt dimensions/grade marks Grade marks (bolt strength) Length (in inches) Thread pitch (number of threads per

~ inch)

Metric bolt dimensions/grade marks

P L_ T D_

Property class (bolt strength) Length (in millimeters) Thread pitch (distance between threads in millimeters) Diameter

© Va So Nominal diameter (in inches)

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 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 aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be applied to it. The figures listed here are approximate for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners laid out in a pattern, such as cylinder head bolts, oil pan bolts, differential cover bolts, etc., must be loosened or tight-

ened in sequence to avoid warping the com-

Maintenance techniques, tools and working facilities

Dial indicator set

Micrometer set

ponent. 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

identify the two halves with numbered pieces of masking tape so they can be easily reconnected.

assembled

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

finger-tight

only.

Next,

Gasket sealing surfaces

they

should be tightened one full turn each, in a criss-cross or diagonal pattern. After each one has been tightened one full turn, return to the first one and tighten them all one-half

turn, following

the same

pattern.

Finally,

tighten each of them one-quarter turn at a time until each fastener has been tightened to the proper torque. To loosen and remove the fasteners, the procedure would be reversed.

pressure can sometimes cause the two parts

to stick together so tightly that they are very difficult to separate. Often, the assembly can be loosened by striking it with a soft-face hammer near the mating surfaces. A regular hammer can be used if a block of wood is placed between the hammer and the part. Do not hammer on cast parts or parts that could be easily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed.

Component disassembly Component disassembly should be done with care and purpose to help ensure that the parts go back together properly. Always keep track of the sequence in which parts are removed. Make note of special characteristics or marks on parts that can be installed more than one way, such asa grooved thrust washer on a shaft. It is a good idea to lay the disassembled parts out on a clean surface in the order that they were removed. It may also be helpful to make sketches or take instant photos of components before removal. When removing fasteners from a component, keep track of their locations. Sometimes threading a bolt back in a part, or putting the washers and nut back on a stud, can prevent mix-ups later. If nuts and bolts cannot be returned to their original locations, they should be kept in a compartmented box or a series of small boxes. A cupcake or muffin tin is ideal for this purpose,

Avoid using a screwdriver or bar to pry

apart an assembly, as they can easily mar the gasket sealing surfaces of the parts, which

must remain smooth. If prying is absolutely necessary, use an old broom handle, but keep in mind that extra clean up will be necessary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated with a special chemical to soften it so it can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is recommended because it is usually softer than the surfaces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire

since each

cavity can hold the bolts and nuts from a particular area (i.e. oil pan bolts, valve cover bolts, engine mount bolts, etc.). A pan of this type is especially helpful when working on assemblies with very small parts, such as the carburetor, alternator, valve train or interior dash and trim pieces. The cavities can be marked with paint or tape to identify the contents.

brush, but regardless of the method

used,

the mating surfaces must be left clean and smooth. If for some reason the gasket surface is gouged, then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components. For most applications, a non-drying (or semi-drying) gasket sealer should be used.

Whenever wiring looms, harnesses or

connectors are separated, it is a good idea to

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

Hose removal precautions closely parallel gasket removal precautions. Avoid scratching or gouging the surface that the hose mates against or the connection may leak. This is especially true for radiator hoses. Because of various chemical reactions, the rubber in hoses can bond itself to the metal spigot that the hose fits over. To remove a hose, first loosen the hose clamps that secure it to the spigot. Then, with slip-joint

pliers, grab the hose at the clamp and rotate it around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone or other lubricants will ease removal if they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inside of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced with a new one anyway), the rubber can be slit with a knife and the hose peeled from the spigot. If this must be done, be careful that the metal connection is not damaged. If a hose clamp is broken or damaged, do not reuse it. Wire-type clamps usually weaken with age, so it is a good idea to replace them with screw-type clamps whenever a hose is removed.

Tools A selection of good tools is a basic requirement for anyone who plans to maintain and repair his or her own vehicle. For the owner who has few tools, the initial investment might seem high, but when compared

to the spiraling costs of professional auto maintenance and repair, it is a wise one. To help the owner decide which tools are needed to perform the tasks detailed in this manual, the following tool lists are offered: Maintenance and minor repair, Repair/overhaul and Special. The newcomer to practical

mechanics =

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Maintenance techniques, tools and working facilities

Compression gauge with spark plug hole adapter

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General purpose puller

Valve spring compressor

Valve spring compressor

0-12

Maintenance techniques, tools and working facilities

Cylinder hone

Clutch plate alignment tool

Tap and die set

start off with the maintenance and

Phillips screwdriver (No. 2 x 6 inch)

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

Combination pliers - 6 inch Hacksaw and assortment of blades

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 1/2-inch drive set.

Brake cylinder hone

should

most repair and overhaul procedures and will add tools from the special category when it is felt that the expense is justified by the frequency of use.

Maintenance and minor repair tool kit The tools in this list should be considered the minimum required for performance of routine maintenance, servicing and minor repair work. We recommend the purchase of combination wrenches (box-end and openend combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench.

Combination wrench set (1/4-inch to 7 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)

Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush Battery post and cable cleaning tool Oil filter wrench Funnel (medium size) Safety goggles Jackstands (2) Drain pan Note: /f basic tune-ups are going to be part of routine maintenance, it will be necessary to purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because

they are absolutely necessary for tuning most vehicles properly.

Repair and overhaul tool set These tools are essential for anyone who plans to perform major repairs and are in addition to those in the maintenance and minor repair tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because of their versatility, especially when various extensions and drives are available. We recommend the 1/2inch drive over the 3/8-inch drive. Although the larger drive is bulky and more expensive,

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Socket set(s) Reversible ratchet Extension - 10 inch Universal joint Torque wrench (same size drive as sockets) Ball peen hammer - 8 ounce

Soft-face hammer (plastic/rubber) Standard screwdriver (1/4-inch x 6 inch) Standard screwdriver (stubby 5/16-inch) Phillips screwdriver (No. 3 x 8 inch) Phillips screwdriver (stubby - No. 2) Pliers - vise grip Pliers - lineman’s Pliers - needle nose Pliers - snap-ring (internal and external) Cold chisel - 1/2-inch Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch) Steel rule/straightedge - 12 inch Allen wrench set (1/8 to 3/8-inch or 4mm to 10 mm)

A selection of files Wire brush (large) Jackstands (second set) Jack (scissor or hydraulic type) 2 i Pp

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Maintenance techniques, tools and working facilities Note: Another too/ which is often useful is an electric drill with a chuck capacity of 3/8-inch and a set of good quality drill bits.

Special tools The tools in this list include those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturer’s instructions. Unless these tools will be used frequently, it is not very economical to purchase many of them. A consideration would be to split the cost and use between yourself and a friend or friends. In addition, most of these tools can be obtained from a tool rental shop on a temporary basis. This list primarily contains only those tools and instruments widely available to the public, and not those special tools produced by the vehicle manufacturer for distribution to dealer service

departments.

Occasionally,

references to the manufacturer’s special tools are included in the text of this manual. Generally, an alternative method of doing the job without the special tool is offered. However, sometimes there is no alternative to their use. Where this is the case, and the tool cannot be purchased or borrowed, the work

should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor Piston ring groove cleaning tool Piston ring compressor Piston ring installation tool Cylinder compression gauge Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge Micrometers and/or dial calipers Hydraulic lifter removal tool 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 the tool selection. Building a tool ally allows the cost of the tools to over a longer period of time and mechanic the freedom to choose

to expand set gradube spread gives the 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,

but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers

and

sockets,

because

they

won't last very long. The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools.

Care and maintenance of tools Good tools are expensive, so it makes

sense to treat them with respect. Keep them clean and in usable condition and store them properly when not in use. Always wipe off any dirt, grease or metal chips before putting them away. Never leave tools lying around in the work area. Upon completion of a job, always check closely under the hood for tools that may have been left there so they won’t get lost during a test drive. Some tools, such as screwdrivers, pliers, wrenches and sockets, can be hung ona panel mounted on the garage or workshop wall, while others should be kept in a tool box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or impact from other tools. When tools are used with care and stored properly, they will last a very long time.

Even

with the best

of care,

though,

tools will wear out if used frequently. When a tool is damaged or worn out, replace it. Subsequent jobs will be safer and more enjoyable if you do.

How to repair damaged threads Sometimes, the internal threads of a nut

or bolt hole can become stripped, usually from overtightening. Stripping threads is an all-too-common occurrence, especially when working with aluminum parts, because alu-

minum is so soft that it easily strips out. Usually, external or internal threads are

only partially stripped. After they’ve been cleaned up with a tap or die, they’ll still work. Sometimes, however, threads are badly damaged. When this happens, you’ve got three choices: 1) Drill and tap the hole to the next suitable oversize and instal! a larger diameter bolt, screw or stud. 2) Drill and tap the hole to accept a threaded plug, then drill and tap the plug to the original screw size. You can also buy a plug already threaded to the original size. Then you simply drill a hole to the specified size, then run the threaded plug into the hole with a bolt and jam

nut. Once the plug is fully seated, remove the jam nut and bolt. 3) The third method uses a patented thread repair kit like Heli-Coil or Slimsert. These easy-to-use kits are designed to repair damaged threads in straightthrough holes and blind holes. Both are available as kits which can handle a variety of sizes and thread patterns. Drill the hole, then tap it with the special included tap. Install the Heli-Coil and the hole is back to its original diameter and thread pitch.

Regardless of which method you use, be sure to proceed calmly and carefully. A little impatience or carelessness during one of these relatively simple procedures can ruin your whole day’s work and cost you a bundle if you wreck an expensive part.

Working facilities Not to be overlooked when discussing tools is the workshop. If anything more than routine

maintenance

is to be carried

out,

some sort of suitable work area is essential. It is understood, and appreciated, that 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,

the overhaul or repair be completed

that

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 sol-

vents, 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.

0-14

Booster battery (jump) starting Observe the following precautions when using a booster battery

to start a vehicle:

Dead 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

q

_

Booster battery

A

2

©

one in the vehicle. e) The two vehicles MUST NOT TOUCH each other. f) Make sure the transmission is in Neutral (manual transaxle) or Park (automatic transaxle). g) If the booster battery is not a maintenance-free type, remove the vent caps and lay a cloth over the vent holes. Connect the red jumper cable to the positive (+) terminals of each battery. Connect one end of the black cable to the negative (-) terminal of the booster battery. The other end of this cable should be connected to a good ground on the engine block (see illustration). Make sure the cable will not come into contact with the fan, drivebelts 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

©

C000CO

©0G000

— 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)

Jacking and towing Jacking

Towing

The jack supplied with the vehicle should only be used for raising the vehicle when changing a tire or placing jackstands under the frame. NEVER work under the vehicle or start the engine when the vehicle supported only by a jack. The vehicle should be parked on level ground with the wheels blocked, the parking brake applied and the transmission in Park (automatic) or Reverse (manual). If the vehicle is parked alongside the roadway, or in any

Equipment specifically designed for towing should be used and attached to the main structural members of the vehicle. Optional tow hooks may be attached to the

other hazardous situation, turn on the emer-

gency hazard flashers. If a tire is to be changed, loosen the lug nuts one-half turn before raising off the ground. Place the jack under the vehicle in the indicated position (see illustration). Operate the jack with a slow, smooth motion until the

wheel is raised off the ground. Remove the lug nuts, pull off the wheel, install the spare and thread the lug nuts back on with the beveled side facing in. Tighten the lug nuts snugly, lower the vehicle until some weight is on the wheel, tighten them completely in a criss-cross pattern and remove the jack. Note that some spare tires are designed for temporary use only - don’t exceed the recommended speed, mileage or other restriction instructions accompanying the spare.

frame at both ends of the vehicle; they are

intended for emergency use only, for rescu-

ing a stranded vehicle. Do not use the tow hooks for highway towing. Stand clear when using tow straps or chains, they may break causing serious injury. Safety is a major consideration when towing and all applicable state and local laws must be obeyed. In addition to a tow bar, a safety chain must be used for all towing. Four-wheel drive vehicles may be towed with all four wheels on the ground with no speed or mileage restrictions. Turn the ignition key to the OFF position to unlock the steering column, shift the transmission in gear (manual) or Park (automatic) and shift the transfer caSe to Neutral. Two-wheel drive vehicles may be towed with four wheels on the ground for a distance of 15 miles or less, as long as the speed doesn’t exceed 30 mph. If the vehicle has to be towed more than 15 miles, place the rear wheels on a towing dolly. If any vehicle is to be towed with the front wheels on the ground and the rear wheels raised, the ignition key must be

Front and rear jacking points

turned to the OFF position to unlock the steering column and a steering wheel clamp-

ing device designed for towing must be used or damage to the steering column lock may occur.

0-15

Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum, varnish and carbon. Most carburetor cleaners leave a drytype lubricant film which will not harden or gum up. Because of this film it is not recommended for use on electrical components. Brake system cleaner is used to remove grease and brake fluid from the brake system, where clean surfaces are absolutely necessary. It leaves no residue and often eliminates brake squeal caused by contaminants. Electrical cleaner removes oxidation, corrosion and carbon deposits from electrical contacts, restoring full current flow. It can also be used to clean spark plugs, carburetor jets, voltage regulators and other parts where an

oil-free surface is desired. Demoisturants remove water and moisture from electrical components such as alternators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive, non-corrosive and non-flammable. Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and, depending on the type, are rinsed off either with water or solvent.

Lubricants Motor oil is the lubricant formulated for use in engines. It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) from 0 to 50. The recommended weight of the oil depends on the season, temperature and the demands on the engine. Light oil is used in cold climates and under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights from 5W-20 to 20W-50. Gear oil is designed to be used in differentials, manual transmissions and other areas where high-temperature lubrication is required. Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered, such as for wheel bearings, balljoints, tie-rod ends and universal joints. High-temperature wheel bearing grease is designed to withstand the extreme _ temperatures encountered by wheel bearings

in disc brake equipped vehicles. It usually contains molybdenum disulfide (moly), which is a dry-type lubricant. White grease is a heavy grease for metal-to-metal applications where 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 main and rod bearings and cam lobes) for initial start-up of a new engine. The assembly lube lubricates the parts without being squeezed out or washed away until the engine oiling system begins to function. Silicone lubricants are used to protect rubber, plastic, vinyl and nylon parts. Graphite lubricants are used where oils cannot be used due to contamination problems, such as in locks. The dry graphite will lubricate metal parts while remaining uncontaminated by dirt, water, oil or acids. It is electrically conductive and will not foul electrical contacts in locks such as the ignition switch. Moly penetrants loosen and lubricate frozen, rusted and corroded fasteners and prevent future rusting or freezing. Heat-sink grease is a special electrically non-conductive grease that is used for mounting electronic ignition modules where it is essential that heat is transferred away from the module.

Sealants used

RTV sealant is one of the most widely gasket compounds. Made from sili-

cone, 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, 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.

Chemicals Anti-seize compound prevents seizing,

galling, cold welding, rust and corrosion in

fasteners. High-temperature anti-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 pis-

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

0-16

Conversion

factors

Length (distance) Inches (in) Feet (ft)

X X

25.4 0.305

=Millimetres (mm) = Metres (m)

X X

0.0394 3.281

= Inches (in) =Feet (ft)

Miles

X

1.609

= Kilometres (km)

X

0.621

=Miles

X X. X X X X X X

16.387 0.568 1.137 1.201 0.946 4.546 1.201 3.785

= Cubic centimetres (cc; cm’) =Litres (I) = Litres (I) =US quarts (US qt) = Litres (I) = Litres (I) =US gallons (US gal) = Litres (I)

X x x X X x X xX

0.061 1.76 0.88 0.833 1.057 0.22 0.833 0.264

=Cubic inches (cu in; in’) = Imperial pints (Imp pt) = Imperial quarts (Imp qt) =Imperial quarts (Imp qt) =US quarts (US qt) = Imperial gallons (Imp gal) =Imperial gallons (Imp gal) =US gallons (US gal)

X X

28.35 0.454

=Grams (g) = Kilograms (kg)

X X

0.035 2.205

=Ounces (oz) =Pounds (Ib)

X X X

0.278 4.448 0.1

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

x X Xx

3.6 0.225 9.81

= Ounces-force (ozf; oz) = Pounds-force (Ibf; |b) = Newtons (N)

X

0.070

= Kilograms-force per square

X

14.223

= Pounds-force per square inch

X

14.696

=Pounds-force per square inch

Volume (capacity) Cubic inches (cu in; in’) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

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

Force Ounces-force (ozf; 0z) Pounds-force (Ibf; Ib) Newtons (N)

Pressure Pounds-force per square inch

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

centimetre (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

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

1.152

= Kilograms-force centimetre

X

0.868

= Pounds-force inches

X

0.113

(kgf cm; kg cm) =Newton metres (Nm)

x

8.85

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

X

0.083

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

x

12

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

X

7.233

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

X X

0.738 9.804

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

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

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

(atm)

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

Pounds-force per square inch

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

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

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

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

Kilopascals (kPa)

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

= Kilopascals (kPa)

Torque (moment of force) Pounds-force

inches

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

(Ibf in; Ib in) xX 0.138 X X

1.356 0.102

(kgf m; kg m)

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

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

X

0.0013

=Horsepower (hp)

X

1.609

= Kilometres per hour (km/hr; kph) X

0.621

=Miles per hour (miles/hr; mph)

X

0.354 0.425

= Kilometres per litre (km/I) = Kilometres per litre (km/|)

2.825

=Miles per gallon, Imperial (mpg)

2.352

=Miles per gatlon, US (mpg)

Power Horsepower (hp)

(W)

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

Fuel consumption* Miles per gallon, Imperial (mpg) Miles per gallon, US (mpg)

X

X X

Temperature Degrees Fahrenheit

=

(°C x 1.8) + 32

Degrees Celsius (Degrees Centigrade; °C)

*/t is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (I/100km), where mpg (Imperial) x 1/100 km = 282 and mpg (US) x I/100 km = 235

= (°F - 32) x 0.56

Safety first! Regardless of how enthusiastic you may be about getting on with the job at hand, take the time to ensure that your safety is not jeopardized. A can result in an observe certain The possibility

moment’s lack of attention accident, as can failure to simple safety precautions. of an accident will always

exist, and the following points should not be considered a comprehensive list of all dangers. Rather, they are intended to make you aware of the risks and to encourage a safety conscious approach to all work you carry out on your vehicle.

Essential DOs and DON’Ts DON’T rely on a jack when working under the vehicle. Always use approved jackstands to support the weight of the vehicle and place them under the recommended lift or support points. DON’T attempt to loosen extremely tight fasteners (i.e. wheel lug nuts) while the vehicle is on a jack - it may fall. DON’T start the engine without first making sure that the transmission

is in Neutral (or

Park where applicable) and the parking brake is set. DON’T remove the radiator cap from a hot cooling system - let it cool or cover it with a cloth and release the pressure gradually. DON’T attempt to drain the engine oil until you are sure it has cooled to the point that it will not burn you. DON’T touch any part of the engine or exhaust system until it has cooled sufficiently to avoid burns. DON’T siphon toxic liquids such as gasoline, antifreeze and brake fluid by mouth, or allow them to remain on your skin. DON’T inhale brake lining dust - it is potentially hazardous (see Asbestos below). DON’T allow spilled oil or grease to remain on the floor - wipe it up before someone slips on it. DON’T use loose fitting wrenches or other tools which may slip and cause injury. DON’T push on wrenches when loosening or tightening nuts or bolts. Always try to pull the wrench toward you. If the situation calls for pushing the wrench away, push with an open hand to avoid scraped knuckles if the wrench should slip. DON’T attempt to lift a heavy component alone - get someone to help you.

DON'T rush or take unsafe shortcuts to finish a job.

DON’T allow children or animals in or around _ the vehicle while you are working on it. ‘ DO wear ne apr ae when using power

etc. and when working under a vehicle. DO keep loose clothing and long hair well out of the way of moving parts. DO make sure that any hoist used has a safe working load rating adequate for the job. DO get someone to check on you periodically when working alone on a vehicle. DO carry out work in a logical sequence and make sure that everything is correctly assembled and tightened. DO keep chemicals and fluids tightly capped and out of the reach of children and pets. DO remember that your vehicle’s safety affects that of yourself and others. If in doubt on any point, get professional advice.

Asbestos Certain friction, insulating, sealing, and other products - such as brake linings, brake

bands, clutch linings, torque converters, gaskets, etc. - may contain asbestos. Extreme care must be taken to avoid inhalation of dust

from such products, since it is hazardous to health. If in doubt, assume that they do contain asbestos.

Fire Remember at all times that gasoline is highly flammable. Never smoke or have any kind of open flame around when working ona vehicle. But the risk does not end there. A spark caused by an electrical short circuit, by two metal surfaces contacting each other, or

even by static electricity built up in your body under certain conditions, can ignite gasoline vapors, which in a confined space are highly

carefully. Never use materials from unmarked

containers. Never run the engine in an enclosed space, such as a garage. Exhaust fun ntain carbon monoxide, which is extreme ly poisonous. If you need to run thieengine always do so in the open air, or at least have the rear of the vehicle outside the work ar If you are fortunate enough to have use of an inspection pit, never drain o gasoline and never run the ene? while the vehicle is over the pit. The fumes 1g heavier than air, will concentrate in the pit with possibly lethal results.

The battery Never create a spark or allow a bare light bulb near a battery. They normally give off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery ground (-) cable at the battery before working on the fuel or electrical systems. If possible,

loosen

the filler caps

or

cover when charging the battery from an external source (this does not apply to sealed or maintenance-free batteries). Do not charge at an excessive rate or the baitery may burst. Take care when adding water to a non maintenance-free battery and when carrying a battery. The electrolyte, even when diluted,

is very corrosive and should not be allowed to contact clothing or skin. Always wear eye protection when cleaning the battery to prevent the caustic deposits from entering your eyes.

explosive. Do not, under any circumstances,

use gasoline for cleaning parts. Use an approved safety solvent. Always disconnect the battery ground (-) cable at the battery before working on any part of the fuel system or electrical system. Never risk spilling fuel on a hot engine or exhaust component. It is strongly recommended that a fire extinguisher suitable for use on fuel and electrical fires be kept handy in the garage or workshop at all times. Never try to extinguish a fuel or electrical fire with

Household current

water.

Secondary ignition system voltage

Fumes Certain fumes are highly toxic and can quickly cause unconsciousness and even death if inhaled to any extent. Gasoline vapor falls into this category, as do the vapors from some cleaning solvents. Any draining or pouring of such volatile fluids should be done in a well ventilated area. When using cleaning fluids and solvents, read the instructions on the container

’

oye

et oe

~

,

When using an electric power tool, inspection light, etc., which operates on household current, always make sure that the tool is correctly connected to its plug and that, where necessary, it is properly grounded. Do not use such items in damp conditions and, again, do not create a spark

or apply excessive heat in the vicinity of fuel or fuel vapor.

A severe electric shock can result from touching certain parts of the ignition system (such as the spark plug wires) when the engine is running or being cranked, particularly if components are damp or the insulation is defective. In the case of an electronic ignition system, the secondary system voltage is much higher and could prove fatal.

Troubleshooting Contents Symptom EMm@ine Engine Engine Engine

Section

Symptom

Section

DACKTINGS x. .rcccsoee. ce taste eee een escent ke csvornsccaceedaveduneeas diesels (continues to run) after switching Off.........:.::cee hard to start wihemiColG eoirecvtcs:cseenccece trees: sercevsnxn-ccnavoansaepede hand: to:stant WheninOtesscanessesaseeteceeeeeae-cctcterevance=cces-oeeaneess

13 15 4 5

Noisyiin one particular’ Qe@al secre. ac.c.scccnes-vazecsceuevesssekeeeeeeeesee Reena Oil \OAKAGC.. u..05-cecesseccecccacgeteetdecdssbeneeessvesdeensdyiesnes'esdst teen Slips out Of high Gear ?...5..ci.de.cccgecseevewavensZqnenencvacssscese seestaeee eee : ay e

Eniginie LACKS DOWER Bulacan cree etek clue elas esoceateactrene

12

Automatic transmission

Engine lopes while idling or idles erratically...........ccccseceeesseeeeeeseees

8

FWA TO AKAGE oh aiccdss cis cntsceceenencteesstsesnwts ayeteaceettee 2-a.0e eee eee

42

Engineimissesiat Idle'speed!t.

fe)

General shift mechanisM ProbleMs ..........::cccceceeeseseesteneeeesereneeneneee

39

Transmission slips, shifts rough, is noisy or has no drive In fORWardiOr TEVErSE GOAN .

EVIDENCE OF PHYSICAL CONTACT WITH CAP

38.10 The ignition rotor should be checked for wear and corrosion as indicated here (if in doubt about its condition, buy a new one) and replace the wires one at a time to avoid mix-ups in the firing order. The wire routing is extremely important, so be sure to note

exactly how each wire is situated before removing it. 9 Remove the distributor screws. On V8 engines, it will be necessary to disconnect the EGR valve transducer vacuum lines and electrical connectors for access. Pull up on the cap, with the wires attached, to separate it from the distributor, then position it to one

side. 10 The rotor is now visible on the end of the distributor shaft. Check it carefully for cracks and carbon tracks. Make sure the center terminal spring tension is adequate and look for corrosion and wear on the rotor tip (see illus-

CRACK

CARBON TRACK

CARBON TRACK

WORN OR DAMAGED ROTOR BUTTON

38.13 Shown here are some of the common defects to look for when inspecting the distributor cap (if in doubt about its condition, install a new one)

tration).

If in doubt

about

its condition,

replace it with a new one. 11 ‘If replacement is required, detach the rotor from the shaft and install a new one. The rotor is a press fit on the shaft and can be pried or pulled off. 12 The rotor is indexed to the shaft so it can only be installed one way. It has an internal key that must line up with a slot in the end of the shaft (or vice versa). 13 Check the distributor cap for carbon tracks, cracks and other damage. Closely examine the terminals on the inside of the cap for excessive corrosion and damage

(see illustration). Slight deposits are normal.

Again, if in doubt about the condition of the cap, replace it with a new one. Be sure to apply a small dab of silicone dielectric grease to each terminal before installing the cap. Also, make sure the carbon brush (center terminal) is correctly installed in the cap - a wide gap between the brush and rotor will result in rotor burn-through and/or damage to the distributor cap. 14 To replace the cap, simply separate it from the distributor and transfer the spark plug wires, one at a time, to the new cap. Be very careful not to mix up the wires! 15

Reattach the cap to the distributor, then

install the screws to hold it in place.

2A-1

Chapter 2 PartA Inline six-cylinder engine

2A —

Contents Section

Section

Air filter and CCV filter replaceMent .............:ccceeeseeeeeeeees See Chapter 1

General infOnmatlOninecs

eee

1

Camshaft, bearings and lifters - removal, inspection

Intake/exhaust manifolds - removal and installation...........0..0006

7

PRAM eAtAl ELUIDI eeeet ca.eaten ce sc dees os eeace ce Ree ciouocdcs

,

>

Ae

4

aa”

a 10

—_

10-16

Chapter 10

Suspension and steering systems

shaft and slip the wheel onto the shaft. Install

fasteners to the torque listed in this Chapter’s

the nut and tighten it to the torque listed in

Specifications.

this Chapter’s Specifications. 7

8

;

15

Connect the negative battery cable.

:

Steering linkage

r

;

inspection,

removal and installation

Install the airbag module and tighten the

——— nn

Inspection Refer to illustrations 15.1a ana-15.1b 1 The steering linkage (see illustrations) connects the steering gear to the front

CLOCKSPRING

wheels and keeps the wheels in proper relation to each other. The linkage consists of the Pitman arm, fastened to the steering gear

HUB sae the

DRIVER SIDE

14.5b

Details of the

AIRBAG WIRE

airbag system

shaft, which moves the drag link back and

Paes iain!

clockspring (1999 and later models); when properly centered, the

forth. The back-and-forth motion of the drag link is transmitted to the right steering knuckle. A tie-rod transmits motion to the left

CLOCKSPRING

alignment arrows

steering knuckle. The tie-rod is made up of a

CASE

should be pointing at each other, and the

tube, clamps and two tie-rod ends. A steering damper, connected between the drag link

oblong hub pin should

(1998 and earlier models) or tie-rod (1999 and

be at the top

later models) and the front axle housing

LOCKING

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15.1a Steering linkage components -

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15.1b Steering linkage components - 1999 and later models

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15.8 Use a two-jaw puller to detach the tie-rod end from the te Nuts a Knuckiethis «nou Sroering removed; willceprevent the components

separating violently

ne nh =

|

Chapter 10

10-17

Suspension and steering systems

replacement, follow Steps 9 and 10 of this Section. 18 Installation is the reverse of the removal procedure. If the ballstuds spin when attempting to tighten the nuts, force them into the tapered holes with a large pair of pliers. Be sure to tighten all fasteners to the torque listed in this Chapter’s Specifications.

Pitman arm 19

Refer to Section 16 of this Chapter for

the Pitman arm removal procedure.

Steering damper 20 Raise the front of the vehicle and support it securely on jackstands. 21 Separate the steering damper from the

j 15.9 if a tie-rod end must be replaced, count the number of threads visible at the end of the adjuster tube and install the new tie-rod end with the same number of threads showing

reduces shimmy and unwanted forces to the steering gear. 2 Set the wheels in the straight ahead position and lock the steering wheel. 3 Raise one side of the vehicle until the tire is approximately 1-inch off the ground. 4 Mount a dial indicator with the needle resting on the outside edge of the wheel. Grasp the front and rear of the tire and using light pressure, wiggle the wheel back-and-

forth and note the dial indicator reading. The gauge reading should be less than 0.108inch. If the play in the steering system is more than that, inspect each steering linkage pivot point and ballstud for looseness and replace parts if necessary. f 5 Raise the vehicle and support it on jackstands. Check for torn ballstud boots, frozen joints and bent or damaged linkage components.

Removal and installation

drag link (1998 and earlier models) or the tie15.16 To disconnect the drag link from the tie-rod, use a small puller 10 Lubricate the threaded portion of the tierod end with chassis grease. Screw the new tie-rod end into the adjuster tube and adjust the distance from the tube to the ballstud by threading the tie-rod into the adjuster tube until the same number of threads are showing as before (the number of threads showing on both sides of the adjuster tube should be within three threads of each other). Don’t tighten the adjuster tube clamps yet. 11 To install the tie-rod assembly, reverse the removal procedure. Install the nuts and tighten them to the torque listed in this Chapter’s Specifications. If a ballstud spins when attempting to tighten the nut, force it into the tapered hole with a large pair of pliers.

12

Refer to illustrations 15.8 and 15.9 6 Loosen the wheel lug nuts, raise the vehicle and support it securely on jackstands. Apply the parking brake. Remove the wheel. 7 Remove the cotter pins and loosen, but do not remove, the castle nuts from the ballstuds on each end of the tie-rod. 8 Using asmall puller, separate the tie-rod end from the steering knuckle (both knuckles

on 1999 and later models) and, on 1998 and earlier models, the drag link (see illustration). Note: On 1999 and later models

the steering damper must also be detached from the tie-rod. Remove the castle nuts and pull the tie-rod from the knuckle and drag link. Caution: The use of a picklefork-type balljoint separator most likely will cause damage to the balljoint boot. 9 If a tie-rod end must be replaced, count the number of threads showing and jot down

this number to maintain correct toe-in during ssembly (see illustration). Loosen the

STE

cotter pins. If necessary,

‘ nut with the hole in the ballstud. 13 Tighten the adjuster tube clamp nuts to the torque listed in this Chapter’s Specifications. The adjuster tube clamp bolts should be nearly horizontal. 14

Tie-rod

Install new

‘tighten the nut slightly to align a slot in the

Install the wheel and lug nuts, lower the

vehicle and tighten the lug nuts to the torque listed in the Chapter 1 Specifications. Drive the vehicle to an alignment shop to have the front end alignment checked

rod (1999 and later models) using the technique described in Step 16. 22 Unbolt the damper from the axle hous-

ing and remove it from the vehicle. 23 Installation is the reverse of removal. Be sure to tighten the steering damper fasteners to the torque listed in this Chapter’s Specifications.

16

Steering gear - removal and installation

Warning: Make sure the steering shaft is not turned while the steering gear is removed or you could damage the airbag system clockspring. One way to prevent the shaft from turning is to place the ignition key in the LOCK position or run the seat belt through the steering wheel and clip the seat belt into place.

Removal Refer to illustrations 16.2, 16.4, 16.5, 16.6a and 16.6b

1 Raise the front of the vehicle and support it securely on jackstands. Apply the parking brake. 2 Place a drain pan under the steering

and, if neces-

sary, adjusted.

Drag link Refer to illustration 15.16 15 If you’re working on a 1999 or later model, loosen the left front wheel lug nuts. Raise the front of the vehicle and support it securely on jackstands. Apply the parking brake. Remove the wheel (1999 and later models). 16 Loosen, but do not remove, the nuts securing the drag link ballstuds to the tie-rod (1998 and earlier) or, on 1999 and later mod-

els, the steering knuckle. Separate the drag link from the steering knuckle (see illustration 15.8) and, on 1998 and earlier models, from the tie-rod (see illustration) with a twojaw puller, then remove the nuts. 17 Separate the drag link from the Pitman arm using the same technique. If the tie-rod end on the end of the drag link is in need of

el ee CNS Oke

ee

16.2 Loosen these fittings (arrows) and — disconnect the power steering fluid lines from the steering gearbox, then mark the relationship of the intermediate shaft Ujoint to the steering gear input shaft and loosen the pinch bolt

7

Chapter 10

16.4 Before removing the Pitman arm, mark its relationship to the steering gear shaft

Suspension and steering systems

16.5 Use a puller to separate the Pitman arm from the steering gear shaft

16.6a On 1998 and earlier models, the steering gear is mounted to the frame rail with three bolts (arrows)

Installation gear. Remove the hoses/lines and cap the ends to prevent excessive fluid loss and contamination (see illustration). If available, use a flare-nut wrench to remove the hoses/lines. 3 Mark the relationship of the intermediate shaft lower universal joint to the steering gear input shaft. Remove the intermediate shaft lower pinch bolt. 4 Remove the Pitman arm nut and washer. Mark the relationship of the Pitman arm to the shaft so it can be installed in the same position (see illustration). 5 Separate the Pitman arm from the shaft with a two-jaw puller (see illustration). 6 Support the steering gear and remove the mounting bolts (see illustrations). Note: If you’re working on a 1999 or later model, you'll have to unbolt and reposition the windshield washer fluid reservoir for access to the two forward bolts. Lower the unit, separate

7 Raise the steering gear into position and connect the intermediate shaft, aligning the marks. 8 Install the mounting bolts and washers and tighten them to the torque listed in this Chapter’s Specifications. 9 Slide the Pitman arm onto the shaft. Make sure the marks are aligned. Install the washer and nut and tighten the nut to the torque listed in this Chapter’s Specifications. 10 Install the intermediate shaft lower pinch bolt and tighten it to the torque listed in this Chapter’s Specifications. 11. Connect the power steering hoses/lines to the steering gear and fill the power steering pump reservoir with the recommended fluid (See Chapter 1). 12 Lower the vehicle and bleed the steering system (see Section 18).

the intermediate shaft from the steering gear input shaft and remove the steering gear from the vehicle.

16.6b On 1999 and later models, the steering gear is mounted with four bolts (the fourth bolt, not visible in this photo, is behind the windshield washer fluid reservoir)

17.2 Power steering pump line and hose connections (typical)

17

Power steering pump - removal and installation

Refer to illustrations 17.2, 17.3a, 17.3b,

17.3c, 17.4, 17.5a and 17.5b 1 Loosen the pump drivebelt and slip the belt over the pulley (see Chapter 1). 2 Using a suction gun, suck out as much power steering fluid from the reservoir as possible. Position a drain pan under the pump and disconnect the high pressure line

and fluid return hose (see illustration).Itmay be necessary to remove the air cleaner housing for access to the return hose (if so, see Chapter 4). Cap the ends of the lines to prevent excessive fluid leakage and the entry of contaminants. 3 Remove the mounting fasteners (see illustrations) and detach the pump from the engine. 4 If it is necessary to remove the pulley from the pump, first measure how far the pump shaft protrudes from the face of the pulley hub (this is only necessary if the pump has a plastic pulley). Remove the pulley from the shaft with a special power steering pump pulley removal tool (see illustration). This tool can be purchased at most auto parts stores. 5 A special pulley installation tool is also available for pressing the pulley back onto the pump shaft (see illustration), but an alternate tool can be fabricated from a long bolt, nut, washer and a socket of the same diameter as the pulley hub (see illustration). If the pulley is plastic, push it onto the shaft until the shaft protrudes from the hub the previously recorded amount. If the pulley is metal, press it on until it is flush with the end of the shaft. 6 Installation of the pump is the reverse of the removal procedure. Be sure to tighten the fasteners securely, and bleed the power steering system following the procedure in Section 18.

Chapter 10

Suspension and steering systems

10-19

17.3a Power steering pump and bracket mounting details - six-cylinder engine

INTAKE MANIFOLD

PUMP ASSEMBLY

DRIVE PULLEY

LEFT CYLINDER

SCREW 17.3b

PUMP BRACKET

17.3c Power steering pump mounting details 4.7L V8 engine

STEERING PUMP

Power steering pump and bracket mounting details 5.2L V8 engine

17.5b ...along bolt with the same thread pitch as the internal threads of the power steering pump shaft, a nut, washer and a

17.4 This special tool, designed for — ues

power steering pump pulleys, is

vailable at most auto parts stores

17.5a_There's also a special tool avaliable iter

aes power sieerog pump

pulleys, but...

socket that is the same diameter as the pulley hub can also be used to install the

pulley on the shaft

—

; ‘ Af

10-20

Chapter 10

Suspension and steering systems

ar Pan

19.4 Instail a spacer and a lug nut on the stud, then tighten the nut to draw the stud into place

19.3 Use a press tool to push the stud out of the flange 71

Hub flange

2

Lug nut on stud

18

Power steering system - bleeding

1

Following

any operation

in which

power steering fluid lines have been nected, the power steering system bled to remove all air and obtain steering performance. 2 With the front wheels in the ahead position, check the power

the

disconmust be proper straight steering

fluid level and, if low, add fluid until it reaches

the Cold (C) mark on the dipstick. 3. Start the engine and allow it to run at fast idle. Recheck the fluid level and add more if necessary to reach the Cold (C) mark on the dipstick. 4 Bleed the system by turning the wheels from side-to-side, without hitting the stops. This will work the air out of the system. Keep the reservoir full of fluid as this is done. 5 When the air is worked out of the system, return the wheels to the straight ahead position and leave the vehicle running for several more minutes before shutting it off. 6 Road test the vehicle to be sure the steering system is functioning normally and noise-free. 7 Recheck the fluid level to be sure it is up to the Hot (H) mark on the dipstick while the engine is at normal operating temperature. Add fluid if necessary (see Chapter 1).

19

3

Press tool

1

2

Hub flange

flange with a press tool (see illustration). 4 Insert the new stud into the hub flange from the back side and install some flat washers and a lug nut on the stud (see illustration). 5 Tighten the lug nut until the stud is seated in the flange. 6 __ Reinstall the brake drum or disc. Install the wheel and lug nuts. Lower the vehicle and tighten the lug nuts to the torque listed in the Chapter 1 Specifications.

20

Wheels and tires - general information

Refer to illustration 20.1 The vehicles covered by this manual are equipped with metric-sized fiberglass or steel-belted radial tires (see illustration). Use of other size or type of tires may affect the ride and handling of the vehicle. Don’t mix different types of tires, such as radials and

METRIC TIRE SIZES /

P 18 TIRE TYPE

P-PASSENGER

ye

Rage i Hesse A

80 R 13

ASPECT RATIO

RIM DIAMETER

(SECTION HEIGHT) (SECTION WIDTH)

7 75

SECTION WIDTH

(MILLIMETERS)

80

185 195

R-RADIAL

:3 15

B-BIAS - BELTED D-DIAGONAL (BIAS)

=«— SECTION i WIDTH

SECTION HEIGHT

20.1

(INCHES)

CONSTRUCTION TYPE

Wheel studs - replacement

Refer to illustrations 19.3 and 19.4 Note: This procedure applies to both the front and rear wheel studs. 1 Loosen the wheel lug nuts, raise the vehicle and support it securely on jackstands. Remove the wheei. 2 Remove the brake disc or drum (see Chapter 9). 3 Install a lug nut part way onto the stud being replaced. Push the stud out of the hub

Spacer

Metric tire size code

Chapter 10 TOE

Suspension and steering systems

TOE

FRONT OF VEHICLE 21.1 Toe-in is the only normally adjusted alignment setting

bias belted, on the same vehicle as handling

may be seriously affected. It’s recommended that tires be replaced in pairs on the same axle, but if only one tire is being replaced, be sure it’s the same size, structure and tread

design as the other. Because tire pressure has a substantial effect on handling and wear, the pressure on all tires should be checked at least once a month or before any extended trips (see Chapter 1). “| Wheels must be replaced if they are bent, dented, leak air, have elongated bolt holes, are heavily rusted, out of vertical symmetry or if the lug nuts won’t stay tight. Wheel repairs that use welding or peening are not recommended. | Tire and wheel balance is important to the overall handling, braking and performance of the vehicle. Unbalanced wheels can adversely affect handling and ride characteristics as well as tire life. Whenever a tire is installed on a wheel, the tire and wheel should be balanced by a shop with the proper equipment.

21

1998 and earlier models are caster and toein; on 1999 and later models the only adjustment possible is toe-in. Getting the proper front wheel alignment is a very exacting process, one in which complicated and expensive machines are necessary to perform the job properly. Because of this, you should have a technician with the proper equipment perform these tasks. We

will, however, use this space to give you a basic idea of what is involved with front end alignment so you can better understand the process and deal intelligently with the shop that does the work.

10-21

Toe-in is the turning in of the front wheels (see illustration). The purpose of a toe specification is to ensure parallel rolling of the front wheels. In a vehicle with zero toe-in, the distance between the front edges of the wheels will be the same as the distance between the rear edges of the wheels. The actual amount of toe-in is normally only a fraction of an inch. Toe-in adjustment is controlled by the tie-rod end position on the tierod. Incorrect toe-in will cause the tires to wear improperly by making them scrub against the road surface. Caster is the tilting of the top of the front steering axis from vertical (see illustration). A tilt toward the rear is positive caster and a tilt toward the front is negative caster. This angle is adjusted on 1998 and earlier models by adding caster adjustment cams (available at a dealer parts department) at the front of the lower control arm (this angle is not adjustable on 1999 and later models). Camber (the tilting of the front wheels from vertical when viewed from the front of the vehicle) is factory present at 0-degrees and cannot be adjusted. If the camber angle isn’t correct, the components causing the problem must be replaced. Caution: Never attempt to adjust the camber angle by heating or bending the axle or any other suspension component!

VERTICAL-——>| !~———CASTER ANGLE

21.2 Caster (the tilting of the top of the steering axis from vertical) affects the self-return characteristics of the steering system; it is not a routine adjustment, but should be checked whenever the front axle housing or front suspension arms are changed (it can be adjusted on 1998 and earlier models, however)

Front end alignment - general information

Refer to illustrations 21.1 and 21.2 A front end alignment refers to the adjustments made to the front wheels so they are in proper angular relationship to the suspension and the ground. Front wheels that are out of proper alignment not only affect

’,

.

vo

hod

a

CS

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steering control, but also increase tire wear. The only front end adjustments possible on

rs.sve

10-22

Chapter 10

Suspension and steering systems

Notes

aAnt

Chapter 11

Body

Contents Section

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Section

2 6 = 13 19 28 15

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