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Automotive Repair Manual
Ford Mustang Mercury Capri
Automotive Repair Manual by Larry Warren, Alan Ahlstrand and J...
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Automotive Repair Manual
Ford Mustang Mercury Capri
Automotive Repair Manual by Larry Warren, Alan Ahlstrand and John H Haynes Member ollhe Guild at Motoring Wmers
Models covered : All Ford Mustang models - 1979 through 1992 All Mercury Capri models - 1979 through 1986
(lW6- 654)
Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 lawrence Drive Newbury Park California 91320 USA
,---
Acknowledgements We are grateful to the Ford Motor Company for assistance with technical information, certain illustrations and vehicle photos. The Champion Spark Plug Company supplied theillusirations of vari· ous spark plug conditions.
©
Haynes North America, Inc. 1990,1992 WIh~"""'JH ~ & Co.Ud.
A book in the Haynes Automotive Repair Manual Series Printed In the USA All rights rHef"Yed. No part of this boo« rNy be reproduced ortTansmined In any form or by any means, .-ctronlc or mechanical, Including photocopying, recording or by any Information storage or retrieval system, without permlulon In writing from the copyright holder.
ISBN 1 56392 026 3 library of Congress catalog card Number 92-70520 While every aHempt i. made to ensure that the information in Ihls rNrwalls correct, no Ilablltty can be accepted by the authors or pubIIshws for to.., ct.mage or Injury caused by any e"ora in, or omissions from, the Information gl~ .
,,...,. •
Contents Introductory pages About this manual InaoductJon to the Ford Mustang/Mercury Capri Vehicle Identification numbers
BUying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting Jacking and towing Automollve chemicals and lubrICants
Salety IIrsll ConverSion factors TroobieshootlOg
0.. 0-6 0-7 0-8 0-8 0-15 0-16 0-18 0-19 0-2JIllI· 2"'~ U_RGAWII NUll
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1 Idle speed too htgh (see Chapter 1). 2 Electncal solenoid at side 01 carburetor nollunctlOnlng properl)' (not all models. see Chapter 4). 3 Ignillon liming Incorrectly adjusted (see Chapler 5) . 4 Thermo-controlled air clean8f heat valve not operating property (see Chapter I) . S Excesslveenglne operaling l emperature Probable causes of this are malfunctioning Ihermoslat. clogged radiator. faulty water pump (see Chapler 3)
0-24
Troubleshooting
Engine electrical system 16 1 ter 2 3 4 5 6 7
Baltery will not hold a charge
4 Thermostat faulty (see Chapter 3). 5 Fan blades broken or cracked (see Chapter 3). 6 Radiator cap no! maintalnmg proper pressure Have cap pressure lested by gas stallan or repair shop 7 Ignition IImmg incorrect (see Chapter 5)
Alternator dnvebell defecHve or not adjusted properly (see ChapI).
Electrolyte level low or battery discharged (see Chapter 1). Battery termmals loose or corroded (see Chapter 1), Alternator nOI charging properly (see Chapter 5) Loose. brOken or faulty Wiring In Ihe charging Circui t (see Chapter 5) Short In vehiCle wiring causing a continual drain on battery. Battery defective internally.
22 1
2
23
,7
Faull in alternator or charging circuit (see Chapter 5). Alternator driyebelt defective or not properly adjusted (see Chap· ter 1). 1
External coolant leakage
Detenorated or damaged hoses or loose clamps Replace hoses and! or tighten clamps at hose conneclions (see Chapter t). 2 Water pump seals defectlye. If thiS IS the case. water Will drip from the weep hole In the waler pump body (see Chapter 3) . 3 Leakage from radiator core or header tank. ThiS Wil l require the radla· tor to be prolesslonally repaired (see Chapter 310r remoyal procedures).
Alternator light lalls 10 come on when key Is turned on
Warning light bulb defective (see Chapter 12). Alternator laulty (see Chapter 5). 3 Faull in Ihe printed Circuit, dash wifing or bulb holder (see Chap· ter 12)
1
2
Fuel system 19
Thermostat faulty (see Chapter 3) Inaccurate tempe rature gauge or sender (see Chapter 3).
Alternator light stays on
2
18
Qyercoofing
EKCesslye luel c onsumption
Dirty or clogged air filler element (see Chapler 1). Incorrectly set ignition timing (see Chapter 5). 3 Choke sticking or improperly adjusted (see Chapler 1). 4 Emission system not functioning properly (not all vehicles. see Chapter 6) 5 Carburetor Idle speed andlor mixture not adjusted properly (see Chapter 1) 6 Carburetorlfuel injection parts excessively worn or damaged (see Chapter 4) 7 Low tire pressure or Incorrect tire size (see Chapter 1).
24
Internal coolant leakage
Note: Internal coolant leaks can usually be delected by examinmg the oil. Check the dipstick and mSlde of the rocker arm cover(s) for waterdeposlls and an all COnslslency like thaI 01 a mllkshake. 1 Leaking cyl inder head gasket. Haye the cool ing system pressure tested 2 Cracked cylinder bore or cy linder head. Dismantle engine and inspect (see Chapter 2).
1
2
25 1 2 3 4
26 20
Fuel leakag e and/or fuel odor
Leak In a fuelleed or vent hne (see Chapter 4). Tank oyerfilled. Fill only to automatic shu t·off. Emissions system clogged or damaged (see Chapter 6). Vapor leaks from system lines (see Chapter 4). 5 Carburetorlfuel injection internal parts excessiyely worn or ou t of adjustment (see Chapter 4). 1 2 3 4
Cootant loss Too much coolan t In system (see Chapter 1). Coolan t bOIling away due to overheating (see Section 21). Internal or ex ternal leakage (see Sections 23 and 24). Faulty radiator cap. Have the cap pressure tested.
Poor coolant circulation
Inopera\lye water pump. A qUick test IS to pinch the top radiator hose Closed wi th your hand while the engine IS Idling. then let It loose. You should feel the surge 01 coolant if the pump IS working properly (see Chapler 3). 2 Restriction in cooling system. Dram, flush and refill the system (see Chapter 1). If necessary. remove the radiator (see Chapter 3) and have it reverse flushed. 3 Water pump driyebelt detective or not adjusted properly (see Chap· ter I). 4 Thermostat sticking (see Chapter 3).
Cooling system 21
Ove rheating
1 InsuffiCient coolant In system (see Chapter 1). 2 Waler pump driyebel1 defectlye or nol adjusted properly (see Chapter 1). 3 Radiator core blocked or radiator gnlle dirty and restricted (see Chapter 3).
Clutch 27
Fails to release (pedal pressed to the floor - shift leyer does not move freely In and out of Reyerse )
Clutch lark 011 ball stud. Look under the vehicle. on the lett Side 01 transmiSSion.
Troubleshooting 2 Clutch cable OUI 01 adjustment or broken (mechanical release sys tem) (see Chapter 5) 3 Master or slave cy lmder faulty. faulty hydraulic line, low flu id level or air In system (hydraulic release system). 4 Clutch self-adjus ter quadranl laulty (1981 alld laler models) (see
Chapter 8). S 6
Clutch plale warped or damaged (see Chapter 8) IIlhe pedal makes a ralchetmg nOise while travelling to the lloor. the seH-ad)uster quadrant IS probably faulty (see Chapler 8).
28
33
0-25
Noisy in Neutral wllh engine running
Worn clutch release bearmg (see Chapter 8) (release bearing IS con· stantly engaged). To determme whether noise is from release beaflng or transmiSSiOn. disconnect clutch cable Irom release lever and puN release lever away Irom cable. It the noise Slops, It IS the release beanng. llit conhnues. It IS from the transmlssioo. 2 Damaged maIO drive gear bearing. 3 Worn counlershaft beaflngs. 4 Worn or damaged counters halt end play shims
Clutch slips (engine speed increases wllh no Increase in vehicle speed)
34
Noisy in all gears
Clutch plate 011 soaked or Ilntngworn. Removeclutch (see ChaplerS)
and Inspect 2
Clutch plale not sealed II may lake 30 or 40 normal starts lor a new
1 2
Any oltha above causes. and/or: InsulfiCientlubflcant (see checking procedures In Chapter I).
one 10 seal 3
Pressure plale worn {see Chapter B}. 35
29
Grabbing (chattering) as clutch Is engaged
I
2
01 on clutch plate IInll'lg Remove (see Chapter 8) arid Inspect Cor· recl any leakage source 2 Worn or loose engine or IransmlSSlon mounts These umts move slightly when clu tch IS released Inspect mounts and bolts 3 Worn splines on clutch plate hub. Remove clulCh componenls (see Chapter 8) arid Inspect 4 Warped Pfessure plate or lIywheel, Remove clu tch componenl s and Inspect
30
36
Worn, damaged or chipped gear teeth lor that particular gear Worn or damaged synchronizer 101 thaI parllCUlar gear
Slips out of high gear
t
TransmisSion mounting bolts loose Shltt rods not working freely. 3 Damaged mamshall pilol beanng 4 Olrt t:..etween transmiSSion case and engine or mlsaltgnmentot trans· miSSion
2
Squeal or rumble with clutch lully engaged (pedal relea sed) 37
1 Worn. delecllve or brOken release beanng (release beaflng IS con · stantly engaged on all models) (see Chapter 8) 2 Release beanng blrldlng on transmiSSion beaflng relalner, Remove clutch components (see Chapter 8 ) and check bearing Remove any burrs or nicks. clean and relubrlcate before relnslallahon
Squeal or rumble with clulch lully disengaged (pedal depressed)
Worn. defectIVe or broll.en release beamlg (see Chapter 8), Worn or broken pressure plate spnngs (or diaphragm Ilngers) (see Chapter 8) 3 All In hydraulic line (see Chapter 8). I
2
Dilliculty In engaging gears
Loose. damaged or out·ol-adJustment shlltllnkage Make a thOrough Inspection, replaCIng parts as necessary 2 Clutch cable oul of adlustment (1979-1980) Of self-adjusting mecha msm worn or damaged (1981 and later) (see Chapter 8).
38 31
Noisy in one par1icular gear
Lubricanlleakage
1 ExceSSive amount ollubncant In transmiSSIOn (see Chapter t 10fCOf reet checking Pfocedures) , Dram lubflcant as required. 2 Side cover loose Of gasket damaged. 3 Rear 011 seal or speedometer oil seal In need of replacement
Automatic transmission 32
Clutch pedal slays on lloor when disengaged
1
Bind In clulch cabfe Inspecl cable as necessary Blndmg release beanng Removeclu tch housll'lg (see Chapler 8) and Inspect 3 Faulty self·adJustlng system (t98t and lalermodels) (see Chapter 8).
Note: Due /0 the complex/IYof the automa/lc tfansmlSSI(}I'I, It IS diffICult for /he home mechaniC /0 ptoperly diagnose and servICe thIS component For probJemso/her !han !he folloWIng, the vehICle should be /aken /0 a dealer or reputable repa/( shop
2
Manual transmission Nole: All the folloWing references are fa Chapter 7. unless otherwise
ooled
39
General shill mechanism problems
1 Chapter 7 deals With checkIng and adjusting the shift linkage 00 aulo· matlc transrruSSlons. Common Pfoblems whICh may be annbuted to poorly adjusted linkage are; Engme slartlng In gears other than Park or Neutral Indica for on shllter pomtmg to a gear a/her than the one actually bemgused
0-26 2
40
Troubleshooting
Vehicle moves when in Park Refer to Chapter 7 to adjust the linkage.
Transmission will not downshift with accelerator pedal pressed to Ifoor
45
Pronounced wear In the universal joint beanngs Check as described in Chapte r 8.
46 Chapter 7 deals with adjusting th e downshift cable, downshift SWitch or TV cable to enable the transmission to downshift properly.
Metallic grinding sound consistent with vehicle speed
Vibration
Note: Before assummg that/he dnveshaf/ls allault, make sure the tires
are perfectly balanced and perform Ihe lollowing lest
41
Transmission slips, shifts rough , is noisy or has no drive In forward or reverse gears
There are many probable causes for the above problems. but the home mechanic should be concerned with only one poSSibility - !IUld level. Before taking the vehicle to a repai r shop, check the level and condl ' 2 tlon of Ihe tluid as described in Chapler 1. Correct flUid level as necessary o r change Ihe fluid and liller i! needed. II Ihe problem persists. have a professional diagnose the probable cause
42
Fluid leakage
Automat!c transmiss!on IIUld IS a deep red color. Fluid leaks should not be con fused With engine oil, which can eas ily be blown by air Ilow to the transmiSSion. 2 To pinpoint a leak. IIrst remove all bUl lt·up dirt and grime lrom around the transmission . Degreasmg agents and/or steam cleanmg wi ll achieve this. With the underSide clean . drive the vehicle at low speeds so ai r flow will not blow the leak far Irom its source. Raise the vehicle and determine where the leak is coming Irom. Common areas 01 leakage are: a) Pan : Tighten mountll)9 bolts and lor replace pan gasket as neces· sary (see Chapters ,' and 7) . b) Filler pipe: Replace the rubber seal where pipe enlers the transmiSSion case . c) Transmission all lines: Tighten connectors where lines enter transmission case and/o r replace lines. d) Vent pipe : Transmission overfilled andl or water In lIuld (see check · Ing procedures. Chapter'). e) Speedometer connector : Replace the O'flng where speedome ter cable enters transmiSSion case (see Chapter 7).
t Install a tachometer Inside the vehicle to moOitorengine speed as the vehic le is driven. Drive the vehicle and note the engine speed at wh ich the Vibration (roughness) IS most pronounced. Now shi ft the transmiSSion to a different gear and bnng the engine speed to the same point 2 If the Vi bration occurs at the same eng ine speed (rpm) regardless 01 which gear the transmiSSion IS In , the dflveshalt is NOT at fault since the dflveshaft speed varies . 3 II the vlbrallon decreases or 15 e liminated when the transmiSSion IS In a dltferent gear at the same engine speed, refer to the lollowlng probable causes . 4 Bent or dented dflveshaft Inspect and replace as necessary (see Chapter 8). 5 Undercoating or built-up dirt. etc on the dflveshalt. Clean the sha lt thoroughly and recheck 6 Worn universal JOin t bearings. Remove and Inspect (see Chapter B). 7 Dnveshaft and/or companion f lange out-aI-balance. Check lor miss Ing weights on the shaft. Remove the driveshatt (see Chapter B) and rein stall t BO-degrees from Original posItion . then retest Have the driveshalt profeSSionally balanced II the problem perSists
Axles 47 1
2
3
48
Noise Road nOise. No corrective procedures availab le Tire noise Inspect the tires and check lire pressures (see Chapter 1). Rear wheel bearings loose. worn or damaged (see Chapter 8).
Vibration
See probable causes under DriveshaTt Proceed under the gUidelines listed lor thedr iveshalt . 11 the prob lem perSists. check the rear wheel bearIngs by raising the rear 01 the vehicle and spinn ing the rear whee ls by hand. Li sten lor eVidence 01 rough (no isy) bea rings Remove and Inspect (see Chapter B) .
Driveshaft 43
Oil leak allront 01 driveshaff
Oelectlve transmission rear all seal. See Chapter 7 for replacement procedures. While thiS is done, check the splined yoke l or burrs or a rough cond llJon which may be damaging the seal. Burrs can be removed Wi th crocus cloth or a fine whetstone .
49
Oil leakage
Pinion seat damaged (see Chapte r 8) Axleshaft oil seals damaged (see Chapter 8) . 3 Dllferenlla l lnspectlon cover leaking Tighten the bol ts or replace the gasket as reqUired (see Chapters 1 and 8 ). t 2
Brakes 44
Knock or clunk when Ihe transmission is under initial load (lust atter transmission is pul inlo gear)
Loose or disconnected rear suspenSion components . Check all mounting bolts, nuts and bushings (see Chapter 10). 2 loose driveshaft bolts. Inspect all bo lt s and nuts and tighten them to the specilled torque , Worn or damaged universal JOint bearings. Check for wear (see 3 Chapter 8).
Note: Before assummg that a brake problem eXISIS. make sure that the tires are m good condition and Inflated properly (see Chapter t), that the front end alignment IS correct and thai the vehicle rs not loaded wrth Weight
m an unequal manner 50
Vehicle pulls to one side during braking
Defective, damaged . or 0 11 contaminated brake pads or shoes on one Side. Inspect as described In Chapter 9
Troubleshooting 2 E~cessl ... e we ar 01 brake shoe or pad material or drum'dlsc on one side. Inspect and correct as necessary 3 loose or disconnected Irani suspension componen ts. Inspect and lighten ail bolts 10 the specified lorque (see Chapter 10), 4 Defective drum brake or caliper assembly Remove the drum or cal!per and Inspect lor a stuck piston Df other damage (see Chapter 9).
51
Noise (high-pi tched squeal with the brakes applied)
56
0-27
Brake pedal pulsates during brake application
\ Wheel bearings not adjusted propeny or in need of replacement (see Chapler I) . 2 Catlper nOI sliding properly due 10 improper Installation or obstrtJC· hons Remove and Inspect (see Chapter 9). 3 Rotor 01 drum defective Remove the rolor or drum (see Chapter 9) and check for excessive lateral !Unout. out-ot·round and parallelism Have the drum or rotor resurtaced or replace It With a new one
Note : OccaslOna/squealJsnormal Severecondilionssuchassno w, ram,
sail. mud. extreme cold or extreme heat may make the condition worse An occaSIOnal squeal does no/ necessarily mdlCale loss of braking ef/ec-
Suspension an d steering systems
IHleness or a need for correc/lve actlOlJ DISC brake pads worn out The noIse comes flom the wear senSOf rubbing ag3ms! the diSC. Replace lhe pads With new ones Immediately (see Chapter 9). 2 MISSing or damaged brake pad Insulators (diSC brakes). reptace pad insulators (see Chapter 9), 3 Linings contaminated With dirt or grease. Replace pads or shoes. 4 Incorreclllnings Replace With correct linings
S2
57
Vehicle pull s to one side
Tire pressures uneven (see Chapter 1). Delecti ve Ille (see Chapter I). 3 ExceSSive wear in suspension or steenng components (see Chapter \0). 4 Front end out 01 alignment. 5 Front bfakes draggIOg Inspect the brakes as deSCIlbe
2
Excessive brake pedallravel
58 Partial brake system fai lure Inspect the entire system (see Chap ter 9) and correct as required 2 InsuffiCient flUid In the maSTer cylinder, Check (see Chapter 1), add nul(! alld bleed the sySTem II necessary (see Chapter 9) 3 Rear brakes not adtustlng properly (drum bfakes). On models wllh rear drum brakes (an except Muslang SVO), make a senes 01 starts and stops WIth the vehicle 10 Reverse II thiS does not correct the SituatIOn, re move the drums and Inspect the self-adlusters (see Chapter 9).
Shimmy. shake or vibration
1
Tire or wheel ou t-ot -balance or ou t-ot -round. Have protesslonally bal anced 2 loose_worn or oul -ot -adjustment wheet beamlgs (see Chapters 1 and 8). 3 Shock absorbers and 'or suspenSion components worn or damage::! (see Ch apter 10).
S9 S3
Brake pedal leels spongy when depressed
\
Au In Ihe hydrauliC lines Bleed lhe brake syslem (see Chapter 9). Faulty fleXible hoses Inspect an system hoses and lines Replace parts as necessary 3 Master cylinder mounting bolts'nu ts loose 4 Master cy linder defective (see Chapter 9).
2
\
Detective shock absorbers Replace as a set (see Chapter 10). Broken or weak spnngs and or suspension components Inspect as descflbed In Chapler 10
2
60 54
Excessive effort requ ired to slop vehic le
\
Power brake booster not operating properly (see Chapter 9). Excessively worn linings or pads Inspect and replace If necessary (see ChapTers 1 and 9) 3 One or more caliper pistons or wheel cylinders seized or Slicking,lnspect and relxlIld as required (see Chapter 9) 4 Brake linings or pads contaminated wllh 011 or grease, Inspect and replace as reqUired (see Chapters 1 and 9 ) 5 New pads or shoes Inslaned and nol yet seated It will lake a while lor the new matenaj to seat against the drum (or lotor)
2
S5
Excessi ve pitching andlor rol1ing around corners or during braking
1
2 3 4
5
61
Excessively stilt steering Lack ot flUid In power steenng reservolf (see Chapter 1). Incorrect tile pressures (see Chapter I ). Lack ot lubncatlon at steeling 101niS (see C hapter I ). Front end oul ot alignment See Section 62
Excessi ve play in sleerlng
Loose Iront wheel beanngs (see Chapter 1). ExceSSive wear In suspenSion or steeflf'IQ components (see C hapter (0 ). 3 Steering gearbox out of adjustment (see Chapter 10). I
2
Pedallr8vels 10 the lIoor with tittle reslslance
Lmle or no lIuid In the master cylinder reservotl caused by leaking wheel cyllnder(s)_ leakmg caliper piston{s). loose, damaged Of disconnected brake lines Inspect the entire system and correct as necessary 2 Worn master cylinder flUid seals (Ihe problem can occur even when the master cylinder IS tull of flUid) (see Chapter 9)
62
Lack 01 power assistance
Sleefing pump dllvebeltlaulty or nol adjusted properly (see Chapter I). 2 FlUid level low (see ChapTer 1).
0 - 28
Troubleshooting
3 4
Hoses or lines restricted. Inspect and replace parts as necessary. Air In power steering system. Bleed the system (see Chapter 10).
63
Excessive tire wear (not specific to one area)
3 Front end alignment Incorrect (excessive toe-in). Have pfOl esSionally aligned. 4 Suspension arm bent or twisted (see Chapter 10) .
65 1 2 3 4
Incorrect tire pressures (see Chapter 1). Tires out-ai-balance. Have professionally balanced. Wheels damaged. Inspect and replace as necessary. Suspension or steering components excessively worn (see Chap or 10).
64
Excessive Ure wear on Inside edge
1 2 3
Inllalion pressures incorrect (see Chapter 1) Front end alignment incorrect (toe·out). Have professionally aligned. Loose or damaged steering components (see Chapter to).
66
TIre tread worn in one place
1 2 3
Tires out·of-balance. Damaged or buckled wheel. Inspect and replace if necessary. Defective tire (see Chapter 1).
Excessive tire wear on outside edge
1
Inflation pressures incorrect (see Chapter 1).
2
Excessive speed in turns.
Chapter 1
Tune-up and routine maintenance
Conlents
Air lilter replacement. Automatic transmission lIuld and litter cha!'lge Automatic transmiSSIon lIuld level check AlJtomatlc \ransmlSSJOfl shift linkage lubrication
Battery check and maintenance Brake system check Carburetor choke check . ChasSIS lubncalJon Clutch linkage lubncahon and adjustment
CompresSion check . .
16 12
, "
26
25 32
"
27 See Chapter 2
Cooling system servicmg (draining. flushing and relilhng)
22
Cooling system check Crankcase vent filter replacement DIfferential (rear axle) lubrlCanllevel check and change Orivebelt check, adjustment and replacement Engine 011 and hlter change E~hausl system Check Fluid leyel checks . . From wheel beanng check, repack and adjustment
"" "" 7
23 3 28
Fuel liner replacement Fuel system check
Idle speed check and adjustment (carbureted models) IntroductJOnJmalnlenance schedule Manual transmiSSion lubrlcanllevel check and change Owner salety checks PCV valve Check and replacement Power steeflng lIuld level check Spar1l plug Wire, distributor cap and rotor check and replacement Spark plug replacement
Steering and suspenSIOn check Tire rotallon Tire and tile pressure checks Tune-up general in/ormation _. UnderhQOd hose check and replacement Valye clearance check and adjustment (2.8l V6 engines only) Windshield WIper blade check and replacement
20
'9 33
,•
,.•
3'
31
30 2' 9 8 2 13 29 3
~
• 0"...,1·,0I>'Id
• T_",
Ol..act"'""...,.,
0_,,_
u"..,.,,_
8.3
This chart wilt help you determine the condition of your tires, the probable cause(s) of abnormal wear and the correcllve action necessary
1-18
Chapter 1 Tune-up and routine maintenance
8.4a If a tire loses air on a steady basis, check the valve core Ilrst to make sure it's snug (special Inexpensive wrenche s are commonly available at auto parts stores) alter a nail has embedded Itself In the tfead 11 a slow leak pe rsists, check the valve slemcore to make sure 11 is ttght (see Illustration). Exsmlnelhe tread lor an object that may have embeddeclltsell in the tlfe or for a "plug" that may have begun 10 leak (radial tire punClures ate repaired wllh a plug thai IS Installed In Ihepuncl ure). 11 a punc1ure ISSUspecled, llean be easdy
verilled by sp!'aylng a solution of soapy water onto the puncture (see IIlustt8110n) The soapy solution WIll bubble ilthers 15 a leak. Unless the punctUfe IS unusually large, a lire shop or service sl atlon can usually repair the tire 5 Carelully inspect Ihe Inner sidewall 01 each lire lor evi dence 01 brake Iluid leakage. II you see any, inspectl he brakes Immediately. 6 Correct air pressure adds miles to the hfespan 01 the tires. Improves mileage and enhances overall nde quahty, Tire pressure cannot be accu rately estimated by looking at a tire, especially II it's a radial. A lire pressure gauge IS essenllal. Keep an accurale gauge In the glove compartment The pressure gauges attached 10 the nozzles 01 air hoses algas Sl allons are olten Inaccurate 7 Atwayscheck tire pressure when the Ilres are cold. Cold. In Ihls case, means Ina vehicle has not been dnven over a mile In the th ree hours preceding a tire pressure check, A pressure flse 01 Ioor 10 eighl pounds is not uncommon once the tires are warm. S Unscrew Ihe valve ca p protruding from the wheel or hubcap and push the gauge hrmly onto the valve stem (see illustration), Note the reading on the gauge and compa re the figure to th e recommended tire pressure shown In your owner's manual Of on the lire placard on Ihe passengefs side door or door pillar Be sure 10 reinslallthe valve cap 10 keep din and
8.4b
IIlhe valve core Is l ight, raise the corner of the vehic le with
Ihe low lire and spray a soapy water solution onlo the tread as the Ure is rotaled - slow leaks will cause small bubbles to appear mOIStureoul 01 the valve stem mechanism. Check all lour tires and, If nec· essary, add enough air to bring Ihem to the recommended pressure 9 Don l lorgel to keep the spare lire Inllated \0 the specllled pressure (reler 10 yoor owne(s manual Of the placard attached to the door pillar). Nole thai the pressure recommended tor temporary (mini) spare Ilr95 IS hlOher Ihan lor the 'Ires on the vehICle
9
TIre r otation
Refer to If/ustra tion 9.2 , The !Ires should be rolaled at Ihe specilled intervals and whenever uneven wear IS noticed Smce the vehICle ... 111 be raised and the tires checked anyway. chei! .
14 .4 Here are some 01 the more common problems associated with drivebelts (check the belts very caretully to prevent an untimely breakdown) 4 With the engine oN, open the hood and local e the dnvebalt(s) al the front 01 the engme. With a flashlight. ched,
IlNGINE ... IR CU: ... NER INLET TU8E ... mMIllY
Four·cyfinder EFI non-turbo 7 Qlsconnecllhe vacuum hose and outlellube from the air cleaner cov er(see illustration) Remove the cover retaining screws and 11ft thecover oil 8 Remove the filter 9 Wipe the InSide 01 the air cleaner hOUSing with a clean cloth. to Ptace the new air htter In the hoUSing If the hlter IS marked TOP, be sure the marked Side laces up
~\"-.
'iROKTOF ~NGINE
" 16.7
Air cleaner assembly (four-cyllnder non-turbo models)
1-30
Chapter 1 Tune-up and routine maintenance fliES'" AlII
INLET TUBE
AIR CU A NEII TUBE ADAPTER
Hose CLAMP
...
VIEW l
HOSE C L AMP
fR ONT OF (NGINE
#>
AIR CLEANER
AlA CLE A NER OUTLET tu e E
A IR CLEANER BRACKET
16.13
Air cleaner assembly (lour-cylinder turbo models)
""'"""~ ~~
f'LHRRH" 'NE" ... .. C L£ .. NE .. SHEU I"H .I
(
Ut+OUSI:";,":... - • "'(0'0 '8-12 I... Ln 'SHIIl ... "" - PRfIID21 - LIGH'
CIRCUIT
~ HOUSI'IG .. NO LEVER ASSE"'llV
10-2OfT· US 11'·11 N-", '
(NCAGE
'L""~'
.ru
'~ ~ OJU'TlNO
33.15
Adjusting the last Idle on a model 5200 carburetor
5C"'W
Locations of the TSP-on and TSP-ott adjusting screws on a model 6500 carburetor
6
Alter a few minutes, the choke plate should be fully open to the verti -
cal poSition. 7 Note that the engme speed corresponds to the plale opening angle.
With the plate closed, the engine should run at a last Idle speed. As the plate opens, the engine speed Will decrease. The last idle speed IS controlled by the fast Idle cam, and even though the choke plale IS open completely, the Idle speed w ill remam h igh unliithe thr2tt1e p late IS opened, releaSing the faslldle cam. Check the drop In Idle speed as the choke pla l e opens by occasiona lly -blipping" Ihe Ihroltle 8 II the choke doesn't work as deSCribed, shut off the engine and check the shaft and linkage lor deposits which could cause binding, Use a sprayon choke cleaning solvent to remove the depoSits as you operate the linkage. T his should loosen up the linkage and the shaft and al low the choke to work properly. If the choke stili falls to function correctly, the chok-e bimetal assembly IS malfunctioning and the carburetor may have to be overhauled. Re fer to Chapter 410r carburetor overhaul In forma \lon , 9 AI regular In terva ls, clean and lubricate the choke sha ft. the fast Idle cam and linkage and the vacuum d iaphragm pulldown rod to ensure good choke performance.
33
Idle speed check and adjustment (carbureted models)
Note: The followmg adjustments are for carbureted models only. Idle speed does nOl reqUire penodlc adjustment on fueHn/ected models If the procedure below conflicts With the procedure listed on the Vehicle EmiSSion ControUnforma/lon label m the engme compartment, the procedure on the label IS correct 1 Connect an accurate tune -up tachometer to the engine, fo llOWing lhe manufacturer's Instructlons_ On models so equipped. conneCI the ta chometer pickup to the TACH TEST terminal on the Ignition COil Block the vehiC le's wheels so It cannot move while adjustments a re being made
Model 5200/6500 carburetor Refer /0 II/ustratlons 33. 10 and 33./5 2 The Holley /W eber Model 5200 carburetor IS used on early (through 1982) four·cyl lnder models firsl sold oUls ide California The Model 6500, a feedback verSion of the same carburetor deSign , is used on Ca llforma four-cylinder models through 1982 3 Remove the air cleaner and plug all vacuum lines that were al\ached to the air cleaner at the vacuum source end 4 Apply Ihe park ing brake and block the wheels so the vehicle Will nol ro ll 5 Check and adjust, II necessary, the choke and throttle hnkageforfreedam of movement
6
Start the engine and run it up to normal operating temperature, Disconnect the EGA vacuum line at the valve , and plug the line Where applicable, set the air conditioning to OFF. 9 Where applicable, remove the spark delay valve and route the primary advance vacuum signal line directly to Ihe distributor vacuum diaphragm UI1l\ (advance Side). 10 Place the transmission In Park (automatiC) or Neutral {manual) , then run the engine at normal operating temperature, Check that the choke plates are closed, then set the throttle so thai the fast idle adJusung screw contacts the kick-down step of the choke cam ; adjust the fast idle adjusting screw to obtam the specified fasl idle rpm (see illustration) t 1 Set the throttle to the high step of the choke cam and allow the engme to run for apprOXimately hve seconds t 2 Rotate the choke cam un\ll the fast Idle adjusting screw contacts the choke cam kick -down step _Al low the engine speed to stabi lize, then re check the fast Idle rpm, as deSCribed in Steps 10 and 11 . readjust il neces sary, then repeal the procedure given In the first sentence of thiS paragraph to ensure the same, conSlslenl result 13 A llowthe engme to return to the normal Idle, then , for automatlctransmiSSion models , select Dflve Warning: Be sure the parl<mg brake IS sel secure/yand the wheels are blocked before selec/lng Dnve. Do not accelerate the engme while It'S in DrIVe. and stand to the Side of the vehicle, not in front of II. wh/le makmg Ihe follOWing adjustments 14 Where no TSP assemblyis filted, adlust the curb idle screw in or out to obtam the speCified curb Idle speed, then proceed to Step 18 15 Where a TSP assembly is tilled , adlust the curb Idle screw which contacts Ihe solenOid plunger to obta in the speCified curb Idle speed (the solenOid is energized and the plunger ex tended when the igl1ltlon IS On) (see illustration) 16 Now collapse the solenOid plunger by forCing the thrott le linkage against the p lunger, grasping the throttle lever and solenOid housmg between the thumb and index finger to alleviate movement of the solenoid assembly poSition. 17 AdJust the TSP-ofi adJusling screwto obtam the speCihedTSP-olf idle speed 18 Open the throtlle slighlly to allow Ihe solenoid plunger 10 extend, 19 PrOVided that all adjustments are now satisfactory, stop the eng me, then Install the air cleaner and ItS associated vacuum Imes 20 Restart the engme and. II necessary. run It up to normal operallng tempera ture. With the engme running at 2000 rpm (apprOX imately). select Park (automatic transmiSSion) or Neutral (manual transmission) . AllOW hve seconds (apprOXimately) for the speed to stabHlze, then let the engine relurn to Idle; sel aulomatic transmiSSion models 10 Olive. Recheck Ihe curb idle speed, and. If necessary readjust as deSCribed begmnmg at Step 12. 21 Reconnect all vacuum lines as they were Originally
7 8
1
Chapter 1 Tune-up and routine maintenance
1 - 48
33.35
33.28
Fast idle adjustment (YFA carburetor)
YFA 1 V carburetor ReIer fa !/Iusrrallons 33.28 and 33.35 22 Thiscarburetor,lnfeedbackand non-feedback verSions. was usedon 1983 through 1986 non-turbocharged verSions of the four-cylinder englOe. The adjustments thallallow apply to both versIOns. 23 Warm the engine to normal operating temperature. 24 Place the lranSmiSSlOn In Pa~ (automallc) or Neutral (manualJ,lhen shut the engine of! 25 Leave the key in the on poslhon arid make sure the air condilloner (If so eqUlpPe
I~
~ PIN
$l'RI N GWASHER
4.5
Rocker arm shaH component s - exploded view
,.
2B-4
Chapter 2 Part B
4.8a Lubricate the pushrod ends with molv-base grease or engine assemblv lube belore installation
3.3 liter inline six-cylinder engine
4.8b Make sure Ihe pushrods are engaged in the rocker arms belore Installing the bolts
4.10
Tighten the rocker arm shalt bolts to the specified torque
8 Instalilhe pushrods (see illustrations) and posllion the rocker arm shaft assemblV on Ihe cV llnder head 9 Inslall and Ilghl en aU lhe rocker arm support boilS 112-turn at a time 11"1 the recommended sequence (see Illustration 4.4) unlil the supports con· lact the cylinder head. 10 Tighten the bolts to the speCIfied torque In Ihe same sequence (see Illustration) 11 Check Ihe valve clearance followll"lg the procedure in Chapter 2. Part E 12 Clean the rocker arm cover and cvlmder head gasket sunaces. 13 InSl ali a new gaskel in the cover Make sure all the gasket tangs are engaged in the notches prOVided 10 Ihe cover 14 Install the cover tsee 11Iustratlon) and tighten Ihe bolts 10 two steps First tighten the bolts to lille It-Ibs.then retighten them to hve It-Ibs agam two mlOutes later 15 Inslail lhe accelerator cable bracket 16 Install the crankcase ven\l lallOn system and air cleaner assembly 4.14 Make sure all gasket surfaces are clean belore installing the rocker arm Caller - if the COlier flange is distorted (this usually happens around the bolt holes), use a hammer and block 01 wood to lIatten and restore it
5
Valve spring , retainer and seal- replacement
Refer to il/ustratlons 5 4 and 5 10
5.4
Use an air line adapter and compressed air to hold the vallie closed while compressing Ihe vallie spring
Nole: Broken valve spnngs and defecllve lIalve stem seals can be reo placed wlthoul removmg the cylinder head Two special tools and a compressed alrsource are normally reqUired to perform thiS operation. so read through thiS Secllon carefully and renl or buy the tools before begmnmg the Job If compressed all Isn'l available. a length of nylon rope can be used to keep the valves from falling 1010 the cylmder durmg thiS procedure. I Rel erto Section 4 and remove the rocker arm cover from Ihe cy llOder head 2 Remove the spark plug from Ihe cyl inder which has the del ectlye component If all of the vallie Slem seals are bell"lg replaced. all of Ihe spark plugs should be removed. 3 Turn Ihe crankshaft untillhe piSlon 11"1 the allected cylinder IS al top dead cente r on the compreSSion stroke (refer to Section 3101 instructions). If you're replaCing all of Ihe valve stem seals. begin With cylinder number one and work on the valves lor one cY"l lnder al a lime Move from cylinder· lo·cyllnder follOWing the fir ing order sequence (see this Chapter's Speci!i· callons) 4 Thread an adapter into Ihe spark plug hole (see illustration) and connect an air hose Irom a compressed all source to It Most aula parts stores can supply the air hose adapter Note: Many cylmder compression gauges utilize a screw-m flllmg that may work With your alf hose qUick ·dlsconnect fl/fmg
Chapter 2 Part B
3.3 liter inline six-cylinder engine
2B -5
rope was used Instead of 3Jr pressure, turn the crankshatt In the nofmal dlfecllon 01 rotatlOO untlt slIght resIstance is leI\. I S Lubricate the valve stem With engine all and ,"slall a new seal 16 Install the spring and sleeve In poSition over the valve . 17 Install the valve spnng relalner. Compress the valve spring and carefully poSition the keepers," the groove. Apply a small danolgrease to Ihe ,"side 01 each keeper to hold it in place. I 8 Remove the pressure from the spring tool and make su re the keepers are seated. 19 Disconnect the al( hose and remove the adapter from the spark plug hole. II a rope was used in place 01 alt pressure. pull it oul 01 the cylinder 20 Reier to Section 4 and install the rocker arm assembly and pushrods 21 tnstallthe spark plug(s) and hook up the Wlr~s) . 22 Reter \0 Secllon 4 and Install the rocker arm cover 23 Start and run theengme , then check lor 011 leaks and unusual sounds coming from the rocker arm cover area
, 5.10 Removing Ine umbrella-type valve stem seal - when installing Ihe new seal, Ihe open end must lace the cylinder head 5 Loosen Ihe rocker arm shalt support bolts unlit valve spring tenSion IS relieved. Slide the rocker arms to the SIde and restrain them WIth pieces 01 wire . then remove both pushrods Irom Ihecyllnderto be servICed Note: If ai/ the valvesrem seals must be replacecJ. remove l/lerocker arm assembly (refer /0 Sec/Ion 41_ 6 Apply compressed air 10 Ihe cylinder Warning : The PIston may be
lorced down by compressed alf, causing the crankshaft to /Urn suddenly If Ihe wrench used when posi/lofllng the number one'piston al TOC is 5/1// attached 10 the boll in the crankshaft nose. II could cause damage or injury when the crankshaft moves
7
The valves should be held In place by the alf pressure. It the valve taces or seats are In poor condition, leaks may prevent air pressure trom retaining the valves - refer to the alternative procedure below 8 II you don·t have access to compressed air. an alternative method can be used POSlilon the piston at a pOint lust before TDC 0f1 the compression stroke. lhen teed a long piece 01 nylon rope through the spark p lug hole unlliit hils the combustion Chamber. Be sure to leave the end of the rope hanging oul ot the engine so It can be removed eaSily Use a large ratchet and socket to turn the cranksha/t In the normal direction at rOtation until shght resistance IS felt 9 Siult shop rag s Into the cyhnder head holes above and below Ihe valves to preven t parts and 100ls trom fai ling Into the engine. then use a valve spnng compresso r 10 compress Ihe spring, Remove the keepers With small needle-nose pliers or a magnet. Note: A couple of different types 01100/5 are available for compressing the valve springs wl/h the head In place One type grips Ihe /o wer spring COIls and plesses on the relalfler as the knob IS turned. while the other type (see Illustration 5.4) utlhzes rhe rocker arm shafl for leverage Both types work very well. although the lever type IS usually less expenSive to Remove thespnng retainer steeve and valve spnng. then remove the umbrella-type gUide seal (see Illu stration ) Note : If air pressure falls to hold the valve IfI lhe closed posilion durmg Ihls operallon. the valve face or
sealrs probably damaged. If sO,lhe cylinder head will have lobe removed lor addilional repalf operaflOns. II Wrap a rubber band or tape around the top o t Ihe valve stem so the valve won I lalllnlO the combustion chamber, then release Ihe air pres sure. No te: /I a rope was used Instead of alfpressure, tum the crankshaft
slightly In the alrec/lon opposite normal rotairon 12 Inspect the valve stem tor damage Rotate the valve In the guide and check the end tor eccentnc movement. which would Indicate the valve IS
be" 13 Move the valve up-and-down In the guide and make sure It doesn t bind If the valve stem binds. either the valve IS bent or the gUide IS dam aged In either case, the head Wi ll have to be removed lor repair_ 14 Reapply air pressure to the cyl inder to fetaln the valve in the closed posllion, then remove the tape or rubber band Irom the valve stem. II a
6
Cylinder head - removat and Inslal1ation
Refer /0 lIIus/ratlon 6.30
Removal Nole: If the engme has been removed 'rom the vehICle. you can slop Steps I through /4
1 Dram the cooling system (Chapter I) . 2 Remove the 3Jr cleaner and hoses/ducts leading to the alf cleaner_ 3 Detach the PCV valve trom the rocker arm cover and remove the valve 4 Remove the vent hose from the intake manllold inlet tube . S Dlsconnecl the 'uelline lead,"g tram the tuel pump \0 the carburetor_ 6 Detach all vacuum IKles tram the carburetor. 7 Disconnect the choke cable al the carburetor and poSi tion It out of the way. 8 Disconnect the accelerator cable or accelerator linkage Irom the carburetor. Remove the return spnng 9 Disconnect Ihe klCkdown link at the carburetor. 10 Remove the upper radIator hose trom the thermostat outlet 11 Remove the heater hose at the coolant outlet elbow 12 Remove the nuts sea.mng the e.haust pipe to the e.haust manifold and support the pipe out of the way t3 Mark the Wires leading to the coil and disconnect them_Remove the COil bracket bolt and secure the coli and bracket out of the way 14 Remove the rocker arm cover (Section 4 ). 15 Remove the rocker arm shalt assembly (Section 4) . 16 Remove the pushrods, Labe l them so they can be remstalled in thelf Oflglnallocatlons - a numbered box or rack Will keep Ihem organized. 17 Disconnect the spark plug wires al the spark plugs. 18 Loosen the cylinder head bolls In 1/ 4-lum Increments unliithey can be removed by hand It you have an engine hOIst or Similar deVICe handy. attach eyelet bolts at the ends 01 the head In the holes provided and lift the head olf the engine block. II equipment of thiS nature Isn't avaltable, have a helper available and carefully pry the head up. olt the block_ Caution : Do nol wedge any tools between the cylmder head and bIocIc gasket matmg surlaces 19 Turn the cyhnder head upside-down and place lion a workbench Note: New and rebUll1 cylinder heads are commonly available 'or engines al dealerships and aulo parts slores Due 10 /he lacI thaI some specialized
tools are necessary for disassembly and inspection of Ihe head, and re placement parts may nOI be readily available. 1/ may be more practICal and economIcal for the home mechanIC /0 purchase a replacement head and install II
20 Another alternatIVe at thIS POint IS to take the cylinder head 10 an automOhVe machine shop or shop Specializing in cylinder heads and e.change It or leave 11 for an overhaul. 21 11 the complete engine IS being overhauled at thiS lime, however, it may be wise to walt until the Other components have been Inspected 22 II you're attempling to repair a part of the cylinder head assembly. or It YOU're gOing 10 Inspect the components yourself. reler to Chapter 2,
Part E
2B
28-6
Chapter 2 Part 8
3.3 liter inline six-cylinder engine INSTRUCT IONS
'NSl .o.u
311- 16 STUD . . .... SH{ " ASSE " BlY _ HOLES ",UMB ERED • • ~ TOROUf TOSl'£C IF leA"ONS. l(8.18 X 2.6180LT _ HOLES l-6-1-. TORQUE TO Sl'EeiFI CATIONS. 318-1& X ' . ' 7 8 0LT - " OLES 1·'·9- ' 0. " TORQUE TO Sl'EClf IC... · TION S.
6.30 Cylinder head bolt TIGHTENING sequence (reverse th e sequence when loosening the bolts)
,
Installation
( X..... USTM ..... ,. O LD
23 The ma\lng surfaces althe head and block must be perfeclly clean
when the head
IS
may not seal correctly and leaks may develop. When working on the block, irs a good Idea to cover the lifters With shop rags to keep debriS oul of them. Use a shop rag or vacuum cleaner to remove any debriS that falls into the cylinders. 25 Check the bfock and head mating surfaces for nicks, deep scratches and other damage. II damage is sligh1. it can be removed With a file: if irs exceSSive, machining may be the only alternative. 26 Use a tap of the correct size to chase the threads in the head bolt holes. Dirt. corrosion. sealant and damaged threads wi ll affect to rque readings. 27 POSition the new gasket over the dowel pins in the block. Some gas· kets are marked TOP or THIS SIDE UP to ensure correct Installation. 28 Carefully position the head on the block without disturbing the gasket. 29 Using the previOusly installed lilting hooks (or a helper), carefully low· er the cylinder head into place on the block. Don ·tlflove the head sideways or scrape It across the block. as It can dislodge the gasket andlordamage the mating surfaces. 30 Coat the cylinder head bolt threads with light engme oil and thread the bolls into the block. Tighten them In the recommended seQuence (see iI· lustrati on). Work up to the final torque in three steps to avoid warpmglhe head 31 Inslallthe pushrods. the rocker arm assembly and the rocker armcov er (Section 4). 32 The remaining steps are the reverse of the removal procedure. 33 Start the engme and allow il to reach operating temperature. Shut It off. allow It to cool completely. then retorque the head bolts. Note: Besure to read the Instructions wl/h Ihe new head gasket. Some gaskets do not reqUire retorqUing - the Instructions With rhe gasker should be followed If they differ from the mstructions here.
7
Man llolds - removal and installation
Refer to Illustration 7.7
Removal 1 Remove the air cleaner assembly and related parts. Tag all wires and vacuum hoses to Simplify Inslallatlon. On later mod· 2 els, a light·off catalyst IS bolted directly to the outlet 01the exhaus t manilold and must be disconnected from the manifold flange . 3 Remove or disconnect the EGR tube and all other emission compo· nents which would mterfere with the removal of the manifold. 4 Remove the manifold mounting boltsmuts. It may be necessary to apply penetrating all to the threads. 5 Detach the manifold.
Installation 6
7.7
installed.
24 Use a gasket scraper to remove all traces of carbon and old gasket matenal, Ihencleanthe matmg surfaces With lacquer thinner or acetone. II there 's oil on the mating surfaces when the head is installed, the gasket
Clean the mating surfaces 01 the mani fold and cylinder head.
Exhaust manifold bolt TIGHTENING sequence
7 Install a new gasket. il applicable. Position the manifold on the cylln· der head and install the bolts/nuts. Tighten the bolts/nuts In sequence to the specified torque (see illustration). 8 Position the light·off catalys t Unit on the exhaust manifold. 9 Install and tighten the mounting nuts . 10 Install or connect the emission component vacuum hoses and wires preVIOusly disconnected. 11 Install the air cleaner assembly and related parts. 12 Start the engine and check for leaks at the manifold{s).
8
Cylinder Iront cover and timing chain - removal and Installation
Refer to illustration 8.5
Removal Drain the cooling system and disconnect the hoses Remove the cooling fan. dTivebetts and the crankshaft and water pump dTive pulleys. 2 Remove the Iront cover-to·englne block and all pan bolts. Carefully pry the cover away from the engine block at the top. Do not nick or gouge the mating sunace of the engine block. 3 Scrape all gasket mateMI and seal anI off the engine block and cover ma\lOg sunaces. then clean them With lacquer thinner or acetone. 4 Before removing the timing chain and sprocke ts. the chain deflection must be checked as follows · a) Turn the crankshaft counterclockwise and take up the slack on the left Side of the cha in. b) Establish a reference point to the left of the tlmmg chain. Measure the distance from the reference point to the cen ter of the left run of the cha in. c) Turn the crankshaft clockWise and take up the slaCk in the right run of the timing chain. d) Press the slack cham In the left run toward the center With your thumb and measure the distance from the reference point to the cen ter of the slack chain on the left run e) Subtlact the smaller figure from the larger and the difference Wi ll be the total deflectIOn. Note: If riming cham deflection is greater than 114·inch, rhe timing chain and sprockets must be replaced. Never replace lust rhe cham or sprockels. replace rhem as a set. S Rotate the crankshaft until the two timing marks on the sprockets are aligned (see illustration) 6 Remove the camshaft sprocket bolt and pull both sprockels away from the front 01 the engine . 7 Clean the chain and sprockets In solvent If you have decided 10 reuse them. Inspect the sprocket teeth for damage and wear and the cham for a distinctive wear pattern. II a wear pattern exists on the cham or the sprock· ets, we recommend that you Install new pans
Chapter 2 Part 8
8.5 The camshaft and crankshaft sprocket timing marks (arrows) must be aligned with each other during installation
3.3 liter inline six-cylinder engine
9.4 Special tools are available for removing lifters. bullhey aren'l always necessary
9.88
28-7
II the bottom 01 any lilter Is worn
concave, scratched or galled. replace the entire set with new ones
2B
Installation 6 POSition the camshaft and crankshaft sprockets In the cham with the tlmmg marks on the sprockets aligned . 9 Slide the two sprockets. comp lete with thellmmg cha in. onto the ends of thE! crankshah and camshaf1 10 Install the camshaft sprocket bolt and lighten II to the specified torque, 11 Belore installing the front cover, check the condition of the oil seal If the seal is dned out or been leakmg, II must be replaced (see Section 13). 12 Apply ATV-sealantlo the new front cover gasket and posItion thegasket on the cover. Coat all exposed portions of the gasket with sealant 13 Install the cover To prevent damage 10 the seal as It passes over the Woodruff key on the crankshaft. place a thin-wail socket over the crank shaft end Make sure the outSide diameter of the socket IS less Ihan the mSlde diameter of the seal 14 Tighten all mounllng bolls lathe specIfied torque 10 three orfour equal sleps. Follow a Criss-cross pattern to avoid warpmg the cover
9
lifters and camshaft - removal , inspection and installation
Lihers
9.8b The foot of each lifter should be slighUy convex -Ihe side of another lifer can be used as a s traightedge 10 check il; if it appears lIal. It's worn and must nol be reused
Refer /0 !I/ustranons 9 4. 9.8a, R8b and 9.8c A nOISy va lve lifter can be isolated when the engine IS Idling Hold a mechafllc's ste thoscope or a length of hose near the loca\lon 01 eaCh valve while listening at the other end Another method IS to remove the rocker arm cover and. with the engine Idling. touch each of the valve spnng retainers. one at a time If a valve hfter IS detective. 11"11 be evident from the shock felt allhe retainer each lime the valve seats. 2 The most likely causes of nOISy valve lifters are dirt trapped InSide the hlter and lack 01 011 flow, VISCOS ity or pressure. Belore condemn ing the hfters, check the oil tor fuel contamination. correct level. cleanl iness and correCI VISCOS ity
Removal 3 Remove the cy linder head and gasket as descnbed In Section 6. 4 There are several ways 10 extracllhe lifters from Ihe bores in the block. A special tool designed to gnp and remove lifters (see iIIustralion)IS manulactured by many tool co mpanies and is Widely available. bu t it may not be reqUired In every case On newer engines without a lot Of var· nlsh bUildup. the lifters can olten be removed With a small magnet or even With your fingers . A machinist's scnbe With a bent end can be used to pull the lilters out by positioning the point under the retainer rmg In the top 01
each litter. Caution: Don '/ use plters to remove the lifters unless you Inlend to replace them With new ones (along wrlh the camShaft). The pliers may damage the preCISion machined and hardened MIers, renderrng them useless 5 Selore removing the lifters. arrange to store them rn aclearly labelled box to ensure they're reinstalled in their original locations. Remove the lifters and store lhem where Ihey won't gel dirty inspection and installation 6 Parts for va lve lifters are not available separately. The work required to remove them from the engine again II cleaning IS unsuccessful outweighs any poten\lal savtngs Irom repairing them. 7 Clean the lifters With solvent and dry them thoroughly Without mlxrng them up. S Check each lifter wall. pushrod seat and fOOl lor SCUffing , score marks and uneven wear (see illustration) Each lifter fOOl (the surface thaI Jides on the cam lobe) must be shghtly convex, although thiS can be difficult 10 delermrne by eye (see illustration). If Ihe base of lhe lifler IS concave. the Irfters and camshaft must be replaced If the lifter walls are damaged or
2B-8
9.6c
Chapter 2 Part B 3.3 liter inline six-cylinder engine
Check the pushrod seal (arrow) In the top of each litter lor wear
9.21 Apply mol y-base grease o r engine assembly lube to the lobes and journals on the camshaft prior to installation
worn (which isn't very likely) , Inspecllhe hlter bores in the engme block as well. If the pushrod seats (see illustration) are worn , check the pushrod ends 9 If new lif1ers are being Installed , a new camshaft must also be installed. If the camshaft is replaced. then install new litters as well. Never install used litters unless the original camshaft is used and the II/ters can be Installed in their onglnallocations! When installing hfters. make sure
Installation 21 Camshaft Installation IS the reverse 01 removal . Coat the cam bearIngs and Journals With a thick , even layer of moly-base grease or engine assembly lube (see illustration)
they 're coated with moly-base grease or engine assembly lube. Soak new
10
Oil pan and oil pump - removal and Installation
hiters in oil to remove trapped air.
Camshaft Refer /0 Illus/ration 9.21
Removal 10 Remove the front COlier, but leave the liming chain and sprockets in place. t t Check the camshaft endplay before removing the camshaft. Install a diaJ Indicator on the Irontolthe engine so the plunger 01 the Indicator rests on the ef'ld of the camshaft. Push the camshall as far to the rear 01the engine block as It Will go and zero the indicator. Push the cams halt to the front of the block as far as it Will go and record the movement indicated on the diaJ indicator. This is the endplay. If Ihe endplay exceeds the service limit given in Ihe specifications. the thrust plate will have to be replaced 12 Remove the timing chain and sprockets (Section S). 13 Remove the bolls and detach the camshaft thrust plate. t4 Carefully pull the camshaft out of the blOCk. Oon'l damage the bearings With the cam lobes. Inspection 15 Aller the camshaft has been removed from the engine. cleaned With solvent and dned. inspect the beanng Journals for uneven wear, pilling and evidence of seizure. If the journals are damaged, the beanng Inserts in Ihe block are probably damaged as well. Both the camshaft and bearings Will have to be replaced . t6 Measure the bearing Journals Wi th a micrometer to de termine If they 're e~cessively worn or out-of-round . 17 Check the camshaft lobes and beaflng Journals lor heat discolorallon. scoremark.s, chipped areas, pitting and uneven wear. If the lobes and journals are In good condilion , the camshaft can be reused . 18 Check the bearings In the block for wear and damage. look for gall1n9, pining and discolored areas. 19 The Inside diameter of each beaflng can be del ermined Wllh a small hole gauge and oulslde micrometer or an inSide micro meier. Subtract the camshall beaflng journal dlameter(s) trom the corresponding beaflng InSide diameter(s) to obtain the bearing 011 clearance. II irs e~cessive, new bearings will be required regardless of the condition of the onginals. 20 Camshaft bearing replacemen t requires speciallools and expertise that place It outside the scope of the home mechanic. Remove the engine and take the block to an automotive machine shop to ensure the job IS done correctly.
Refer /0 II/usrrallons 10.25 and 10.29 Note: This procedure IS for removal and ms/aliallOn of /he 011 pan With the engme 10 the vehicle only. If /he engme has been removed for an overhaul. follow Step II andS/eps 13/hrough27
Removal Dram the engine oil and disconnect the negative cable at the battery. Remove the oil dipstick. 2 Drain the cooling system. 3 Remove the radiator as descnbed In Chapter 3 RaJse the vehicle and support II securely on jackstands. Disconnect 4 the starter cab le at the starter, 5 Remove the sl arter Irom the bellhousmg 6 Remove the four nuts and bolts anaching the sway bar to the chaSSIS and allow the sway bar to hang down 7 Remove the K·brace . 8 Remove the bolt retalrllng the flex coupling to the steering gear. Unbolt the steenng gear Irom the chaSSIS and poSllion It forward and down 9 Remove the engine Iront insulator'lo-support bracket retaming nuts. loosen the two rear engme support boilS. 10 Raise the fronl of the engine With a Jack. Place a thick wooden block between the Jack and the all pan. II Place 1-1/4-inch wood blocks between the Iront support insulators and the support ing brackets 12 Place a jack beneath the tranSmiSSiOn and raise It ,ust enough to pro· Vide removal clearance for the oil pan. 13 lower lhe engme on to the spacer blocks and remove the jack. 14 Remove the all pan bolts. 15 lower lhe pan to the crossmember 16 Remove the two all pump Inlet tube·to-oll pump retainmg bolts. t7 Remove the all pump inlet assemply and allow It to rest in Ihe oil pan. IS RemovetheOl1 pan from the vehicle. 11 may be necessary to rotate the crankshafl for the coun terweights to ctear the pan. 19 Clean all old gasket materiallrom the matmg surlaces of the block and the pan. 1
Installation 20 Remove the rear main beaflng cap 011 pan seal. 21 Remove the timing cover 011 pan seal
Chapter 2 Part B
3.3 liter inline six-cylinder engine
2B-9
28
10.25
Oil pan gaskets and seals
J/8 · 1~ NUT TIG HTEN TO Sf'ECIF ICATIOfllS
OIL P UMP A,SSY.
31 Raise the engine with a jack and a block of wood underneath the 011 pan and remove the wood spacers previously Installed under the support brackels. 32 Lower the engine to the correct Installed position and mslalilhe front and rear engine mount bolts/nuts. 33 The remainder of installation is the reverse of the removal procedure. 34 Start the engine and check carefully for leaks at the oil pan gasket surfaces
11
ThiS procedure is essen tially the same for all engines Refer to Part A and fo llow the procedure ou tlined there.
FRONT OF ENGINE '--
~ 10.29
Flywheell driveplate - removal , Inspection and installation
011 pump Installation details
22 Clean all matmg sunaces and seal grooves. 23 Install a new 011pan to-front cover 011 seal 24 Install a new rear main bearmg cap seal. 25 Inslall new 011 pan Side gaskets on Ihe block (see Illustration) Apply a thin coal of RTV -sealanl to both Sides of the gaskets. 26 Make sure the labs on thelron! and rear seals ill properly into the mal ing slots in the 011 pan Side seals. A small amount of RTV-sealantat each jOint Will help prevent leaks allhese cri tical spots 27 Clean Ihe inlet tube and screen assembly and place 1\ In the oil pan . 28 Posillon Ihe oil pan undernea th Ihe engine 29 Llftlhe inlet tube and screen assembly from the oil pan and secure lIto the 011 pump With a new gaskel (see illustration). Tigh ten the two retain · 109 boilS to the specified torque 30 Attach the oil pan 10 the engine block and install the boll s TIghten the bolts to Ihe specIfied torque. slamng from the cen ler and working out In each direction.
12
Engine mounts - check and replacement
This procedure is essentially the same for all engines. Refer to Part A and fo llow the procedure outlined there
13
Crankshaft oil seals - replacement
Front seal Refer to illustrations 13.6a and 13.6b Note: The factory recommends special tools for proper seal ins/allatloo. 1 Drain the coolant and engine oil (Chapter 1). 2 Remove the radiator. 3 Remove the crankshaft pulley and the timing cover (Section 6). 4 Drive out the 011 seal With a pin punch. 5 Clean out the recess 10 the cover.
28-10
Chapter 2 Part 8
3.3 liter inline six-cylinder engine
13.6b lithe speci al tools aren't available, the seal can be Installed with a secllon of pipe o r a sockellhat has the same outside diameter .$ the seal hdes. remove the dnveplale. 11 Remove Ihe I!ywheel and engine real cover plate Note: Some mod·
13.68
The factory recommends speclallools for InslatlaUon althe Iront cr ankshaft oil seal In the liming cover
6 Coat the outer edge 01 the new seal With grease and Install I! uSing the speclallOOls des'9ned tor this operation (see lIIuslraUon). As an aJtema
live. a large PIece 01 PIpe or a socket can be used to push the new seal In (see illustration). However, use e.-\remecaullon as the seal can be dam· aged eaSily. Drive In the seal unlll It'S completely seated In the recess Make sure !he spring IS properly positioned within the seal. 7 The rest of Inslallallon IS the reverse altha removal procedure
Rear seal Nole : If rear crankshaft 011 seal repiacemen/IS rhe only opera/Ion bemg performed. 1/ can be accomphshed with Ihe engine In the vehJC/e. II, flowever Ihe oil seal IS bemg rep/aced along with the rear mam beanng. the
engme must be removed B Disconnect the negative battery cable from the battery. th en remove the starter 9 Remove the transmisSion (Chapter 7) 10 On manual transmisSion eqUipped vehicles. remove the pressure plate. diSC and clutch assembly On automatIC transmiSSIon equipped ve-
els mcorpora/e a tWO·pl8Ce. spli/·I,p seal which reqUires removal of the re8rmam beanng cap. ff thiS IS /hecase wi/h your vehicle. reler /0 /heprocedure m Chap/er 2, Part E. One,plece seals can be seNlced as follows 12 Use an awl 10 punch IwO holes In Ihe seal Punch the holes on Oppel' Slle SideS ollhe crankshaft. JUSI above Ihe beanng cap-to-engine block Junction 13 Thread a sheet melal screw Into each punched hole 14 Use Iwo large screwOlivers or small pry bars 10 pry against both screws at Ihe same time. removing Ihe seal Blocks of wood placed against the engine Will provide addilionalleverage. 15 Be very careful when periormlng thiS operation - do not damage the seal contacl suriaces 16 Clean the seal recess In Ihe rear 01 the engine block and Ihe main beallng cap t 7 Inspect and clean Ihe 011 seal contact sur1ace 01 the crankshalt t 8 Coat Ihe new 011 seal With engine 011 19 Coat the crankshalt With engine Oil 20 Start the seal Into the cavity in the back 01 the engine With the seal lip laCing lorward, uSing the speCial dflve tOol Make sure the 1001 stays In alignment With the crankshaft untillhe tool contacts tile block See Slep 6 lor seal installation alternatives 21 Inslall the engine rear cover plate 22 Attach the lIywheel (or dnveplale) to the crankshaft 23 Theremalnder a! Inslallallon IS the reverseo! the removal procedure
2C
Chapter 2 Part -C
2.8 liter V6 engine
Contents Camshaft - removal, inspection and installation . 13 15 Cranksha ft 011 seals - replacement . See Chapter 2E Cylinder compression check Cylinder heads - removal and installation ••. 9 Drivebell check. adjustment and replacement See Chapter 1 Engine front cover - removal and Installation 10 Engine 011 and Iilter change. . . . ........... . See Chapter 1 Engine mounts - check and replacement . . 17 See Chapter 2E Engine overhaui- generalmlormation Engine - removal and installa tion See Chapter 2E Exhaust manifolds - removal and installation 8 FlywheeVdnveplale - removal and installation 16 ....... . ..•... General in formation
Intake manitold - removal and installation 7 14 Oil pan and pump - removal and installaTIon Repair operations poSSible With the engine In the vehicle . Rocker arms and pushrods - removal, inspection and Installation . 5 Rocker arm cover(s) - removal and Installation See Chapter 1 Spark plug replacement 11 Timing gears - check, removal and installation 3 Top Dead Center (TDC) for number one piston - locating Valve springs. retainers and seals - replacement 6 12 Valve lifters - removal. Inspection and installation See Chapter 3 Water pump - removal and installation .
, ,
Specllicalion s
General Displacement Cylinder numbers (front· to-rear) left (driver"s) side Right side Firing order ..
2.8 111ers
4-5-6 '·3 1·4·2-5-3-6
Camshah lobe hit (intake and exhaust) Allowable lobe lilt loss . Theoretical val .... e lift@ zero lash (Intake and exhaust) Endplay Standard Service limit . Journal-lo·beanng (oil) clearance Standard Service limil .
0.255 in 0.005 in 0 .3730 In 0.0008 to 0.004 In 0.006 In 0.001 10 0 .002S In O.OOSln
!C-2
Chapter 2 Part C 2.8 liter V6 engine
Journal diameter
No.' No 2
No3 No 4 Journal runoul. maximum (totalllldlCalor reading) Journal OUI-ohoune!. maximum (totallOdlcatof reading) Beam'lg tnSlde diameter
No No No No_
1
2 3 4
Camshaft gear backlash
1.6497 to 1.6505 In 16347 to 1.635510 16197101.620510 1.6047 to 1.6055 In 000510
00003 In 16515to1652311'1 1.6365 to 1 637311'1 1.6215 to 1.6223 In 1 6065 to I 6073 In 0006 to 0010 In
Torque specifications
Fl-Ibs
Camshaft gear bolt
30 to 36 12 to 15 9210103
Camshalllhrus\ plate boilS Crankshaft damper bolt Cylinder head boil S
Slep 1 SIep2 51ep3 Exhaust manifold mounting bolts Exhaust Plpe-Io-manlfold nuls Flywhee~dnyeplale bolls FrOn! cover plate boilS FrOn! cover bol\s Intake manifold bolts/nulS
Step 1 SIep2 Step 3 5tep4 all pump Inlel lube-la-pump boll 0.1 pump Inlet lube· Ie-main bearing cap boll
011 pan bolts Rocker arm cOver boIl S
Rocker arm shalt support bolts
29 to 40 40 to 5 1 65 to 80 271049 251035 47 to 51 12 to 15 12 to 15
3 to 6 610 \I \I 10 15 15 to IS7to 9 12 to 15 710 10 3 to 5 43 to 49
'Retlghten in sequence to 7510 18 fr-Ibs after engine has been run
General inlormaUon ThiS Pan o! Chapter 2 IS devoted to In-vehlc!e repair procedures lor the 2.8 Iller V6 engine AU In!ormation concerning engine removal and in· staUalion and engine block and cylinder head overhaul can be !ound In Pan E 01 thiS Chapter. The 10Uowing repair procedures are based on the assumption that the engille IS Installed In the vehicle. If the engine has been removed Irom the vehicle and mounted on a stand. many 01 the steps ouliined In thiS Pan 01 Chapter 2 Will not apply The SpeCilicauons II'Icluded In thiS Pan 01 Chapter 2 apply only to the procedurescontalnedtn thiS Pan. Pan E 01Chapter 2 con tains the SpeCI"callons necessary lor cylinder head and engine block rebUilding
2
engine In the vehicle The Intake and exhaust manifold gaskets. liming cover gaskets. 011 pan gasket. crankshatt 011 seals and cylinder head gas· kets are aJi acceSSible With the engine In place Extenor engine components, such as the Inlake and eMhaust manIiolds, the oil pan (and the 011 pump), the waler pump, the starter malar. the alterna tor, the distributor and the luel syslem components can be removed lor repall With the engme m place Since the cylinder heads can be removed Without pulling the engine. valve component servlcmg can also be accomplished With the engine In the vehICle. Replacement ot the camshatt and liming gears IS also poSSI· ble WIth the engine In the vehicle In eMtreme cases caused by a lack 01 necessary equipmen t. repall or replacement of plSIon lings. pistons. connectm9 rods and rod beanngs IS poSSible Wit h the engine In the vehicle. However. thiS practice IS not rec· ommended because 01 the cleaning and preparation work that must be done to the components involved
Repair operaUons pos sible with Ihe engine In Ihe vehicle
Many maJOr repan operallons can be accomplished Without removtng the engine Irom the vehicle Clean the engine compartmen t and the exterior 01 the engine With some type 01 degreaserbelore any work is done. It Will make the lob easier and help keep dirt out 01 the tnternal areas 01 the engine, Depending on the components involved, It may be helplul to remove the hood to Improve access 10 the engine as repairs are perlormed (reler to Chapler tll l necessary). Cover Ihe lenders to p!'eventdamage to the pamt SpecIal pads are available. but an old bedsp!'ead or blanket will also wo~
II vacuum, exhaust, 011 or coolant leaks develop, Indicating a need lor gasket or seal replacement. the repairs can generally be made With the
3
Top Dead Center (TOG) tor number one piston - locating
Note: The follo wmg procedure IS based on /he assumptIOn that the spark plug wires and dlS/fibUlor are correct/yms/alled If you are Irymg /0 locale TDC /0 mslall the dlstflbulor correctly. pIs/on poSlflon must be delermmed by feelmg for compression at the number one spark plug hole. then align· mg the tgmtlon tlmmg marks as deSC(lbed In step 8 1 Top Dead Center (TDC) IS the highest POII'I, m the cylinder thaI each piston reaches as 1\ Iravels up-and ·down when the crankshalt turns. Each piston l eaches TOC on the compression stroke and again on the exhaust stroke. but TOC generally relers to Piston poSition on the complesslon Sl roke
Chapter 2 Part C 2 POSItiOning the piston(s) at TDe IS an essential pan of many procedures such as rocker arm removal. camshaft and liming gear removal and distributor removal 3 Before beginning thiS procedure , be sure to place the transmiSSion In Neutral and apply the parking brake orbiock the rear w heels. Also , disable the Ignition system by detaching t~e cOil wire from the center terminal of the distribu tor cap and grounding It on the block with a Jumper wire. Remove the spark plugs (see Chapter 1). In order \0 bring any p iston to TDC. the crankshaft must be turned us4 mg one of the methods outlined below. When looking at the fron t of the en gme, normal crankshaft rotation IS clockWise. a) The preferred me thod IS to lum the crankshaft with a socKet and ratchet at1ached to the bott threaded Into the front of the crankshaft b) A remote starter SWitch , which may save some time. can also be used. Follow the instructions Inctuded w ith the SWit ch. Once the piston IS c lose 10 TDC, use a socket and ratchet asdescnbed In the prevIous paragraph. c) II an assistant is available 10 turn the IgOillon SWitch to the Sl art poSition In short bursts. you can get the piston close to TDC without a remote starter SWi tch. MaKe sure your assistan t IS out 01 the vehicle, away from the ignition SWitch. then use a socket and ratchet as described In Paragraph a) to complete the procedure. 5 Note the position of the te rminal lor the number one spark plug wife on the distributor cap. II the termlnallsn 't marked. follow the plug WIre Irom the number one cyl inder spark plug to the cap. 6 Use a felt-lip pen or chalk to make a mark on the distributor body d" rectly under the term inal 7 Detach the cap from the dlstnbutor and sel lt aSide (see Chapter 1 If necessary). a Turn the crankshaft (see Paragraph 3 abovel untlt the notch in the crankshaft pulley IS aligned with the "TC" mark pointer on the engine front
2.8 liter V6 engine 7 thiS a 9
5
2C - 3
Inslallthe cover and lighten the screws evenly to the torque listed In Chapter's Specifications. The remainder of installation is the reverse of the removal steps. Run the engine and cheCK tor oil leaks.
Rocker arms and pushr ods - removal , Inspection and i n stallation
Remo va l Reier /0 Illustra/ions 5.3 and 5 4 1 Refer to Sec\lOn 4 and detach the rocKer arm cover(s ) from the cylinder head(s) . 2 Loosen the rocker arm shalt support bolls two turns at a time. working from the center out. unlll the bolts can be remolled by hand . lIfl the rocker assembly and all baHle oH of the cylinder head (see il3 lustration) The pms Will hold the components together. 4 Lift the pushrods out of the engine (see IIlustraUon). Place the pushrods In order in a holder so they can be returned to thei r ongmal poSitions.
2e
cover. 9 Look at the dlstnbutor rotor - It should be pOin ting directly at the mark you made on the dis tributor body 10 II the rotor is laO-degrees 011, the number one piston IS at TDC on the e~haust stroke 11 To gel the piston to TDC on the compreSSion stroke. turn the c rank shaft one complete turn (36D -degrees) clockw ise. The rotor should now be pointing at the mark on the distributor When the rotor IS polnllng at the number one spark plug wire terminal In the d,stllbutor cap and the Ignition timing marks are aligned. the number one piston is at TDC on the compression stroke, 12 Afterthe number one piston has been positioned at TDC on the compression stroke, TDC lor any of the remaining pistons can be located by turning the crankshaft and following the filing order, Mark the remaining spark plug Wire terminal locations on the distribu tor body just like you did lor the number one terminal , then number the marks to correspond w ith the cylinder numbers. As you turn the crankshaft. the rotor Will also turn When It'S pointing directly at one of the marks on the distributor. the piston lor that particular cylinder is at TDC on the compression stroke,
4
5.3
Lift off the rocker assembl y and pu shr od s as s hown
Rocker arm cover (s ) - remollal and installation
Remove any emiSSion control components that obstruct access to the cover (see Chapter 6), 2 Mark the spark plug w ires . then disconnect them Irom the spark plugs and lay them back out ot the way (see Chapter 1). 3 Detach the throtlle linkage Irom the carburetor. if necessary. 4 Remove the rocker arm cover screws and lilt the cover 011. II it won 't come 011 eaSily, don't pry It loose. Make sure all screws are removed . then tap lightly on the end of the cover With a rubber mallet or a block at wood and a hammer to break the gasket seal 5 Clean all traces of gasket and sealer from the cover and cylinder head. Aerosol gasket remOllers , available from auto parts stores. can be used to ease gasket removal 6 Coat the rocker cover sideol a new gasket w ith ATV sealer, then Slick the gasket to the cover
5.4
RemOlle Ihe push rods and place them in a rack so they can be returned to their or iginal po sitions
Chapter 2 Part C 2.8 liter V6 engine
2C-4
Rocker arm
flJV\J\!VI
Support
Spring Shaft
::-::- .,
Support
:
Spring wa, har
. -_ __ _ __ Pin
5.5
. oJ
Rocker assembly - exploded view
Inspection Refer /0 ,/Ius/ratIon 5.5 5 Aemove the PIns and disassemble the rocker arm assembly (see illustration ) Place the parts in order on a clean workbench 6 Check each rocker arm for weal , cracks anctotherdamage. especially where the push rods and valve siems conl ae! the locker arm l aces 7 Make Sure the hole al lhe pushrod end 01 each locker arm IS open
Plugging can be cleared with a piece of wire 8 Check each rocker arm bore , and li S correspondmg poSi tion on the rocker shatt olor wear. cracks and galling II the rocker arms or shalt are damaged. replace them wIth new ones 9 Inspeclthe pushroos IOf cracks and excessIVe wear althe ends. Roll each pushrod across a PIece 01 plale glass 10 see II Irs benl (II II wobbles. lIs benl). 10 If necessary, remove Ihe plug from each end of Ihe rOCKer shall. Dn!1 lniO one plug and Insel'1 a long sl eel rod through It to KnOCK out lhe other plug KnOCK out the lirSl plug In lhe same manner 11 II the rOCKer shaft plugs we re removed. tap in new ones With a hammer and SUitable dnll 12 Assemble Ihe rOCKer assembly (see illustration 5.5). lubricate all InctlOfl pomts With engine 011 or assembly lube 13 Installnewconer pms In the ends 01 the rockershalt. Besuretherock· er shalt notches l ace down when the shaft IS Instal!ed
used 10 keep Ihe valves from falling mto Ihe cylinder during Ihls procedure 1 Refer to Secllon 4 and remove Ihe rocker arm cover Irom Ihe affected cylinder head If all of Ihe valve slem seals are being replaced. remove both rOCKer arm covers 2 ~emove lhe spark plug from Ihe cylinder which has Ihe defective component II all 01 the valve stem seals are being replaced . all 01 the sparK plugs should be removed 3 Turn the cranksha ft until the piston In the aHected cylinder is al top dead center on the compression stroke (refer to Section 3 for inSlruC110ns). II you 're rep laCing all of the valve stem seals. begin With cylinder number one and worK on Ihe valves loronecyllnOef at a lime. Move Irom cyllnderto-cylinder lollowlllQ Ihe linng order sequeroce (see Ihls Chapter's Speafl· cabons) . 4 Thread an adapter Into the sparK plug hole (see illustration) and con· nect an air hose Irom a compressed an source to It Most auto parts stores can supply the an hose adapter Note : Many cylinder compression gauges u/l/lze a screlllf-m fl/lmg Inal may work Wllh your alf nose qUick ·dls· connect fitting
Installation 14 Coat each end of each pushrod With assembly lube, then install them In the engine (see illustralion 5.4). 1\ you are relnsta!hng the angina! push· rodS . be sure to return them to their ongmal poSitions 15 Coat the rocker arm pads With lubrrplate or eqUivalent. 16 loosen Ihe valve adjusllng screws several turns 17 Install the all bailie and rOCKer assembly on the engine The nol ch on the shalt should face down 18 PoSItion the rOCKer arm ball ends In the push rods 19 Tighten the rOCKer sha ft suppol'1 bolts two lurns at a lime, from the center oul. to the torque hs ted in 1hls Chapter 's Speclhcatlons 20 The remainder of installation IS the reverse of removal 21 Adjust the valve clearances (see Chapter I ). 22 Run,he engine and check lor leaKS
6
Valve springs, retainers and seals - replacement
Refer 10 Iflus/rallons 6.-4. 6 9and6. to Note: Broken valve spnngs and defeelwe valve slem seals can be replaced wi/hout (emoVlng the cylinder heads Two special tools and a com · pressed air source are normally reqUired to perform thiS operatron, so read Ihrough thiS Section carelully and rent or buy the lools before begmnmg the Job If compressed air isn ', available. a lenglh of ny lon rope can be
6.4
Use an air line and adapter to hold the va lve closed while com pressing Ihe valve spri ng
Chapter 2 Part C
6.9
2C-5
2.8 liter V6 engine
Val ves and rel ated components - exploded view
6.10 The valve stem seals are removed and installed
5 Removethe rocker arm assembly(ies) and pull out the pushrod(s) fOI the cylinder{s) being seNlced. II all of the valve stem seals are being re-
with this special Ford tool or equivalent
placed, all of the rocker arms and pushrods should be removed (refer 10 Seclion 5).
3
6 Apply compressed all to the cylinder. Warning : The piston may be forceddownbycampressedalf. causing Ihecrankshaft to rurnsuddenly./f the wrench used when positioning the number one piston al TDC IS 51111 attached to the bolt In the crankshaft nose. II could cause damage or mjury when the crankshaft moves 7 The valves should be held In place by the air pressure. If the valve faces or seats are in poor condition. leaks may preyen\ alf pressure from retain ing the valves - refer to the alternative procedure below. 8 If you don't have access to compressed air, an alternative method can be used. PosItIOn the piston at a point just before TDC on thecompression stroke. then feed a long piece 01 nylon rope through the spark plug hole until It fills the combustion chamber. Be sure to leave Ihe end of the rope hanging out of the engine so It can be removed eaSily. Use a large ralchet and socket to rotate the crankshaft In the normal direction of rotation until slight resistance IS fell 9 Stull shop rags inlo the ~ylinder head holes above and below the va lves to prevent pans and tools from falling into the engine. then use a valve spring compressor to compress Ihe spring. Remove Ihe locks with small needle·nose pliers or a magnet(see lllustraUon). Note: A couple of different types of 10015 are available forcompressing the valve springs with Ihe head m place One type gnps the lower spring Calls and presses on the retainer as the knob is turned. while the other type. shown in Illustra tion 64. utilizes the rocker shaft for leverage. Both types work very well. al· though Ihe lever type is usually less expensive. 10 Remove the spring reta iner and valve spring, then remove the stem seal With a seal removal tool (see illustration). Note: If air pressure fails 10 hold the valve in /heclosedpositionduring Ihisoperalloo. lhe valve face or seat IS probably damaged. If so, the cylinder head will have to be removed lor addilional repal( operations. 11 Wrap a rubber band or tape around the top of the valve stem so the valve won't fall into the combuslJon chamber. then release the air pressure. Note : If a rope was used instead of air pressure, turn the crankshaft s/lgh/ly in the dlfecllon opposite normal rotation. 12 Inspect the valve stem for damage. Rotate the valve in the guide and check the end for eccentfiC movement, which would indicate thallhe valve IS bent 13 Move the valve up·and -down In the gUide and make sure it doesn't bind . It the valve stem binds. either the valve is bent or the guide is damaged. In either case. the head will have to be removed for repair. 14 Reapply alt pressure to the cylinder to relain the valve in the closed poSition, then remove the tape or rubber band from Ihe valve stem. If a rope was used mSlead of alt pressure. rota te the crankshalt in the normal direction ot rotallon unlll slight resistance is felt. 15 Lubricate the valve stem With engine oil and install a new seal. 16 Install the spring in pesilion over the valve. 17 Install the valve spnng retamer. Compress the valve sprmg and care
,
7
2
2C
6 7.7
8
4
Intake manifold bolt locations and tightening sequence
tully position the locks in the groove. Apply a small dab 01 grease to the inside of each keeper to hold it in place. 1B Remove the pressure Irom the spring tool and make sure the locks are sea ted. 19 Disconnect the air hose and remove the adapter from the spark plug hole. If a rope was used in place of air pressure, pull il out of the cylinder 20 Re ier to Section 5 and IOstalithe rocker armIs) and pushrod(s). 21 Insl all the spark plug(s) and hook up the wire(s). 22 Refer to Section 4 and install the rocker arm cover{s). 23 Start and run the engine. then check foroilleaks and unusual sounds comi ng from the rocker arm cover area.
7
Intake manifold - removal and Instatiation
Removal 1 Disconnect the negative battery cabla from the battery. 2 Remove the air cleaner (see Chapter 4) and disconnect the accelerator cable. 3 Drain the cooling system (see Chapter 1). Disconnect the radiator hose from the thermostat housing and 1he by -pass hose from the mtake manifold (see Chapter 3). 4 Remove the distnbutor (see Chapter 5). 5 Remove the fuel filler (see Chapter 1) and luel hne. 6 Remove the rocker arm covers (see Sechon 4). 7 Aemove the intake manifold bolls and nuts (see illustration). Note: A special crows -fool wrench (Forti tool T72C·65190requivalenl) is required /0 loosen or tighten boll number six when the carburelor IS m·
2C -6
Chapter 2 Part C 2.8 liter V6 engine
RI GHT SIDE
J
CD ,-\ 1
lEFT SIDE
QUI RED
9 .10
8
3REQUIREO::::::::::.:::..----"Qk 8.6 Exhaust manifold bolt/s tud locations and tightening sequence stalled II you don ', have the special 100/, remove the carburetor (see
Chapter 4). B Remove any Wires, hoses or other components that would Interfere with removal, then 1If! the manilold off If the manifold IS slucJ,l!"'I,1I
""IWI
'-...
Chapter 2 Part 0 3.8L V6 and all V8 engines Contents Camshatt and beanl'"lQs - removal. inspectIOn and installatIon Crankshaft 011 seals - replacemenl
0.1 pump - removal and InstallatIOn • Repair operatIOns poSSible With the eno1ne
IJ
\6 See Chapter 2E
Cylinder compression check Cylinder heads - removal and installation
Drlvebelt check, adjustment and replacement Flywheel 'dnvaplate - removal and InstaliallOn Engine mounts - check and replacement Engine 011 and hlter change
Engine overhaul- general information Engine - removal and InSlalialion Exhaust mamlolds - removal and installatIOn General mlormallOn
Intake mamlold - removal and installation 0.1 pan - removal and InstallatIOn
9 See Chapter 1 17
18 See Chapter I See Chapter 2E See Chapter 2E
• \
7 \4
Rocker arm covers - removal and installation Rocker arms alld pushrods - removal, inspection . ...•..... and Installation, •. , , . . Spar\l. plug replacement Timing chai n and sprockets - Inspection. removat and installallon ... Timing chain cover - removal and Installation Top Dead Center (TOC) lor number one piStOfl- locating •... Valve lifters - removal, Inspection and installatIOn Valve spnngs, retamers and seals - replacement . Water pump - removal and Ins lallatIOn
Specifications
V6engine
/
General Olsplacement Cylmder numbers (Ironl· to-rear) left (dnvers) Side RlQht side Flnng order Valve slem·lo·rocker arm clearance
3.8111ers 4·5-6
H·3 1·4,2·5·3·6 0.08810 0.189 in
Camshaft Lobe hit Inlake Exhaust Theorellcal valve hlt@ zero lash Intake Exhaust Endplay Journal diameter (all) Cam bearrng Inside diameter JournaHobeanng (011) clearance Journal/unout limit Journal OUI·ol-round limit
0.240 in 0.24\ In 0. 4t5 in OA171n None (camshaft IS restramoo by SPflng) 2.0515 to 2.050510 2.0535102.0525 0.001 \0 0 .003 In 0.002 in (rul"\Oul at no. 2 or 3 relative to I and 4) 0.001 in
COUNTERCLOCKWISE
FRONT OF VEHICLE
•
CAP CLIP POSITION
Cylinder locations and tiring order - 3.8l V6 engine
" 2
10 the vehicle
4
5 See Chapter t \I
\0
3 12 6 . See Chapter 3
I 20-2
Chapter 2 Part 0
3.8l V6 and all V8 engines
Oil pump Reliel .... alve spring tension
171 to 15 2 1bs at 120 In o 0017 10 0.0029 In 0.008 to 0 .00121n 0,002 to 0.0055 In 0005 to 0.0055 in
Reliel valve-to-bore clearance
Gear backlash .. Gear radial clearance Gear height (beyond housing)
o
Torque specifications CamshaU sprocket bolts
Ft-Ibs (unless otherwise indicated) 151022 151022 151022 60 10 106 In-Ibs 18 t022
........ . .
Timing chain cover-la-block bolts Water pump-la-liming chain cover bolts 011 pan mounhng bolts
011 pump cover bolls . Cylinder head bolts
1983 Step 1
47
SIep2 SIep3 Step 4
55 63
"
Loosen all bolts 2 or
SlepS 1984 on Step 1 Step 2
3 turns . then repeat tightening sequence
37 45
52 59
Step 3 Step 4
Loosen all bolts 2 or 31Urns. then repeat lighlenlng sequence
Step 5 Rocker arm fulcrum bolts
Slep 1 Step 2
5to 11 181026
Intake manifold-1o-cylinder head bolts
1983 Slep t Step 2 Slep 3 1984 on
5 10 18
Step 1
7
Step 2
15 24
Step 3 Exhaust manifold bolts Rocker arm cover-to-cylinder head 1983 (screw) .. 1984 on (boIUstud) Crankshaft pulley-la-vlbrallOn damper bolts Vibration damper bolt •
Flywheel/dflveplate mounting bolts.
15 to 22 36 to 61 in· lbs 80 to 106 In·lbs 201028 9310121 54 to 64
va engine General Oisplacemenl 1979 and 1963 on . 1980 through 1982 Cylinder numbers (front to rear) LeU (driver"s) Side Right side Firing order Except HO .
HO
5,0 Illers (302 cubic Inches) 4 2 Illers (255 cubiC Inches)
1·5·4·2·6·3 7·8 1·3· 7·2·6·5·4·8 COUNTERCLOCKWISE
FRONT OF VEHiClE
•
CAP CLIP POSITION
Cylinder locations and firing order - va engines except HO
Chapter 2 Part 0 Vallie stem·to rocker arm clearance DeSlIed except HO
3.8l V6 and all V8 engines
0.09610 O. 14
HO
20-3
In
0.123100.14610
Allowable
except HO
0.071 to 0 171
HO
0.098100 198 In 050 in
Timing cham dellecllon
In
Camshaft Lobe hft
1979 0.2373 In
Intake
0.2474 In
Exhaust
0.2375 In
1980 through 1982 (Intake and exhaust)
1983 on (except HO) 0.237510 0.2474 In
Intake
exhaust 1983 through 1985 (HO) Intake
0.2600 In 0.2780 in
EXhaust 1986 on (HO) (Intake and exhaust) Theoretical vallie lift @ zero lash 1979
0.2780 In
0.3823 in 0.3980 In 03753 In
Intake
exhaust 1980 through 1982 (lOtake and exhaust) 1983 on (e)(cept HO) Intake
0.375310 0.390910
Exhaust 19831hrough 1985 (HO) Intake
Exhaust 1986 on (HO) (mtake and exhaus t)
.
2D
a 4130ln 0,4420 In a 4420 in
Endplay 19841hrough 1987
Standard Service IIml!
0001 to 0.007 In 0.009 In
1988 on Standard Service limit Journal diameter No 1 No 2
No3 No 4 No 5 Beanng InSide diameter No 1 No.2 No.3 NO.4 No 5 JournaHo-beanng (Olt) clearance Standard
0.0005 to 0.0055 In 0,009 In 2 080510 2.08151n 20655102.0665 In 2.0505102.0515 In 2.0355102.0365 In 2.020510202151n 2.0825 to 2.0675 to 2.0525 to 2.0375 to 2.0225 to
2 0835 In 2.0685 In 2.0535 In 2.0385 In 2.0235 In
0,001 to 0 003 In o 006 In
Runout limn Out-ol-round limit Camshaft gear baCKlash Front bearing location
0.0051n (total indicator reading) 0.0005 In (Iolallndlcalor reading) 0.006100.011 In 0.005 to 0,020 in below fronl face 01 blOCk
Torque specifications
FI -Ibs 401045 91012 121018
Camshail sprOCKet bolt Camshaft thrust plate-Io·englne block bolts Timing chain cover bolts . Cylinder head bolts Step I Step 2 Vibration damper-to-cranKshaft bolt Exhaust manifold boilS
55 to 65 65 to 72 70 to 90 181024
20-4
Chapter 2 Part 0
Torque specifications Intake manlfold-Io-cylinder head bolts Oil filter insert-la-engine block adapter bolt Oil pan mounting bolts
3.8l V6 and all V8 engines Ft-Ibs 23 to 25' 20 to 30
1979 First step Large bolts ....... , Small bolts Second step
lIto 13 7 t09
Large bolts ........... .
151017
Small bolts ........... . 1980lhrough 1987 ....... .
10 10 12
1988 on Oil pump mounting bolts Oil pick-up lube-la-oil pump bolts 19791hrough 1987 ............... • . 1988 on Oil pick-up lube-Io-main beanng cap nul Drivebelt pulley-la-vibration damper bolls . Rocker arm lulcrum bolts •..•... Flywheel/dnveplale mounting boilS.
9 10 11 6 109 2210 32 1010 12 to 22to 35to 18to
15
18 32 50 25
75to 85
• Ahar assembly, reforque with the engme hOI
General information This Part 01 Chapter 2 is devoted to In-vehicle repair procedures tor the 3.eL V6 and va engines. All information concerning engine removal and Installation and engine block and cylinder head overhaul can be found in Part E of this Chapter. The followmg repair procedures are based on the assumption that the engine is installed in the vehicle, lithe engine has been removed from the vehicle and mounted on a stand, many of the steps outlined in thiS Part of Chapter 2 wilioot apply. The Specifications included In Ihls Part of Chapter 2 apply only to the procedures contained in this Part. Part E of Chapler 2 contains the Specifications necessary lor cylinder head and engine block rebuild·
m9·
2
Repair operations possible wlIh the engine in the vehicle
Many major repair operallons can be accomplished Without removing the engine Irom the vehicle. Clean the engine compartment and the ex tenor 01 the engine with some type of pressure washer belore any work is done. It Will make the Job easier and help keep dirt out 01 the internal areas of the engine. I! may help to remove the hood to improve access to the engine as reo pairs are performed (refer to Chapter 11 II necessary) . II vacuum. exhaust. oil or coolant leaks develop. indica ting a need for gaskel or seal replacement, Ihe repairs can generally be made With the engine in the vehicle. The intake and exhaust manifold gaskets. timing cover gasket. all pan gasket. crankshaft oil seals and cylinder head gaskels are all accessible with the engine In place. Ex terior engine components. such as the intake and exhaust manifolds. the all pan (and the all pump). the water pump. the starte r motor. the alternator. Ihe distributor and the fuel system components can be removed lor repair With Ihe engine in place. Since the cylinder heads can be removed without puUingthe engine. valve component serviCing can also be accomplished with the engine In the vehicle. Replacement of the timing chain and sprockets is also POSSI' ble With the engine in the vehicle. In extreme cases caused by a lack 01 necessary equipment, repair or replacement of piston rings. pistons. connecting rods and rod bearings is poSSible with the engine in the vehicle. However. this practice is not recommended because of the cleaning and preparation work that must be done to the compone,lts Involved.
3
Top Dead Center (TOG) lor number one piston - locating
Refer /0 Illustrations 3.6a and 3.6b Top Dead Cen ter (TOC) is the highest POint In the cylinder thai each piston reaches as It travels up-and-down when the crankshaft turns Each piston reaches TOC on the compression stroke and again on Ihe exhaust stroke. bul TOC generally refers to piston position on the compreSSion stroke. The timing marks on the vlbrallon damper Installed on the lront of the crankshaft are referenced to Ihe number one piston at TOe on the compression stroke .• 2 PositiOning the plslon(s) at TOe IS an essential part of many procedures such as rocker arm removal. valve adjustment, timing chain and sprocket replacement and distribu tor removal . 3 In order to bring any piston 10 TOC. the crankshaft must be turned us· Ingone 01 the methods outlined below. When looking al the front 01 the en· glne. normal crankshall rotation is clockWise. Warning : Before beglnmng thiS procedure, be sure to pface the transmiSSion In Neutral and ground the Call wire attached to the center terminal ofthe dlstflbutor cap to disable the Igmtlon system. a) The preferred method IS 10 turn the crankshaft With a large socket and breaker bar attached to the vibration damper bolt threaded InlO the front of the crankshaft. b) A remote starter SWitch. which may save some time. can also be used. Attach the swi tch leads to the S (SWitch) and B (battery) ter· minals on the starter motor. Once the Piston IS close to TOC , use a socket and breaker bar as deSCribed In the prevIous paragraph. c) If an assistant is available 10 turn the ignlhon SWitch to the Start po. siliOn In short bursts, you can getlhe pislon close to TOC Without a remote slarterswllch , Use a socket and breaker bar asdescflbed in Paragraph a) to complete the procedure 4 Using a tell pen, make a mark on the distributor hOUSing di rectly below the number one spark plug wire term inal on the distributor cap. Note: The terminal numbers are marked on the spark plug wires near 'hedlslributor 5 Remove the distributor cap as described in Chapter t . S Turn the crankshaft (see Paragraph 3 above) until the zero or groove on thevlbrallondamperis aligned With the pointer orTOC mark (see iIIustrallons). The pointer orTOC mark and Vibration damper are located low on Ihe lront 01 th e engine. near the pulley Ihat turns the dflvebell. 7 The rotor should nOW be pomllng directly at the mark on the dlstnbutor housing. It it isn't. the piston IS at TOe on the exhaust stroke 8 To get th e piston to TOe on the compression stroke. turn the crank· shaft one complete turn (360·degrees) clockWise. The rotor should now be pointing at the mark. When the rotor is pointing at the number one spark
Chapter 2 Part 0
I
FAOHT
I
3.8l V6 and all V8 engines
20-5
,me
~~T o_ . . .
C>
'"
ROTATION - . .
3.68 Turn the cfankshal1 until Ihe zero on the vibration damper scal e Is directly
opposite Ihe pointer
3.6b Some engines may have the scale on the Umlng chain cover and Ihe timing mark on Ihe damper
4.2
The s park plug wi re ro uting cli ps (arrow) pull afflhe stud s
plug wire terminal In Ihe dlstnbutor cap (whICh IS Indicated by the mark on Ihe houSing) and the IgnltlOl'l timing marks are aligned, Ihe number one piston is a\ TOC on the compression stroke 9 After the number one piston has been posItioned at ToC on Ihe compression stroke. TDC l or any at the remaining cylinders can be located by turning the crankshaft and lollowlng the firing order (refer to the Specifications).
4
2D
Rocket arm cover s - removal and Installation
Removal ReIer ro Illus/rarions 4 2. 4
!,
and 4 12 1 Disconnect the negalive cable Irom the battery 2 Note their Iocalions. then detach the spa~ plug wire clips Irom the rocker arm cover studs (see illustration) 3 Reier to Chapter 1 and detach the spark plug Wires Irom the plugs POSlllOn the wires out 01 the way 4 II so eqUipped, detach the dlvel1er valve and hoses Irom the rocker arm cover 5 On vehicles With cruise control, disconnect the servo linkage at the carburetor or throttle body and remove the servo bracket
4.11 Remove the oil IiIler cap and, atter d isconnectin g th e exhaust heat conlrol valve vacuum hose (arro w), pu s h It asi de
Right side 116 engine 6 POSllion the all cleaner out 01 the way (Ch apter 4) and remove the PCV valve Remove the automaliC choke heat tube (carburetor eqUipped vehicles only). 118 engine 7 Remove the air cleaner assembly (Chapter 4) and disconnect the PCV tube 8 Remove any solenOids attached to the rocker arm cover 9 Remove the automatIC choke heat tube (carbureted models only). 10 Disconnect the EGR vacuum amplltier hoses (models so equipped)
left side 116 engine t t Remove the 011 filler cap and the e~haust heat control valve vacuum hose (see Illustrati on) (II equipped). 12 Remove the bolts and SWivel the exhaust heat control valve out 01 the way (see IIlustraUon) 13 On carbureted models equipped With crUise control. detach the an cleaner and move It out 01 the way Detach the cruise control servo chain irom the carburetor. detach the servo bracket and place the bracket and servo out ollhe way
4,12
Remove the bolt s and swivel Ihe exhaust hea t con trol va llie 9O-degree s count er clockwise
20-6
Chapter 2 Part 0
3.8L V6 and all V8 engines
• "TT.lC'"ING IIOLl
5.2 The rocker arm fulcrum bolls (arrow) may nol have to be completely removed - loosen them several turns and see if the
mAE.o.DEO PEDESTAL
rocker arms can be pivoted Oul ollhe way to allow
_1!i:";;:;JI/
pushrod removal 5.3
Exploded view of a rocker arm and its related components
cover(s) On engines that don't have gaskets, apply a 3i l6·mch bead of RTV sealant to the cover flange , mSlde 01 the bolt holes 19 Cdrefully poSItion the cover on the head and install the bolts/nuts, 20 Tighten the bolt,; mthree orlour steps to the torque listed In thiS Chapter's SpecificallOns_ PlastiC rocker arm covers are easily damaged, so don'l overt igh ten the boltsl 21 The remaining InstaliaMn steps are the reverse of removal 22 Stan the engme and check carefully l or all leaks as the engine warms up
5 SA A perforated cardboard bOI( can be used 10 store the pushrods to ensure Ihal they are reinstalled in their original locations - note the label Indicating the Iront of Ihe engine
Rocker arms and pushrods - removal , inspection and installation
Removal
Installation
Refer 10 Illus/rallons 5.2. 5.3 and 5 4 1 Reier to Section 4 and detach Ihe rocker arm cover(s ) from the cy lm· der head(s). 2 Begmnmg at the front of one cylinder head, remove the rocker arm fulcrum bolts (see illustration) Store them separa tely m marked containers to ensure thaI they Will be reinstalled In thelf oflglnalloca\lons. Note: If Ihe pushrods afe the only Items bemg removed, loosen each boll Just enough /0 aI/ow the rocker arms /0 be rotated to the Side so the pushrods can be Mled OUI 3 Uft of/the rocker arms, fulcrums and fulcrum gUides (If used) (see illustration). Store them In the marked containers With the bolts (they must be reinstalled In thell onglnallocallons) 4 Remove the pushrods and store them separately to make sure they dont get mixed up during installation (see illustration)
16 The mating sur/aces of each cy lmder head and rocker arm cover must be perlectly clean when the covers are mstalled Use a gasket scraper to remove all traces of sealant and old gaske t matenal , then clean the mating surlaces with lacquer thinner or acetone. II there 's sealant or oil on the mating surlaces when the cover IS Installed, all leaks may develop. 17 Clean the mounting bolt threads With a die 10 remove any corrosion and reSlore damaged threads, Make sure the threaded holes In the head are clean - run a tap Into them to remove corrOSion and restore damaged threads . Apply a small amount of light all to the bolt threads 18 The gaskets should be maled to the covers before Ihe covers are m· stalled. Make sure Ihe tabs on the gaskets(s) engage m the slots In the
5 Check each rocker arm lor wear, cracks and other damage, espeCial· Iy where the pushrods and valve stems contact the rocker arm faces 6 Make sure Ihe hole at the pushrod end of each rocker arm is open. 7 Check each rocker arm pIVot area afld fu lcrum for wear. cracks and galling 11 lhe rocker arms are worn 01 damaged, rep lace them With new ones and use new fulcrums as well 8 Inspect the pushrods for cracks and e~cesslve wear at the ends. Roll each pushrod across a piece of plate glass 10 see If It'S bent (If II wobbles. lIS benl) _
va engine 14 On 1983 through 1985 models. remove Ihe air cleaner assembly (Chapter 4) and Ihe solenoids anached to Ihe rocker arm cover
Both sides 15 Remove the rocker arm cover bolts/nuts. then detach the cover from the head Note : If the COl/ens stuck to/he head. bumponeendwllhabioci< of wood and a hammer /0 lant/cose. /I that doesn 't work, fry /0 slip a flex Ible puny knife between the head and cover to break Ihe gasket seal. Don 'l pry al the cover-Io,head jomt or damage to the sealing surfaces may occur (Ieadmg to all leaks m the future). Some rocker arm covers are made of piastre - be mara careful when lappmg or pulling on them.
Inspection
Chapter 2 Part 0
3.8l V6 and all V8 engines WITH NO I U TOC . AT ENO OF COM""(5SION STROKE, MAKE A CHALK MARl< AT I'OINTS 2 AND l APPROlClMA T ELV 110 DEGR USA'ART
5.12 A special 1001 Is required to bleed down Ihe lifters when checking the valve slem-Io·rocker arm clearance
20-7
IElCCE'l 6CVL ENVIN(5)
POSITION 1 _ NO I AT TOC , AT ENO OF CO MPR ESSION STROI
Nut
3
A C FUNCTION Eo TE MPUIA!l.JAE CON TROL "''''LVE "'SSEM8l~ ... C
~ACUU M
HOSE
HARNESS & BlOCI( ASSEMBLY
A C FAN CONTROL
SWI TCH ASS(M Bl v
12.1,. Heater control assembly - exploded view (1987 through 1989 models)
3 -18
Chapter 3 Cooling, heating and air conditioning systems
! : Df; ~:~"
FAN CONTROL
CONTAOL ASSV
.~
"'l(aJ.,
INSTRUMENT PANEL , _ _ _ _ _ _ _ SOCI(ET '" aULB ...sSY.
; l!"---
TEMPERATlJRE CO NTRO\. SYSTEM
•
BRACKET
, & TENPeRATURE CONTROL VALVE ASS'"
12.11 b
'''''''''~ "OSITION
fOA INST4LLAT'QN OR RE -AD.lUST ... tNT
C.... LE END RnAINU!
I
~ CONTROL ''''lIlf ASSfM8L v
L 00" "0' . , "
/
n~ _0
Heater conlrol assembly - exploded view (1990 models)
j
-
WII";( END lOOP
... ~
"""' _
SEL F AOJUSTING Cll'
14.1
~
Heeler conlrol cable
-~
-
SN"LL SCREwOAlveR
preset adjustment
3 On 1979 through 1986 models, detach the conlrolleverlang from the knob With a screwdriver and remove the knob. 4 On 1987 and laler models, pull the knob off. 5 Remove the SWItch attachmg screw(s) and take the switch out. 6 Installallon is th e reverse at removal
14
Healer conl rol cables - adjustment
Refer 10 II/us/rallon 14. 1 1 Before installing the cable: a) Slip a small screwdriver blade into the wire coil on the end of the cable (see Illustration) b) Use pliers to slide the sell -adjusting clip along the cable until It IS about one Inch Irom the wire loop. c) Install the cable (see Secllon 15).
2
It the cable IS already Installed: a) Move the control lever or knob to the Cool posillon. b) On vehicles eqUipped Wllh control levers (not rolallng knobs). move the function control lever to the all poSition. 3 If equipped With control levers. place the temperature control lever in the Warm poSition and the function con\rollever in the Del poSition 10 adJusl lhe cable. 4 If equipped with rotat ing control knobs. quickly rotate the knob to the Warm poSition to adjust the cable.
15
Heater conlrol cables - replacement
Detach Ihe cable housing from the heater case. On 1979 through 1986 models. use the special 1001 or equivalent (see Section 12). 2 Slip the self-adjusting clip off the crank arm at the healer case. 3 Remove the heater control assembly (see Seclion 12).
Chapter 3 Cooling, heating and air conditioning systems
16.1
4 5
Right venti1alor and register ducl (1979 through 1986 models)
Detach Ihe cable trom the contrOl assembly and take 1\ out. Install the cable by reverSing Steps 1 through 4 Adjust Ihe cable as
descnbed In Sec lion 13 16
Blower motor - replacement (1979 through 1984 models)
Without air conditioning Refer fa rl/()Srralions 16. I. 16.8 and 169 1
3 -19
Remove one screw 10 delach Ihe right register duel from 115 mounTIng
bracket (see Illustration) 2 Remove two screws and detach the vent!lalorcontrol assembly trom the lower edge 01 the instrument panel 3 Remove the glovebox liner 4 Remove the ventilator gnlle moun,mQ pms, lhen lake the gnlle ouI 01 Ihe vanlilator 5 Remove Ihe nghl register duct. 6 Removelhe lour venlliator assembly screws. One screw 15easB), accessible Access 10 lhe olher screws IS as tallows: a) Upper lell screw - through Ihe glOvebox opening
Chapter 3
3-20
Cooling, heating and air conditioning systems
MOTOI'! SHAFT
HUB CLA MP
16.8
16.9
Blower motor wheel installation details (1979lhrough 1986 models)
Blower motor Instatiation details (1979 thrOugh 1986 models)
SFlACKH
BOLT AND WASHER
TO fRONT
Of VEH ICLE eVAPORATOR
AND BLOWER
"sseMBl Y
OUTSIDE REelRe DOOR VACUUM
MOTOR SCREW
ANO BLOWER ASSEMBl V
'"' 16.11 Air inlel duct and blower housing assembly (1979lhrough 1984 models with air conditioning)
b) lower right screw - through Ihe vent ilator grille opening c) Upper right screw - through the register duel opening. usmg a long extension 7 Remove the venlilator assembly to the right and down and take it out from under the instrument panel a Remove the hub clamp spring (see Illustration) and pull the blower wheel off ItS shaft. 9 Remove the blower motor mounting screws (see iIIuslration) Pull the motor out. disconnect its wiring connector and remove the motor.
VIEW SHOWI"-l(i 8RACKETS AND EVAPOFIATOIII & BLOWER AS5EMBl Y VIEVI' A
10 InstallallOn IS the reverse 01 removal POSition the hub clamp spring In relat ion to the ttat on the motor shaft as shown In Illustration 16.8.
With air conditioning Refer 10 illustraMns 16 II and 16,18 11 Remove the glovebox liner. Reach through the opening and dlseon· nect the vacuum hose Irom the outslde 'reclfe door vacuum motor (see iI· lustration)
Chapter 3
Cooting, heating and air conditioning systems
3 - 21
ItOWEIII MOTOR AND 'tAn ASSE MB LY
W-.. EE t HUB
AIR INLET DUCT
"u.
e .....""
MOTQfI
$PAING
SH"' FT
"-.OWER IoIOVStN G
",SlfUl l Y
OUTSI DE- REti Re
000' C LIP
3 16.18
Air inlel duel and blower housing assembly - exploded view (1979 lhrough 1984 models with air condilioning)
12 Remove .he boll secUring the lower nght side 01 the Instrument panel
to the cowl Remove the tom panel lrom the righ t side ol \he passenger footwall 13
Remove 1he screw thai secures .he lOp 01 the support brace to the air
Inlel nul 14 Disconnect the blower molor wiring althe lohne electrical connector
way when the malar IS Installed 24 Place Ihe alr Inlel dUCI and blower hOUSing assembly In lIS Installed posi tron on the evapora tor case Slip Ihe tlange al the lop of the blower ouUet Into ItS opening in the evaporator case 25 Place Ihe blower hOUSing lower bracke t on ItS s tUd, inslallthe nul on Ihe sl ud to secure th e hOUSing 10 Ihe b racket. Note : Roule the OIower mo-
15 Remove the nut [hal secures the blower houSing lower suppon black-
lar Wiring toward the passenger's side ol/he evaporator case
ei lO the evaporalof case
26 Connect a hand vacuum pump to the Irrung on the outslde-Iecllc door vacuum motor Apply vacuum to hold Ihe outsrde·reclrc door open. then spm the blower wheel by hand There should be no rnterlerence It there IS, COffBClihe problem before continuing 27 Connectlhe blower mol ar elect neal COnl'lBClor 28 Insl alilhe screwlhal secures Ihe lop 01 the air Inlet ducllo Ihe evaporator case 29 Connect the vacuum hose to Ihe vacuum motor 30 Install the glovebox Irn e r 31 InSlal1the bolt securrng the lower right Side 01the Instrument pane l la the cowl Install the 111m panel on Ihe fight side ol lhe passenger"s Side footwelL
16 Remove ,he screw that secures !he lOp altha air mlet duclla the evap
0lal01 case 17 Pull the ai' mlet duct and blower hoUSing assembly dow n to separate It Irom the evaporator case 18 Remove Ihe lour screws that secure the blower mounting ptate to the hOUSing assembly (see ittustration) lift l he blower and wheel out o l lhe hOUSing Cau l lon : Do nol separate the moummg plate from Ihe blo wer
molar 19 II necessary, remove Ihe spring clamp Irom the blowe r shall and pull the blower wheel 011 20 lithe blower wheel was removed Irom the shall. slide II onl o Ihe shalt Pas Ilion Ihe outer edge 01 the blower wheel 3 5 8-II'lChes from the motor mounhng plate Secure the blower wheel WITh a new spong clamp, POSIIroned so lIS ends are 90 degrees trom the lIat on the motor shaft (see illustration 16. 18) 21 Place the blower molar on the hOUSing POSition the lIat Side 01 the motor lIange toward Ihe blower outlel 22 InSlalilhe blower motor attaching screws through the mol ar Ila nge Into the hOUSing 23 Tape Ihe blower molar wIfing to the air Inlet duct so It won' l be in Ihe
17
Blower motor - replacement ( 1985 and 1986 models)
Without air conditioning Refer /0 Ii/uSlra/!On 17.2 1 2
Remove the glovebox_ Re move six screws that secure the lower d uct to the upper duct and
3- 22
Chapter 3 Cooling, heating and air conditioning systems
SCREW 1'1 FlOOf'l ...oAPTtR DUCT AS5V
GASMH
BLOWER MOTOR ASSV
WHEel
""'"
GEAR SHAFT
HEATER CORE
17.2
Heater assembly (1985 and 1986 models)
heater case (see Illustration). 3 Remove the hub clamp spring (see illustration 16.8) and pull the blower wheel off liS shafl. 4 Remove the blower motor mounting screws (see Illustration 16.9) Pull the motor out. disconnect its wiring connector and remove the motor 5 Installation IS the reverse at removaL Position the hub clamp spring
ends gO -degrees from lhe lIat on the maIO! shalt (see illu stration 16.8).
With air conditioning 6 Replacement of the blower motor on 1985 and 1986 models wllh a lf condi1l0ning IS the same as for 19791hrough 1984 models wllh air candi lIaning (see Section 16)
Chapter 3 Cooling, heating and air conditioning systems ...;I""
.LOWI • .."" >UTI . SOlMI"
3-23
to detach liS retaining tabs Irom the Instrument panel Pull the glovebox out and lei II hang down 2 Disconnect the blower motor COOling hose and electrical connector 3 Remove the four blower moior mounting screws and lake the molor out (see illustration). 4 It necessary, separate the blower wheellrom the motor Remove the
_",..., "'-OWl" """OO ..... "
• " ... ., O
BR "C ~ H
3-29
ASSV
IU ~P ["I
BRACKET .. ssv IL H. I
23.5
Air condilionlng condenser inslallatic.n details - 1979 through 1981 models
3
23.12
, 2
3 4
5
Air conditioning condenser Installation detalls-
1982 and laler models Condenser assembly U-nuts Scre ws Lower mounting bracket assembly Lower mounting
bracker assembly
6
7 8
Upper mounting bracket assemblies Aif conditiomng lag SLC clip
9
SLCcilp
B
Radiator support Refrigerant/me connec/lon Refrigerant Ime connection
C 0
o
3-30
Chapter 3
Cooling , heating and air conditioning systems 3
24
Air conditioning system accumulator - remo val a nd Installation
Reier /0 Illus/rallOn 24 3
Warning: The air conciitlOflJng system IS under hl{Jh pressure 00 NOT dlsassembleanypartofthesystem(hoses. compressor Ime flttmgs. etc} un/JI after the system has been depressurized by a dealer servICe deparr men! or servICe statIOn
1 2
Have the air condltlonmg system discharge
4 Disconnect the refrigerant hne tram the accumulator Use a back-up wrench to prevent twisting the tubing 5 Plug the open flnings to prevent entry of dirt and mOisture 6 loosen the holddown bracket pinch bolt and 11ft the accumulator oul. 7 If a new accumulator IS being Installed remove the Schrader valve and pour the all out Into a measunng cup. IlOtlng the amount Add fresh lefngelanl 01110 the new accumulator equal 10 lhe amount removed from the old Unll plus one ounce. 8 Instaitallon IS Ihe reverse of removal. 9 Take the veh icle back to the shop that discharged It. Have Ihe au con· ditloning system evacuated, charged and leak tested
25
24.3
Details 01 th e air conditioning accumulator
A
ElectrICal connector
B
Refrlfjer8nt Ime connectlOll
C
HokkJown bracket pmch bol/
Unplug the electrical connector from the pressure SWitch near the lOP
of the accumulator (see Illustration)
Air conditioning syslem receiver drier - removat and installation
Warning : The air condlliDmng system IS under high pressure DO NOT disassemble any partof lhe system (hoses. compressor. Ime fltlings. elc) un/!! after Ihe system has been depressuflzed by a dealer service depart· ment or servICe slatlOn I A receiver dner IS used on 19791hlOugh 1981 models 2 Have the an condl\lOntng system discharged (see Warning above). Remove the radlalor grille (see Chapter II). 3 4 POSition the ambient cutoff SWitch out 01 the way. 5 Disconnect the refrigeranliines Irom the rece iver/drie r (see Illustra· lion 23.5). 6 Remove the recelverldner anachlng screws and take II 011 the con· denser 7 Installallon IS Ihe reverse at removal 8 Takethevehlcteback tOlheshoplhat discharged II HavethealrcQfl' dl110nlng system evacuated. charged and leak lested
Chapter 4
Fuel and exhaust systems
Contents Air cleaner housing - removal and installation ..•. B Air tiller replacement . . . . . . . . . . . ......... See Chapter 1 Carburetor - diagnosIs, removal . overhaul and installation 10
Fuel hnes and linings - replacement . ......... . Fuel pressure rehef procedure (lueHnjected models) Fuel pump - check •.
Carburetor choke check. Central Fuellnjecllon (eFt) system -
Fuel pump - removal and mstallallon . ...••.. Fuel syslem check .,. Fuel lank - cleanmg and repair .•.. 6 Fuel tank - removal and mstallatlon 5 General Information ... Sequenllal Electronic Fuel Injection (SEFI) and Electronic Fuel Injection (EFI) systems - component replacement . 14 Throltle cable - replacement . . . . . . . . . . . . . . . . . 9 16 Turbocharger - removal and Installation Underhood hose check and replacement See Chapter 1
See Chapter'
component replacement 13 Electronic Fuel lnjeC!ion (EFI) system - component replacement (four-cyl inder engine) t5 Exhaust system check. See Chapter 1 Exhaust system servicing - general information . ........... 17 Fuel hlter replacemen t See Chapter 1 Fuel lnJec\lon systems - generalmformation 11 FuellnJ€cllon system - pressure check 12
Specifications
Fuel pressure Carbureled models Central FuellnlectlOn (CFI) . EFI and SEFI fuel-inject ion systems .
6108psl 14.5 pSI 301045 psi
Torque specifications
Ft-Ibs
Carburetor' lo-mtake manifold nulslbolls Model 5200/6500 Model YFA IV Model 2150 2V Model 7200 -VV Model 4180-C4V Mechanica l fuel pump-to -block boilS 2.3l lour-cylinder 3.3l six -cy linder 2.8l V6
VB
10 to 14 13 to 14 14 to 16 12 1015 141020 14to 12 to 12 to 19 to
21 18 15 27
Fuel chargmg assembly·to-mtake manifold nuts (CFI-eqUipped models) 1984 and 1985 10 1986 12 to 15
3 2 4 7 See Chapter t
4
4-2
Chapter 4
Fuel and exhaust systems
Torque specifications (continued)
Ft·lbs
va engines with SEFI UpPer intake manifold·le·lower intak e manifold bolts
'987 1988 on Lower Intake manlfold·to-cylinder head bolts Air Intake throttle body mounllng nuts ..
Fuel rail bolls
t5 t022 t210 18 231025 t2to 18 70 to 105 In· lbs
Four-cylinder engines with EFI Lower intake manifold mounllng bolts 1984 al'ld 1985
121015 141021 15 to 22
1986 1987 on Fuel supply manifold mounting bolts 1984 and 1985 1986aJ'ld 1987
12 to 15 151022 141021 15 t022
1988 on UpPer Intake maniloJcHo· lower imake manifold bolts
Turbocharger Carbureted engines Compressor houSing bolts Turbine houSing botts ••.
145 to 165 In· lbs 164 to 18tln·lbs 164to 1811n·lbs
Outlet elbow and waslegale assembly boilS EFI engines E~hausl ptpe-Ie-exhaust manifold bolts . Tul1Jocharger-Io·exhaust manifold nuts .. Outlet elbow-Io-turbocharger hoUSing •...
251035 28 to 40 141015
General information
Fuel system The fuel system conSists of the fuel lank. the luef pump. an air cleaner assembly. either a carburetor or a fuel injection system and Ihe vanous steel. plastic and/or nylon lines and finings connecting everything logelh·
..
"
Models covered by thiS manual are eqUipped with one of four general types olluel systems. carburelor; Central FuellnjecliOn (CF I); Bosch/Ford Eledroruc Fuel tnlectlon (EFt); and SequentlaJ ElectronIC Fuel InjeCtIOn (SEFt). To identily the system whICh applies 10 your vehICle . refer to Sec· tions 8, 10. 11 and 13 The luel pump on carburetor equipped models IS a mechanical t~pe mounted on the engine block and driven off the camshaft. Early luel' In' jected models have a Iow·pressure pump mounted Inside the fuel tank and a high pressure pump mounled on the chassIs. In tater years . fuel·lnJected models have only a Single hlgh.pressure pump Installed InSide the fuel tank The turbocharger used on some early lour ·cyllnder engines IS a draw' through type whICh pulls air and luel through a one·barrel carburetor The laler turbocharger blows air into an electronic fuel )nJectlon system. The turbocharger used With Ihe Mustang SVO Includes an Intercooler and boosl control system.
Exhaust system All models are eqUipped with one (lour and Inllne slx·cyllnder ) or two (V6 and V8) exhaust manllolds, a catalybc convener, an exhaust pipe and a mullier. Any component of the exhaust system can be replaced See Chapter 6 for further delalls regarding the catalytiC converter.
2
Fuel pressure reliel procedure (luel·lnJected models)
R.r.r /0 rlluslr3/1OfI2
,
The fuel pump SWitCh - sometimes called lhe "Inertia sWltch- - which 1 shuts 011 luet to the engine In the evenl of a ColliSion. aHords a Simple and convenient means by which fuel pressure can be relieved belore servicing
L
J
l'iI SPARE TIR E
WE l l
2.1 On most models, the luel pump switch assembly Is tocated in the luggage compartment - the reset button (arrow) must be pushed In 10 reactivate the switch /pump
luel lnJectlon components. The SWitch IS located In the luggage compart· ment. In a vallety 01locations (see lIIustration) and IS usually covered by Ihe carpet which comes up the Sides 01the trunk In some cases the wifing Irom the luel pump to the luel pump SWitch can be traced 10 M lp locate Ihe swi tch . 2 Unplug Ihe inertia switch electncal connector 3 Slartthe engine and allow II torun until It SlOpS Th lsshould take only a lew seconds 4 Thetuel system pressure IS now relieved When yourefl mshed work Ing on the luet system. Simply plug the electrICal connector back Into the SWitch and push the reset button on th e lOP 01 the SWitch (see Illustration 2.1).
4-3
Chapter 4 Fuel and exhaust systems
[}-c",, __
•
" 0" RINCiS
800Y
SPACERS
/
3.S An exploded view of the hairpin clip type push
PU SH UNTIL
CLICK IS HEARO
connect litting
,
Fuel lines and liltings - replacement
••
Refer to II/ustratlons 3.5, 3.9. 3. 10. 3. 13,3. 14 and 3.26 Warning: The fuel system pressure must be relIeved before dlsconnect-
mg fuel/ines and f!ttmgs on fuel-injected models (see Section 2). Gasolme IS extremely flammable, so exIra precautions must be taken when workmg on any part of the fuel system, DO NOT smoke or allow open flames or bare light bulbs near the worK area . Also, don "' work In a garage where a
3.9
Reassembling push connect fitUngs
natural gas appliance such as a water healer orelo/hes dryer is present
Push connect fittings - disassembly and reassembly Ford uses two differenl push connect fi tting designs. Fittings used wi,h 3/8 and 5/16-inch diameter lines have a "hairpin" type clip: finlngs used wi th 1/4-lnch diameter lines have a "duck bill" type clip. The proce· dure used for releaSing each type of fitting IsdlHerent. The clips should be replaced whenever a connector is disassembled. 2 Disconnect all push connect fittings from fuel system components such as the fuel filter, the carburetor/fuel charging assembly. the fuel tank. etc_ before removing the assembly.
3/8 and 5/16-inch fittings (hairpin Clip) 3 Inspect the Internal portion 01the fitting for accumulations 01 dirt. If more than a light coating 01 dust IS present, clean the lining before disassembly. 4 Some adheSion between the seals In the fining and the line Will occur over a peflod 01 lime. Twist the li!ting on the line, then push and pull the litllng unlilit moves freely. 5 Remove the hairpin clip Irom the fitting by bending the shipping tab down unlil it clears the body (see illustration). Then, uSing nothing but your hands, spread each leg about 1/8-lnch to disengage Ihe body and push the legs Ihrough the flltlng. Finally, pull lightly on the tflangularend of Ihe clip and work II clear of the line and fitting . Remember, don't use any tools to perform this part of the procedure. 6 Grasp the fitting and hose and pull It straight oH the line. 7 Do not reuse the original clip in the lilling. A new clip must be used.
8 Before reinstalling the fitting on the line, Wipe the line end With a clean cloth. Inspect the Inside of the filling to ensure that it's free of dirt andlor obstructions. 9 To reinstall the fitting on the line, alrgn them and push the lining IntO place. Whenthefitl ing is engaged. a definite click will be heard. Pull on the filling 10 ensure that It'S completely engaged (see illustration). To install Ihe new clip, insert It inlo any two adjacent openings in the fitting with the triangular portion of the clip poinllng away trom the fitting opening. Using your Index finger, push Ihe clip In unlillhe legs are locked on theoulsideot the filling .
1/4-inch fittings (duck bill clip) 10 The duck bill clip type fitt ing conSists 01a body, spacers, O'nrlgs and the retaining clip (see illustration). The clip holds Ihe titling securely in place on Ihe line. One ol lhe two follOWing methods must be used to disconnect this type of 111Iing. 11 Before attempting to disconnect lhe titung, check Ihe visible inlernal portion of the fi tting for accumulations 01 dirt. II more than a Irght coallng 01 dust is eVident. clean the litting belore disassembly. 12 SomeadhesionbelweenthesealSlnlhefilllngandlrnewilioccurover a penod ol time. Twislthe fitting on the line, then push and pull the fitting unllll! moves freely. t3 The preferred method used 10 disconneclthe Irtting requires a specIal tool. Todisengage the line Iromlhefitting, alrgntheslolln Ihe pushconnecl disassembly tool (Ford Part No. T82l -9500-AH or equivalent 1001) With ei ther tab on the clrp (90·degrees from the slots on the Side of the tittlng) and lrtsert the tool (see illustration). This disengages the duck bill from the
3.13 3.10
A push connect fitting with a duck bill clip
Duck bill Clip tltlfng disassembly using the specIal Ford 1001
4-4
Chapter 4
Fuel and exhaust systems 4
Fuel pump - ch eck
Mechanical fuel pump (carburetor equipped models) If a probfem occurs In the fuel pumpltsell. It will normally either delIVer no fuel at all or not enough to sustain high engine speeds or loads 2 When an engine develops a lean (tuel starved) condllion. the tuel pump IS otten to blame, bulthe same symptoms Will be eVident lIthe carburetor float bowl hiler IS clogged A lean condition Will also occur 1/ the carburetor IS malfunctlomng, the fuel lines and hoses are leaking, kinked or resTficted or the electrical SySTem IS shorting OUT or malfunctioning
3. 14
Pulling 0 11 Ine duck bill clip type pus h connec t filling
line Note: Some fuel/mes have a secondary bead which aligns with the Qu/ersurface of Ihe clip The bead can make 1001 msemon dlfflcull If nec·
.essary. use Ihe allematlve disassembly method descflbed In Slep 16 14
Holdlnglhe 1001 and Ihe line with one hand, puillhe lilling ott (see 11-
luslrat ion ). Note: Only madera/eeffort/s necessary" lhec/Jplsproper/y drsengaged The use of anything olher than your hands should not be f8
qUlred. 15 Alterdlsassembly,lnspec\ and clean the line seahng surface Also Inspectlhe inSide ollhe Iilling and Ihe hne lor any Internal pans thaI may have been dislodged from the lining Any loose internal parls should be Immediately remstalled (use Ihe line to Insertlhe parts), 16 The alternative disassembly procedure reqUires a pair of small adJustable pliers. The pliers must have a jaw WidTh of 3 16-lnch or less 17 Align Ihe Jaws 01 the pliers Wllh Ihe openings In The Side 01 Ihe liUlng and compress the portIOn of the retaining clip that engages the body ThiS disengages the retaining clip from the body (of len one side 01 the CtlP Will disengage betore the other - both sides must be disengaged) 18 Pull the fitting off the tine_ Note: Only moderate ef/or/ls required If the re/ammgcl!p has been properly disengaged Do nOI use any /ools for thiS procedure 19 Once the lining IS removed from the line end. check ThefllTlng and line for any Internal parts that may have been dislodged from the l ining. Any loOse internal pans should be Immediately reinstalled (use the line to insert the parts). 20 The relamlng clip Wilt remain on the hne. Disengage the clip from the hne bead TO remove it. Do not reuse the retaining clip - Install a new onel 21 Before reinstalling the littlng. Wipe the line end With a ctean ctoth Check the inside of the lilting to make sure that it's free of d irt and/o r obstructions 22 To reinstaillhe littlng, align II wllh the hne and push II Into place When the lilting IS engaged, a dellmte click will be heard. Pull on the fitllng 10 ensure that ItS fully engaged 23 Instalilhe new replacement clip by Insenlng one of the serrated edges on The duck bill portion Into one of the openings Push on the other side until the clip snaps Into place.
Spring lock couplings - disassembly snd reassembly 24 The fuet supply and return lines used on EFt engines utilize spring lock couplings at the engine fuet rail end Instead 01 plastiC push connect IIlImgs. The male end 01 the Spring lock COUpling. which IS girded by two O-MgS, IS Insened mto a lemale flared end engine filling The coupling IS secured by a garter spring which prevents disengagement by gripping the flared end of the female lilling On later models, a cup-tether assembly provides additional securlly 25 To disconnect the 112-lnch (12.7mm) spring lock coupling supply flltlng. you Will need to obtain a SPring lock COIJphng 1001 D871-9280·B or ItS eqUIValent, for the 318-lnch (952mm) return finmg, get Tool D87L-9280-A or ItS eqUivalent 26 Study the accompanying Illustrations caletully before detachmg either sprmg lock coupling IIl1ing (see illustration) ,
General check 3 If the fuel pump IS noisy a) Check lor loose fuel pump mounting bolTS and,ll necessary, lighTen them 10 the specified torque. Replace the gasket I! necessary b) Check for loose or mlssmgluel line mounTIng clips Loose or miSSIng clips Will sound louder when you are SlUing InSide the vehicle than when Slandlng outSide 01 it Tighten the clips on the fuel lines If necessary c) Check tor a worn, or slicking fuel pump pushrod 4 Before assuming a fuel pump IS deleetJVe a) 8e sure the Tan).. has luelln IT b) Be sure the fuel hlter IS not plugged 1111 hasn't been changed recently. mstall a new one c) Inspect all rubber hoses from the fuel pump to Ihe luel tank forklnks and cracks With the engine Idling. check all fuel lines and rubber hoses and connections from the luel pump to the fuel lank tor fuel leaks. Tighten any loose connecTions and replace kinked , cracked or leaking luellmes or hoses as reqUired Leaking or kinked lines or hoses Will severely affecl fuel pump performance d) Inspect the fuel pump mlet and outleT connechons tor fuel leaks, Tighten them It necessary e) Inspect the fuel pump diaphragm cnmp (the area where The stamped steel seeMn IS attached to Ihe cas!lng) and the breather hole{s) in the casting for eVidence 01 fuel or oil leakage Replace the pump It It'S leaking.
Output (capacity) test Warning : GasolmfJ IS extremely flammaO/e SO extra precautlOflS mus/ be taken when workmg on anyparT 01 Ihe luelsystem DO NOT smoke or allow open flames or bare light bulbs In or near the work area Also. doni work m a garage If a natural gas appliance such as a waler healer or clo/hes dryer IS present. 5 Remove the air cleaner assembly (see SecMn 8). 6 Carefully disconnecT the fuef line althe luelfiller Inlel (see Chapter I ). 7 Anach a sectIOn of rubber fuel hose 10 the end 01 the disconnected line WIth hose clamps and route the end 01 the hose Into an approved gasoline ec;ntalner(1 12-lIteror I PInt minimum) Note: Itmaybenecessaryroarrach a sectIon of hose to Ihed,sconnected fuel Ime m order 10 reach theconlamet Disconneclthe high tension wire lrom the Call and ground It on the en· glne With a jumper wire Crank the engine over about 10 revolutions The fuel pump should deliver at least 1/3-pln t of fuel 8 If the outpullS adequate, pertorm Ihe pressure lest below 9 If Ihe output IS less than speclhed repeat The leST With a remole tuel supply. Detach the hose from the fuel pump Intetllne and al1ach a separate section ol fuel hose to the tme wllh a hose clamp Route the end 01 the hose inTO The lemote fuel supply (an approved gasohne contamer alleast half lull ofluel) and repeat The procedure m Step 7 If the output Is now as specifled. the problem IS either a plugged in-tank filTer or a kinked or leaking fuel hose. Make the necessary repalrs_
Pressure test 10 Connect a fuel pressu:e gauge (0 to IS pSI) to the fuel filter end of The
"00 II Start the engine -It should be able to run lor over 30 seconds on the fuel m the carburetor bowl - and lead the pies sure aller len seconds Compare your reading \0 the specified pressure,
Chapter 4
REMCNE CUP
~
USE SPECIFIED
4-5
Fuel and exhaust systems
•
COUPUNO
use
,"EC
TOOL:
HXX. OR
f.~~
EOUIVALENT
De7L·928I:).A - 318 INCH D87L-i280-8 -
112 INCH
C'GE
CLEAN FfTTlNGS WITH SOlVENt CHECK FOR MISSM) OR D.AAtAGEO ().RINGS. RE~ MISSNl O-RINGs. F EITHER ().RN] IS DAMAGED. REPUCE 80rH Q.RINGS.
OPENING
so
FIT TOOl TO COUPliNG THAT TOOL CAN ENTER CAGE OPENING TO RELEASE THE GARTER SPRING .
•
PUSH TOOL INTO CAGe OPENING
NOTE : SPECFEO lOOt.. WIll FIT AAOUNO RU88EA COVERED FUEL LINE. PUSH THE TOOL INTO THE CAGE OPENING TO RELEASE THE FEMALE FITTING FRDM THE GARTER SPRING
GAATER SPRING
•
TO ENSURE COUPUNO ENGAGEMENt; PULL ON flT'TlNG AND VISl.IM.lY CHECK TO BE sum: GARTER $MINGo IS ewER FlAR'EO END Of
FEMAlE FITTING
UN'
PULL THE COUPLING MALE AND FEMALE FlnlNOS
APART
REMOVe THE TOOL fROM THE DISCONNECTED SPAINO lOCI( COOP\..ING
3.26
o
•
YES
Connecting and disconnecting spring lock coupling fittings -later models use a tethered clip to secure the lines
4
4-6
Chapter 4
Fuel and exhaust systems
2 AEQ' O
2 REQ'O
,,,.," 5.5 Typicalluel tank and littings
12 II pump pressure IS not as specified Install a new fuel pump irefer to Seellon 7). 13 Reconnect the luell!nes and Install the all cleaner
Electric fuel pump 14 An electric fuel pump malfunction wi ll usually result
In
a loss olluel
flow andior pressure lhat is often reilecl ed by a corresponding drop In per, formance II you suspect an electric fuel pump problem, disconnecl the Wife harness from the pump(s) (sea Section 7), attach a fused jumper be tween the battery and the pump and carefully hslen to the pump It II 5 not running replace It 1111 IS funning. then the problem lies Within Ihe tuel pumpClfcult Of elsewhere (see Troubleshootmg) DiagnoSiS 01 thiS CirCUIt IS beyond the scope at the home mechaniC. Take the vehICle to a dealer and have the fuel pump CirCUit checked by a profeSSional.
5
Fuel tank - removal and Installallon
Refer /0 Illus/ra/ion 5.5 Nole: Don't begin /hls procedure unttl/he gauge Indreates that the tank IS emptyornearlyempty If the lank must be removedwheMts full (forexampie, If the fuel pump malfunctions). Siphon any remaining fuel from Ihe lank PfJor Iv removal. Warning : Gasoline IS ex/remely flammable so extra precautions mus/be laken when working on any part of the fuel system. DO NOT smoke oral low open flames or bare light bulbs In or near the work area Also. don t work In a garage II a na/ural gas appliance such as a waler heater or clo/hes dryer is present I On luel-lnJected modets. relieve the fuel pressure (refer IOSectlOn 2) 2 Detach the cable from the negallve termmal of the battery 3 Raise the vehicle and support It securely on jacks tands.
4 Unless the vehICle has been dnven tar tlnough to completely empty the tank_ It s a good Idea to Siphon the resldu ... , tuel out belore removing the tank Irom the vehICle Siphon Of pump the fuel out through the luel hiler pipe On US mOdels a small diameter hose may be necessary because of the smalluap door Installed m the fuel hlier pipe to prevent vapors from escaping dUfing refueling luel-Injected models have reservOirs InSide the l ank to maintain luel near Ihe pump pickup dUring vehicle cornenng rna· neuvers and when the fuel level IS low The reservOirs could preven t SIphon tubes or hoses from reaching the bottom 01 the luel tank ThiS Situation can be overcome by repositioning the Siphon hose several limes, 5 Remove the hiler neck bracket bolt secunng the luel filier neck and the breather hose to the lueltank (see iIIustrallon) 6 If poSSible disconnect the luel and vapor hnes (on some models. the fittings ale on lOp of the tank and cannot be reached until the tank IS partially lowered) 7 Remove the electriC fuel pump (If equipped) and sending unu wife harness clips With a screwdflver The harness connector IS on top 01 the tank and inaccessible. Since no intermediate connection point IS provided the harness cannot be disconnected trom the luel sender until the tank IS par\lally lowered B Place a lloor lack under the tank and poSition a block 01 woOd between the lack pad and the tank Raise the jack unlilils sUPPOl1lng the tank 9 Remove the bolts or nuts tram the Iront ends 01 the fuel tank straps (see Illustration 5.5). The straps are hinged at the other end so you can sWing them out 01the way 10 lower the tank tar enough to unplug the wifing harness 11 Slowly lower the Jack while steadYing the tank Remove the lank from • the vehICle t2 II you fe replacly In the lower Intake mamfold 39 Secure the fuel rail assembly with the lout retaining bolts and tighten them to the specllied torque 40 The remainder 01 Inslallal lon IS the reverse of removal
Fuel pressure regulator Removal 41 Relieve Ihe system luet pressure (see SectIOn 2). 42 Detach the cable from the negative lermlnal of the banery 43 Remove the vacuum hne at the pressure regulator. 44 Remove the three Allen retaining screws from the regulator hOUSing 45 Remove the pressure regulator assembly, gasket and O·lIng DIS· card Ihe gasket and Inspect the 0 -lIng lor Signs 01 cracks or detenoratlon 46 If scraPIng IS necessary. be carelut not to damage the luel pressure regulator or luel supply line gasket surfaces
Installation
14.34
An exploded view ollhe SEFIluel rail assembl y on a VB engine
47 Lubncate the l uel pressure regulator O-flng With engine 011 Note : Never use sllrcone grease II will clog Ihe Injectors 48 Ensure that the gasket surl acesol thefuel pressure regulator andluel ra il assembly are clean. 49 Install the O·ong and new gaske t on the regulator 50 Install the fuel pressure regulator on the fuel rail assembly Tighten the three screws securely 51 The remainder 01 installatIOn IS the reverse 01 removal
Fuel injector Fuel rail assembly
Refer /0 il/us/ra/lons 1455. 14 56 and 14.57
Refer fa illus/ratlon 1434
Removal
Removal
36 Use a rocking, side·lo-slde mOllon while IIU1nO to remove the Injectors
52 Re lieve Ihe system fuel pressure (see Section 2) 53 Remove the upper Intake mamfold assembly (see above). 54 Remove the luel rail assembly (see above), 55 CarE'fully remove the electncal harness conneclors from the IndlVlClu· a! InJectors as reqUi red (see Illustration) 56 G ra sping the Injector body. pull up while gently rocking the Injector • _ _.. from side-to·side (see lIIuslralion). 57 I nspecllhe Injector O ·flngs (two per injector) for Signs of deterioration (see illus tration ). Replace as required 58 Inspect the injector plastIC "hal" (covariflQ the !M]&Ctor PIntle) and washer for Signs 01 deterioration. Replace as required If the hailS miss· Ing. look lor 111M the !Mtake mamfold
!rom the luel lall
Installation
Installation
59 Lubflcate the newO·rlngs With IIghl grade oil ESE·M2C39-F or eqUIValent and Install two on each Inlector. Nole : Do no/ use silicone grease. II Will clog Ihe Injec/ors. 60 USing a ligh t. tWlstiflQ motion. install the injector(s). 6 1 The remainder 01 InstallatIon IS the reverse 01 removal
30 31
Relieve the fuel pressure (see Seellon 2) Detach the cable Irom the negative terminal 01 the banery
32 Remove Ihe upper manifold assembly (see above). 33 USing the special spnng lock coupler 1001D87l·9280-A or equivalent disconnect the crossover tuel hose from the fuel rail assembly. 34 Remove the IOUf fuel fall assembly retaining boits (two on each side)
(see illustration) 35 Carefully disengage the fuel lall l Tem the fuel Injectors and remove thaluel fatl Nole : /I maybeeaslfJrtoremove the Injectors with the fue/ra,1
as an assembly
37 Ensure that the Injector caps are ctean and free of contamlnallon . 38 Place the luellnlectorfuel ra il assembly over each ot the InJeclorsand seat the InJeclors 1010 the luel rail. Ensure that the Injectors are well seated 10 the fuel rail assembly Note: 1/ may be easier 10 seat Ihe InjlJClors In the
PINTlE PfIIC) IECIIOfoI CJ# cPV>S"C: ..... , I
14.55 Be ca relul when unplugging the electrical connector hom a luel injector
14.56 The proper way to remove an injector from the Intake manifold Is to grasp the body and pull up while gently rocking the injector from slde-to-slde
14.57 Note the proper location oltha two injector ().rlngs, the washer and the plastic hat that protects the pintle
4-16
Chapter 4
Fuel and exhaust systems
15.' 8 An exploded view of the EFI system used on the 2.3L four-cyllnder engine (1990 and earlier model shown, laler models similar
1 2 3 4
Throttle Throttle Throttle Throttle
body assembly body retaining nut body retaining stud body /0 intake
manifold gasket
5 6 7 8 9
15
Upper to /ower manifold screw Upper to lower manifold stud Intake upper manifold TP sensor bracket retaining screw TP sen5()( retaining screw
20
21 22
10
Throttle Position (TP) sensor
11
Throttle Position (TP) sensor
24
gasket
25
23
12
Air bypass valve retaining screw
13 14 15 16 17 18
Air bypass valve Air bypass valvegaske/ IdJescrewspring Throttle stop screw Throttle body retaining bofl Secondary throttle rod
26 27 28 29 30
'9
Throttle control lever assembly (automatics)
32
37
S8COndary throttle control lever washer Secondary throttle control lever spacer
Secondary throttle control lever spacer Carburetor thronJe return spring Accelerator pump bushing Upper-Io-/ower Intake manifold gasket Lower Intake manifold assembly
Nipple Fuel pressure regulator screw Fuel rail manifold assembly Fuel pressure relief valve assembly Valve cap Fuel inlector electrical connector wire harness
Electronic Fuel InJection (EFI) system - component replacement (four.cyllnder engine)
Refer to il/ustrations 15. 1a and 15. 1b While the appearance and deSign of the various components of this system vary somewhat from those in the previous Section, the procedures there will apply to this system as well. Exploded and assembled views of the four-cylinder engine fuel system are included here to help identify and locale the components (see illustrations),
16
Turbocharger - removal and Installation
EFlmodels Removal Refer to illustrations 16. I and 16. 10 1 The turbocharger is mounted low on the right side of the engine (see illustration). Make sure the engine has cooled overnight (or for several hours) before beginn,ng work on the turbocharger.
33 34 35 36 37
38 39 40 41
Regulator assembly Fuel regulator gasket Fuel pressure regulalor O-ring seal Fuel rail to lower manifold screw Injeclor assembly Lower in/ake mamfold-to -engine gaskt;'1 Llftmg eye Fuel pulse dampener Fuel pulse dampener screw
2 Detach the cable from the negative terminal of the battery. Drain the engine coolant (see Chapter 1). 3 lithe turbocharger is not eqUipped With an Intercooler. remove the two bolts retaining the throttle body discharge tube to the turbocharger and loosen the hose clamp on the inlet hose. 4 If th e turbocharger is equipped with an intercooler. loosen the upper and lower clamps secunng the hoses to the intercooler. Detach the aspira· tor hoses at the intercooler and loosen the bolts securing the bracket to the intercooler hOUSing. Pull the upper lront bracket pinS out 01 the lower bracket. rolale the housing clockwise to disengage the upper rear bracket, then remove the intercooler together With the upper brackets. 5 Clearly label. then disconnect. the vacuum hoses and tubes. 6 Detach the PCV tube from the turbocharger air inlel elbow. 7 li the turbocharger is not equipped With an Intercooler. remove the throttle body discharge tube and hose as an assembly. 8 II the turbocharger is equipped with an intercooler (Mustang SVO). loosen the clamp and detach the air inlet tube trom the Inlel elbow. 9 Disconnecuhe electrical ground wire and turbocharger air inlet elbow and remove the air inlet elbow. Discard the old gasket. 10 Remove the waler connections and fittings Irom the turbo center housing (see illustration). Note: Some coolant will drain from theengine block.
Chapter 4
Fuel and exhaust systems
4-17
16.1 The turbocharger used with EFI model s Is l oca ted o n th e right side of the engine - it's bol ted dlreclly 10 the exhau st manifold where it can lake full advantage 0 1 Ihe hal exhau st gases thal lI u ses 10 spIn Ihe l urbine
15.1b An assembled v iew of the EFt system used on the 2.lL four-cyUnder engine (1990 and earlier model shown, laler models similar)
11 Remove the lufbocharoer oil supply. 12 Detach the o)()'gen sensor connector althe turbocharger. 13 Raise the vehicle and place it securely on Jackslands. 14 Disconnect the e~haust Pipe by removing the two exhaust pipe-to-Iul' bocharger bolts. 15 Remove the two bolts Irom the oil return line located below the turbo· chalger. Do nOI kink or damage the line as it is removed. 16 Remove the lower turbocharger brackeHo·block stud.
4
17 Lowerthe vehicle. 18 Remolle the front lower turbocharger retainlOg nul. 19 Simultaneously. remove lh9threeremalnlng nuts while sliding Ihetur· bocharger all the studs. 20 Remove the turbocharger assembly from the vehicle.
Bearing clearance check 21 Manually move the turbocharger blade shaft assembly as far in one direction as possible. Spin the shaft by hancl. 22 Manually move the shaft in the opposite directIOn as far as posSIble and spin the shaft again. 23 If neither the tulbine blade nor the compressor blade contacts any portIOn of their respective hoUSings, the bearings are stitt good. 24 If either blade comes In contacl with the housing, the bearings are wom and Ihe turbocharger should be replaced.
Installation 25 Apply pipe sealant With Teflon D8AZ·19554·A or equivalent to the wa· ler inlet 9O-degree elbow fining . Install the lining in the turbocharger as· sembly center houSing. Tighten it securely and rotate it clockwise so that the fining is Within 5 degrees 01 vertical, pointing Clown. 26 Position a new turbocharger gasket on the mounting studs. Make sure that the bead laces out. 27 Install the turbocharger assembly on the mounting studs. Note: Use four new mounting studs. 28 Install the turbocharger bracket on the two lower studs, Start the two lower retaining nuts followed by the two upper retaining nuts. 29 Raise the vehicle and place 1\ seaJrely on jackstands. 30 Install the lower bracket·to·bIock bolt. Tighten it securely. 31 Install a new oil return hne gasket. Bolt the all return hne fitting to the turbocharger and tighten It securely.
16.10
The v ar ious coolant tu be assem blies connected t o the EFt turbocharger
32 Connect the water inlet tube assembly to the Inlet fining at Ifle turbo· charger assembly. Tighten the hose clamp SeaJrely.
33 Install the e)(haust pipe and ttghten the retaining nuts to the specified torque. 34 Lower the vehiCle. 35 USing four new nuts. tighten the turbocharger·to·e)(haust manifold nuts to the specified torque. 36 Apoly pipe sealant with Tellon D8AZ· 19554·A or equivalent and in· stall the water fittings In the turbocharger center hOUSing. Tighten se· curely 37 Connect Ihe water lube assemblies 10 the fining on the turbocharger and tighten It seaJfely. Be sure to use a backup wrench to hold the water outlet fitting while tightening. 38 Use a new gasket and install the compressor inlet elbow.
Chapter 4
4 -18
Fuel and exhaust systems
39 Attach the air inlel tube \0 the turbocharger mlel elbow. Tighten the hose clamp securely 40 Install the PCV lube fming alld tighten the clamp securely. 41 AUach all vacuum lines. 42 Connect the oxygen sensor 43 Connect the electrical ground wire to the air mle\ elbow, 44 Install the turbocharger oil supply line. Tighten the fiHlng securely. 45 Inslalilhe turbocharger intercooler assembly. Tighten the clamps and the nul securely. 46 Fill and bleed the cooling system (see Chapler 1). 47 Connect the cable to the negatlve terminal 01 the battery 48 Start the engine and check for leaks
Carbureted models Refer to Illustrations 1657 and 16.63
49 Disconnectlhe negallve battery cable from the baltery 50 Remove the two nuts which hold the turbocharger heat shield to the turbine housing and remove the shield 51 Raise the vehicle and position It securely on Jackstands 52 Remove the lour bolts which attach the crossover pipes to the turbo· charger. Remove the crossover pipe at that end 53 Disconnect the eKhaust Pipe from the check valve located just above the catalytic converter. 54 Remove the bolts which attach the crossover pipeS to the eKhaust mamfold. loosen and lower the crossover pipe. Remove the eKhaust pipe retaining bolts at the Inlet 01 the rear catalytic converter. 55 Remove the rear turbocharger brace bolts and the brace. 56 Remove the jackstands and lower the vehicle. Remove the air clean· er and duct assembly. Place a shop rag over the carburetor mou tn to pre· vent dirt and parts Irom failing in. 57 Disconnect the oil supply line from the turbocharger central hOUSing (see Illustration). 58 Disconnect Ihe two hoses from the wastegate actuator diaphragm 59 Remove the accelerator cable and liS two mountmg bolts from the In· take manifold. 60 Disconnect lhe turbocharger vacuum line at the Intake mamtold. 61 Remove the engine 011 dipstick bracket bolt 10 proVide removal ac· cess 62 loosen the tlange nutl1tl both ends olthe EGR tube. then remove the lube. 63 Remove three nuts and one bolt that secure the turbocharger to the Intake manifold (see Illustration). 64 Label and detach any remaining vacuum hoses 65 lift lhe turbocharger oul of the engine compartment. 66 Installation is the reverse of removal. Use new O·rlngs. lightly coated With clean engine 011. at the follOWing points
a) Compressor inleHo· manllold iOlnt b) Compressor outleHo·mamfold JOint c ) 011 drain line adapter·tO· lntake manifold JOint
17
EKhaust system servicing - general information
Warning : Inspection and repair 01 exhaust system components should be done only af/er enough time has elapsed af/erdrivmg the vehicle /0 allow the system components tocoolcomple/ely Also. when workmg under Ihe vehicle. make sure II is securely supported on jacks/ands 1 The eKhaus t system consists olthe eKhaus t mamlold{s). the catalytic conve rt er. the muffler. the tailpipe and all connecting pipes. brackels. hangers and clamps. The eKhaust system is att ached to the body Wi th mounting brackets and rubber hangers 1\ any of the parts are improperly installed. eKceSSlve nOise and vibration Will be transmitted to the body 2 Conduct regular inspections of the eKhausl system 10 keep It sale and quiet Look for any damaged or bent parts , open seams. holes. loose connecllons, excessive corrOSion or other de tects which could allow exhaustlumes to en terthe vehicle. Deteriorated exhaust sys· tern components should not be repaired : they should be replaced Wit h new parts 3 lithe exhaust system components are extremely corroded or rusted together. weld ing equipment Will probably be reqUITed to remove them The convenient way 10 accomplish this is to have a muffler repair shop reo move the corroded sections with a cutting torCh. ff . however. you want to save money by dOing It you rself (and you don't have a welding outfit With a cutting torch ). simply cut off the old components With a hacksaw. If you have compressed air. special pneumatic cutting chisels can also be used. If you do deCide to tackle the job at home. be sure to wear safety goggles to protect youreyes from metal chips and work gloves to protect your hands. 4 Here are some simple guidelines tofollow when repairing the e ~ haust system ' a) Work from the back to the fron t when removing exhaust system components. b) Apply penet ra~ng oil to the exhaust system component fastene rs \0 make them easier to remove c) Use new gaskets. hanger.. and clamps when Installing exhaust systems components. d) Apply antl·selze compound to th e threads of all exhaust system fastene rs during reassembly e) Be sure to allow suffiCient clearance between newly Installed parts and all points on the underbody to aVOid overhea\lng the floor pan and pOSSibly damaging the in terior carpet and Insulation Pay par· licularly close attention 10 Ihe cata lytiC converter and heat shield
16.63 16.57
Turbocharger connections - carbureted turbo models
Turbocharger mounting bolts and nuts - carbureted turbo models
Chapter 5
Engine electrical systems
Contents Alternator brushes - replacement (EVA type alternator)
15
Alternator - removal and installation.
14
......•.....
Ignition module - replacement ................. . 10 6 Ignition system - check. . . . . . ............ . 5 Ignition system - general information ........... . 9 Ignition timing - check and adjustment ........ . See Chapler I Spar\( plug replacement ................. . Spar\( plug wire, dislributor cap and rotor - check See Chapler I and replacement ........ . ....... Staner motor - ,emoval and installat!on ......... . . . . . . . . 20 Staner relay - removal arid installat!on .. . 21 Starting system - general information '8 Staner motor and circuit - in·vehicle check . Voltage regulator/alternator brushes - replacement (tAR·type alternator) ............. . 17
Battery cables - check and replacement ............ 4 Battery check and maintenance .................. See Chapter 1 3 Battery - emergency jump stanmg .. . . . . . . . . . . . . . . . Battery - removal and installation . .. ...................... 2 Charging system - check .. .. .......... 13 Charging system - general informaMn and precautions .. 12 Crankshaft liming sensor ............ 11 Distributor - removal and Installation ....••..•........ 8 Orivebelt check, adjustment and replacement ....... See Chapter 1 16 External Voltage Regulator (EVA) - replacement ........... General information ..... ... . . . . . .. .. I .......... 7 Ignition coil - check and replacement
"
Specifications
Orlvebelt deflection
See Chapter 1
Battery vOltage Engine off . Engme running
12·volts 14·to·15 volts
Firing order
See Chapter 2
Ignition coil-to-distributor cap wire resistance Duraspar\( II systems . TFI·IV system .
5000 ohms per inch 5000 ohms per 1001
Ignition coli resistance Duraspar\( II and lit syslems Primary resistance Secondary resistance Ba)last resistor ........ . TFI·IV system Primary resistance SecondaJy resistance
Ignition timing ...... .
0.8 to 1.6 ohms 7.71010.5 K·ohms 0.8 10 1.6 ohms 0.310 1.0 ohms 8.010 11 5 K-ohms See Ihe Vehicle Emissions Conlrollnlorma!ion label in Ihe engine compartmen t
Alternator brush length New .....
Minimum
1
Generallnlormatlon
The engine electrical systems include all ignition, charging and starting components. Because 01 their engine-related functions. these compo· nents are considered separately Irom chassis electrical devices ~ke the lights, instruments. etc. Be very carelul when working Ofl Ihe engine eleclncal components. They are easily damaged II checked, connected or handled improperly. The alternator is driven by an engine drivebelt which could cause serious
tf2 in 114 in
mjury il your hands, han or clothes become entangled in it with the engme running, Both the starter and alternator are connected directly to the bat· tery and could arc or even cause a fire if mlsharldled, overloaded or shoned oul. Never leave the Ignition Sw!lch on lor lOng periods 01 time with the en· gine off. Don't disconnect the battery cables while the engine is running. Correct polarity must be maintained when connecting battery cables trom another source, such as another vehicle, dullng jump staning. Atways diS' connect the negative cable first and hooII. it up last or the battery may be shoned by the too) being used to loosen the cable clamps.
5
5-2
Chapter 5
Engine electrical systems
2.2 To remove the battery, detach both cables (negative tlrst) and remove the battery hold-down bolt and clamp (arrow)
6.2 To use a calibrated Igniti on lester (available at most auto parts store s), simply disconnect a spark ptug wire, attach the wire to the tester, clip the tesler to a convenient ground (like a rocker arm cover boll) and operate the starter - It there 's enough power to tire the plug, s parks will be visible between the electrode tip and the tester body
Addllional safety related information on Ihe engine electrical systems can be found in Safety first near Ihe front of this manual. It should be re ferred 10 belore beginning any operation included in this Chapter.
2
Battery - removal and Installation
Refer /0 illus/rallon 2.2
Note: On models eqUipPed with the Distributor/ess (DIS) Igmlion System. some precautions must be taken after disconnecting Ihe battery cab/e(s). When the battery cable(s) has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor within the
ignition system relearns its adaptive strategy. The vehicle may needla be driven 10 mi/{Js or more to relearn the stra tegy. Caution should be taken dunng this penod of Ume. t Disconnect both cables from the battery terminals. CauUon : Always disconnect the negative cable first and hook it up /ast or the battery may be shorted by the tool being used to loosen the cable clamps. 2 Locate the battery hold·down clamp at the base of the battery (see illustration) Remove the bolt and the hold-down clamp 3 Lift out the battery. Special straps that attach to the battery posts are available -lifting and moving the battery is much easier if you use one. 4 Installation Is the reverse of removal
3
Battery - emergency jump start ing
Refer 10 the Booster battery (jump) starting procedure at the fron t of thiS manual.
4
Battery cables - check and replacement
Periodically inspect the entire length 01 each battery cable for damage, cracked or burned insulation and corrosion. Poor battery cable con· nections can cause starting problems and decreased engine performance. 2 Check the cable-to-terminal connections at the ends of the cables for cracks, loose wire strands and corrosion. The presence of white. fluffy deposits under the insulation at the cable terminal connection is a Sign that the cable is corroded and should be replaced. Check the terminals fordis tortion. miSSing mounting bollS and corrosion. 3 When replacing the cables, always disconnect the negative cab le fi rs! and hook it up last or the battery may be shorted by the tool used to loosen the cable clamps. Even if only the positive cable is being replaced , be sure to disconnect the negative cable from the battery first.
4 Disconnect and remove the cable. Make sure the replacement cable is the same length and diameter. 5 Clean the threads of the relay or ground connection With a wire brush to remove rust and corrosion. Apply a light coat of petroleum jelly to the threads to preven tl uture corrOSion. 6 Anach the cable to the relay or ground connection and tighten the moun\lng nuVbolt securely. 7 Before connecting the new cable to the battery, make sure that it reaches the battery post Without haVing to be stretched. Clean the battery posts thoroughly and apply a light coat 01petroleum jelly to prevent corrosion. B Connectlhe positive cab le first , followed by the negative cable. 5
Ignition system - general information
Distributor type (Duraspark II and TFI-IV) The ignition system is a solid state electronic design consisting of an ignition module, coil, distributor. the span.. plug wires and the spark plugs. Mechanically. the system Is similar to a breaker point system. except that the distributor cam and ignition points are replaced by an arma ture and magnetic pickup unit. The COil pflmary CirCUit IS cofllrolled by an amplifier module. When the ignition is SWitched on, the ignition primary circuit is energized. When the distributor armature "teeth" or "spokes' approach the magnetic coi l assembly, a voltage is induced which signals the amplifier 10 turn 011 the coi l primary current. A timing Circuit in the amphlier module turns the coil cur rent back on alter the coil held has collapsed. When irs on. current tiows from the battery through the ignition SWi tch. the coil primary Winding, the amplifier module and then to ground. When the current is interrupted, the magnetic field in the Ignition coil collapses. inducing a high voltage in the coil secondarywmdings. The voltage is con ducted to the distributor where the rotor directs it to the appropriate spark plug. This process is repeated continuously. All vehicles are equipped With a gear dflvefl distributor with a die cast base housing a "Hall Effect' vane switch stator assembly and a device lor fixed octane adjustment. However. there are a few differences between earher Canadian and US distributors. Duraspark distributors have a two piece cap. When removing the cap, the upper hall is removed. then the rotor is removed. then the lower half of the cap is removed . TFI·IV dlstflbutors have a conventional one piece cap. The distributors on earlier Canadian vehicles are equipped With centrifugal and vacuum advance mechanisms which control the actual point
Chapter 5
Engine electrical systems
01 '9nlllOn based on engine speed and load. As engine speed increases, two weights move out and alter the poSltJon of the armature In relation to the distributor shalt. advancing the tgnilion tlmmg. As engine load In-
creases (when climbing hills or accelerall/1g. 101' e~amplel. a drop in intake manllold vacuum causes the base plate to move sllghlly in the opposite directIOn (clockWise) under the actIOn 01 !he spring in the vacuum unit retarding the liming and counteracting the centnlugal advance. Under light loads (moderate steady speeds, lor example). the comparatively high in· take manifold vacuum acting on the vacuum advance diaphragm causes the base plale assembly to move In a counterclockwise directIOn to pro· vide a greater amoont of \!mlng advance Early models may be eqUIPped With OtJraspatk I (DSI) or Duraspark II (OSU) ignition modules. MOSII983 and 1984 models are eqUipped With the standard Duraspar\o; II '9M1on module. Later models use the Thick Film Integrated IV [TFI-IV) ignitIOn module. which is housed in a molded thermoplastic box mounted on the base of the distributor. The Important difference between the 0511 and TFI-IV modules is that the TFI-lV module is controlled by the Electronic Engine Control IV (EEC-IV). while the Duraspar\o; I and II modules are not. The TFI-IVIEEC·IV type distributor is similar to the Duraspark II model but has neither a centrllugal nor a vacuum advance mechanism (advance is handled by the computer instead). The TFI-IV module does, however, include a "push start" mOde that allows push starting of the vehicle il necessary.
Distributorless (DIS) type The 1992 2.3L lour ·cyllnder engines ate eqUipped With the Distributorless IgmtlOn System (DIS) that IS a solid state electronic design. It consists of a crankshaft Itmlng sensor, EDIS module, one ignitIOn coil pack, the spark angle portion of the EEC IV, the spark plug wires and the spark plugs ThIs ellglne features a twin spark plug cylinder head and IS eqUipped WIth an igmtlon coli lor each pair 01 spark plugs. This IgMlon system does not have any moving parts (no distributor) and all engme tlmlllg and spark dlstnbullon IS handled electronically. This system has fewer parts that reqUire replacement and prOVide more accurate spark timing Dunng engine operaIJon, the EOIS igmtlon module calculates spark angle and determines the turn-on and linng time 01 the ignition COil The crankshaft timing sensor Is a vanable reluctance·type sensor consisttng 01 a 36-tooth tflgger wheel With one missing tooth that is incorpo· rated Into the crankshaft front damper The signal generated by thiS sensor IS called a Variable Reluctance Sensor Signal (VRS) and it provides the base timing and engine RPM inlormallon to the EDIS ignition modules. The main functIOn of the EOIS module is to synchronize the ignition COils so they are turned on an off In the proper sequence lor accurate spark con trol.
5-3
and check them as descnbed In Chapter 1 or install new ones. 4 If flO sparll.s or inlermlttent sparks occur, remove the distributor cap and check the cap and rOlor asdescribed in Chapter \. If motsture IS present, dry out the cap and rotor, then reinstall the cap and repeal the spark test. 5 If Ihere's still no spark. detach the secondary COil wire from the distributor cap and hook It up to the lester (reattach the plug wife 10 the spark plug), then repeat the spark check 6 If no sparks OCCUr, check the pnmary (small) wire coonecbons at the coil to make sure they're clean and light. Refer to Section 7 and check the ignillon COIl supply voltage clfcui1. Make any necessary repairs, then repeat the check again. 7 II sparks now occur, the distnbutor cap. rotor. plug wlfe(s) or sparll. plug(s) (or all of them) may be defective. B II there's stili no spark. the coil·to-cap wife may be bad (check the resistance With an ohmmeter and compare it to the Specifications). If a known good wire doesn't make any difference in the test results, the ignition COil, module or other Internal components may be defective.
Alternative method Note: If you're unable /0 obtain a calibrated ignilion leSlor, Ihe following melhod will allow you /0 delermin6 if Ifw /gnilion system has spark, but il won't lell you if Ihere 's enough voltage produced /0 actually iniliale combustion in Ihe cylinders 9 Removethewire from one of the sparll.plugs. Using an insulated tool. hold the wire about 1I4-lnch from a good ground and have an assistant crank the engine. 10 If blight blue. well·deflned sparks occur, suffICient voltage is reaching the plug to fire it. However. the plug(s) may be fouled , so remove and check them as described in Chapter 1 or install new ones. 11 If there'S no spar1
I 0>
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"" 6,2 On early models (except Inllne sb:-cytlnder engine), remove the clutch locknut and adjusting nut to detach the cab le from Ihe release fork
Ul !200C I,O.f 6.3 On models wilh an tnline six-cylinder engine, pull the adjusting nut clear of the rubber Insulator before Irying 10 turn II
8-6
Chapter 8
Clutch and driveline
· CLUTCH ~'~~ ~': ~.";"~
...F::::>l:::"_ . . OJU$ fM ENT REOUI I'IED
_~""' OUST SHIELD
l .ll EN GIN I C"ILI ADJUSTMENT NUT
6.5
Clutch cable and relaled components - early models with a manually adjusted cable and without a starter/clutch interlock swUch
quadrant Do not use any prying /oolto al,Jch lhe cable /0 /flequad-
5 RemOlle the retamlng clip that secures Ihe cable to the lop 01 thl" clUICh pedal ( see illustration) Detach thecablehom the peda!.\henlake II oul altha vehicle 6 Installanan IS the reverse of the removal steps Ad)uSllhe cable (see
mm b) Alter the cable IS Installed. depress the Clutch pedal several limes to adjust the cable
Chapter, ).
Self-adjusting cable (later models) Refer /0 Illustrallon 6. 7
7 lift the clutch pedal all the way up 10 disengage the pawl andquadranJ (see illustration) Push Ihe quadrant forward and unhook the cable Irom the quadrant Allow lhequadranl to SWing slowly 10 the leaf The quadran! IS under SPring pressure - don t allow It to snap back Into poSllion 8 Open the hood and remove the retaining screw that holds lhe cable to the dash panel 9 If equipped, remove the screw that secures the cable bracket to the front Sldemember 10 Raise the vehicle and support It securely on lackstands. t t Remove the dust cover from the bellhouslng. 12 Remove the retainer ring holding the cable to the belthouSlng t3 Disengage the clutch cable from the release lever a) On all e~cept 1987 and tater lour·cyl lnderenglnes. slide the ballon the endol the cabte through the hote In the clutch release lever and remove the cable b) On 1987 and laterlour..qllnderenglnes. remove the cJlpandclevls pin Irom the end 01 the cable 14 Installallon IS the reverse 01 removal With the lollowlng notes a) To Install the cable Into the adJusling assembly, hft the clutch pedal to disengage the pawl and Quadrant Caution : The clutch pedal must be lifted /0 prevent damage to the pawl and quadrant While pushmg the quadrant forward. hook the cable over the rear of the
7
Sell-adjusting mechanism - removal and Installation
1 Dlsconneclthe negallve battery cable Irom the battery 2 Remove the steeling wheel (see Chapter 10). 3 Remove the lower leh Instrument panel sectIOn (see Chapter 11 ). then remove the steenng column shrouds 4 Disconnect the hood release mechanism InSide the vehICle 5 Disconnect the master cylinder pushrod and stoplight SWitch Irom the brake pedal (see Chapter 9) 6 Carelully rOlale the QuadranllofWard unlll you can unhook the clutch cable Irom It (see iliustraUon 6.7). Hold the Quadrant and allow 1110 move slowly rearward. 7 Move the Inlerval wlpC!r governor (It equipped) out of the way and diSconnect all of the steering column electrical connectors 8 Detach the sleerlng column from the brake pedal bracket and let the column rest on the floor of the vehicle 9 Unbolt the brake pedal bracket support brace from the left·hand Side 10 Remove the brake booster mounllng nuts (see Chapter 9). II Unbolt lhe brake pedal suppor1 bfack.et from the Instrument panel and lake the bracket out t2 Remove the clutch pedaj (see SectIOn 12) Take the sell·adjushng mechamsm out of the brake pedal sUPPOr1 bracket 13 Remove the sell-adjusting mechanism shaft bushings trom the brake pedal support bracket. Inspect the bushings and reptace them If they are worn
Chapter 8
8-7
Clutch and driveline STAATERIClVTCH IHTERI..()()( SWITCH
"""
8R.AKE PEDAL
PIVOT BUSHING
CLUTCH PEDAl. 8EllHOUSII+G
twR PIN CUP
""""'"
2 3L OHC ENGINE GAEEN TAPE 5.CIl ENGINE PURPLE TI face In.
Installation 7.4
Disconnect the brake line tilling (A) , then remove the two wheel cylinder boits ( e)
4 Dlsconnecl the brake line (see illustration) Don'l puilihe brake line away from the wheel cylinder 5 Remove the wheel cylinder moun\lng bolts. 6 Detach the wheel cylinder from the brake backing plate and place it on a clean workbench Immediately plug the brake line to prevent lIuld toss and contammallon.
Overhaul Refer /0 II/us lfallon 7. 7 7
Remove the bleeder screw. Cups. pistons. boots and spring assembty
13 Place the wheel cylinder in positron and mSlalllhe bolts t 4 Connect Ihe brake hne and Instail ihe brake shoe assembly 15 Bleed the brakes (Section II ),
8
Master cylinder (1979lhrough 1986 models) - removal , installation and overhaul
Removal and installation Refer to Illus/raftons 8, la. 8, Ib and 8.2 I Unscrew the brake Imes from the primary and secondary outlet ports of the master cyl inder (see illustration). Plug the ends 01 the hnes to pie· vent contam ination, Place ne wspapers or rags under the connections to catch the bl ake flUid thaI will spilt (see mustralion)
;;;~~~"~ ASSV I AND CUP E 7.7
8.1 a Disconnect the fluid lines allhe master cylinder with a flare-nut wrench, being careful nolto bend them
An exploded view of the rear wheel cylinder
8.1b Uflthe master cylinder from the engine compartment - note the newspaper to catch dripping brake fluid , which could damage paint
8.2 Remove Ihe two nuts to detach the master c ylinder from the brake booster or engine compartment fire wall
Chapter 9
Brakes
9 - 15
----
COVEF! !'lET ""N~R
PUSH ROD 1...... "'U ... l 8RAI(E ONlVI
MA.STER CYLINDER BODY
0
... SSEMllV
,,,.,"' 0"""
8."
8.14
An exploded view 01 the master cvlinder used on 1979 through 1986 models
Remove Ihe snap-ring from the master cvlinder bore
2 Remove the two nuls secunng the master cylinder to the Inewall or power boosler un!! (see illustration) :3 Puilihe master cylinder forward and hllll from the vehicle (see iUusIralion 8.1b). Brake lIuld will damage pam t. so don', spill any on the ve-
hicle. 4
InStallation 15 Ihe reverse 01 the removal procedure
5 Note: Whenever the master cylinder IS removed, rhe comple/e hydraulIC system must be bled The lime reqUired /0 bleed the system can be (educed If the master cylinder IS ,,/led wl/h Iluld and bench bled (refer 10 Steps 6lhrough 10) before the maslercyllnder IS mstalledon the vehICle 6 Insen threaded plugs 01 the correct size Into the cylinder oullet holes and lill the reservOIrs with brake lIuld The master cylinder should be sup· PC)r1ed In such a manner that brake IIUld Will not spill dunng the bench bleeding procedure 7 Loosen one plug al a lime, stanlng With the lear oullet pon first. and use a large Phillips screwdnver to push the piston assembly Into the bore
1
8
~~----::"~~::~J:~+-S(CO"OARV lUIE SEU
OUTlH
----0
to 100ce all from the master cyhnder. To prevent all from being drawn back into the cylinder, the appl'Opnate plug must be replaced before allOWing the piston to return to ItS onglnal poSitIOn 8 Stroke the piston three or lour times for each outlelto ensure that all air has been el(pelled. 9 Smce high pressure IS nollnvolved In the bench bleeding procedure_ an allernallve to the removal and renlacement of the plugs With each stroke of the ~ston assembly IS available Before pushing In on the piston assembly. remove one ot the plugs completely Before releaSing the PISton. however. instead of replaCing the plug. Simply put your tlnger tightly over the hole to keep air Irom being drawn back Into the master cylinder Wait several seconds for the brake lIuld to be drawn from the reservolf to the piston bore, then repeat the procedure. When you push down on th e ~ston 1\ Will torce your finger olt Ihe hole, allOWing the air inSide 10 be el(' pelled. When only brake fluid IS being ejected from the hole. replace the plug and go on to the other pon 10 Relill the master cylinder reservOIrs and Install the diaphragm and cap assembly
Overhaul Refer 10 illustrations 8.11 . 8.14.8 15. 8 17 and 8 19 Note : Beforedecldmg looverhaulthe maslercyimder. check on theaval/' ability and cost of a new or factory rebulit Ulllt and also !he availability of a rebuild kit 11 Clean the el(tenor 01the master cylinder and Wipe dry With a hnt free rag. Remove the cover and gasket from the top of the reservOir and pour out any remaining brake lIuid (see illustration ) 12 Use a large Phillips screwdriver to depress the PIston assembly. then remove the secondary PIston stop boll from the bottom at the master cylln· der body, If eqUipped 13 Remove the bleed screw. It eqUIpped 14 Depress the piston assembly again. then remove the snap-flng Irom the groove allhe rear of Ihe master cylinder bore as shown In the accompanYing Illustration.
9
9-16
8.15
Chapter 9
Remove the primary piston from the bore
8.17
Brakes
--
Remove the secondary piston
8.19 If the master cylinder Is made from cast iron, use a hone and drill motor to remoye minor scratches Irom the bore - 00 NOT hone the bore on aluminum cylinders
from the bore alter removing the slop screw, II equipped
15 Remove the pnmary piston assembly (see illustration) 16 00 not remove the screw an the primary piston or disassemble the
piston, The piston assembly IS replaced as a unit 17 Remove the secondary piston assembly (see illustration) 18 00 not remove the lube seals, lrom the master cylinder body 19 Examine the bore 01 the cylinder carefully lor SCOfing or fldges If the bore IS smooth. the cylinder body can be reused, If there IS any doubt 01 the condl\lon 01 the bore, Install a newor rebUilt master cylinder. Ifthecyhnder IS made 01 cast Iton. minor scratches or SCOring In the bore can be removed USing a hOfllng 1001 (see Illustration) . Caution: Do nor hone /he bore on alurrnnum maslercylmders; the haT(jened surface In the bore Will be removed. 20 If the seals are swollen or yery loose on the pistons. suspect 011 contamlnallon In the system . Oil Will swell these rubber seals and II one IS found to be swollen. others In the brake system may also be damaged
Flush the sys tem thoroughly (tollow the bleedmg procedure In section 11) With clean brake I'uid alter oyerhaul to remove the all. 2t Thoroughly clean all parts In clean brake lIuld or alcOhOl. 22 All components should be assembled weI after dipping Ihem In flesh make flUid 23 Insert the complete secondary piston and relurn spnng assembly mto Ihe master cylinder bore. easmg Ihe seals Into the bore 24 Insert Ihe pnmary PIston assembly InlO the master cylmder bore 25 Depress the pnmary piston and Install the snap-nng mto the cylinder boregrooye 26 Fit the secondary piston stop boit and O-m'IQ Into the bonom of the master cylmder body 27 Reinstall the gasket onto the coyer. malung sure f\IS correclly seated. and replace the coyer
MAS TER CVUNOE R
BOOSTER ASSY
9.2
Master cylinder and brake booster Installation on 1987 and later models - typical
'"'
SCR...
Chapter 9
9.7
Use a Phillips head screwdriver to push the primary pi ston Into the cylinder, then remove the s nap-ring
Brakes
9.8 Remo ve the primary piston assembly from the cylinder
9.10 If you must remove Ihe fluid reservoir (10 replace leaking seats or a br oken reservoir), genU'll pry il all wilh a screwdriver or prybar
9. t4
9-17
9.9 Tap the master cylinder against a block 01 wood to eject the secondary piston assembly
Coatlhe Sefake lIuld. a clear contamer partially filled With clean bfake flUid. a length 013 16-lOch plastiC. rubber or Vinyl tubil'lg 10 ht over the bleeder valve and a wrench to open and close the bleeder valve 7 Beginning at the fight rear wheel. loosen the bleeder valve slightl~. then lighten It to a pomt where It IS snug but can stili be loosened qUickly and eaSily 6 Place one end of the tublOg over the bleeder valve and submerge the other end In brake lIU1d In the contamer (see Illustrati on) 9 Have the assistant pump the brakes slowty a lew times to get pres· sure In the system, then hold the pedal !lrmly depressed to While the pedal IS held depressed open the bleeder valve Just enough to allow allow 01 Ifuld to leave the valve Watch lor air bubbles to e~lt the submerged end of the tube When the lIuld 1101'1 slows atter a couple of seconds. close the valve and have your assistant release the
p.,,,,
t t Repeat Steps 9 and 10 until no more air IS seen leavmg the tube. then lighten the bleeder valve and proceed to the left rear wheel. the nght Iront wheel and the lelt front wheel. In that order. and perform the same procedure. Be sure to check the IIUld In the master cylinder reservOlrtrequenlly 12 Never use ok! brake flUid It contains mOisture whICh Will deteriorate the brake syslem components. t 3 Ref ill the master cylinder With lIuld at the end 01 the operalion 14 Check the operation ot the brakes. The pedal should feel solid when depressed. With no spongmess II necessary. repeat the enlire process Warn i ng: Do nol operate the vehICle If you a18 rn doubl about the elfec-
tlveness of the brake system
12
Parking brak e - adjustment
Models with rear drum brakes Refer /0 IllustratIon 124 Block the Iront wheels so the vehICle cant rollin either dlrecllon Jack up the rear 01 the vehicle and support the axle securely on Jack stands. DO NOT get under a vehicle that IS supported only by a Jackl 3 Release the parkmg brake and place the transmission 10 Neutral 4 On early models, loosen the equalizer locknut (see illu stration ) Slowly tighten the adjusting nut on the equalizer rod until the rear brakes Just begm to drag 5 On later models. lighten the adJusling nut against lhe cabte equalIzer unlll the rear brakes Just begin to drag 6 loosen the equalizer adjusting nut just enough so the rear wheets turn Ireely, then secure the adjuSling nul With the locknut 7 Remove the lackstands and lower the vehicle Unblock the Iront wheels and tes t parkmg brake operation t
2
Refer /0 illustration II 8 Warn ing : Wear eye pro/ec/lon when bleedmg the brake syslem If the
fluid comes m contact With your eyes. Immedlalely nnse them With water and seek medical alten/lon Nole : Bleedmg the hydraulIC system is necessary /0 remove any air thai manages 10 find liS way mto Ihe syslem when I/S been opened dUfing removal and InSlalla/lon of a hose, lme, caliper or master cylinder. II Wil l probably be necessary to bleed the systemat ali iourbrakes If an has entered the sys tem due to low lIuld level. or II the brake lines have been dIsconnected at !he master cylinder 2 II a brake hnewasdlsconnected only at a wheel. then only that caliper or wheel cylmder must be bled 3 II a bfake tlOe IS disconnected at a IIl1lng located between the master cylinder and any 01 the brakes. that part 01 the system served by the diSconnected line must be bled
Models with rear disc brakes Refer/oi/lustra/ron 12.8
8
To adjust the parking bi'ake on vehICles eqUipped With rear diSC brakes. reler to the Illustration
13
Parking brake - releasing c able tensi on ( 1987 and l ater model s)
Refer roi/lus/ratron 13 1 I ThiS procedure IS necessary to remove parKing bfake system compo· nents on 1967 and later models. which use a ratchet wheel at the parking
9
9- 20
Chapter 9
Brakes CD MAKE SURE EACH REAR OISC BRAKE
BACK OFF THE P.o.RI(IIIIG BRAKE
CABLE "'()JUSTING NUT UNTil THE CABLES ARE lOOSE.
IS PElOf'EAl Y "OJUSTEO BY MOVING THE CALIPER LEVEA IN THE APf'LIED
DIRECTION. IF THE LEVER MOVES MORE TH"'" XI OEGREES, USING HAND PRESSURE Of loU ~P. (SO PSI, MAXIMUM. "OJVST THE SERVICE BRAt::ES PER SECTION 1'·~.
~;~~::::=========l---------ill
TIGHTEN THE PARKING SR""E CA aLE ADJUSTING NUT UNTIL ONE OR 80Tft OF fH£ PAAI(HII(l BRAKES ACTUATI NG LEVERS JUST BEGIN TO MOVE.
PARI(ING BAA,KE ACTUA,TING LEVER (LH SHOWN. AH TYPICALI
---r,
CALIPEFl _ _ LEVER STOP
PARI,." ••," " '''''"''
IIOll ... ' ''OOUCTION Hli'IKIl '1"" ITn,CAI,. · IJI'!'EII. LOWI!II "INOU. Dflill. T.. IIOVGH HOI.E ,II TOI' HINGE "'" ~ TO IAt .... riM IN TWO"fCn fOOl "."OVAl. 01'11111 OUT lowtll HINGE " .. AND "'TA'N 'OI'IlIf~NST"lL" T'OOI
", .. GE HAlf ON 000I'I (WELDED)
DOOR·flIGHT .... NO SIDE ILEFf SIDE TV 'IC"'L I
"-
'IIOOITO. YOUell
"DOOR CHE C.. A" M·OUTHI
14.3 Door hinge components
000111 CHICK ........ 'NNU.
11 -12
Chapter 11
Body ADO .0.$$'1'
LINK IlSSV.
ReTAINER
.00 REMOTE
"'S$'!' SCI'IEW STRIItER
"'_m
CLIP
_1.411 130·50 FT·UlSI
::--
RIVET
IUIotOTt ASSY. C~TI'IOL
RDOA$$Y
RETAINER ASSV ACTUATOR ASS'!'
•
14.4
Door lock mech anlsm . - "p'Ical
PANEL ASSEM8L Y
W VIIW· ... ..... "'IRTR_' a,~
/\
II'IACKET
• 000'
CONSOLE ASSEMSLY
\
SCI'IEW
TOFAO'H~ /'
BRACKET _
15.1 Center console
exploded view I early models)
BODY
Chapter 11
utermodels
11 -13
Remove one oltha quarler armrests (if equipped). Remove the seatback lower retaining screws, then lift the sealbadt up and out. 9 Installation is the reverse 01 removal. 7
ReftJ,toillustrstiol"ll5, 14 7 II equipped with a center BlTTlresl, pry out !he armrest bolt access covers at the rear of the console. Unbolt the armrest and lake it out. S Pry 001 the shift lever trim panel. II equipped with manuallransmission, remove the shift knob, then slide the trim panel and shift boot off the shift lever. 9 Sellhe parking brake 10 positioo the lever out of the way. Remove the lour screws thai secure the top panel, Iifllne panel and disconnect the
electrical connectors. 10 Carelully pry out the front upper trim panel by Inserting a small screwdrtver into ltIe two notches at the bottom. 11 II the vehicle doesn'1 have a radio , pry the radio opening cover panel out 01' the opening. 12 If the vehICle has a radio , remove it (see Chapter 12). t 3 Open the glove compartment door. II the vehicle has a remote fuel fill· er SWitch, detach it. Lower the glove compartment, then remove two screws thaI secure the console to the instrument panel. 14 Remove the lour screws thaI secure the console to its bracket, then remove the console from the vehicle (... lIIuatratlon). 15 Installation is the reverse of removal.
111
Body
Seata - remova' and inatallation
Front seats Refer to Hfustration 16.1 1 Remove the seat track retaining bolts and nuts, disconnect any eleclricaJ or other conneclors and lift the seat and track assembly from the vehicle (... illustration). 2 Installation is the reverse of removal. TIghten Ihe retaining nuts and bolts securely.
Conventional rear seats (early models) 3 Early models - remove the screws that secure the seat cushion to the Hoor, then 11ft the seat cushion oul. lift the seatback up and out. 4 5 Installation Is the reverse of removal.
Conventlonsl resr sests (later models) 6 Kneel on the seat cushion to push itdownward, then push it rearward to unhook it from its supports. lift the cushion out.
8
Fold~own resr sests 10 Fold the seat down. then carelully pry out fIVe push pins that secure the carpal to the seat back. 11 Remove the three screws thaI secure the folding arm to the seat back. Slide the seal outboard, off its center pivot and take it out. 12 Installation is the reverse of removal.
17
Instrument panm - removal and InawllaUon
RefIJr to iflustration 17.4 1 Disconnect the cable from \he negative terminal of the battery. 2 On early models, remove the instrument panel pad from the top of \he Instrument panel. 3 On later models. remove the lloor console (see Section 15). 4 Remove the steering column trim shroocls and covers (... lIlualralion). 5 Remove the steering column nuts and carefully lower and suppol1 the steering column. On early models, reach between the steering column and instrument panel and Iiflthe selector cable oft the shifllever. Remove the cable clamp Irom the steering column tube. 6 Remove the screws and/or nuts attaching the instrument panella the brake pedal suppol1 and to any braces below the radio orglove compart· ment. 7 On later models, r&mOVe!he defroster grille and the speaker grilles. 8 Remove the attaching screws at each end of the instrumenl panel. 9 Remove the screws along the top edoe 01 the cowl and supporl the Inslrument panel. Note: On 88rly mocIels, it will be flBCfIssary to USlJ an angle Phillips screwdriver to rBmove tfNJ top scrows. 10 Pull the instrument panel to !he rear and disconnect the speedometer cable and any electrical connectors. vacuum lines. or control cables that are attached to the instrument panet. Note: On later models it may be fI&C. 8SS8ry to disconnect ttI6 electrical conl16CtOls from ttI6 main wiring har· ness uncler the hood, thBn push ttI6 wiring harness through the grommet in
th8 firowall to create some slack. • 11 Remove the instrument panel. If you're replacing the instrument panel, tfanster all components, wiring and hardware to the new panel. 12 Installation Is the reverse of removal .
WITHPOW£R
_""",
ASSIST SlOE
11
15.14 Center console - exploded view (later models)
11-14 18.1
Chapter 11 Body
Front . .at and track installation - exploded vMtW CUS" 'ON itoSU WI LY
.. ..
."' ,.,
"'~':~~
"!lEW ANO WAlKE" ,,"lMIL'!
~ It<STIIU"(HT 'AN(L ~ IUGlSTEfI ASS£M8U' _ A ..
~
NOINSl.Il"" OII
INS'"UMEHT ' l'.NfL SPUKEII ASSEMllY - II H.
Gl.OVt COMPAATM(NT
SfUlllNG COlut.IN UPP(fIt SHAOUO
17.4
Instrument panel· exploded view (typical)
Chapter 12
Chassis electrical system
Conlents Bulb replacement Circuil breakers - general mlo/mallon Connectors - gene /allolo/matlon Electrical troubleshooting - generalmlormallon Fuses - general mformatlon Fusible links - generalmlo/matlon General lnlo/mallcn Hazarclilurn Signaillashers - replaeemen! Headhghts - removal and Inslallallon Headlight SWitch - replacement
14
6 3 2 4
5 11
'3
Ignition key lock cylinder - replacemen t Ignition SWitch - replacement Instrument cluster - removal and installation RadiO - removal and Installation Turn Slgnallhazard flasheri dlmmer (mulu -functlon ) SWitch - replacement . Windshield wiper 'washer SWitch and motor - removal and InstallatIOn Wiring diagrams and color codes - genelallnformatlon
"
Generallolo/mation Warning : To prevent alec/fica/shorts. fifes and inJury. always disconnect Ihe cable from the negative termmal of Ihe battery before checking. repa'" Ing or replacing eloc/f/cal components The chassIs eleclflcal system ollhls vehICle IS a 12-..,01t. negatIVe ground type. Power lor Ihe lights and all electrICal accessories IS supplied by a lead/acid-type bauery whICh IS charged by the alternator. This chapter covers repair and servICe procedures lor vanous chassIs (non-engine related ) electncal components. For Inlormatlon regarding the engine electrical system components (battery. al ternator. distributor and starter motor). see Chapter 5
2
9 8 16
15
,
,. "
Electrical troubleshooUng - generallnformaUon
A typical electncal circuli consists 01 an electrical component. any sWitches. relays. motors. fuses. fUSible links or CirCUit breakers. etc _re o lated to that component and the wiring and connectors that link the compo· nents to both the battery and Ihe chaSSIS. To help you pmpomt an electncal Circuit prOOlem. Wlnng diagrams are InctUded at the end 01 thiS book Belore tackling any troublesome electrical CIrCUit. first study the appro· pilate Wifing diagrams toget a complete understanding 01 what makes up thaI IndiVidual CircUit. Trouble spots. for Instance. can often be Isolated by nollng If other components related to that CirCUli are routed through the same fuse and ground connections.
12
12 - 2
Chapter 12
Chassis electrical system
.......ws
GRASP THE WillES WllH 80"• A.NO PUll THE COtlNECTOfI """"1
,~.
VIEwe
INUrn A 'LA'........OIIICflEWOfIIVIEJIIN
..
THI! LOCItIHQ u,. ANO TWIST. GIUoP THE LOCKING AFIE ON B01H W!ftfS AND I'UlL UNn. T" LOCI(IItG TAlI SIDES OF THE CI:JoNNECTOR • ON lHl! RA ..... ~ THE CONNltlOll
u,es
OVIl'! AHO IWH.AllHlI'flOClOURf ON TO« THI. CONHICTOIII . THEN 1oN0 """-L ,vAIIT
~n '101 OF QIt.\U 1lIE _ U
"' 3.1
Some ot the various Iypes 01lnll08 connectors used on Ihese models
Electflcal problems usually stem from Simple causes such as loose or
corrodedconneclors, a blown luse, a melted fusible link Of a bad relay VI sually inspect the condition of aliluses, wires and connectors In a problem CirCUit before troubleshooting It
The baSIC lools needed lor electrical troubleshooting Include a CirCUit lesler. a high Impedance (10K-ohm) digital voltmeter, a contlnUily lester and a JUmper W1re With an inline Circuli breaker fOf bypaSSing electrical components Belora attempting 10 locale or delfne a problem With electrical test Instruments. use the WIring diagrams to decide where to make the necessary connec1I()nS.
Voltage checks Perlorm a voltage check first when a ClrCUlt is nOI functioning properly. Connect one lead of a cirCU it tester to either the negallve battery terminal or a known good ground. Connect the other lead to a connector in the CirCUit being lested . prelerably neal est \0 the battery orluse. JI the bulbol the lesler hghtsup. voltage IS present. whICh means that the part of the CirCUit between the connector and the battery IS problem free . Continue Checking the rest 01 the CirCUit in the same lashlOn When you reach a pomt at whICh no vOltage IS present. the problem lies between thai pomt and the tastIest POint with voltage. Most of the time the problem can be traced to a loose connection. Note: Keep In mind thaI some CIfCUltS receive vol/age only when the Igmtlon key IS In the Accesso·
ry or Run POSIflOn.
Finding a short circuit One method 01 finding shorts In a ClrCUltlS 10 remove the l use and con· nect a lest ligh t or voltmeter In ItS place There should be no voltage presentln the CIfCUII. Move the wIfing harness from Side-to-side while watching the test light lIthe bulb goes on, there IS a short to ground somewhere In that area. probably where the insulatIOn has been rubbed through. The same test can be perlormed 00 each component In a Circuli. even a SWitch
Ground check Perlorm a ground test to check whether a component IS properly grounded. Disconnect the battery and connect one lead 01 a sell· powered test light. known as a conllnulty tester. 10 a known good ground. Connect Ihe other lead to the wl'e or ground connection being tested. lithe bulb goes on. the ground is good. II th e bulb does not go on. the ground is nOI
good
Continuity check A conltnulty check determines II there are any breaks
In
a clfcull- if
It IS conducllng electfiClly properly Wllh the CirCuit olf (no power In the CIf'
CUlt), a sell-powered conlinUity tester can be used to check the CIrCUit Connect the test leads 10 bolh ends 01 the CIrCUit, and If the test light C.1mes ontheclfCUlllS passing current properly 1/ the light doesn't come on, there IS a break somewhere In the CIrCUit The same procedure can be used to test a switch, by connecting the conlinUlty tester to the power In and power out sides 01 the SWItch. With the SWitch turned on, the test Itght should come on
Chapter 12
Chassis electrical system
12 -3
readily seen lor checkmg MiniatUrized fuses are used on later models These compact luses, With blade termInal desl{ln, allow fingertip removal and replacement. II an electrical component lalls, always check the luse IIrst. A blown luse is easdy identified through the clear plastIC body, With the fuse removed. Visually Inspect the element for eVidence 01 damage (see illustration), 11 a conlinUity check IS called lor, place the luse back In the fuse panel af"ld turn the IgOillon key to the ON poSition. Connect one lead of a l est ligh t to a good ground and connect the other lead to each 01 the luse's e~posed terminal ends The test light Should hght when connected 10 each end, II it doesn't light when connected to one of the terminal ends. the fuse IS open and should be replaced . Be sure to replace blown luses With the correct cype and amp rating Fuses 01 dlHerent ra\1ngs are phYSIcally interchangeable, but reptaong a fuse WIth one 01 a higher or lower value than specified IS not recom · mended EachelectncalClfCUlt needs a spectficamountolprotecllon. The amperage value 01 each luse IS usually molded Into the luse body. DIHer· ent colors are also used to denote luses 01 different amperage types . Cau tion : Always /Um off all elec/rical components and the igmllon SWitch before repfac!I1g a fuse. Never bypass a fuse wi/h pieces of metal or fori Fife anellor serious da mage 10 the electrical syslem could result. 11 the replacement fuse immediately tails, do not replace It again until the cause of the problem (a short cirCUit) IS isolated and correctftd
4.2 To tesllor a blown miniature luse, pull It out and inspect it lor an open (1), then, with the luse Installed and the ignition key turned to ON, probe each of the terminal ends (2) with a tesllighl
Finding an open circuit When diagnosing for possible open CirCUits IllS olten difhcult to locale them by sight because DxJdallon or terminal misalignment are hidden by Ihe connectors Merely wiggling a connector on a sensor or In Ihe wiring harness may correct the open circuit condition Remember this if an open circulI is Indicated when troubleshooting a CirCUli. Intermittent problems may also be caused by oxidized or loose connections. Electrical troubleshooting IS Simple If you keep In mind that all electrical CirCUits are basICally electrICity runnll'lg from the banery. through the Wires, SWitches, relays , luses and fusible hnks to each electrical component (Itght butb, motor, etc ) aOOthen to ground, Irom whICh IllS passed back 10 the battery. Any electrical problem IS an InterruptIOn In the flow 01 electriCity to and Irom Itle banery.
3
Connectors - general information
Refer /0 lIIustra/lon 3. 1 Always release Ihe lock lever(s) before attempting 10 unplug inhne type connectors, There are a vaflety o f lock lever conhguratlons (see illustration) , Although nothing more than a finger IS usually necessary to pry lock levers open. a small pockel screwdnver IS et/ectlve lor hard-to· release fevers . Once the lock levers are released , try 10 pull on the connectors themselves. nol the WIres. when unplugging two connector halves (Ihere are times , however. when thIS IS not poSSible - use QOOd judgment). It Is usually necessary 10 know which Side, male Of lema Ie, 01 the con· nector you 're checking . Male connectors are easily distinguished from fe· males by the shape 01 thelf Internal pinS When checking continuity or voltage With a ClfCUl' tester, insertion of Ihe lest probe InIOthe receptacle may open the 11111n9 to the connector and result In poor contact Instead, insert the l ast probe from the wife harness side 0 1 the connector (known as -backproblng ").
4
Fuses - general information
Refer 10 illus/rallOfl 4 2 The electrical CirCUitS are protected by a combinatIOn of fuses . fUSible ~nks and CirCUit breakers. The luse panel IS located under the left end of the dashboard. Two types 01 luses are used , depending on date 01 manufacture. Early models use a glass tube deSign where the metal elemenllnSlde can be
5
Fusible links - general inlormatlon
Some CirCUi tS are protected by fUSible links The links are used In Clf ' CUltS whICh are nol ordinanly fused . such as the Ignition CIrCUit Although the fUSible links appear to be a heaVier gauge than the wire they are protecting. the appearance IS due to the thick Insulation. All lus ible links are lour wire gauges smaller than the wife they are designed to protect. Fusible links cannot be repaired, but a new Itnk 01 the same size wife can be put In lIs place. The procedure is as follows ' a) Disconnect the negallve cable from the battery b) Disconnect the tusible link Irom the Wifing harness c) Cut the damaged fUSible link out of the Wifing Just behind the con · nectO!' dl Strip the IOsulatlOl'1 back approXimately 112-loch. e) POSition the connector on the new luslble link and cnmp It IOtO place I) Use rosIO core solder at each end 01 the new link to obtain a good solder JOint. g) Use plenty of electrical tape aroul'ld the soldered JOint. No wires should be e xposed. h) Connect the banery ground cable. Test the cirCUit lor proper opera· tlon
6
Circuit breakers - general inlormation
CIfCUII breakers prOlect accessorl8S such as power WIndows. power door locks, the WindshIeld WIpers. Windshield washer pump, interval WIPer. low washer Iluld. etc. CirCUit breakers are located In the luse bo)[, Reter to the luse panel gUide In your owner's manual lor the location of the ClfCUIt breakers used in your vehicle Because a circuit breaker resets Itself automatically. an electrical overload in a ClfCUlt breaker protected system Will cause the cirCUit to lail momentartly, then come back on. II the circuil does not come back on. check II Immediately a) Remove the CirCUIt breaker Irom the luse panel. b) USing an ohmmeler. verify that there IS continUity between bolh ter minals 01 the CirCUIt bfeaker. If there IS no continuity. replace the Clr· curt bfeak8f. c ) Install the old Of Il8W ClfCUlt breaker. lilt continues to cut out. a short CirCUit IS Indicated. Troubleshoot the appropnate CIrcuit (see the Wifing diagrams at the back of thiS book) or have the system checked by a prolessional mechanIC
12
12 - 4
Chapter 12
Chassis electrical system
8.5 An easy-out tool Is required to remove the two break-oil head bolts (arrows ) retainIng the Ignition switch to the lock cylinder housing
7
9.6 Wilh Ihe lock cylinder in Ihe Run position. pu sh in Ihe release lever wi1h a liS-Inch diameter punch 10 release the cylinder
Turn signal /hazard Ilasher/d lmmer (multl-Iunclion) switch - replacement
1 DIsconnect the negatIve cable Irom the banery 2 Remove the sleering column cover 3 Unplug the SWitch electrical connectors 4 Remove Ihe SWitch mounting screws and take the SWi tch off the sleel ing column. S Installalion IS the reverse 01 removal
8
Ign ition switch - replacement
Refer 10 illus/rallon 8.5
I
10
Disconnect the negauve cable from the banery Remove the S188f1ng column covers
2 3 Turn Ihe IQnlllOn key lock cylinder [0 the On (Run) poSItion. 4 Unplug the 'Onilion switch electocal connector 5 Use a IIS-mch drill bit to drill out the break-ort head bolls Ihal connect Ihe SWllch to Ihe lock cylinder hOUSing (see illustration) 6 Remove bolh bolts Wllh an easy -oullool 7 Disengage Ihe ignition SWitch 'rom Ihe acluator pin 8 Makesure the actuator pm 5101 In Ihe new ignitIOn SWIlch IS m Ihe Run poSition. Nole: A new replacement SWitch assembly will be sel In Ihe On (Run) poSlllon 9 Place Ihe new SWitch In position and Instalilhe break·oll head bolts Tighten Ihe boilS untillhe heads break 011 10 Pluglhe electrICal connector 1Il\0 Ihe SWitch 11 InsI3111he steerlng column cover 12 Connect the negallve battery cable
9
cylinder Depress Ihe punch while pulling out on the lock cylinder to remove II tram Ihe column housmg (see illustration) 7 Install the lock cylinder by lurnlng II to Ihe Run position and depressmg the retaining pin. Insert Ihe lock cylinder Into the lock cylinder housmg Make sure Ihe cylinder is completely sealed and aligned In Ihe Inl erlocklng washer belore turn ing Ihe key to the Of! poSition ThiS Will permit Ihe retammg pm to extend Inlo the hole S Turn the lock to ensule thai operallon IS COfrect m all poSitions 9 The remamder of installation IS the reverse 01 removal
Ignition key lock cylinder - replacement
Refer 10 lf/uslratlOn 9.6 1 Disconnect the neg. e cable from the battery II your vehicle is equl~d wilh a lilt column. remove the upper ex ten· 2 Slon shroud by snapping It loose Irom ItS retammg clip 3 Remove Ihe sleermg column cover 4 Locate the smgle key warning buzzer wire and disconnect II 5 Turn the IQflIllOn SWitch to the Run positIOn 6 Place a t ·S-Inch punch m the hole m Ihe casllng surrounding the lock
•
Windshield wiper/washer switch and motor - removat and inslallation
Wiper switch Refer 10 IIlustrallon 104 t Disconnect the negative cable tram the battery 2 Remove the steerlng column shroud 3 Unplug the SWitch electflcat conneclor Note: On some models_ It may be easier 10 remove the SWllch from the sleeting column flfSI. then unplug the elec/flcal connector. 4 Remove the SWitch mounllng screws and take th e SWltcholithesteerIng column (see Illustration) Nole: Laler models use Torx scre ws to se· cure Ihe SWitch Be sure to use the proper s,ze Torx drrver. 5 InstallaTion IS the reverSe at removal
Front wiper motor Refer 10 Illustrallon 10.7 6 Remove the cowl lop glille 7 Remove the link retamlng clip and detach the Wiper linkage from Ihe motor (see Illustrati on) 8 Remove the mOtor mounilng screws and take the molor ou t 9 Installailon IS Ihe reverse of removal Make sure the Wiper blades are In the parked position before attach ing the linkage 10 Ihe motor
Rear wiper motor Refer to ,IIUSlrallOfl 10.14 10 Raise the wiper arm 011 the rear WIndow Pull the slide latch and tift away the Wiper arm. 11 Remove Ihe pivot shalt nuts and washers
Chapter 12
•
Chassis electrical system
12 - 5
~----
ID~--- ""'. ,. NDWASHt R AS$t Me l Y
.....RNESS
.-
10.4
12 Aemove the 1,llgale trim screws and panel. 13 Disconnect the motor electrical connector. 14 Remove the screws that secure the motor and Imk.age to the litigate
Wiper switch installation - typical
(see Illustration). 15 RemOlle the motor and linkage as an assembly. 16 Installallon IS the reverse of removal.
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\
.--" IIIMQVAL
10.7
Wiper linkage connection details
" -....J 0· 10.14
12 J
Rear window wiper inslallation - typical
12 - 6
Chapter 12
Chassis electrical system
The lurn sign al lIasher IS loc ated in the front
a_posed side 01 the luse
CIRCUIT BREAKER
panel
HAZARD FI.ASJoIER
The hazard lIasher Is loca ted on the backSlde of the fuse panel direct ly behind the turn signal Ilasher.
11 .28
11
11.2b
Turn signal and hazard flashers on early models are boln mounted on the luse bOll
On laler models, only the lurn signallissher Is mounted on th e fuse box ...
INSTRVMENT PANEL REINFORCEMENT
Hazard/turn signal Ilashers - replacement
Referral/lus/rallons 112a. 1t.2band 1I .2c Note; No functional or operal/On check of the hazard lurn ssgnal flashers 1$ necessary. /f they slop working replace them 1 Delach the cable trom Ihe battery negallve terminal 2 The lurn Signal lias her IS located on the luse panel On some early models, Ihe hazard lIasher IS located opposite the turn signal flasher in the fuse paneL On tater models, the hazard lias her is located on the instrument panel brace above the glove comparlment (see Illustrations)
,
Turn signal flasher or fuse box-mounted hazard flasher
""",,0
It you art! replaCing a fuse box-mounted lIasher. unplug it 110m the fuse panel On some very early models. the flasher pulls straight out On
''''"''
3
later models, remove the Uasher by turning it 9O-degrees counterclock wise and pulling straight out 4 Install the new lIasher unit Be sure to hne up the metal contacts With the slots In the fuse panel and press the tlasherhrmly InlO place If you had to turn the lIasher to unlock It, lurn It 9O-degrees clockWise to lock It
Hazard flasher (mounted above glove box) 5 6
To remove the hazard lias her. pull 11 stralQht out of the Installation IS the reverse of removal
connector
l'.2c
... while the hazard flasher Is mounted on a brace above the glove comparlmenl
Pull the head lamp switch to Ihe On position Reach under the instrument panel and press the knob lelease bunon (see illustration) Remove the knob 4 Remove the SWitch retaining nut and take the sWitch out 5 Disconnect the electrical connector trom the sWitch 6 Installallon IS the reverse of removal 2
3
Later models 12
Headlight switch - replacement
Early models Refer /0 II/ustratlon 123 t
Disconnect the negailve battery cable from the battery
Refer /0 Illus/rallon 128
7 Disconnect the negatIVe battery cable flom the banery 8 Locatethe twO lock tabs that secure the SWItch. These are behind the SWitch levers. Use a small screwdriver to disengage the lock tabs (see illustration) 9 Pull the SWit ch out and disconnect the electrical connectors
Chapter 12
Chassis electrical system
12 -7
KNOB RELEASE BUTTON
PANEL
FOG lAMP
12.3
Headlight switch - early models
10 To Install , connect Ihe wiring connectors to Ihe SWitch Push It Into Ihe instrument panel untilihe lock tabs engage
13
Headlights - removal and installation Disconnecilhe negative battery cab le from the battery
Sealed beam headlights Refer /0 Illus/ralion 13.2
2 Remove the headlight bezel screws and remove the bezel (see iIIustraUon ) 3 Remove the headlight retaining screws. Pull the headlight out 01 the frame, disconnect the electrical connector and take the headlight out. Caution: Do nol disturb the (usually larger) adJustmgscrews or the headlight 81m Will be altered
4 InSlallahonlS the reverseo! removal. Havethe headlights adjusted by a properly equipped shop
Aero headfights Refer to IllustratIOn /3.7 Open the hood
5
12.8
Headlight switch -later models
6 Disconnect the electrical connector Irom the back of the bulb 7 Rotate !he retain ing ring about t /B-turn counlerclockwlse (Viewed from the rear ) and slide It 011 the base (see illustration) B Carefully pull the bulb straigh t out 01 the socket 9 Insert the bulb into the socket. Position the flat on the plastic base upward. 10 Align the socketlocatmg tabs With the grooves m the forward part of the plastic base. then push the socket firmly mto the base. Make sure the base mounting lIange contacts the socket I I Slide the retaining ring on. Turn It clockwise until It hits the stop 12 Connect the electflcalconnector. Test headlight operation . then close the hood. 13 Have headtight aim checked by a properly equipped shop
14
Bulb replacement
The lenses 01 many lights are held In place by screws. which makes It a simple procedure to gam access to the bulbs 2 On some lights the lenses are held in place by clips. The lenses can be removed either by unsnapping them or by usmg a small screwdriver to pry them off
BULB
RETAINIIIIG
"NO
12 PLASTIC
REFLECTOR 13.2
Removing the headlight bezel - early models
13.7
BASE
Aero headlight bulb components -later models
12-8
Chapter 12
Chassis electrical system
=
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15.3
Radio Installation - typical
3 Severallypesol bulbs are used. Some are removed by pushing In and turning them counterclockwise . O1hers can simply be unchpped from the terminals or pulled straight oul 01 the socket. 4 To gain access to the Instrument panel lights, the Instrument cluster WIll have \0 be removed lirs!
6 Puillhe clusler the rest ot the way out and disconnect ilS wIring can· nectors 7 Apply a 3 t6-lflch diameter ball of SilICone damping grease to the dn... e hote In the speedometer head. 8 The remaJOder 01 InSlallalion IS the re ... erse 01 remo ... al
15
17
Radio - removal and installation
1979 through 1986 models Refer 10 II/ustrallon 153 1 Disconnect the negative battery cable from the battery 2 Disconnectihe power. speaker ar.d antenna wires from the radiO 3 Pull 011 the knobs and discs. then remove the radiO retaining nuts (If eqUipped) (see illustration)
4 5 6 7
Remove Itle upper support screws (If eqUipped) Remove the rear support nul or screw Take the radiO oul Installation is the reverse 01removal
1987 and later models 8 RadIO remo ... al reqUifes special tools and should be left to a properly eqUipped shop.
16 t
Instrument cluster - removal and installallon
Disconnect the negati... e ba1l6ry cable Irom the battery On 1988 and la ter models. remo ... e the SWitch assemblies tram either Side al the instrument panel (see Section 12). 3 Remo...e the screws secUring the trim panel to the cluster. Remo ...e the tnm panel Remo ... e tour clusler relaJOlflg screws 4 5 Pull the cluster out Reach behind It and disconnect the speedometer cabte .
2
Wiring diagrams and color codes - general Information
Slflce It Isn t poSSible to Include all wIOng diagrams torevery year co ...· ered by thiS manuaJ. l he lollowlng diagrams are those that are tYPIcal and most commonly needed. Prior to trouble shOaling any CirCUitS. check the fuse and Circuit break· ers (if eqUIPped) to make sure they're In good condition . Make sure Ihe banery IS properly charged and check the cable connectIOns (see Chap ler I ) When checklflg a CIrcuit. make sure thai all connectors are clean . With no broken or loose terminals. When unplugging a connector, do not pu ll on the wires Pull only on the connector houslflgs the msel... es.
Color codes Wire colors In Wifing diagrams are Idenlilied by one or two-character alphabetical codes. The follOWing list tells the color IIldlcated by each of these codes B .. Black BR .. Brown DB .. Dark blue OG .. Dark green GY .. Gray LB Light blue LG .. Lighf green N .. Natural O . Orange B
P .. Purple
PK .. Plilk A _ Red T . Tan W .. White Y .. Yellow (H) .. Hash' (D) .. Dot'
Nole: The presence 01 a Iracer on rhe WIre ISIndICated by a secondarycoJ· or foflowecl by an -H" for hash or -0 - for dot A s/rtpe IS understood If no letter follows
Chapter 12 Wi ring color key Primary colo.s Black
Brown
"" R"
Pink Orange Yellow Dark green LiJ:Ih\
green
Dark blue Light blue Purple
Diag
Component
10 07 9 C1
o Stereo tapa/AMfFM/MPX Radio Regulator Alternator Ins!flJmen! cluster voltage Relay Back window heat cOntrol Carburetor choke control Electric fuel pump Engine cooling fan mo tor Engine electronic con t,ol Exh gas recire sol vac valve Light sensor Starter mO tor Starter mo tor Resistor Blower motor
Blower motor
Sender Fuel gauge
Wale. lemperature mdici110r 3 Servo 11 Speed cont,ol
01
Solenoid Ale CLutch Ale Clutch Ale Clutch
F4
F4
conI
B J
FJ '"
C6
Ale Cluu;h
Dl0 Dll
E2
D16 DI5 C7 Dl' D13 E6
FB F7 DI3 AB
'D D' lD D5
, 2
B B
, 2
DI5 D12 C9 811 DB B6
eo
" '"E10 F12 11 11
"
BJ
7 B B 7 B 7 B
"D6
7
B7
B2
D5 D7 BJ E6
7
A12
B
E7
2
E1
J
C5
,,6 ,, ,, ,
Cl'
2
"
B6
B
D9
C7
D12 CI5 E15 BJ
815
Wiring diagram key -1979 and 1980 models
F5
J
6
5 5 6 6 5 9 B 6 5 5 6 5 5 6 6 5
E1J D2
F1
00"'
D9 D1D
E5 F5
'" f12
EJ
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6
7
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3
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Carb thrOllle em'SSI(H'l
Carb th.onle emission Carburetor floa! bowl vent Edlaust gas rec"c vac valve Speaker R.H . Front radio receiver R.H Front radio receiver Radio receiver Radio receiver Radio receiver RadiO receiver Radio receiver rear seal Radio leceiver rear seat Radio receiver rear seat Radio receiver rear seat RadiO receiver rea' seal Radio receiver rear seat SWitch AlC Mode Back window heater control Backup lamp Backup lamp Carb Idllt thermactor air pump Cou!1esy lamp Couflesy lamp Dual brake warning Fan mota, Fan motor Fue l pump Gear shift neutral Gear shift neutral Headlamp l lQnition Ignition Ignition key warnmg LH . Power door lock luggage camp door lock Oil pressure Oil pressure Oil pressure Park brake signal lamp R.H Power door lOCk Rear windOW washer Rear water courtesy lamp Seat belt buckle Seat belt warning indicator Seat belt warning indica tor Speed control Stoplamp Stop lamp Turn and emergency signal W/SNo/ Washer W ! SIW Washer AlC Control Tachometer Thermostat AlC EvaporalOf Valve Dis tribu10r modula!or
,
7 7 7 7 7 7
7 7 7 7
"DB C16 E1 D1 D6 010 F2
"F6 Fe
7
E10 E16
B
81J A13
7
6
6 6
BJ
9 9 J
B5 B7
, "D2 ,, ,
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J
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6
81
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9
6 9 2 2
, J 6 11
9 J J 9
" 5" 5
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"
I
D9 A16 '16 '16 E7
DI5 DI3 C1D CIJ
DI< BI< D5 D2 B5
A5 C5
811 Bl' Dll DI2 E1J
EJ
12
12 - 10
Chapter 12
Chassis electrical system
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12
12 -16
Chapter 12
Chassis electrical system
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Chapter 12
Chassis electrical system
12 -17
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12 -18
Chapter 12
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12 - 22
Chapter 12
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Chapter 12
12 - 34
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Chapter 12
Chassis electrical system
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ero PICk· UP. LTD II. Mercury Montego, Comet, XR,7 & lInc:oWI VellllUies (IS Ihrv '88) .....~. Mlr(:UfJ ~.M modeII iocIuding Turbo ' 91hru '92 MUNng VI .. models ·fi.4.1 1211Wu 73 MU'~ • at • tyI, V6 & V8 models 7. Ihru 8 Pinto. Yercury 80beM 81 models "151hru '80 ' 1170 ProW all mode'- '89 \tIru '92 Ranger' Bronco II all 9ilsoline models '831tlru '92 'IU1 T,uru.' Metc ury SllbII '861t1rv '92 ' 1.18 Tempo' Mlrcu1.Topaz at ~mcdeII ' !hru'91
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GENERAL MOTORS A..c.,. - Cnevrolet ~ Century. Pontilc 6000 & Ie Cutlass Cieri .11 models '82 \tIru '90 J..CfiI - Chevrolet C.vaUe< . Ponllac J ,2000, Oldsmobile Firen~ • • 6uoeIr. SIl)'hIwiI & Cedillac Cmarron II modeII'82 Ihru "92 "1. 20 H-C. ... - 6uoeIr. 5omerM! "85t1Vu '87. Ponllac Grand Am and ClIcbmobie Call.. '85 Ihru '91, BuoeIr. $kyIaIIr. '86 Ihru '91 ' 1871 GM: Bulek Regal , Chevrolet l.umIna, 0IdIm0bI1I CUt!au ~eme. Pontiac Grind Pri •. aa ront....ntel drive models '88 \tIru '90 GM : C~ Lumll\l APV, DIdamobIIe SllhoI.oIttI, PonIIK T...nI Sport '90 thru '92
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shown wilt! an asterisk ( , ) indicaftl model COVfII"8f1tI tiS oIlt1is pmtinfl. Th4nuI tifJtIs wilt btl ptI(IOdicBl1y
updated to Include IBIfK model years - COfIS!JIr JIOI.N Haynes dealer for mor. lnlonnation.
Haynes North AmerIca, Inc., 861 Lawrence DrIve, Newbury Park, CA 91320 • (805) 498-6703
HAYNES AUTOMOTIVE MANUALS
(continued from J"VIouI page)
NOTE: New manuals 8(8 added to this list on 8 periodic basis. If you do not see a listing for your vehicle. consult your local Haynes dealer for the lB tssl product N1formstion.
HONDA 351 Acconl cvee aMmodftIs 761hru '83 "1221 AcconI ai ~ '8111hru '89 1&0 Civic 1200 allTIOOtIt 731hru 79 &33 Civic 1300 .. 1500 CVCC .I/TIOOeI$ 'SO Ihru '83 m C ivic 1500 cvee III models 7Stt1lu 79 ' 1m Civic all modals '$(thru '91 '601 PreI. . . CVCC tJI ~ 79 Ih..... '89
HYUNDAI "552
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'1341 '771 '116
'1112 '11111
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JEEP
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163
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MAZDA 621 Sedan & Coupe ('N'....tINI (Iriye) all models 79 thru '82 621' MX.e (Iront wn..t cSrt .... ) aN models '631htu '91 Gl C ~tchbeck (rNr W'-I ~J .. models 771hru '83 OLe (front whMI drive) .. models '811hru '86
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MERCEDES-SENZ ' 11143 '80 5erlH allOUfqlinder ~ models, '84 Ihru '88 348 230. 250 • :zeD Sedan. Coupe & ~ aU 8 eyI tohc models 'l!.8 \t'U1J '72 983 280 123 s.n.. •• gasoline modeb
698 U7
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111
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MITSUBISHI ' 1&611 Corella, rr.dIJ., Galanl, Preela & '2022
Nw.ge '83lhru '90 Plc:k-. & MonI«O '83 thru '9 '
MORRIS 074 !AUllln) N.lrln. 1,1 .. models '71l1'1ru '80 024 MII'IOf 1000 ~n 8. wagono '56lhru '71 NISSAN 1137
Pul.., all models '83 ttvu '96 Senlta " models '82 Ihru '90 SlIonu ." model, '82 Ihru '90
va model. 741hru 'ell
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ISUZU ' 1&41 Trooper. Plck-up, aR gasoIina model'
"47'
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3OOZX aJl Turbo"non-Turbo models '''' Ihru '89
504 . 1 dlGsei models '14 Ihru '83
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PLYMOUTH F(H all PL YIIOI./TH m/ft, _ DOOGE 1I. 1Ing.
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RENAULT
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Tran, porte, 1100 all models '68 1hru '79 TrlntpCM't4or 1100, 1100 .. 2000 .. models 721t1ru 79 Type 3 1SOO .. 1 tIOO ,I models '631hru 73 Vana-gon all ail-