Chilton's Auto Repair Manual 1998-2002 - Perennial Edition [Perennial Edition] 0801993628, 9780801993626

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THOMSON

Chilton

*

Part No. 9362

DELMAR LEARNING

1 998

- 2002

Digitized by the Internet Archive in

2015

f

https://archive.org/details/chiltonsautorepa00john_0

CHILTON AUTO REPAIR MANUAL 1998-2002 Edition

——

:

THOMSON *

DELIVIAR LEARNING

Chilton Auto Repair

Manual 1998-2002

Channel Manager:

Production Editor

Alar Elken

Beth A. Lutz

Elizabeth

Executive Director, Professional Business Unit;

Marketing Coordinator:

Custom

Greg Clayton

Bnan McGrath

Claudette Corley

Publisher, Professional Business Unit:

Production Director:

Technology Project Manager

David Koontz

Map'

David Porush

Vice President, Technology and Trades

SBU:

Ellen Black

Editorial Assistant:

Production Manager:

Kristen Shenfield

Larry

Hough

Publishing Coordinator

Editors:

Main

Rich Rivele Christine L. Sheeky

Tun Crain

Thomas A. Mellon

COPYRIGHT 2003

by Delmar Learning, a

sion of Thomson Learning, Inc.

Thomson

1

ing

is

a trademark used herein under

divi-

Learn-

license.

ALL RIGHTS RESERVED. No part of this work covered by

the copyright hereon

may

ISBN: 0-8019-9362-8 be

reproduced in any form or by any means graphic, electronic, or mechanical, including pho-

Printed in the United States of America 1

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XX 05 04 03

tocopying, recording, taping,

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NOTICE TO THE READER Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein. Publisher does not assume,

expressly disclaims, any obligation to obtain and include information other than that provided to

it

and

by the

manufacturer.

warned to consider and adopt all safety precautions that might be indicated by the and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions. The reader

is

expressly

activities herein

The publisher makes no representation or warranties of any kind, including but not limited t£>, the warranties purpose or merchantability, nor are any such representations implied with respect to

oi fitness for particular

the material set forth herein,

and the publisher takes no responsibility with respect to such material. The pubnot Ee liable for any special, consequential, or exemplary damages resulting, in whole or part, u'"1ers' use of, or reliance upon, this material.

'isher s.-^H t

1111

Table of Contents Unit Repair Sections

Specifications

1

Specifications, Scheduled Maintenance Interval and Scheduled Mainte-

nance Labor Time Charts

Heater Cores

2

Heater Core Removal and Installation Procedures

Timing Belts

3

Timing

Brakes

4

Brake System Component Service Procedures

Belt

Removal and

Installation

Procedures

Table of Contents Car Sections

Chrysler Corp.

Ford Motor Co.

General Motors

5

Concorde, LHS, 300M,

6

Sebring Coupe, Avenger

7

Talon

8

Neon

9

Cirrus, Sebring Convertible, Stratus. Breeze

Intrepid, Vision

10

PT Cruiser

11

Contour, Mystique, Cougar (1999-01)

12

Taurus, Sable

13

Continental

14

Escort, Tracer

15

Focus

16

Lincoln LS

17

Mustang

18

Mark

19

Crown

20

Thunderbird

21

C-

VIII

Victoria,

Town

& H-Bodies— Le

Car,

Grand Marquis

Sabre, Park Ave., Eighty Eight, LSS, Regency,

Bonneville

& K-Bodies

—

22

E-

23

F-Body— Camaro,

Deville,

26

— J-Body — L/N-Body—

27

N-Body— Skylark,

28

V-Body— Catera

29

W-Body

24 25

G-Body

Riviera,

Concours, Eldorado, Seville

Z28, Firebird, Trans

Am

Aurora

Cavalier, Sunfire

Intrigue,

—

Malibu, Cutlass Achieva, Alero, Grand

Century, Regal, Impala, Lumina, Monte Carlo, Cutlass Supreme,

Grand Prix

—

Am

30

Y-Body

Geo/Chevrolet

31

Metro, Prizm

Saturn

32

LW,

Corvette

SC1.SC2,

SL, SL1.SL2,

SW1.SW2

Model Index Section No.

Model

5-1

14-1

F

Achieva

27-1

Alero

27-1

Aurora

24-1 6-1

21-1

Bonneville

Firebird

23-1

Focus

15-1

G Grand

Am

Grand Marquis

B

Breeze

C

31-1

PT Cruiser

10-1

R Regency

21-1

19-1

Riviera

24-1

12-1

29-1

Saturn Coupe

32-1

Saturn Sedan

32-1

Intrepid

Catera

28-1

Intrigue

29-1

L 21-1

Le Sabre

S Sable

Camaro

Century

21-1

Prizm

27-1

5-1

25-1

Park Ave.

29-1

i i

Impala

29-1

P

Regal

23-1

Cavalier

Section No.

29-1

Grand Prix

9-1

Model

22-1

Escort

A

Avenger

Section No.

Eldorado

3

300M

Model

Saturn

Wagon

32-1

Sebring Convertible

9-1

Sebring Coupe

6-1

Cirrus

9-1

LHS

Seville

22-1

Concorde

5-1

Lincoln LS

16-1

Skylark

27-1

Concours

22-1

LSS

21-1

Stratus

9-1

Continental

13-1

Lumina

29-1

Sunfire

Contour

11-1

LW

32-1

Corvette

30-1

Cougar (1999-01)

Crown

Victoria

Cutlass

Malibu

9-1

Mark

9-1

Supreme

D DeVille

M

1-1

'6-1

Cutlass

25-1

T 7-1

Talon

26-1

Taurus

12-1

18-1

Thunderbird

20-1

Metro

31-1

Town Car

19-1

Monte Carlo

29-1

Tracer

14-1

Trans

VIII

Mustang

17-1

2-1

Mystique

11-1

1-1

Neon

N

E Eighty Eight

5-1

Am

23-1

V 5-1

Vision 8-1

z

Z28

23-1

EDITORIAL POLICY Manufacturer and Model Coverage

make and model that is currently available on the market. Rather, the Chilton Editorial Staff makes makes and models warrant coverage. Those that are included herein represent Chilton’s judgement as to the make up 90% of vehicles that will be presented to the average technician for diagnosis and repair. In general, this Manual

This Manual does not seek to cover every judicious decisions as to which

makes and models

that

does not cover:

•

Dodge

Exotics (e.g. Rolls-Royce,

Romeo,

Viper; Alfa

OEM’s with no U.S. presence (e.g. Fiat) • OEM’s that have not sold enough units to be a

etc.)

•

factor in the repair market.

Model Year Information

Every

effort is

made

to

gather current data for use

in this

Manual. Data

acquired from manufacturers

is

at the

time

when each

OEM

chooses

to

choose to release their new model information at different times of the year, ndeed, the same manufacturer can be early one season with information, and then late the next season. As a result, not all models are equally curent when each edition of this Manual goes to press. You will note that the Editorial Staff has taken care to indicate the currency of coverage for each model. release

Different manufacturers

it.

Safety Notice

Proper service and repair procedures are

vital to

all motor vehicles, as well a> the personal safety of those perand repairing vehicles using safe effectivemethods. The procedures contain

the safe, reliable operation of

forming the repairs. This manual outlines procedures

for servicing

many NOTES, WARNINGS and CAUTIONS which should be followed along injury or improper service which could damage the vehicle or compromise

It

is

t*

eliminate the possibility of personal

safety.

important to note that repair procedures and techniques, tools and parts for servicing vehicles, as wel as the

individual performing the

work vary widely.

serviced, or to provide cautions as to

all

any other process

Some

that

It

not possible to anticipate

fluids,

hazards that

may

of the

all

result.

and experience

skill

conceivable ways or condtions under which vehicles

Standard and accepted

safe’/

of the

may be

precautions and equipment should

and safety goggles or other protection should be used dung

cutting, grinding, chiseling, pry-

can cause material removal or projectiles.

procedures require the use

of tools specially

completely satisfied that neither your personal

Although information

is

of the possible

be used when handling toxic or flammable ing, or

with standard safety procedures its

in this

manual

is

safety,

designed

for a specific

purpose. Before substituting aother tool or procedure, you must be

nor the performance of the vehicle will be endangered

based on industry sources and

is

as complete as possible

at the

me

of publication, the possibility

some vehicle manufacturers made later changes which could not be included here. Information o very late models may not be available in some circumstances. While striving for total accuracy, the Publisher cannot assume responsibility fr any errors, changes, or omissions that may occur in the compilation of this data. exists that

LOCATING AND USING INFORMATION Organization

The Table

of Contents, located at the front of the

book,

lists

each Unit Repair Section and Model Specif section

in this

manual.

is located in the book, you need only look in the Tablof Contents. Once you have found the where specific procedures are located in that section. Turn to the lnd< at the front of the model specific section. At the upper left-hand side is a listing of the main topics within that section and the page number onvhich they may be found. Following the main topics is an alphabetical listing of all of the procedures within the section and their page numbers.

To find where a particular model specific section

proper section, you

may wish

The Mode! Index, located any vehicle model covered

to find

just after the Table of

in this

manual.

Contents

in

the beginning of this manual,

may

also besed to locate the specific section for

Specifications

Specifications charts for

all

models covered

in this

book are located

Chapter

in

1.

They include: Vehicle and Engine

Identification, General

Engine Specifications, Engine Tune-Up Specifications, Capacities, Valve Specifications, Crankshaft & Connecting Rod Specifications, Piston & Ring Specifications, Engine Fastener Torque Specifications, Brake Specifications, Maintenance Interval Specifications, Ball Joint Specifications

Wheel

&

Tire Specifications,

and Wheel Alignment Specifications.

Unit Repair Sections

the applicable

URS

models for the specific system or component, unless specifically noted othermodel specific sections, therefore refer to the URS for the service procedures for

to cover all applicable

The three Unit Repair Sections are written wise. The procedures covered in the

are not repeated in the

systems or components. Refer

to the Table of

Contents

for

URS

coverage.

Model Specific Sections

The model specific sections are grouped by manufacturer and arranged

in alphabetical order The text anc llustrations that comprise the sermodel specific section are arranged in the following order of systems and components: Engine Repair (Gasoline, then Fuel System (Gasoline, then Diesel if applicable), Drive Train, Steering and Suspension

vice procedures in each

Diesel

if

applicable),

All illustrations

are located as close as possible to the applicable procedure. Procedures are for

all

models

in

the particular section unless

specifically noted otherwise.

Part

Part

Numbers

numbers

listed in this

book are not recommendations by the Publisher

for

any product by brand name. They are references

that

can be

used with interchanges manuals and aftermarket supplier catalogs to locate each brand supplier's discrete part number.

Special Tools

Special tools are

recommended by

the vehicle manufacturer to perform their specific job.

absolutely necessary, they are referred to priate part let.

number, from your

in

the text by the part

number

local dealer or regional distributor, or

Before substituting any tool for the one

recommended, read

Use has been kept to a minimum, but where These tools may be purchased, under the appro-

of the tool manufacturer.

an equivalent tool can be purchased locally from a tool supplier or parts out-

the previous Safety Notice.

ACKNOWLEDGMENTS

This publication contains material that distribution of the Ford

is

reproduced and distributed under a license from Ford Motor Company. No further reproduction or

Motor Company material

is

allowed without the expressed written permission from Ford Motor Company.

Portions of the material contained herein have been reprinted with permission of General Motors Corporation, Service Technology Group.

SPECIFICATIONS GENERAL MOTORS

CHRYSLER CORP. Chrysler Sebring

1-2

Avenger Chrysler Cirrus • Sebring Convertible • Stratus •

Chrysler

LHS

Dodge

300M

1-10

Eagle Vision

1-37

Concours • Eldorado •

1-53

1-61

Ford Contour • Mercury

1-70 1-83

Ford Thunderbird Ford Crown Victoria •

Town Car •

Chevrolet

1-90

ZX2 • 1-100

Mercury Tracer

1-113

LS

1-122

1-132

VIII

SHO

•

Buick Regal • 1998-01 Century •

Supreme •

Intrigue •

Pontiac Grand Prix

GENERAL MOTORS G-BODY

GENERAL MOTORS

Buick Riviera • Oldsmobile

Chevrolet Corvette

1-197

1-274

GEO/CHEVROLET Metro • Prizm

1-284

SATURN

Chevrolet Cavalier • Pontiac Sunfire

1-255

Y-BODY

GENERAL MOTORS

1-210

GENERAL MOTORS

LS • LSI • LS2 • LW1 • LW2 • SCI • SC2 • SL • SL1 • SL2 •

SW1

Chevrolet Malibu • Oldsmobile Cutlass

1-145

1-246

Cutlass

1-187

L/N-BODY

Ford Mustang • Lincoln

Cadillac Catera

Monte Carlo • Oldsmobile

J-BODY

Ford Focus

1-234

Chevrolet Impala • Lumina •

Camaro • Pontiac

Aurora

Mercury Grand Marquis

Mercury Sable

1-174

Seville

Grand Am GENERAL MOTORS V-BODY

GENERAL MOTORS W-BODY

GENERAL MOTORS

Firebird

Cougar & Mystique

Mark

&

F-BODY

Lincoln Continental

Ford Taurus • Taurus

E-

Cadillac DeVille • DeVille

FORD MOTOR CO.

Lincoln

1-158

Pontiac Bonneville

1-23

1-45

PT Cruiser

Eagle Talon

Ford Escort • Escort

Achieva • Alero • Pontiac

K-BODIES

Dodge/Plymouth Neon

Lincoln

LSS

Buick Skylark • Oldsmobile

• Regency •

GENERAL MOTORS

• Concorde •

• Dodge Intrepid •

Chrysler

GENERAL MOTORS N-BODY

&

Buick LeSabre • Park Avenue • Oldsmobile Eighty Eight • Ninety Eight •

Plymouth Breeze

C-

H-BODIES

Coupe • Dodge

1-223

•

SW2

1-297

SPECIFICATIONS

1-2

CHRYSLER CORP.

CHRYSLER CORP. Chrysler Sebring

Coupe

•

Dodge Avenger

ENGINE AND VEHICLE IDENTIFICATION Model Year

Engine

Code©

Liters (cc)

Cvl.

Fuel Sys.

Engine Type

N

2.5 (2497)

152

V6

MFI

Y H

2.0 (1996)

122

14

MFI

V6

MFI

SOHC DOHC DOHC

3.0 (2972)

Cu.

In.

181

Eng. Mfg.

Code©

Year

Mitsubishi

W

1998

Chrysler

X

1999

Chrysler

Y

2000

MFI: Multi-port Fuel Injection

1

2001

DOHC: Double Overhead Camshaft

2

2002

SOHC:

© ©

Single

Overhead Camshaft

8th position ol the Vehicle Identification

Number (VIN).

10th position of VIN. 93461 C01

GENERAL ENGINE SPECIFICATIONS measurements are given

All Engine

Engine

Displacement

Series

Fuel

Horsepower

@

rpm

Year

Model

Liters (cc)

(IDA/IN)

System

1998

Avenger

2.5 (2497)

N

MFI

155 @5500

2.0(1996)

Y

MFI

2.5 (2497)

N

MFI

2.0(1996)

Y

MFI

2.5 (2497)

N

2.0(1996)

Sebring Coupe

Avenger

1999

Sebring Coupe

2.5 (2497)

2.0(1996)

in inches. Net

Net

Torque

@ rpm

Oil

Pressure

Ratio

lbs.)

(in.)

3.29x2.99

140 @6000

130 @4800

3.44x3.27

155 @5500

161

3.29x2.99

140 @6000

@4400 130 @4800

MFI

155 @5500

161

@4400

3.29x2.99

Y N Y

MFI

140 @ 6000

130 @4800

3.44x3.27

MFI

155 @5500

161

@4400

3.29x2.99

MFI

140 @6000

130 @4800

3.44 x 3.27

@4400 @4400

3.29x2.99

9.4:1

3.29x2.99

9.4:1

@4400 @4400

3.29x2.99

9.4:1

3.29x2.99

9.4:1

3.59 x 2.99

Avenger

2.5 (2497)

N

MF!

155 @5500

161

2.5 (2497)

N

MFI

155 @5500

161

Avenger

2.5 (2497)

MFI

155 @5500

161

Sebring Coupe

2.5 (2497)

MFI

155 @5500

161

Sebring

3.0 (2972)

N N H

MFI

200 @5500

20504400

2001-02

Compression

@4400

(ft.

161

Sebring Coupe

2000

Bore x Stroke

9.4:1

©

9.6:1 9.4:1

3.44x3.27

©

9.6:1 9.4:1

d)

9.6:1 9.4:1

©

9.6:1

© © © ©

9.0:1

®

rpm

35-75 @3000 25-80 @3000 35-75 @ 3000

25-8003000 35-75 @3000 25-80 @ 3000 35-75 @ 3000

25-80 @ 3000 35-75 @3000 35-75 @3000 35-75 @3000 35-75 @ 3000

43-100© 3500

Avenger Coupe MFI: Multi-port Fuel Injection

©California -9.0:1 93461 C02

f

SPECIFICATIONS CHRYSLER CORP.

ENGINE TUNE-UP SPECIFICATIONS Idle

Engine

Spark Plug

ignition

Fuel

Speed

Valve

Gap

Timing

Pump

(rpm)

Clearance

(deg.)

Displacement

Engine

Year

Liters (cc)

IDA/IN

(in)

1998

2.0(1996)

Y

0.033-0.038

2.5 (2497)

N Y N N N H

0.039-0.043

1999

2.0(1996) 2.5 (2497)

2000

2.5 (2497)

2001-02

2.5 (2497) 3.0 (972)

NOTE: The

0.033-0.038

0.039-0.043 0.039-0.043 0.039-0.043 0.039-0.043

Vehicle Emission Control Information label often reflects specification changes

© © © © © © © made dunng

(psi)

MT

AT

In.

Ex.

47-50

800

800

HYD HYD HYD HYD HYD HYD HYD

HYD HYD HYD HYD HYD HYD HYD

47-50

—

750

47-50

800

800

— — — —

47-50 47-50 47-50 47-50 production.

The

label figures

750 750 750 750

must be used

if

they

differ

from those

m this chart.

HYD: Hydraulic

©

Basic ignition timing

is

not adjustable.

0*6100

2.5L (VIN N) Engine Firing Order:

1-2-3-4-5-6

Distributor Rotation: Clockwise

GENERATOR TENSIONER PULLEY

PULLEY

COM-

PRESSOR PULLEY 10- 20mm

CRANK SHAFT PULLEY

(0 4-0 Bin)

MB991660 (MICROPHONE) O461G01

Accessory drive belt routing 3.0L engine

For complete service labor times, order the Chilton Labor Guide

—Chrysler

SPECIFICATIONS

1-4

CHRYSLER CORP.

CAPACITIES Engine Oil with

Transmission

Fuel

Cooling

Displacement

Engine

Filter

(Pis.)

Tank

System

Liters (cc)

ID/VIN

(qts.)

Manual

2.0(1996)

Y

4.5

4.2

18.2

16.9

2.5 (2497)

N

4.5

—

18.2

16.9

7.4

2.0(1996)

Y

4.5

4.2

18.2

16.9

7.4

2.5 (2497)

N

4.5

—

18.2

16.9

7.4

2.0(1996)

Y

4.5

4.2

18.2

16.9

7.4

2.5 (2497)

N

4.5

—

18.2

16.9

7.4

2.0(1996)

Y N N N N H

4.5

4.2

18.2

16.9

7.4

18.2

16.9

7.4

18.2

16.9

7.4

18.2

16.9

7.4

18.2

16.9

7.4

8

16.3

8.5

Engine

Avenger

1998

Sebring

Coupe

Avenger

1999

Sebring Coupe

2.5 (2497)

2000

2001-02

Avenger

2.5 (2497)

Sebring Coupe

2.5 (2497)

Avenger

2.5(2497)

Sebring NOTE:

©

All

Coupe

capacities are approximate.

Overhaul

till

Add

3.0 (2972) fluid

capacity with torque converter

gradually and ensure a proper

fluid level is

4.5

— — — —

4.5

4.2

4.5 4.5

4.5

Auto.©

W

(gal.)

7.4

obtained.

empty 93461 cof

VALVE SPECIFICATIONS Engine

Seat

Face

Displacement

Engine

Angle

Angle

Year

Liters (cc)

ID/VIN

(deg.)

(deg.)

1998

2.0(1996)

Y

45-45.5

44.5-45

1999

2001-02

Stem-to-Guide

Stem

Installed

Clearance

Diameter

Pressure

Height

(lbs.

@

in.)

60® 1.496

(ia)

(in.)

(in.)

Intake

Exhaust

Intake

Exhaust

1.496

0.0009-

0.0020-

0.2336-

0.2325-

0.0026

0.0037

0.2343

0.2332

0.0016-

0.2360

0.2360

2.5 (2497)

N

44-44.5

45-45.5

6061.740

1.740

0.0008-

0.0040

0.0060

2.0(1996)

Y

45-45.5

44.5-45

6061.496

1.496

0.0009-

0.0020-

0.2336-

0.2325-

0.0026

0.0037

0.2343

0.2332

0.0008-

0.0016-

0.2360

0.2360

0.0040

0.0060

0.0008-

0.0016-

0.2360

0.2360

0.0040

0.0060

0.0008-

0.0016-

0.2360

0.2360

0.0040

0.0060

0.0008-

0.0016-

0.2400

0.2400

0.0019

0.0027

2.5 (2497)

2000

Spring

Springiest

2.5 (2497)

2.5 (2497)

3.0 (2972)

N

N

N H

44-44.5

44-44.5

44-44.5

44-44.5

45-45.5

45-45.5

45-45.5

45-45.5

6061.740 6061.740

6061.740 6061.740

1.740

1.740

1.740

1.740

93461 C05

© SPECIFICATIONS

1-5

CHRYSLER CORP.

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS measurements are given

All

in inches. Connecting Rod

Crankshaft

Engine Displacement

Engine

Main Brg.

Year

Liters (cc)

ID/VIN

Journal Dia.

1998

2.0(1996)

Y

Main Brg.

Shaft

Thrust

Journal

Oil

Side

Clearance

End-play

on No.

Diameter

Clearance

Clearance

2.0469-

0 0009-

0.0035-

3

1.8894-

0.0010-

0.0051-

2.0475

0.0024

0.0094

1.8900

0.0023

0.0150

0.0020-

3

1.9700

0.0008-

0.0039-

0.0020

0.0098

3

1.8894-

0.0010-

0.0051-

Oil

2.5 (2497)

N

2.3600

0.0008-

0.0016

0.0098

2.0(1996)

Y

2.0469-

0.0009-

0.0035-

2.0475

0.0024

0.0094

2.5 (2497)

N

2.3600

0.0008-

0.0020-

0.0016

0.0098

2000

2.5 (2497)

N

2.3600

0.0008-

0.0020-

0.0016

0.0098

2001-02

2.5 (2497)

N

2.3600

0.0008-

0.0020-

0.0016

0.0098

3.0 (2972)

H

2.00-

0.0008-

0.0020-

2.4000

0.0016

0.0098

1999

1.8900

0.0023

0.0150

3

1.9700

0.0008-

0.0039-

0.0020

0.0098

3

1.9700

0.0008-

0.0039-

0.0020

0.0098

3

1.9700

0.0008-

0.0039-

0.0020

0 0098

3

1.7709-

0.0008-

0.0012-

1.7714

0.0019

0.0270 93461C06

PISTON AND RING SPECIFICATIONS measurements are given in inches.

All

Ring Gap

Engine

Ring Side Clearance

Displacement

Engine

Piston

Top

Bottom

Oil

Year

Liters (cc)

IDA/IN

Clearance

Compression

Compression

Control

1998

2.0 (1996)

Y

2.5 (2497)

1999

2.0

(19%)

2.5 (2497)

2000

2.5 (2497)

2001-02

2.5 (2497)

3.0 (2972)

Y

N N

H

0.019-

0.009-

0.0010-

0.0010-

0.0002-

0.020

0.031

0.026

0.0026

0.0026

0.0070

0.0008-

0.010-

0.016-

0.006-

0.0012-

0.0008-

NA

0.0016

0.016

0.022

0.019

0.0028

0.0024

©

0.009-

0.019-

0.009-

0.0010-

0.0010-

0.0002-

0.0017

0 020

0.031

0.026

0.0026

0.0026

0.0070

0.0008-

0010-

0.016-

0.006-

0.0012-

0.0008-

NA

0.0016

0.016

0.022

0.019

0.0028

0.0024

0.0008-

0.010-

0.016-

0.006-

0.0012-

0.0008-

0.0016

0.016

0.022

0.019

0.0028

0.0024

0.0008-

0.010-

0.016-

0.006-

0.0012-

0.0008-

0.0016

0.016

0.022

0.019

0.0028

00024

0.0003-

0.012-

0.018-

0.008-

0 0012-

0.0018-

0.0008-

0.0090

0.017

0.023

0.019

0.0017

0.0023

0.019

NA: Not Available

© Clearance

at

1

1/16 Inch from the bottom ot the

Oil

Control

0.009-

0.0005-

N

Bottom

Compression Compression

0.0017

0.0005-

N

Top

skirt

Please

visit

our web

site at

www.chiltonsonline.com

NA NA

SPECIFICATIONS CHRYSLER CORP.

1-6

TORQUE SPECIFICATIONS All readings in Engine

Rod

Crankshaft

Head

Bearing

Bearing

Damper

Flywheel

Bolts

Bolts

Bolts

Intake

Year

Liters (cc)

ID/VIN

Bolts

Bolts

1998

2.0(1996)

Y N Y N N N H

©

55

80

69

©

55

80 80 80

2.5 (2497)

1999

2.0(1996) 2.5 (2497)

2000

2.5(2497)

2001-02

2.5 (2497)

3.0(2972)

©

Step

1

:

Faslenere

1

through 6 to 24

Fasteners 7 through 10 to 20

Step

2:

Fasteners

1

Fasteners 7 through

Step

3:

Fasteners

1

Step

4:

©Step Step

Tighten

all

ft.

ft.

lbs.

ft.

lbs.

through 6 to 48 1

0

to

20

ft.

Spark

Lug

Exhaust

Plugs

Nuts 88-103

©

105

70

17

17

20

37

134

68

16

22

18

88-103

©

105

70

17

17

20

88-103

69

37

134

68

16

22

18

88-103

69

37

134

68

16

22

18

88-103

69

37

134

68

16

22

18

88-103

69

37

125

55

17

23

18

80

©

lbs.

through 6 to 48 ft.

lbs.

fasteners 1/4 turn

side bolts to 21 ft

1:20

lbs.

80

©

Man ifold

ft lbs.

Fasteners 7 throught 10 to 20

©Tighten

ft.

lbs.

Main

Engine

Displacement

ft.

Cylinder

lbs.

lbs.

2: 1/4 turn 93461 C08

BRAKE SPECIFICATIONS All

measurements

in inches unless noted Brake Drum Diameter

Brake Disc

Bracket Bolts

Inside

Wear

Machine

Thick-

Thickness

Thickness

Run-out

Diameter

Limit

Diameter

ness

F

0.940

0.880

0.003

—

R

0.390

0.330

0.003

Sebring

F

0.940

0.880

0.003

Coupe

R

0.390

Avenger

F

0.940

0.880

0.003

— © — © —

R

0.390

0.330

0.003

©

Sebring

F

0.940

0.880

0.003

Coupe

R

0.390

Avenger

F

0.940

0.880

0.003

— © — © — © — © — — — — —

Avenger

2000-01

Lining

Maximum

1998

2000-01

Maximum

Minimum

Model

1999

Max.

Original

Year

©

©

0.330

0.330

©

©

0.003

0.003

R

0.390

0.330

0.003

Sebring

F

0.940

0.880

0.003

Coupe

R

Avenger

0.390

©

0.330

©

0.003

F

0.940

0.880

0.003

R

0.390

0.330

0.003

Sebring

F

0.940

0.880

0.003

Coupe

R

0.390

©

0.330

©

0.003

Brake Caliper

Min.

Original

—

© — — — — — — — —

© — © — © —

© — — — — — — — —

—

— —

(ft.

lbs.)

Mounting Bolts (ft lbs.)

0.080

65

54

0.039

—

38

0.080

65

54

0.039

—

38

0.080

65

54

0.039

—

38

0.080

66

54

0.039

—

38

0.080

65

54

0.039

—

38

0.080

66

54

0.039

—

38

0.080

65

54

0.039

—

38

0.080

66

54

0.039

—

38

F: Front

R:

Rear

© Minimum © Maximum

diameter: 9.00

diameter

is

in.

stamped on drum

©Vented

rear disc: 0.790

© Vented

rear disc: 0.720 93461009

6

4 7

SPECIFICATIONS

1-7

CHRYSLER CORP.

WHEEL ALIGNMENT Camber

Caster

Year

Model

1998

ALL

2002

Range

Setting

Axis Toe-in

Inclination

(Deg.)

(W-Deq.)

(Deg.)

(in.)

(Deg.)

+1.50

+4.31

+0.50

0

0+/-0.13

7.31

R

—

—

+0.50

-1.34

0.13+/- 0.13

—

F

+1.50

+4.31

+0.50

0

0+/-0.13

7.31

R

—

—

+0.50

-1.34

0.13+/- 0.13

—

F

+1.50

+4.31

+0.50

0

0+/-0.13

7.31

R

—

—

+0.50

-1.34

0.13+/- 0.13

—

F

+1.50

+4.31-

+0.50

0

0+/-0.13

7.31

R

—

—

+0.50

-1.34

0.13+/- 0.13

—

F

+1.50

+4.31

+0.50

0

0+/-0.13

7.31

R

—

—

+0.50

-1.34

0.13+/- 0.13

—

ALL

2001

Setting

(+/-Deg.)

ALL

2000

Range F

ALL

1999

Steering Preferred

Preferre

ALL

33461C10

TIRE,

WHEEL AND BALL JOINT SPECIFICATIONS OEM

Wheel

Ball Joint

Rear

Size

Inspection

32

29

5.5-J

None

32

29

6.5-JJ

P215/55R16

32

32

6-JJ

None

30

30

6-JJ

None

30

30

5.5-J

Tire Pressures (psi)

Tires

Year

Model

Standard

Optional

1998

Avenger, base

P195/70HR14

P205/55HR16

Avenger ES

P215/50HR17

Sebring JX

P205/65R15

Sebring Jxi

P215/55R16

Sebring LX

P195/70R14

2000

Avenger, base

PI 95/70HR1

Avenger ES

OEM: PSI:

32

29

6-JJ

32

29

5.5-J

P21 5/50HR1

None

32

29

6.5-JJ

Sebring JX

P205/65R15

P215/55R16

30

30

6-JJ

Sebring Jxi

P215/55R16

None

30

30

6-JJ

Sebring LX

P195/70R14

32

29

5.5-J

65-JJ

P205/55HR 1

Sebring Lxi

P215/50R17

None

32

29

Avenger, base

P195/70HR14

P205/55HR16

32

29

5.5-J

Avenger ES

P215/50HR17

None

32

29

6.5-JJ

6-JJ

Sebring JX

P205/65R15

P215/55R16

30

30

Sebring Jxi

P215/55R16

None

30

30

6-JJ

Sebring LX

P195/70R14

P205/55HR16

32

29

5.5-J

6.5-JJ

P215/50R17

None

32

29

Avenger, base

P195/70HR14

P205/55HR16

32

29

5.5-J

Avenger ES

P215/50HR17

None

32

29

6.5-JJ

6-JJ

Sebring

2001-02

None P205/55HR16

P205/55R16

Sebring Lxi

1999

Front

Lxi

Sebring JX

P205/65R15

P215/55R16

30

30

Sebring Jxi

P215/55R16

None

30

30

6-JJ

Sebring LX

P195/70R14

P205/55HR16

32

29

5.5-J

Sebring Lxi

P215/50R17

None

32

29

6.5-JJ

© © © © © © © © © © © © © © © © © © © © © © © ©

Equipment Manufacturer

Original

Pounds Per Square Inch

STD. Standard

OPT: Optional

L

Lower

U:

Upper

©

Replace

It

any measurable movement

is

found 93461 Cl 1

Timing belt service

is

covered

in

Section 3 of this manual

SPECIFICATIONS

1-8

CHRYSLER CORP.

SCHEDULED MAINTENANCE INTERVALS

—Sebring, Dodge—Avenger

Chrysler

VEHICLE MILEAGE INTERVAL TYPE OF

Enqine Coolant Rotate

&

oil

hoses & clamps

level,

tires

Automatic transaxle

30

45

37.5

y

S/I

y

82.5

90

97.5

y

/

/

y

y

y

y

y

y

y

y

y

y

y

y

S/I

y

y

y

y

y

y

y

y

y

y

y

y

y

y y

Brake hoses & disc brake S/I

(xIOOO)

75

y

S/I

fluid level

22.5

y

R

filter

15

7.5

SERVICE

SERVICED

TO BE

60

52.5

'

67.5

pads

& front

Driveshaft boots

y

S/I

suspension components Air

filter

y

S/I

V y

y y y y y

S/I

y

y

y

V y

y y y

S/I

y y y y

S/I

y

y

R

element

Enqine coolant

R

Spark plugs (DOHC)

R

Spark plugs (SOHC)

Accessory drive Ball joints

&

©

R

belts

steering linkage

y y y

y

seals

Exhaust system

S/I

Fuel hoses

S/I

Manual transaxle

PCV

S/I

oil

valve

Rear drum brake

lining

&

rear

y

wheel cylinders

Camshaft timing Ignition

belt

cables

Distributor

cap &

rotor

y y y y

S/I

Fuel system

S/I

Replace

©

y

R S/I

EVAP system

R:

R

S/I:

Service or Inspect

Spark plugs: replace every 100,000 miles.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If

a vehicle

is

operated under any of the following conditions

•

Extremely dusty areas.

•

50%

•

Prolonged idling (vehicle operation

or more of the vehicle operation

is in

In

Frequent short running periods (engine does not

-

Police, taxi, delivery

&

oil filter

is

considered severe service:

32°C (90°F) or higher temperatures, or constant operation

stop and go

-

Oil

it

in

temperatures below 0°C (32°F).

traffic).

warm to normal

operating temperatures).

usage or trailer towing usage.

change: change every 3000 miles.

Disc brake pads: check every 6000 miles. Air

filter

element: change every 15.000 miles.

Automatic transaxle

Rear drum brake

fluid;

linings

change every 15,000

&

rear wheel cylinders:

miles.

check every

1

5,000 miles.

Spark plugs: change every 15,000 miles. 93461C12

SPECIFICATIONS CHRYSLER CORP.

1-9

SCHEDULED MAINTENANCE INTERVALS DAIMLERCHRYSLER CORPORATION CHRYSLER SEBRING (through DODGE AVENGER The In

following should be

estimating

how

t

used as a guide when determining the amount

work required

of

for

a particular service.

long a particular Scheduled Maintenance Service should take, please observe the following:

• • •

Labor Time is time based on field research and data supplied by the vehicle manufacturer Labor time operations are given in hours and tenths of an hour All labor operations are to be used as a guide.

Mechanic

Skill

Level Codes:

(A)

PRECISION: Highly

(B)

GENERAL: Normally skilled with certification MAINTENANCE: Semi-skilled working on certification.

(C)

7500 Mile Service (C) All Models 15000 Mile Service (C) All Models 22500 Mile Service (C) All Models 30000 Mile Service (B) All Models

2000)

skilled with multiple certification.

LABOR

LABOR

TIME

TIME

3 1.5

3 2.1

37500 Mile Service (C) All Models 45000 Mile Service (B) All Models 52500 Mile Service (C) All Models 60000 Mile Service (B) All Models 67500 Mile Service (B) All Models Replace timing belt add

3 1.5

3 2.1

LABOR TIME

75000 Mile Service All Models 82500 Mile Service All Models 90000 Mile Service All Models 97500 Mile Service All Models

(B) 1.5

(C)

3 (B) 2.1

(C)

3

1.3 1 .8 93461CO

Heater Core replacement

is

covered

in Section

2

of this

manual

SPECIFICATIONS

1-10

CHRYSLER CORP.

CHRYSLER CORP. Chrysler Cirrus • Sebring Convertible Dodge Stratus • Plymouth Breeze

•

ENGINE AND VEHICLE IDENTIFICATION Engine

Code©

Liters (cc)

C N

2.0(1996)

Model Year

Code©

Year

Chrysler

W

1998

Mitsubishi

X

1999

Chrysler

Y

2000

Chrysler

1

2001

Chrysler

2

2002

Cyl.

Fuel Sys.

Engine Type

Eng. Mfg.

122

14

MFI

2.5 (2497)

152

V6

MFI

G

2.4 (2351)

148

14

MFI

X

2.4 (2429)

143

14

MFI

U H

2.7 (2736)

167

V6

MFI

3.0 (2972)

181

V6

MFI

SOHC SOHC SOHC DOHC DOHC SOHC

Cu.

In.

Chrysler

MFI: Multi-point Fuel Injection

SOHC:

Single Overhead Camshaft

DOHC: Double Overhead Camshaft

© ®

8th position of

VIN

10th position of VIN 93461C14

SPECIFICATIONS

1.11

CHRYSLER CORP.

>

•

GENERAL ENGINE SPECIFICATIONS All

measurements are given

Engine

Engine

Displacement

Series

Fuel

Horsepower

@ rpm 132@6000

Net

@ rpm 25-80@3000

3.44x3.98

9.4:1

25-80@3000

170@4350 167@4000

3.29x2.99

9.4:1

25-80@3000

3.44x398

9.4:1

25-80@3000

170@4350 129@5000

3.29x2 99

9.4:1

25-80@3000

3.44x3 26

9.8:1

25-80@3000

167 @4000

3.44x3.98

9.4:1

25-80@3000

170@4350

3.29x2.99

9.4:1

25-80@3000

132@6000 150@5200

129@5000 167@4000

3.44x3.26

9.8:1

25-80@3000

3.44x3.98

9

4:1

25-80@3000

168@5800 150@5200 168@5800 132@6000 150@5200 168@5800 150@5200 150@5200 168@5800 168@5800 150@5200 168@5800 150@5200

170@4350 167@4000

3.29x2.99

9

4:1

25-80@3000

3.44x3.98

9.4:1

25-80@3000

170@4350 129@5000 167@4000

3.29x2.99

9.4:1

25-80@3000

3.44x3.26

9.8:1

25-80@3000

3.44x3 98

9.4:1

25'80@3000

170@4350 167@4000 167@4000 170@4350 170@4350 167@4000 170@4350

3.29x2 99

9.4:1

25-80@3000

3 44x3.98

9.4:1

25-80@3000

3 44x3 98

9.4:1

25-80@3000

3.29x2.99

25-80@3000

3 29x2 99

94:1© 94:1©

344x3.98

9.4:1

25-80@3000

167 @4000

3 44x3.98

9.4:1

167 @4000

3 44x3.98

94:1

25-80@3000

MFI

150@5200 168@5800

170@4350

3.29x2 99

9

4:1©

25-80@3000

MFI

168@5800

170@4350

3 29x2.99

94:1©

25-80@3000

MFI

150@5200

167@4000

3 44x3.98

9.4:1

25-80@3000

MFI

168@5800

170@4350

329x299

U

MFI

200@5900

192@4300

3 39x3.09

9.6:1

45-105@3000

G G

MFI

9.5:1

43-100@3500

341x3.94

9.5:1

43-100@3500

MFI

158@4000 158@4000 205@4500 205@4500

3.41x3 94

H H

142@5500 142@5500 200@5500 200@5500

359x2 99

9.0:1

43-1 00@ 3500

359x2.99

90:1

43-100@3500

Cirrus

2.4 (2429)

Cirrus

2.5(2497)

Sebring Convertible

2.4 (2429)

Sebring Convertible

2.5(2497)

Stratus

2.0(1996)

Stratus

2.4 (2429)

Stratus

2.5 (2497)

N

MFI

Breeze

2.0(1996)

MFI

Cirrus

2.4 (2429)

Cirrus

2.5 (2497)

Sebring Convertible

2.4 (2429)

Sebring Convertible

2.5 (2497)

Stratus

2.0(1996)

Stratus

2.4 (2429)

Stratus

2.5 (2497)

Breeze

2.4 (2429)

Cirrus

2.4 (2429)

Cirrus

2.5 (2497)

Sebring Convertible

2.5 (2497)

Stratus

2.4 (2429)

Stratus

2.5 (2497)

Breeze

2.4 (2429)

Cirrus

2.4 (2429)

Cirrus

2.5(2497)

Sebring Convertible

2.5(2497)

C X N X N C X N X X N N X N X X N N

Stratus

2.4 (2429)

Stratus

2.5 (2497)

X N

Sebring Sedan

2.7 (2672)

Coupe

2.4 (2351)

2.4 (2351)

Sebring

Coupe

3.0(2972)

Stratus

Coupe

3.0(2972)

MFI MFI MFI

MFI MFI MFI

MFI MFI MFI MFI MFI MFI

MFI MFI MFI MFI MFI

MFI MFI MFI MFI

MFI

MFI

150@5200 168@5800 150@5200 168@5800 132@6000 150@5200 168@5800

MFI: Multi-point Fuel Injection

®

Pressure

9.8:1

MFI

Coupe

Oil

pression Ratio

System

C X N X N C X

Stratus

Com-

Stroke (in.)

(ID/V1N)

2.0(1996)

Sebring

Borex

3.44x3.26

Liters (cc)

Breeze

2001-02

@rpm

(ft lbs.)

Model

1998

2000

Net

Torque

129@5000 167@4000

Year

1999

in inches.

California: 9.0:1

Brake service

is

covered

in Section

4 of this manual

329x2 99

9.4:1

9

4:1

©

©

25-80@3000 25-80@3000 25-80@3000

25-80@3000

SPECIFICATIONS

1-12

CHRYSLER CORP.

GASOLINE ENGINE TUNE-UP SPECIFICATIONS Idle

Ignition

Engine

Spark Plug

Timing

Fuel

Speed

Valve

Gap

(deg.)

Pump

(rpm)

Clearance

Displacement

Engine

Year

Liters (cc)

1D/VIN

(in.)

MT

AT

1998

2.0(1996)

0.035

©

2.4 (2429)

C X

2.5(2497)

N

0.038-0,043

2.0(1996)

0.035

2.4 (2429)

C X N X

© © © © © © ©

2.5(2497)

N

0.038-0.043

2.4 (2429)

X

0.050

2.4 (2351)

G

0.039-0.043

2.5 (2497)

N

0.038-0.043

2.7 (2672)

U

0.048-0.053

3.0 (2972)

H

0.039-0.043

1999

2.4 (2429) 2.5 (2497)

2000

2001-02

NOTE: The

— — © — — — — — — — © ©

0.050

0.050 0.038-0.043

0.050

Vehicle Emission Control Information label often reflects specification changes

(psi)© 48

49 49 48

49

©

49

made during

47-50

49 58 47-50 production.

© © © © © © © © © © ©

— —

49

© © © ©

AT

© — — ©

49

49

©

NIT

The

label figures

—

© © — © © must be used

© © if

they differ from those

HYD: Hydraulic

© © ©

This reading measured with Ignition timing

vacuum hose disconnected from

cannot be adjusted. Base engine timing

is

fuel

set at

pressure regulator.

TDC during

assembly.

Refer to the Vehicle Emission Control Information label for correct specifications.

r

In.

Ex.

HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD

HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD

in this

chart

SPECIFICATIONS CHRYSLER CORP.

For complete Engine Mechanical specifications, see Section

1

of this

manual

1.10 O

1-14

SPECIFICATIONS CHRYSLER CORP.

CAPACITIES Engine Engine

Oil with

Transmission

Fuel

Cooling

(pts.)

Tank

System (qts.)

Displacement

Engine

Filter

Year

Model

Liters (cc)

ID/VIN

(qts.)

5-Spd

Auto.

(gal.)

1998

Breeze

2.0(1996)

4.5

4.4

16.0

7.4

Cirrus

2.4 (2429)

C X

16.0

9.0

16.0

10.5

Cirrus

2.5 (2497)

N

4.5

Sebring Convertible

2.4 (2429)

X

5.0

Sebring Convertible

2.5 (2497)

N

4.5

— — — —

Stratus

2.0 (1996)

4.4

2.4 (2429)

5.0

Stratus

2.5 (2497)

4.5

— —

Breeze

2.0(1996)

4.5

4.4

Cirrus

2.4 (2429)

Cirrus

2.5 (2497)

C X N C X N

4.5

Stratus

Sebring Convertible

2.4(2429)

X

5.0

Sebring Convertible

2.5 (2497)

4.5

Stratus

2.0(1996)

4.5

4.4

Stratus

2.4 (2429)

Stratus

2.5 (2497)

Breeze

2.4 (2429)

N C X N X

— — — —

Cirrus

2.4 (2429)

5.0

Cirrus

2.5 (2497)

X N

4.5

Sebring Convertible

2.5 (2497)

N

4.5

— — — — — —

Stratus

2.4 (2429)

X

5.0

4.4©

8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8,0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0©

2.4 (2351)

G

4.5

3.1

2.7 (2672)

U N

5.0

4.5

1999

2000-01

Sebring/Stratus

Coupe

Sebring Sedan Sebring/Stratus NOTE:

All

© © Heavy

capacities are approximate.

Overhaul

fill

Coupe Add

fluid

3.0 (2972)

gradually and ensure a proper fluid level

capacity with torque converter empty:

1

5.0

5.0

4.5

5.0

4.5 5.0

is

16.0

9.0

16.0

10.5

16.0

7.4

16.0

9.0

16.0

10.5

16.0

7.4

16.0

9.0

16.0

10.5

16.0

9.0

16.0

10.5

16.0

7.4

16.0

9.0

16.0

10.5

16.0

9.0

16.0

9.0

16.0

10.5

16.0

10.5

16.0

9.0

6.6

16.3

7.4

—

8.0©

16.0

9.5

4.2

8.0

16.3

8.5

obtained.

8.2 pts.

Duty: 5.2 pts. 93461C17

SPECIFICATIONS

-IE

-I

CHRYSLER CORP.

VALVE SPECIFICATIONS Engine Displacement

Engine

Year

Liters (cc)

ID/VIN

1998

2.0(1996)

C

2.4 (2429)

2.5 (2497)

1999

2.0(1996)

2.4 (2429)

2.5 (2497)

2000

2.4 (2429)

2.5 (2497)

2001-02

2.4 (2429)

2.4 (2351)

2.5 (2497)

2.7 (2672)

3.0 (2972)

X N

C X N

X N X

G N U H

Seat

Face

Angle

Angle

-fisau 44.545 45 4544.5

44.545 45

4544.5 45

4544.5 45

4544.5

4544.5

44.545

44.545


1C

SPECIFICATIONS CHRYSLER CORP.

CHRYSLER CORP. Chrysler PT Cruiser ENGINE AND VEHICLE IDENTIFICATION Model Year

Engine

Code©

Liters (cc)

B

2.4 (2429)

Cu.

In.

148

cyi.

Fuel Sys.

L4

SMFI

Engine Type

DOHC

Eng. Mfg. Chrysler

DOHC: Double Overhead Camshaft

©

8th position o(

©10th

Code®

Year

1

2001

2

2002

VIN

position of

VIN 93461 CS7

GENERAL ENGINE SPECIFICATIONS Engine

Engine

Displacement

Series

Fuel

Net

Net

Horsepower Torque

@ rpm

Bore x

Com-

Oil

Stroke

pression

Pressure

Liters (cc)

(IDA/IN)

System

(in.)

Ratio

@ rpm

2001

PT

Cruiser

2.4 (2429)

B

SMFI

1

50(3)5200

164 @4000

3 44x3.98

94:1

25-80@3000

2002

PT

Cruiser

2.4 (2429)

B

SMFI

150(5)5200

164@4000

3 44x3.98

9.4:1

25-80(5)3000

Year

Model

@ rpm

(ft.

lbs.)

SMFI: Sequential Multi-port Fuel Injection

For Tune-up, Capacities and Firing orders, see Section

1

of this

manual

1-46

SPECIFICATIONS CHRYSLER CORP.

ENGINE TUNE-UP SPECIFICATIONS Spark Plug

Engine

Ignition

Fuel

Idle

Valve

Speed

Clearance

(rpm)

In.

Ex.

© ©

HYD

HYD

HYD

HYD

Displacement

Engine

Gap

Timing

Pump

Year

Liters (cc)

IDA/IN

(in.)

(deg.)

(psi)

2001

2.4 (2429)

B

0.048-0.053

49

2002

2.4 (2429)

B

0.048-0.053

© ©

NOTE: The Vehicle Emission HYD:

© ©

Control Information label often reflects specification

changes made during production

49 The

label figures

must be used

if

they differ from those

in this chart.

Hydraulic

Ignition liming is regulated

Idle

speed

is

by the Powertrain Control Module (PCM), and cannot be adjusted.

controled by the Powertrain Control Module (PCM), and cannot be adjusted. 33461C59

t

SPECIFICATIONS

1I _/|7 ** I

CHRYSLER CORP.

CAPACITIES Power

Rear

Oil with

Automatic

Transfer

Drive

Engine Engine

Fuel

Cooling

Displacement

Engine

Filter

Transaxle

Unit

Axle

Tank

System

Liters (cc)

IDA/IN

(qts.)

(qts.)

(qts.)

(pts.)

(gal.)

(qts.)

4.5

20.0

9.5

4.5

20.0

9.5

Model

Year 2001

PT

Cruiser

2.4 (2429)

B

2002

PT

Cruiser

2.4 (2429)

B

NOTE:

All

© 31TH ©

capacities are approximate.

Add

fluid

© ©

gradually and check to be sure a proper fluid level

overload

fill

capacity with torque converter empty: 8 5 qts.

41TE overhaul

fill

capacity with torque converter empty: 9.1 qts

is

© ©

1.22

1.22

obtained

Overrunning clutch: 0 75 pts 93461 CEO

VALVE SPECIFICATIONS Engine

Seat

Face

Spring

Stem-to-Guide

Stem

Spring Test

Installed

Clearance

Diameter

Pressure

Height

Displacement

Engine

Angle

Angle

Year

Liters (cc)

IDA/IN

(deg.)

(deg.)

2001

2.4 (2429)

B

45

44.5-

129-143@

45.0

1.17

44.5-

129-143@

45.0

1.17

2002

©

2.4 (2429)

B

45

(lbs.

@

in.)

(in.)

(in.)

(in.)

Intake

Exhaust

Intake

Exhaust

1.50

0 0018-

0.0029-

0.2340

0.2330

00025

0.0037

0.0018-

0.0029-

0 2340

0.2330

0.0025

0.0037

1.50

Intake valve 44 5 degrees

Exhaust valve: 45 degrees 904E1C6'

For complete service labor times, order the Chilton Labor Guide

SPECIFICATIONS

1-48

CHRYSLER CORP.

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS All

measurements are given

in inches. Connecting Rod

Crankshaft

Engine Displacement

Engine

Main Brg.

Shaft

Thrust

Journal

Oil

Side

Clearance

End-play

on No.

Diameter

Clearance

Clearance

2

1.9670-

0.0009-

0.0051-

1.9685

0.0027

0.0150

1.9670-

0.0009-

0.0051-

1.9685

0.0027

0.0150

Main Brg.

Oil

Year

Liters (cc)

IDA/IN

Journal Dia.

2001

2.4 (2429)

B

2.3610-

0.0007-

0.0035-

2.3625

0.0023

0.0094

2.3610-

0.0007-

0.0035-

2.3625

0.0023

0.0094

2002

B

2.4 (2429)

2

93461 C62

PISTON AND RING SPECIFICATIONS measurements are given in inches.

All

Ring

Engine

Gap

Ring Side Clearance

Top

Displacement

Engine

Piston

Top

Bottom

Oil

Year

Liters (cc)

IDA/IN

Clearance

Compression

Compression

Control

2001

2.4 (2429)

B

0.0009-

0.0098-

0.0090-

0.0098-

0.0011-

0.0011-

0.0022

0.0200

0.0180

0.0250

0.0031

0.0031

0.0070

0.0009-

0.0098-

0.0090-

0.0098-

0.0011-

0.0011-

0.0004-

0.0022

0.0200

0.0180

0.0250

0.0031

0.0031

0.0070

2002

®

Oil control ring

2.4 (2429)

side

rails

must be

B

free lo rotate after

Bottom

Compression Compression

Oil

Control 0.0004-

assembly 93461 C63

SPECIFICATIONS

1-49

CHRYSLER CORP.

TORQUE SPECIFICATIONS All readings in Engine

lbs.

ft.

Cylinder

Main

Rod

Crankshaft

Displacement

Engine

Head

Bearing

Bearing

Damper

Flywheel

Spark

Lug

Year

Liters (cc)

ID/VIN

Bolts

Bolts

Bolts

Bolts

Bolts

Intake

Exhaust

Plugs

Nuts

2001

2.4 (2429)

B

© ©

20

17

20

100

B

© ©

70

2.4 (2429)

© ©

100

2002

100

70

20

17

20

100

©Step Step

1:25 2:

ft

50 Jt

Step 3:50

ft.

©M8

lbs

Ml

lbs.

®

lbs.

Step 4 Plus 1/4 turn

20

bolts:

1

bolts:

Manifold

ft lbs

30 ft.

lbs plus 1/4 turn

Step

1

20 ft

Step

2:

Plus 1/4 turn

lbs

93461 C64

BRAKE SPECIFICATIONS All

measurements

in inches unless noted Brake Drum Diameter

Brake Disc

2001

2002

PT

PT

Cruiser

Cruiser

Max.

Lining

Guide

Original

Minimum

Maximum

Inside

Wear

Machine

Thick-

Thickness

Thickness

Run-out

Diameter

Limit

Diameter

ness

(ft lbs.)

F

0 902-0.909

0.803

0.005

—

—

—

0.313

26

R

0.344-0.364

0.285

0.005

863-8 65

NA

NA

©

16

F

0.902-0 909

0.803

0.005

-

—

—

0.313

26

R

0.344-0 364

0.285

0.005

8.63-8 65

NA

NA

©

16

©Rear Disc

NA: Not Available

0 350

in

F: Front

Rear Bonded Shoes 0 062

in

Rear

Rear Riveted Shoes 0 031

in.

R:

Maximum

Caliper

Pin Bolts

Model

Year

Original

Min.

Please

visit

our web

site at

www.chiltonsonline.com

6

SPECIFICATIONS

1-50

CHRYSLER CORP.

WHEEL ALIGNMENT Camber

Caster Preferred

PT

2001

PT

2002

Cruiser

Cruiser

Axis

Range

Setting

Range

Setting

Toe-in

Inclination

(+/-Deg.)

(Deg.)

(+/-Deg.)

(Deg.)

(in.)

(Deg.)

F

+1.00

+2.45

+0.40

0.00

R

—

-

+0.40

F

+1.00

R

—

Model

Year

Steering Preferred

LO

—

0.00 + 0.40

N/A

+0.20

+0.00 + 0.40

N/A

+0.40

0.00

0.00+0.40

N/A

+0.40

+0.20

+0.00+0.40

N/A

N/A: Not Available 93461 C66

TIRE,

WHEEL AND BALL JOINT SPECIFICATIONS

OEM

Tire Pressures (psi)

Tires

Wheel

Ball Joint

Inspection

Rear

Size

2001

PT Cruser

P205/55R1

None

32

32

5.5-J

2002

PT Cruser

P205/55R16

None

32

32

5.5-J

Model

Year

OEM: PSI:

Original

Standard

Optional

Front

© ©

Equipment Manufacturer

Pounds Per Square Inch

© Replace

if

any measurable movement

is

found 93461 C67

SPECIFICATIONS CHRYSLER CORP.

1

EH

SCHEDULED MAINTENANCE INTERVALS Chrysler

— PT Cruiser VEHICLE MILEAGE INTERVAL

TYPE OF SERVICE

TO BE SERVICED Engine

&

oil

lev^l,

22.5

30

45

37.5

52.5

R

filter

Brake hoses Coolant

15

7.5

S/I

hoses &

(xIOOO)

60

67.5

75

82.5

90

97.5

y y

y y

y y

y y

y

y y

S/I

y

y

y

y

y

y

y

S/I

V

y

y

y

y

y

y

y y y

y y y y

y y y

y y y y

y y y

y y y

y y y

y y y y y y y y

S/I

V

V

R

y

clamps

CV joints & front

suspension

components Exhaust system

Rotate

S/I

Brake

S/I

linings

R

Lubricate ball joints

Engine coolant

S/I

©

R

PCV valve cables

Camshaft timing R: Replace

© ®

y

R

element

Spark plugs

Ignition

y

/ y

S/I

tires

filter

y

S/I

oil

Accessory drive belts

Air

y

S/I

Manual transaxle

S/I:

belt

®

R

Service or Inspect

Engine coolant flush and replace

at

Camshaft timing

20.000 miles

belt:

replace at

1

100,000 miles.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If

a vehicle I* operated under any of the following conditions

•

Extremely dusty areas.

•

50%

•

Prolonged

•

Frequent short running periods (engine does not

•

Police, taxi, delivery

Oil

&

or

oil filler

Rotate

Brake Air

more of the vehicle operation

tires

usage or

trailer

la

considered severe service:

32°C (90°F) or higher temperatures, or constant operation

Idling (vehicle operation In stop

and go

In

temperatures below 0*C (32*F).

truffle).

warm

to normal operating temperatures).

towing usage.

change: change every 3000 miles

every 6000 miles

linings: inspect

filter

is In

It

every

1

2,000 miles.

element: service or inspect every 15,000 miles

Automatic transaxle: change

Manual transaxle

fluid:

fluid

&

adjust

bands every 15.000 miles

replace every 15,000 miles

Engine coolant: replace

at

36,000 miles and every 30,000 miles thereafter

9)461 css

Timing belt service

is

covered

in

Section

3

of this

manual

1-52

SPECIFICATIONS CHRYSLER CORP.

SCHEDULED MAINTENANCE INTERVALS DAMILERCHRYSLER CORPORATION CHRYSLER PT CRUISER The In

following should

estimating

how

be used as a guide when determining the amount

• • •

work required

for

a particular service.

Labor Time is time based on field research and data supplied by the vehicle manufacturer. Labor time operations are given in hours and tenths of an hour. All labor operations are to be used as a guide.

Mechanic

Skill

Level Codes:

(A)

PRECISION: Highly

(B)

GENERAL: Normally skilled with certification. MAINTENANCE: Semi-skilled working on certification.

(C)

7500 Mile Service (C) All Models 15000 Mile Service (C) All Models 22500 Mile Service (C) All Models 30000 Mile Service (B) All Models

of

long a particular Scheduled Maintenance Service should take, please observe the following:

skilled with multiple certification.

LABOR

LABOR

TIME

TIME

37500 Mile Service 7 9 8 1.5

All

Models

45000 Mile Service All Models 52500 Mile Service All Models 60000 Mile Service All Models 67500 Mile Service All

(C)

Models

7 (C) 1.0 (C)

9 (B) 1.9

LABOR TIME

75000 Mile Service All Models 82500 Mile Service All Models 90000 Mile Service All Models 97500 Mile Service All Models ..

(C)

9 (C)

9 (B) 1.9

(C)

7

(C)

8 93461C69

SPECIFICATIONS CHRYSLER CORP.

1

EQ

vJU

CHRYSLER CORP. Eagle Talon ENGINE AND VEHICLE IDENTIFICATION Engine

Code

©

Cu.

Liters (cc)

F *

Y

In.

Model Year

Cyl.

Fuel Sys.

Engine Type

Eng. Mfg.

Code©

Year

DOHC DOHC

Mitsubsihi

W

1998

2.0(1997)

122

4

MFI Turbo

2.0(1996)

122

4

MFI

Chrysler

MFI: Multi-port Fuel Injection

DOHC: Double Overhead Camshaft

©

8th digit of the Vehicle Identification

©10th

digit of

the

Number

(VIN)

VIN 93461 C70

GENERAL ENGINE SPECIFICATIONS All

measurements are given

Engine

Engine

Displacement

Series

Year

Liters (cc)

(IDA/IN)

System

1998

2.0(1997)

F

MFI-Turbo

©

2.0(1996)

Y

MFI

140@6000

MFI

in inches. Net

Net Fuel

Torque

Horsepower

@

rpm

rpm

Bore x

Com-

Oil

Stroke

pression

Pressure

@ rpm

(in-)

Ratio

(?)

335x3 46

8.5:1

@4800

3.44x3.27

9.6:1

(ft.

131

@

lbs.)

©

Multi-port Fuel Injection

©Automatic 205® 6000

2100 6000

Manual:

©Automatic: 2200 3000

21403000

Manual:

® ©

1 1

4 psi or more at curb

40

psi or

more

at

curb

idle

idle

speed

speed 3461CM

Heater Core replacement

is

covered

in

Section

2

of this

manual

4 I

"U 4!

SPECIFICATIOMS CHRYSLER CORP

ENGINE TUNE-UP SPECIFICATIONS Idle

Ignition

Engine Displacement

Engine

Spark Plug

Timing

Fuel

Speed

Valve

Gap

(deg.)

Pump

(rpm)

Clearance

Year

Liters (cc)

ID/VIN

(in.)

MT

AT

1998

2.0(1997)

F

0.028-0.030

5B

5B

2.0(1996)

Y

0.033-0.038

©

©

NOTE: The

Vehicle Emission Control Information label often reflects specification changes

HYD: Hydraulic

© ©

Pressure

at idle with

Basic ignition timing

vacuum is

applied to fuel pressure regulator

not adjustable

made

(psi)© 33

AT 750

800

800

38 during production.

MT 750

The

label figures

must be used

if

they

differ

In.

Ex.

HYD HYD

HYD HYD

from those

in this chart.

SPECIFICATIONS

CC

1

CHRYSLER CORP.

CAPACITIES Engine

Engine

Oil with

Transmission (pts.)

Drive

Displacement

Engine

Filter

Axle

Fuel

Cooling

Year

Liters (cc)

ID/VIN

(qts.)

5-Spd

Auto.

(qts.)

Tank

System

1998

2.0(1997)

F

4.6

©

14.2

1.8

16.0

7.4

2.0(1996)

Y

4.5

4.2

182

—

16.0

7.4

NOTE:

All

©2WD 4WD:

capacities are approximate

Add

fluid

gradually and ensure a proper

fluid level is

obtained

4.6 4.8 93461 C73

VALVE SPECIFICATIONS Engine

Seat

Face

Displacement

Engine

Angle

Angle

Year

Liters (cc)

ID/VIN

(deg.)

(deg.)

1998

2.0(1997)

F

44-44 5

45-45.5

2.0(1996)

Y

45

Spring

Stem-to-Guide

Stem

Spring Test

Installed

Clearance

Diameter

Pressure

Height

(lbs.

44.5-45

@

in.)

5461.570 123-137© 1.153

(in.)

(in.)

(in.)

Intake

Exhaust

Intake

Exhaust

1.570

0.0008-

0.0020-

0.2600

0.2560

0.0040

0 0060

0.0019-

0.0029-

0.2336-

02325-

0 0030

0 0040

0.2343

0.2332

1.496

93461 C 74

Brake service

is

covered

in

Section 4 of this manual

1-56

SPECIFICATIONS CHRYSLER CORP.

CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS All

measurements are given

in inches. Connecting Rods

Crankshaft

Engine

Main Brg.

Shaft

Thrust

Journal

Oil

Side

Clearance

End-play

on No.

Diameter

Clearance

Clearance

0.0008-

0.0020-

3

1.7700

0.0008-

0.0039-

0.0016

0.0071

2.0469-

0.0009-

0.0035-

2.0475

0.0024

0.0094

Displacement

Engine

Main Brg.

Year

Liters (cc)

IDA/IN

Journal Dia.

1998

2.0(1997)

F

2.2400

Y

2.0(1996)

Oil

3

0.0020

0.0098

1.8894-

0.0010-

0.0051-

1.8900

0.0023

0.0150 93461 C75

PISTON AND RING SPECIFICATIONS measurements are given

All

Ring

Engine

in inches.

Gap

Ring Side Clearance

Displacement

Engine

Piston

Top

Bottom

Oil

Year

Liters (cc)

IDA/IN

Clearance

Compression

Compression

Control

1998

2.0(1997)

F

0.0012-

0.0098-

0.0157-

0.0039-

0.0016-

0.0008-

0.0020

0.0138

0.0217

0.0157

0.0031

0.0024

0.0089

0.0005-

0.0090-

0.0190-

0.0090-

0.0010-

0.0010-

0.0002-

0.0017

0.0200

0.0310

0.0260

0.0026

0.0026

0.0070

2.0(1996)

Y

Top

Bottom

Compression Compression

Oil

Control 0.0005-

93461 C76

f

SPECIFICATIONS CHRYSLER CORP.

C7

1

*

TORQUE SPECIFICATIONS All readings in Engine

ft.

lbs.

Cylinder

Main

Rod

Crankshaft

Displacement

Engine

Head

Bearing

Bearing

Damper

Flywheel

Year

Liters (cc)

ID/VIN

Bolts

Bolts

Bolts

Bolts

Bolts

Intake

Exhaust

1998

2.0(1997)

F

© ©

94

94-101

14

Y

© ©

©

2.0(1996)

105

—

17

©Step

1:58

ft.

55

Bolts 1-6:

loosen

24

Step

3: 15*ft lbs

Step

4:

Plus 90 degrees

Step

5:

Repeat Step 4

Bolts 1-6

©Step

1:

18

Bolts 7-10: 20

Step

2:

Plus 90 degrees

14.5 ft

lbs.

20

Bolts 7-10:

Step

lbs.

plus

Nuts

18-22

18

65-80

17

20

65-80

ft lbs

2: Fully

®

Lug

Plugs

©Stepl:

lbs.

Step

ft.

Spark

Manifold

Step

© 20

90 degrees

ft lbs

2:

3:

49

ft lbs

ft.

lbs

Plus 90 degrees

ft lbs

plus

90 degrees 93461077

All

BRAKE SPECIFICATIONS measurements in inches unless noted Bake Caliper Brake Disc

Year

Model

1998

Talon

F:

Front

R:

Rear

Minimum

Bracket

Mounting

Original

Minimum

Maximum

Lining

Bolts

Bolts

Thickness

Thickness

Runout

Thickness

(fibs.)

(fibs.)

F

0940

0.882

0 003

0.080

65

54

R

0.390

0.331

0.003

0.080

—

38

93461078

For complete Engine Mechanical specifications, see Section

1

of this

manual

SPECIFICATIONS

1-58

CHRYSLER CORP.

WHEEL ALIGNMENT Camber

Caster Preferred

Year

Model

1998

Talon©®

F

Talon©© Talon©

©

Range

Setting

Range

Setting

(+/-Deg.)

(D^)

(+/-Deq.)

1.50

+4.69

0.50

Axis Toe-in

Inclination

(Deg.)

(in.)

(Deg.)

-0.08

0+/- 0.12

R

—

—

0.50

+1.30

—

F

1.50

+4.69

0.50

-0.35

0+/- 0.13

R

—

—

0.50

-1.69

0.13+/- 0.13

F

1.50

+4.69

0.50

-0.08

0+/- 0.12

R

—

—

0.50

+1.30

—

—

— — —

Front wheel drive

©With

©With

@

Steering Preferred

All

14 inch wheels

16 inch wheels

wheel drive 93461 C79

TIRE,

WHEEL AND BALL JOINT SPECIFICATIONS

OEM Year 1998

OEM: PSI:

Wheel

Ball Joint

Rear

Size

Inspection

Tire Pressures (psi)

Tires

Model

Standard

Optional

Talon ESi

Front

P195/70HR14

None

32

29

5.5-JJ

Talon TSi

2wd

P205/55VR16

None

32

29

6-JJ

Talon TSi

4wd

P215/50VR17

None

32

29

6.5-JJ

© © ©

Onginal Equipment Manufacturer

Pounds Per Square Inch

© Torque

required

in

inch lbs. to rotate ball joint

when removed from

the knuckle 93461 ceo

SPECIFICATIONS CHRYSLER CORP.

1-59

SCHEDULED MAINTENANCE INTERVALS Eagle

—Talon

VEHICLE MILEAGE INTERVAL

TO BE SERVICED Engine Coolant Rotate

&

oil

(Non-turbo)

filter

level,

TYPE OF SERVICE

7.5

15

R

y

S/I

y y y y V

S/I

y

©

hoses & clamps

Automatic fransaxle

fluid level

&

Driveshaft boots

front

y y

45

52.5

60

67.5

75

82.5

90

y

y

y y y y y y y y

y y y y y y y

S/I

y y y y y y y y

S/I

y

y

S/I

y

y y y y

suspension

y

y

97.5

y y y

y y

y

S/I

Brake hoses & disc brake pads

y y y y y

37.5

y y y

V

S/I

y

30

y y y y

S/I

tires

22.5

(xIOOO)

components Air

R

element

filter

Automatic transaxle

fluid

R

& filter©

R R

Engine coolant

Spark plugs

Accessory drive belts

&

Ball joints

S/I

steering linkage seals

S/I

Exhaust system

S/I

Fuel hoses

Manual transaxle

(including

oil

transfer)

Rear axle

oil

(AWD)

Camshaft timing

R

belt

R

cables

Ignition

EVAP & fuel system R: Replace

Service or Inspect

S/I:

(D

Engine

@

Turbo w/A/T only

oil

&

S/I

(Turbo):

filter

change every 5000 miles

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If

a vehicle is operated

under any of the following conditions

it

is

considered severe service:

Extremely dusty areas •

50%

-

Frequent short running periods (engine does not

or

more

of the vehicle operation

Police, taxi, delivery Oil

&

Air

filter

filter

usage or

trailer

is in

32°C (90°F) or higher temperatures, or constant operation

warm

to

in

temperatures below O'C (32*F)

normal operating temperatures).

towing usage.

change: change every 3000 miles

element: service or inspect every 7500 miles

Automatic transaxle

fluid:

change every 15,000 miles

Spark plugs: change every 15,000 miles Disc brake pads: check

more

frequently than every

7500 miles 3M6!Cai

For Accessory Drive Belt

illustrdtions,

see Section

1

of this

manual

1-60

SPECIFICATIONS CHRYSLER CORP.

SCHEDULED MAINTENANCE INTERVALS DAIMLERCHRYSLER CORPORATION EAGLE TALON The In

following should be

estimating

how

used as a guide when determining the amount

• • •

work required

for a particular service.

Labor Time is time based on field research and data supplied by the vehicle manufacturer. Labor time operations are given in hours and tenths of an hour. All labor operations are to be used as a guide.

Mechanic

Skill

Level Codes:

(A)

PRECISION: Highly

(B)

GENERAL: Normally skilled with certification. MAINTENANCE: Semi-skilled working on certification

(C)

7500 Mile Service (C) All models 15000 Mile Service (B) All models 22500 Mile Service (C) All models 30000 Mile Service (B) All models

of

long a particular Scheduled Maintenance Service should take, please observe the following:

skilled with multiple certification.

LABOR

LABOR

TIME

TIME

6 1.9

6 2.1

37500 Mile Service All models 45000 Mile Service All models 52500 Mile Service All models 60000 Mile Service All models 67500 Mile Service All models

(C)

6 (B) 1.9

(C)

6 (B) 2.4

LABOR TIME

75000 Mile Service (B) All models 82500 Mile Service (C) All models 90000 Mile Service (B) All models 97500 Mile Service (C) All models

1.9

6 2.1

6

(C) :...

.6 93461 C82

f

SPECIFICATIONS FORD MOTOR CO.

FORD MOTOR

C-f

1I

U

I

CO.

Lincoln Continental ENGINE AND VEHICLE IDENTIFICATION Model Year

Engine

Code® V

Cu.

Liters (cc)

In.

Cyl.

FuelSys.

Engine Type

Eng. Mfg.

8

SFI

DOHC

Ford

281

4.6 (4593)

Code©

Year

W

1998

OHV: Overhead Valves

X

1999

DOHC: Double Overhead Camshafts

Y

2000

SFI: Sequential Fuel Injection

1

2001

2

2002

® ©

8th digit ol the Vehicle Identification

Number

10th digit ol the Vehicle Identification

(VIN)

Number

(VIN) 93461 C$3

GENERAL ENGINE SPECIFICATIONS Fuel

Net

Displacement

Engine

System

Horsepower

Engine

Net

Torque

6 rpm

Bore x

Com-

Oil

Stroke

pression

Pressure

(in.)

Ratio

6 rpm

Year

Model

Liters (cc)

IDA/IN

Type

0 rpm

1998

Continental

4.6 (4593)

V

SFI

260@5750

27063000

3.55x3.54

9.8:1

3361500

1999

Continental

4.6 (4593)

V

SFI

27565750

275 6 4750

3.55x3.54

9.8:1

3361500

SFI

275 6 5750

275 6 4750

3.55x3.54

9.8:1

3361500

SFI

275 6 5750

27564750

3.55x3.54

9.8:1

3361500

2000

Continental

4.6 (4593)

V

2001

Continental

4.6 (4593)

V

For

Tire,

Wheel and Ball Joint

(ft.

lbs.)

specifications, see Section

1

of this

manual

SPECIFICATIONS FORD MOTOR CO.

1-62

ENGINE TUNE-UP SPECIFICATIONS Engine

Spark Plug

Ignition

Fuel

Idle

Valve

Displacement

Engine

Gap

Timing

Pump

Speed

Liters (cc)

ID/VIN

(in.)

de 9)
ARK

BRAKE

ANCHOR SPRING

ANCHOR

PLATE

SHOE 93006G13

15. 16.

Install the Install

shoe-to-shoe spring.

the retainer spring.

Kelsey Hayes rear brake assembly

(left

side

shown)— Neon

BRAKES

4-11

CHRYSLER CORP.

discoloration or distorted end coils. Replace

UPPER RETURN WHEEL CYLINDER AUTOMATIC SPRING ADJUSTER MECHANISM LEADING SPRING BRAKE SHOE TRAILING BRAKE HOLD SHOE

DOWN

parts as required.

run-out and diameter.

HOLD

must not exceed

(0.064mm)

BRAKE SUPPORT

maximum To

in

0.0025

30 degrees

surface

in.

rotation, or

360 degrees

in

rota-

brake drums are marked with the

drum diameter

allowable brake

on the face

of the

drum.

install:

Lubricate the 8 brake shoe contact

PARK BRAKE

points with high-temperature grease.

LEVER

used on the rear brakes

•The

brake shoe assemblies

trailing

are unique to the

LOWER RETURN SPRING

PLATE

drum

not to specification,

drum braking

either

(0.089mm)

in.

13.

ANCHOR

If

(0.15mm). The diameter variation

in.

(oval shape) of the

tion. All

DOWN CUP

BRAKE SHOE

for cracks or

reface the drum. Run-out should not exceed

0.006

0.0035

CLIP

drums

Inspect the brake

12.

signs of overheating. Measure the

left

of this vehicle

and

right side of

the vehicle. Care must be taken to

ensure the brake shoes are properly Varga rear wheel brake assembly

side shown)

(left

—

Cirrus, Sebring

Coupe. Stratus. Breeze

installed in their correct side of the

vehicle.

shaped prytool through the auto-

larly

matic adjuster access hole and engage

Then

the teeth on the adjuster quadrant.

When

the trailing shoes are

to the trailing

brake shoe assembly. Do

properly installed on their correct side

not attempt to

remove

of the vehicle, the

it

from the

origi-

shoe assembly or reuse the

nal brake

park brake actuating

lever will be positioned under the

rotate the quadrant so the teeth of the

original actuating lever on a replace-

brake shoe web.

quadrant are moved toward the front of

ment brake shoe assembly. All replacement brake shoe assemblies for this vehicle must have the actuating lever as part of the trailing brake shoe

onto the parking brake lever and

the vehicle. This will back off the adjust-

ment

of the rear

brake shoes.

Continue moving the quadrant

c.

toward the front of the vehicle

until

it

the

drum from

the

hub

the parking brake cable from

the parking brake lever.

the actuating spring from the

Do

not

remove the

mechanism and trailing Remove the upper return

adjuster

brake shoe spring from

Install the

assembly

Make sure

to the

rotating

it

leading shoe and

brake support plate

the leading brake shoe

is

Remove the automatic adjuster mechanism from the brake shoe by fully

squarely seated on the brake support plate

extending the adjuster and rotate the

retainer

10.

4.

Reinstall the automatic sell-adjuster

adjuster

16

install the

brake shoe and attaching pin

inward to attach.

from the brake shoe.

lever

Remove

15

Remove

assembly. 3.

Reinstall the parking brake cable

on the leading brake shoe by 9

Remove

4

trailing

assembly.

stops moving. 2.

1

shoe contact areas, and

on the

install the

brake

pm.

retainer

the brake shoes. 5.

Remove

adjuster out to release from the brake shoe. the lower return spring from

To inspect: 1 1

Remove

the brake

shoe

retainer

Thoroughly clean

.

and lining

pin attaching the leading brake

shoe assem-

should show contact across the entire

replace. Clean

Remove the leading brake shoe and adjuster mechanism as an assembly

The brake

parts

all

width and from heel to toe: otherwise,

bly to the brake support plate

and inspect the brake sup-

7.

the

from the rear brake support

port plate

and the automatic adjuster mech-

anism. Be sure the quadrant (toothed part) of the adjuster is free to rotate

adjuster

mechanism cannot be separated its

from the leading brake shoe

until the

removed from the support 8

Remove

entire tooth contact range

is

shoe

trailing

should be

brake adjuster

Remove

its

pin.

attached to the adjuster

and pin attaching the

shoe assembly

length of

Check the knurled

teeth retainer

full

plate.

the trailing brake

to the

spring are unique to the side of the vehicle they are used on. The springs

are colored for identification. The

throughout

and

is free

is

in

It

mounting

18

to

should be securely

mechanism and

good condition.

If

worn or damaged, replace

leading brake shoe

its

brake shoe.

If

the trailing brake shoe

19

the it.

the trailing brake

left

side)

on the

then on the trailing

Reinstall the self-adjuster spring first

then attach

on

it

is

serviceable, lubricate lightly

to

the adjuster.

shoe assembly.

this vehicle, the parking is

first,

brake support plate. the adjuster

actuating lever

Reinstall the upper return spring

(blue, right side, green,

slot

with high-temperature grease between the

•On

left

side springs are green and the right

brake slide the

shoe and the adjuster mechanism

upper brake shoe return spring and adjuster mechanism actuating

side springs are blue.

The

plate.

Reinstall the lower return spring

•The

the brake shoes. 6.

17.

brake

permanently attached

strut

and the quadrant. Check the brake

springs. Overheating indications are paint

For complete Engine Mechanical specifications, see Section

20.

Reinstall the rear brake

21.

Reinstall the wheel

and

the lug nuts in a star pattern

1

of this

manual

drums. tire.

Torque

sequence

to

n

BRAKES

4"i L

CHRYSLER CORP.

I

about 45

and

pattern

Nm), then repeat the

lbs. (61

ft.

final

torque to

95-100

lbs.

ft.

(129-135 Nm). the brake pedal. Brake shoe adjustment

occur the

first

0.006

through the access hole and engage the

(oval shape) of the

teeth

time the brake pedal

ground. This

will

2.

against the braking surface of the rear brake

of

will

3.

not require any type

manual adjustment.

Road

23.

test vehicle to

check

for

away from off

the

the adjustment

proper

the

the

hub

are

the adjusting lever actuating

To

Remove

14.

Thread the adjuster starwheel

which

into the adjuster,

a 2-shoe leading/trailing

self-adjuster

mechanism used on

this

the screw type adjuster.

The

all

the

remove

will

all

Remove

the upper

is

Remove

shoe assembly

is

the brake

shoe hold-down

drum brakes

mechanism do

the

8.

Gen-

the event that

in

install:

Lubricate the 6 brake shoe contact

15.

Reinstall the

wave washer on the

pivot pin of the parking brake actuating

16.

Install the trailing

brake shoe onto

ating lever. 17.

is

Remove

the automatic adjuster from

and

trail-

the brake

Remove

the retaining clip securing

ing brake shoe. 10.

adjustment time. The

down

Remove

shoe hold-

spring and pin attaching the trailing

1 1

Remove

the trailing brake

shoe from

the brake support plate

only one side of the vehicle at a time.

shoe from the parking brake actuating

automatic adjustment

feature of the parking brake system. the brake shoes are

same

the automatic adjuster will

time,

remove

all

slack from the parking brake cables,

make brake shoe

installation

difficult.

Locate and remove the rubber plug

a.

from the brake support plate (backing

lever.

Insert a brake adjuster tool or simi-

shaped prytool through the auto-

matic adjuster access hole and carefully lever out of

engagement with the adjuster starwheel. While holding the lever away from the

shoe and the parking

brake actuating 20.

lever.

Place the leading brake shoe onto

12.

Clean

and

install the

parts well.

all

21.

Reinstall the lower

The brake

lining

22.

and from heel

brake shoe.

to toe; otherwise, replace.

Clean and inspect the brake support plate

and the automatic adjuster mechanism. Be sure the adjuster

is

If

damaged, replace

free to rotate

the adjuster it.

If

is

as to interfere with the installation of the

brake drum.

the adjuster

are paint discoloration or distorted

is

or

ser-

Check end

drums

for

signs of overheating. Measure the

run-out and diameter. reface the drum.

If

24.

Reinstall the rear brake

Check and adjust

cracks or

drum

not to specification,

Run-out should not exceed

to

drums.

the brake shoes as neces-

sary.

25.

Reinstall the wheel

and

the lug nuts in a star pattern

about 45

Replace parts as required. Inspect the brake

Manually adjust the brake shoes

the furthest adjusted position but not so far

throughout

tion with high-temperature grease.

13.

23.

and spring onto the leading

worn

viceable, lightly lubricate the threaded por-

coils.

and upper return

Reinstall the automatic adjuster actu-

ating lever

entire range.

attaching pin and hold-down

spring.

springs.

the brake springs. Overheating indications

plate).

push the adjuster actuating

on

Reinstall the automatic adjuster

the trailing brake

should show contact across the entire width

its

the rear wheel assembly.

and separate the

To inspect:

If

removed from both

sides of the vehicle at the

shoe retaining

the brake support plate in proper position .

shoes, replace the brake shoes from

Remove

pin.

Reinstall the parking brake actuat-

ing lever-to-trailing brake

19.

the trailing brake

plate.

will

install

to

removing the rear brake

extremely

squarely seated on the

clip.

prior to driving the vehicle.

to the

is

shoe hold-down spring on the

hold-down 18.

brake shoe assembly to the brake support

due

brake shoe

trailing

advisable

adjustment procedure must be done

'When

Position the trailing brake shoe onto

the brake support plate and be sure the

support plate shoe contact areas and

the parking brake actuating lever to the trailit

adjustment manually

initial

shoe from

the leading brake

ing brake shoe.

not require manual brake

initial

Remove

brake support plate.

the parking brake actuating lever

shoes are replaced,

speed up the

larly

allow-

the face of the

self-

9.

b.

maximum

with a self-adjusting

shoe adjustment. Although, the brake

to the

actuated each time

the vehicle service brakes are applied.

which

the

drum diameter on

the attaching pin of the parking brake actu-

the support plate.

mechanism

adjuster

is

marked with

lever.

and lower return

spring and pin attaching the leading brake

7.

vehicle

This

in.

rotation. All brake

wheel

mechanism. The automatic

initial

360°

drum.

Remove

tension from the adjuster.

self-adjuster

1. make

30° rotation, or 0.0035

in

with high-temperature grease.

6.

to

in

(0.089mm)

expanding type with an automatic

internal

erally,

surface

in.

(0.064mm)

able brake

springs from the brake shoes. is

0.0025

the leading brake shoe.

5.

drum brake

drum braking

either

points and the brake shoe anchor points

way

rear

must not exceed

the automatic adjuster actuating lever from

4.

The Sebring Convertible’s

in.

drums

drum from

spring from the leading brake shoe.

brake operation.

Sebring Convertible

Remove

assembly.

drums. Brake shoes should now be coradjusted and

back

will

of the rear brake shoes.

is

depressed, pushing the rear brake shoes

rectly

on the adjuster wheel. Rotate the

adjuster wheel upward

Adjust the rear brakes by depressing

22.

(0.15mm). The diameter variation

starwheel, insert a second prytool

pattern

lbs. (61

ft.

and

final

tire.

Torque

sequence

to

Nm), then repeat the

torque to 100

ft.

lbs.

(135

for

proper

Nm). 26.

Road

test vehicle to

brake operation.

check

BRAKES

IQ O

>1

FORD MOTOR COMPANY

1998-01 FORD

MOTOR COMPANY

Brake Caliper

REMOVAL & INSTALLATION Ford Focus 1

.

Before servicing the vehicle, refer to

the precautions

ir^

the beginning of this sec-

tion. 2.

Remove

or disconnect the following:

•

Front wheel

•

Brake hose from the support

•

Outer brake pad retaining clip

•

Brake caliper from the steering

•

Brake pads

•

Brake hose from the caliper

bracket

knuckle

To install: 3.

Install or

connect the following:

Brake hose to the caliper. Tighten

•

the fitting to 11

lbs.

ft.

(15 Nm).

Brake pads

• •

Brake caliper to the steering knuckle. Tighten the bolts to 21 lbs.

4.

Lift

6.

Remove

from the

(28 Nm).

•

Outer brake pad retaining clip

•

Brake hose

•

Front wheel

to the

7.

support bracket

the caliper off of the brake rotor.

5. ft.

If

the inboard disc brake

caliper.

Bleed the brakes and check

for

proper

caliper

FRONT

and allow

8.

Remove

9.

If

4.

14

15

the brake caliper. is

the wheel and

Remove

tire

assembly

16

tie

prevent strain on the brake

spring

the 2 locator pin covers

and

locator pins.

Free the hose from

lbs.

If

mounting on

removed, caliper.

Reinstall the to

20

ft.

2 caliper locator pins lbs.

(28

Nm)

Reinstall the caliper locator pin cov-

Reinstall the outer disc brake

pad

clip.

Reconnect the brake hose

to the front

Bleed the brake system of

air

strut.

install the

Torque the

brake hose

fitting to

10

18

the master cylinder

ft.

(14 Nm).

1 1

its

17

onto the

clip).

Reinstall the caliper over the brake

ers.

not to be serviced,

To install: 10.

the outer disc brake pad

sure that the outboard disc positioned properly.

and position onto the caliper anchor

and torque

to drain.

the caliper

is

plate.

hose.

Remove Remove

spring clip (anti-rattle 3.

rotor

disposal. Disconnect the brake hose at the

off the caliper to

remove the

removed

from the vehicle, place a pan under the

Ford Contour, Mercury Mystique

2.

13.

the brake caliper is to be

Make

brake pad

caliper to catch the brake fluid for proper

operation.

1

12.

pad

19

Position the inboard disc brake pad

If

Top

the brake pedal feels spongy,

repeat the brake bleeding procedure

20

into the caliper.

and

Reinstall the wheel

tire

assem-

the strut.

Positioning the outboard disc brake pad Position of disc brake pad (brake shoe and lining) spring

clip— Contour, Mystique

View

ot

(brake shoe and lining)

inboard disc brake pad (brake

shoe and lining)— Contour. Mystique

For Accessory Drive Belt

illustrations,

see Section

ofl

when complete

tique

1

of this

manual

—

Contour. Mys-

BRAKES

4-14

FORD MOTOR COMPANY

Torque the lug nuts

bly.

to

62

ft.

lbs.

torque to 30

21.

Pump

to position the to

move 22.

brake pads before attempting

and check

tor

Reinstall the guide pin

and the

the wheel and

tire

assembly.

and conduit from the parking brake

lever at

the disc brake caliper, using a pair of pliers. 3. 4.

Remove Remove Lift

19.

If

the brake pedal feels spongy,

Reinstall the wheel

20.

the rear disc brake caliper off of

bly.

Torque the lug nuts

to

and allow the brake 8.

fit-

caliper.

Discard the

Remove

.

move

brake fluid

lbs.

(128

Reconnect the

Fit

rear brake

hose

brake pads before attempting

.

and check

new washers.

the rear disc brake caliper over

the rotor and position onto the anchor plate.

PARKING BRAKE REAR CABLE AND

Before servicing the vehicle, refer to

DOT

in

3.

the beginning of this sec-

or disconnect the following:

Rear wheel

•

Parking brake cable

•

Caliper mounting bolts

•

Brake

•

Brake caliper

fluid

hose

install: Install or

•

Brake

or disconnect the following:

•

Front wheel

•

Brake

•

Caliper mounting bolts

•

Brake caliper

fluid

the

3 or 4

the beginning of this sec-

connect the following:

Use new copper

fluid hose.

washers and tighten the

Remove

the

Check

necessary.

Remove

tion. 2.

Make sure

Before servicing the vehicle, refer to

•

for

Lincoln LS

in

if

the

tion. 2.

test the vehicle

the precautions

to the

rotors.

brake fluid and add

the precautions

To

T87P-2588-A.

move

the brake pedal to seat the

REAR

the vehicle.

Road

22.

1.

Retract the piston fully into the

caliper using

12.

ft.

35

assem-

FRONT

caliper using service tool 1 1

94

tire

the disc brake caliper.

To instaii:

pump

pads against the

proper brake system operation.

fluid to drain.

washers.

10.

Before attempting to

Finish removing the rear brake hose

and washers from the

9.

5.

level of the

the brake pedal several times

erly.

Crack open the rear brake hose

Bleed the -brake system.

1

Pump

21.

to position the

ting

to

and

bolt to

(47 Nm).

lbs.

4.

vehicle,

Nm).

Place a pan under the caliper to

(35 Nm).

vehicle has a firm brake pedal.

catch any lost brake fluid. Dispose of prop-

7.

when com-

the master cylinder

repeat the brake bleeding procedure.

the anchor plate. 6.

off

plete.

cover and remove the locating pin. 5.

Top

air.

Tighten the mounting lbs.

ft.

Front wheel

•

lever.

Properly bleed the brake system of

18.

the cotter pin and guide pin. the caliper locating pin

ft.

ing the parking brake control several times.

the parking brake rear cable

26

Brake fluid hose. Use new copper

•

cotter

Adjust the parking brake by operat-

17.

Remove Remove

caliper.

washers and tighten the

and conduit onto the parking brake

1.

Brake

Reinstall the parking brake rear cable

16.

REAR

connect the following:

Install or

•

pin.

proper brake system operation.

2.

install:

bolts to

15.

test the vehicle

3.

cover.

the vehicle.

Road

Nm).

Reinstall the caliper locating pin

14.

the brake pedal several times

lbs. (41

ft.

To

and

Reinstall the caliper locating pin

13.

(85

Nm).

ft.

bolt to

36

(48 Nm).

Brake caliper. Tighten the mounting

•

hose

REAR DISC BRAKE CALIPER

lbs.

bolts to

25

(33 Nm).

lbs.

ft.

•

Parking brake cable

•

Rear wheel

4.

Bleed the brake system.

5.

Before attempting to

vehicle,

pump

move

pads against the

rotors.

Make sure

level of the

brake fluid and add if

the

Check the

vehicle has a firm brake pedal.

brake fluid

the

the brake pedal to seat the

DOT

3 or 4

necessary.

Ford Taurus Lincoln Continental

Mercury Sable K

CAUTION

On Continentals, the switch, located

in

air

the

suspension

left

side of the

luggage compartment, must be turned OFF before raising the vehicle. Failure to do so in

unexpected

the air springs

may

result

inflation or deflation of tfiat

may

result in

shifting of the vehicle during service.

FRONT 1.

Remove brake

fluid

master cylinder reservoir is 1/2 full.

from the brake

until the reservoir

A HC

BRAKES

*T

FORD MOTOR COMPANY For Continentals, turn the air sus-

2.

pension switch, located

the

in

compartment,

the luggage

OFF

to the

4.

posi-

3.

Remove

4.

Mark is

it

assembly.

tire

the retaining bolt

the wheel and

assembly.

tire

reinstalled in the correct location.

the hollow bolt connecting

plug the brake hose. Discard the 2 copper

Remove

6.

6.

ing pins

rear disc

Retract the disc brake caliper piston

using an old brake

pad or block

of

wood and

a C-clamp.

bolt to

rotate the rear disc brake

piston and adjuster clockwise until fully

•Make

attached to the brake pads.

rear disc brake piston and adjuster face is

Install

the disc brake pads to the

Make sure

are correctly attached to the brake pad plate

Position the disc brake caliper and

9.

pad assembly above the rotor and with a rotating motion.

install

Make sure

it

the inner

sure one of the 2 slots

positioned so

it

will

in

Apply silicone

dielectric

to the inside of the slider pin

inside of the insulators with silicone grease

Torque the locating pins

25

to

(34

lbs.

ft.

Nm).

10.

Remove

the plug

and

install the

1 1

.

pads are

Remove

13.

Install the

torque the nuts to

wheel and

23-26

lbs.

ft.

85-104

assembly,

(115-142

lbs.

ft.

Nm).

Pump

14.

the brake pedal several times

pads prior

to

moving

the vehicle.

pension service switch

Road

16.

to the

test the vehicle

ON

position.

and check

for

proper brake system operation.

.

master cylinder reservoir is

14.

V2 2.

until the reservoir

For Continentals, turn the

the luggage

in

compartment,

the

air

left

to the

sus-

side of

OFF

tion.

posi-

hose

to the caliper

40

ft.

7.

Torque the

Install the

Tire

,

the banjo bolt securing the

the upper brake caliper

wheel and

the

85-104

Place the brake caliper on the

8

mounting bracket and tire

assembly,

lbs.

ft

mount-

and remove from the vehicle

To install:

filling

9

(115-142

slide into position

the upper brake caliper retain-

Install

ing bolt. Torque the bolt to

Nm).

33-43

ft.

lbs

(45-59 Nm).

Pump

the brake pedal several times

to position the brake

pads prior

to

10. Install the brake

moving

caliper

the vehicle. 17.

to the

test the vehicle

ON

air

Torque the banjo bolt to 16-22

sus-

bolt

and check

for

1 1

.

Connect the parking brake cable

Wheel and Ball Joint

and

tire

assembly

and

disc brake pads.

12.

Install the

13

Bleed the brake system

14

Install the

wheel and

tire ft.

assembly. lbs.

(88-118 Nm).

the disc brake pads.

specifications, see Section

to

bracket bolt.

Torque the lug nuts to 65-87 the wheel

lbs

the operating lever. Position the bracket

FRONT Remove Remove

ft.

(22-29 Nm)

position.

Ford Escort

.

to the brake

using 2 new copper sealing washers

For Continentals, turn the

Road

hose

and secure with the banjo

install the

1

the parking brake cable from

Slide the brake caliper oft the

ing bracket

(54 Nm).

lbs.

Bleed the brake system,

torque the nuts to

2.

For

rotor.

and check the

Remove the wheel and tire assembly. Remove the disc brake pads. Remove the parking brake cable

Remove

6

Mercury Tracer

pension switch, located

brake pads to the brake

test the vehicle

retaining bolt.

from the brake

full.

Road

copper sealing washers.

master cylinder as required

18.

fluid

lbs.

brake hose to the brake caliper Discard 2

proper brake system operation.

Remove brake

assembly.

the brake pedal several times

Remove

5

(31-35 Nm)

the cable retaining clip

pension service switch

REAR

Pump

Remove

4

Using new washers, connect the flex

16.

For Continentals, turn the air sus-

15.

1

13.

brake

15.

to position the brake

ft.

the operating lever

Attach the cable end to the parking lever. Install

retaining bolt to tire

tire

aside.

lock and sealer. Install the pin retainers and

on the caliper assembly.

master cylinder as required.

wheel and

bracket bolt and position the bracket

drop of thread-

1

.

3

Make sure

bracket.

and apply

retainer threads

12.

the

.

2

installed correctly.

new copper washers and torque the hollow bolt to 30-40 ft. lbs. (41-54 Nm). filling

Install the

REAR

boots and the

the residue from the pin

brake

Bleed the brake system,

Bleed the brake system.

9.

1

brake hose to the disc brake caliper. Use 2

12.

(22-29 Nm).

disc brake pads.

compound

Position the slider pins and boots in

torque to

11.

lbs.

8.

10.

slider pins.

the brake

Lubricate the locating pins and the

ft.

brake system for proper operation. 9.

the support bracket. Position the caliper

10.

banjo bolt with 2 new

Install the

on the disc brake pad.

assembly on the support

tioned.

16-22

to position the

engage the nib

the outer anti-rattle spring

properly posi-

brake hose to the brake

install the

(88-118 Nm).

the

and outer pads are properly positioned and is

and

7.

1 1

the brake pad insulators

Install the

Torque the lug nuts to 65-87

seated.

'•’Make sure the clip-on insulators are

caliper.

caliper

rear caliper piston adjuster

T87P-2588-A,

tool

(39-49

lbs.

ft.

copper sealing washers. Torque the banjo

Using

8.

fully in the piston bore,

8.

6.

sup-

To install:

install:

2 brake caliper retaining bolts.

Nm).

the disc brake caliper locat-

and boots from the

Place the brake caliper in position

install

Torque the bolts to 29-36

away

port bracket.

motion.

7.

the rear disc brake caliper

Remove

7.

and

the caliper off the rotor using a rotating

To

Lift

caliper.

install:

5.

and

from the rear disc support bracket.

*

the caliper locating pins

the caliper. Disengage the

brake caliper retaining

and remove the brake

To

the retaining clip from the

at

Remove 2

4.

parking brake cable end from the lever arm.

and

the brake hose to the disc brake caliper

sealing washers.

parking brake

the banjo bolt securing the

copper sealing washers.

bolts

Remove

J

brake hose to the brake caliper. Discard 2

ers. 5.

Remove

3.

and dis-

connect the brake hose from the caliper

the disc brake caliper to ensure

Remove

5.

lift

the wheel and

assembly. Discard the copper sealing wash-

tion.

that

Remove Remove

3.

side of

left

I

15

1

of this

Pump

the brake pedal several times

manual

BRAKES FORD MOTOR COMPANY banjo bolt and torque to 30

ting. Install the ft.

(40 Nm).

lbs.

17.

Bleed the brake system and check for

leaks.

Replace the bleeder screw rubber cap.

18.

Install the

wheel and

Torque the lug nuts

85-105

ft.

(115-142 Nm).

lbs.

Pump

19.

the brake pedal several times

pads before the vehicle

to position the brake is

assembly.

tire

a star pattern to

in

moved.

Road

20.

test the vehicle

and check

for

proper brake system operation.

REAR 1

Remove Remove

.

2.

the wheel and

tire

assembly.

the banjo bolt securing the

brake hose to the disc brake caliper. Sepabrake hose from the caliper and

rate the

plug the hose. Discard 2 copper sealing

washers.

Remove

3. 9. 7

Rear Wheel Brake Caliper

1

Rear Disc Brake Adjuster

16.

Release the tension from the parking

caliper.

Rear Brake Operating Lever

8

Snap Ring

3

Brake Adjuster Screw

9

Dust Seal

4

Rear Disc Brake Caliper

10

Piston

5

Wheel Cylinder Bleeder Screw

11

O-Ring

6

Piston Seal

12

Brake Connecting Link

brake cable and disengage the cable end

from the parking brake lever on the brake caliper.

Rear disc brake assembly

—

Hold the disc brake caliper locating

4.

and remove 2 brake pin 5.

Escort, Tracer

Lift

away from pads

brake

to the

ton(s) using a

remove

C-clamp and an old disc

Road

test the vehicle

On

and check the

brake system for proper operation.

6.

single piston calipers, engage the

To

the insulator.

1 1

Remove

.

the wheel and

tire

assem-

bly.

that

it

the disc brake caliper to ensure

be installed to the

will

same

side

Remove

the banjo bolt that connects

Remove and plug

the brake hose.

Discard 2 copper sealing washers. 4.

On

single piston calipers,

remove

the lower brake caliper locating pin. 5.

Rotate the brake caliper approxi-

mately 90 6.

away from the anchor assembly.

Slide the brake caliper

anchor assembly

until the

away from

brake caliper dis-

engages from the upper locating pin and remove from the vehicle. 7.

clip

On

dual piston calipers,

remove the

and washer with the locating pin and

remove the disc brake

To 8.

caliper.

install: If

required,

caliper.

the brake pads are prop-

the caliper pis-

If

required, use Caliper Piston

T87P-2588-A

on the anchor

8.

plate.

recommended thread locking compound on

the threads. Install the

13.

locating pin

Apply a suitable silicone

9.

10.

lower disc brake caliper to

23

ft.

and

lbs. (31

On

ing

dual piston calipers, place the

Install the

Properly

.

Apply a drop

compound

caliper onto the brake rotor.

to

pin

and

clip

by pressing the caliper down

to

locating

23-26

of suitable thread lock-

to the threads of the brake

retainers.

compress the bias springs and the

the disc brake pads

install

pin retainer bolts

disc brake caliper locating

brake caliper locating pins

the disc support bracket.

in

disc brake caliper over the brake rotor with

Install the

seated.

dielectric

to the inside of the locating pin

the brake pads installed and lower the

15.

rotate

anti-rattle clips.

1 1

Nm). 14.

is

boots and the caliper locating pins.

and boots

and torque

and

the tool clockwise until the piston

locating pins are

to the

to rotate the caliper

piston into the caliper bore. Align the tool

compound due

the brake caliper locating

tips with the slots in the piston

and

install the

brake pin

Torque the brake pin retainer bolts ft.

lbs.

(31-35 Nm) while holding

the brake caliper locating pins with an

open-end wrench. 12.

Attach the 'end of the parking brake

pin into position and secure with the washer

cable to the parking brake lever on the disc

and

brake caliper.

clip.

16.

Unplug and

install the

the disc brake caliper using 2

compress

Remove

Adjuster

Rotate the brake caliper assembly

into place

and

the disc brake caliper from the

install:

7.

properly

erly installed.

K»New

the brake hose fitting to the disc brake caliper.

is

if

both calipers are being removed. 3.

the anti-rattle

Make sure

.

12.

Mark

2.

on

installed

FRONT 1

Make sure

10.

assembly

the disc support bracket

pins and boots from support bracket.

upper disc brake caliper locating pin into

Ford Mustang

retainer bolts.

the disc brake caliper

vehicle.

brake pad or block of wood.

rotor.

open-end wrench

pin hex-heads with an 93006G22

to position the brake

disc brake

at the

Spindle

Spring 2

the retaining clip from the

parking brake rear cable

sealing washers,

1

brake hose to

new copper

on each side

of the

fit-

13.

Unplug and

install the

the disc brake caliper using 2

sealing washers on the

brake hose to

new copper

fitting. Insert

the

banjo bolt through both washers and the

A-17I

BRAKES FORD MOTOR COMPANY brake line

and torque

fitting

30

to

(40

lbs.

ft.

torque the

fitting

nut to

10-18

Torque the lug nuts to 85-105

lbs.

ft.

Properly bleed the brake system and

14.

check

Install the

15.

wheel and

Torque the lug nuts

85-105

ft.

assembly.

pads before moving

moving the

and check the

test ftie vehicle

Road

16.

and check

test the vehicle

Lincoln Mark

REAR

VIII

1

FRONT the wheel

and

tire

assem-

connects the brake hose

(if

Lincoln

the wheel

and

tire

assembly.

the brake fitting retaining

from the disc brake caliper and discon-

line fitting that

bolt

to the brake line at

nect the flexible brake hose from the caliper.

the frame bracket. Plug the brake line.

Plug the hose and the caliper

hose and

the retaining clip from the

fitting

brake cable. Disconnect the cable from the

bracket.

caliper.

Remove

the hollow bolt attaching the

brake hose to the caliper and remove

the

ing pins.

brake hose. Discard the sealing washers.

remove the

caliper

may be

To

equipped).

If

right

and

left

air

the pins

reinstalled correctly.

slots

install:

on the

Fully retract piston into caliper bore

7.

Install the caliper

over the rotor with

the outer brake pad against the rotor's brak-

8.

tool are

in the caliper.

meshed

seated

in the caliper

bore

Make sure

that the

locating pins

Install the caliper

and thread them

into the spin-

the caliper locating pins to

45-65

ft.

lbs.

9.

(if

10.

equipped).

Install

new

and

fitting outlet

install the hollow bolt

through the hose

30

and

lbs. (41

ft.

1 1

and

into the caliper.

Torque the bolt

install the retaining clip.

hose 12.

is

to

the bracket

Make sure

the

not twisted.

Remove

connect the brake line to the brake hose and

disc brake caliper guide

the inner

pad

mark the

If

may be

they

5

Lift

right

removing both

and

left

sides so

reinstalled correctly

the disc brake caliper oft of the

anchor plate

To

install:

is

6

in the pis-

Retract the disc brake caliper piston

piston bore, using an old brake

ton slot. 10.

Apply a suitable thread-locking com-

them

ing pins to .

in

7

by hand. Torque the locat-

19-26

Install the

ft.

lbs.

(26-35 Nm).

new gasket on each

and torque

13.

30-40

ft.

lbs.

pad

8

Position the disc brake caliper onto

Make

sure the inner and

and the

anti-rattle spring is properly positioned

The

to

caliper bleed

screw should be positioned on

top of the caliper

when assembled on

the

vehicle.

equipped).

9

tire

Install

2 new

caliper guide pin bolts.

Torque the bolts to 21-26

3 brake fluid from a closed container.

wheel and

C -clamp

outer pads are properly positioned

and adjust the tension

Install the

a

disc brake pads to the

sure that the brake pad insula-

the anchor plate

Bleed the brake system using clean

15.

Make

caliper

side

Connect the brake pad wear sensor (if

wood and

plate

(40-54 Nm).

Connect the parking brake cable

connector

DOT

to

of

Install the

tors are correctly attached to the brake

brake hose on the disc

brake caliper with a

12.

pad or block

to the caliper locating pin threads

start

14

the plug from the brake line,

Remove 2

4

fully in the

the caliper in

over the rotor with a

Make sure

of the fitting outlet. Insert the retaining bolt fit-

Nm).

Place the brake hose

.

rotor with the anti-rattle

Install the caliper

rotating motion.

1 1

sealing washers on each

side of the brake hose

ting

arm.

and

Connect brake pad wear sensor con-

9.

nector

bolt

caliper Plug the brake hose. Discard the

calipers, 10

Place the disc brake caliper assem-

above the brake

pound

(61-88 Nm).

tire

correct side.

properly positioned with the nub

dle/anchor plate assembly by hand. Torque

and

the front wheel

securing the brake hose from the disc brake

pads are on the

spring located on the lower adapter support

icone dielectric grease.

position before

sealing washers

bly

sil-

OFF

Loosen and remove the banjo

3.

the piston. 8.

to the

assembly

with the

ton boot between the inner brake pad and

inside of the locating pin insulators with

right-

luggage compartment,

pin bolts and discard

ing surface. This prevents pinching the pis-

Lubricate the locating pins and the

of the

Remove

2

Be sure

disc pads in the support

Install the

bracket.

suspension, the

air

raising the vehicle

until the piston is

6.

equipped with

must be turned

pads

piston. Rotate the tool clockwise

on the

If

suspension switch, located on the

hand side

plate using a rotating motion.

Adjuster T87P-2588-A

sides so

retention capability and must not be

Place the Rear Caliper Piston

7.

Once removed, these parts

caliper.

1

the disc brake

washers, per

bolt sealing

and 2 banjo

the disc brake caliper locat-

To install:

removing both

FRONT

reused.

the caliper off the brake rotor

Remove

6.

the caliper locating pins and

mark the

calipers,

they

(if

Remove

Lift

and anchor

Disconnect the brake pad wear sen-

sor connector

Remove

5.

Town Car

lose their torque holding ability or

Release the tension from the parking

bracket and disengage the hose from the

5.

for

—Before continuing with this procedure. make sure to have available. 2 new disc brake caliper guide pin bolts

equipped).

Remove

3.

Loosen the brake

4.

and check

Ford Crown Victoria

for

Disconnect brake pad wear sensor

connector

bly.

3.

test the vehicle

Mercury Grand Marquis Remove

.

2.

Remove

Remove

Road

18.

proper brake system operation.

vehicle, to position the

proper brake system operation.

2.

system

brake pads.

Road

.

Verify proper parking brake

17.

lbs.

operation.

brake system for proper operation.

1

brake pads.

assembly.

ft.

Apply the brake pedal several times

15.

4 before

the vehicle. 17.

tire

85-105

to

Apply the brake pedal several times

16.

(115-142 Nm)

the brake pedal several times

to position the brake

wheel and

Install the

14.

lbs.

before moving the vehicle, to position the

3 brake fluid from a closed container.

Torque the lug nuts

(115-142 Nm).

lbs.

Pump

16.

tire

a star pattern to

in

Bleed the brake system using clean

13.

DOT

for leaks.

ft.

(115-142 Nm).

(13-24 Nm).

Nm).

I

Unplug and

assembly

ft

lbs.

install the

the disc brake caliper using 2

For Wheel Alignment specifications, see Section

1

of this

manual

(28—26 Nm).

brake hose to

new copper

O

i

4

BRAKES FORD MOTOR COMPANY

sealing washers on the banjo bolt. Torque

30-40

the bolt to

(41-54 Nm).

lbs.

ft.

Bleed the brake system,

11.

the

filling

DOT 3 12.

brake fluid from a sealed container. Install

the wheel and

Torque the lug nuts

85-104 13

lbs.

ft.

If

tire

equipped with

ON

Pump

position.

the brake pedal several times

pads

to position the brake

prior to

moving

Road

15.

Install the

12.

test the vehicle

and check

for

wheel and

If

equipped with

air

Pump

the caliper. 1 1

ON

position

,

brake pads prior to moving

and check

for

caliper.

must not be

equipped with

air

hand side

of the

must be turned

suspension, the

OFF

position before

raising the vehicle.

Remove

and

the rear wheel

tire

Loosen and remove the banjo

•

Brake caliper

•

Inner and outer brake pads

To

install:

2.

Compress

21

Remove 2

disc brake caliper locating

brake caliper

bolts. Lift the disc

off

the rotor

ft.

using an old brake

fully in the piston bore,

pad or block

of

wood and

Install the

6.

that the

lbs.

to

Brake hose to the support bracket

•

Front wheel

3.

to

remove the parking

Remove

6.

the inner and outer disc

brake pads.

To

install: If

installing

new

disc brake pads, use

T87P-2588-A

or

the brake fluid from

tire

assembly.

room

for the

new brake

the outer disc brake pad clip).

Install the inner

8.

Remove

4.

and outer disc brake

the 2 locating pin covers

and remove the locating pins.

the locating bolts by

hand

lbs.

Unplug and

Install

only.

and

install the

lbs.

start

Torque both

back

Lift

and

tie

it

off to

prevent

damage

drop

1

of a thread locking

similar sealer.

hose.

Remove

agent or

to the brake ,

Apply a small amount

of disc brake

the outboard disc brake pad caliper slide grease to the shaft of the locat-

to

from the anchor

plate.

ing pin. 8.

Remove

the inboard disc brake pad 12.

from the brake

To

30

ft.

lbs. (41

and torque

Nm).

install: 13.

9.

Reinstall the locating pin

caliper.

to

the

Clean the locating pin threads and

the caliper off of the brake rotor

11.

(41-54 Nm).

rear disc brake caliper

into position over the disc brake pads.

the strut.

7.

new copper

filling

mounting on

10.

sealing washers on the banjo bolt. Torque ft.

its

apply

brake hose

Bleed the brake system,

Free the hose from

5.

6.

(22-27 Nm).

the disc brake caliper using 2

Swing the

9.

of the caliper

bolts. Lubricate the

compound.

30-40

and

ton. This will allow

spring clip (anti-rattle

caliper locating bolts with a suitable sili-

ft.

the wheel

pads.

bushings and locating

the bolt to

rear disc brake caliper

the brake rotor and anchor plate.

pads.

over the rotor with a

Clean the inner surface

9.

pin.

piston clockwise, retracting the caliper pis-

rotating motion.

16-20

!4> of

Remove Remove

2.

rotor with the anti-rattle

Install the caliper

bolts to

and guide

the caliper locating pin

the master cylinder reservoir.

spring located on the lower adapter support

dielectric

the cotter pin

similar tool, to rotate the rear disc brake

assembly above the

cone

for

the wheels.

no need

is

7.

Remove

.

and check

the brake fluid from

rear caliper piston adjuster 1

fluid

brake cable or brake hose.

Mercury Cougar (1999-01 model)

Position the disc brake caliper

8.

Vfe of

Swing the

5.

away from

Mercury Mystique

pads are on the

and add

cover and remove the locating pin.

(28 Nm).

FRONT

correct side.

arm.

Remove Remove Remove

4.

•

10. 7.

fluid level in the

fluid reservoir

test the vehicle

Remove

3.

a C-clamp.

disc brake pads on the

Make sure

caliper.

Road

.

There

Retract the disc brake caliper piston

Check the brake

2.

Ford Contour

install:

5.

1

connect the following:

and anchor plate using a rotating motion.

To

to

REAR

the caliper piston into the

Brake caliper. Tighten the bolts

•

Plug the brake hose and discard

both sealing washers.

the brake pedal several times

the vehicle.

20.

Inner and outer brake pads

•

securing the brake hose to the disc brake

assembly.

(85 Nm).

the master cylinder reservoir.

Install or

3.

bolt

tire

lbs.

ft.

proper brake system operation.

caliper bore.

assembly.

62

as necessary.

Outer brake pad retaining clip

•

right-

move 19.

Brake hose from the support

wheel and to

achieve a good pedal before attempting

master cylinder

bracket

luggage compartment,

to the

or disconnect the following:

Front wheel

•

•

suspension switch, located on the

caliper.

to

Remove

.

reused. If

Pump

18.

Focus

Once removed, these parts

retention capability and

Reinstall the

17.

Torque the lug nuts

1

4.

support

pad spring

Reinstall the disc brake

16.

REMOVAL & INSTALLATION

lose their torque holding ability or

3.

to its

strut.

clip.

banjo bolt sealing washers, per

2.

Secure the brake hose

15.

Disc Brake Pads

^Before continuing with this procedure, make sure to have available, 2

1.

and

(28 Nm).

lbs.

Reinstall the caliper locating pin

on the

REAR

ft.

covers.

proper brake system operation.

proper brake system operation.

air

Reinstall the 2 locating pins

13.

torque to 20 14.

test the vehicle

plate.

the rotor.

the vehicle.

Road

anchor

Position the disc brake caliper onto

12.

the brake pedal several times

to position the

Place the outboard disc brake pad

.

into position in the

suspension, turn

the air suspension switch to the 14.

assembly.

(115-142 Nm).

lbs.

ft.

tire

a star pattern to

in

new pads.

Place the inboard disc brake pad into

10.

Torque the lug nuts

push the

or similar tool to

allow room for the

Replace the rubber rear disc brake

.

15.

the vehicle.

from a sealed container.

fluid

bleeder screw cap.

13.

suspension, turn

air

caliper piston into the caliper bore. This will

3 brake

85-104

(115-142 Nm).

the air suspension switch to the 14.

assembly.

a star pattern to

in

a

DOT 1 1

master cylinder as required. Only use clean

C-clamp

master cylinder as required. Only use clean

If

installing

new

disc brake pads, use pin.

Reinstall the guide pin

and the

cotter

BRAKES

>1.1Q H 3

FORD MOTOR COMPANY

I

Adjust the parking brake by operat-

14.

ing the parking brake control several times Reinstall the wheel

15.

Torque the lug nuts

bly.

and

to

62

assem-

tire

ft.

lbs.

(85

Nm). 16. Adjust the parking brake by operating the parking brake control several

times.

Pump

1 7.

move

the brake pedal several times

good pedal before attempting

to achieve a

to

the vehicle.

Check the brake

18.

master cylinder

fluid level in the

and add

fluid reservoir

fluid

as necessary.

Road

19.

and check

test the vehicle

for

proper brake system operation.

Lincoln LS

FRONT

2

3 4

Rear Disc Brake Caliper Anchor Plate

voir.

Guide Pin

is Vfe full.

fluid level in the reser-

Remove brake

fluid until the reservoir

Discard the removed

fluid.

2.

Remove

the wheel and

3.

Remove

the disc brake caliper locat-

tire

assem-

bly.

Parking Brake Lever

ing pins.

Rear disc brake components

the master cylinder reservoir

cap and check the

Anti-Rattle Clip

5

Remove

1.

Rear Disc Brake Rotor

1

the caliper assembly from the

Lift

anchor plate and

— Contour, Mystique

rotor.

Suspend the

4

caliper inside the fender

housing with wire Do not allow the caliper to

hang from the brake hose.

Remove

5.

the inner and outer brake

pads Inspect the rotor braking surfaces

for

scoring and machine as necessary

To install:

Use

6

or block of

C-clamp and an old brake pad

a

wood

to seat the caliper piston

in its bore.

Remove any

7.

rust buildup

from the

inside of the caliper in the brake pad contact

area

8

Install the inner

pad

in

the caliper

piston.

9

outer pad onto the anchor

Install the

Make

plate

sure the clips are properly seated.

Install the

10.

disc brake caliper onto the

anchor plate 1 1

Install caliper locating

.

torque to 26 12.

2

Rear Caliper Piston Adjuster

Nm)

3

Nibs (Part of T87P-2688 A)

4

Piston Adjuster Slots (Part of

Pump

14.

2BS88) Rear Disc Brake Caliper Piston and Adjuster

brake pads to the

9300SG27

tire

85-104

lb

(115-142

the vehicle to position the

Refill the

rotor.

master cylinder reservoir as

necessary, using only clean

and the adjuster tool— Contour. Mystique

assembly and ft

the brake pedal several times

moving

prior to

15

pins and

(35 Nm).

wheel and

torque lugs nuts to

6

of rear caliper piston

Install

lbs.

Rear Disc Brake Caliper

1

Diagram

ft

DOT 3

brake fluid from a closed container.

For Maintenance Interval recommendations see Section ,

1

of this

manual

or 4

BRAKES

4-20

FORD MOTOR COMPANY

REAR 1

Remove

.

the master cylinder reservoir

cap and check the

is

fluid level in the reser-

Remove brake

voir.

Vz

full.

Remove Remove

2. 3.

fluid until the reservoir

Discard the removed the wheel

and

fluid.

tire

assembly.

the disc brake caliper locat-

ing pins at the support bracket.

5.

Remove Remove

6.

Inspect the rotor braking surfaces for

4.

the caliper. the disc brake pads.

scoring and machine as necessary.

To install: Using Rear Caliper Piston Adjuster

7.

T87P-2588-A, until

it

is fully

clockwise

rotate the piston

seated.

Make

slots in the piston face

is

sure one of the

positioned so

it

engage the nib on the brake pad.

will

Install the

8.

brake pads

bracket. Place the caliper rotor into position

Make

the support

in

assembly over the

on the support bracket.

sure the brake pads are installed cor-

rectly.

Install

9.

and torque the disc brake

caliper locating pin to 10.

25

the wheel and

Install

and torque the lug nuts

to

lbs.

(33 Nm).

tire

assembly

ft.

85-104

ft.

Front disc brake caliper, pads and related

Pump

11.

ing pins.

the brake pedal several times

moving the

prior to

brake pads to the 12.

Refill

vehicle, to position the

DOT

if

3 or 4

Road

test the vehicle

and check the

housing with wire. Do not allow the caliper to

Remove

the inner

and outer brake

install:

wood

Remove any

8.

1.

rust buildup in

side of the

left

luggage compartment, must be turned OFF before raising the

is

Vz

may

vehicle. Failure to do so in

unexpected

result

inflation or deflation of

the air springs that

may

result in

from the

pad

in

the caliper

10.

3.

outer pad onto the anchor

Install the

sure the clips are properly

'•Make sure

the master cylinder reservoir

cap and check the

is

fluid' level in

Remove brake

voir.

Vz

full.

2.

On

Discard the removed

fluid.

Continentals, turn the air suspen-

sion switch, located

in the left

luggage compartment, 3.

the reser-

fluid until the reservoir

Remove

to the

the wheel

and

side of the

OFF

position.

tire

assembly.

Remove

12.

Install

13.

the disc brake caliper onto the

23-28

Install

ft.

lbs.

wheel and

torque lugs nuts to

pins and

(31-38 Nm).

85-104

ft.

lb.

(115-142

Nm) 14. prior to

the brake pedal several times

moving the vehicle

brake pads to the 15.

Refill

position.

tire

assembly.

the screw retaining the rail.

the retaining clip from the the disc brake caliper.

at

;

Remove

the upper disc brake caliper

to position the

rotor.

the master cylinder reservoir as

away from

the rotor.

7.

Remove

8.

Inspect the rotor braking surfaces for

To 9.

the disc brake pads.

it

r

install:

Using Rear Caliper Piston Adjuster

T87P-2588-A, until

Pump

OFF

scoring and machine as necessary.

assembly and

tire

suspen-

locating pin at the support bracket. Rotate

plate.

torque to

to the

the wheel and

air

side of the

left

lever.

the insulators are

Install caliper locating

the

in

the cable end from the parking

the caliper

anchor

Remove

Remove Remove

Remove 6.

installed on the brake pads. .

fluid.

Continentals, turn the

parking brake cable

brake

seated.

1 1

1.

On

fluid until the reservoir

Discard the removed

brake hose bracket to the frame side 5.

Make

fluid level in the reser-

luggage compartment,

10.

shifting of the vehicle during service.

FRONT

full.

2.

the brake pad contact

piston.

plate.

the master cylinder reservoir

Remove brake

4.

Install the inner

9.

Remove

cap and check the

area.

switch, located in the

position.

and check the

REAR

sion switch, located

inside of the caliper

For Continentals, the air suspension

ON

test the vehicle

brake system for proper operation.

to seat the caliper piston

in its bore.

CAUTION

3 brake

Continentals, turn the air suspen-

Road

17.

voir.

Use a C-clamp and an old brake pad

or block of

Mercury Sable

On

16.

pads. Inspect the rotor braking surfaces for

7.

Lincoln Continental

DOT

from a closed container.

hang from the brake hose.

To Ford Taurus

necessary, using only clean fluid

the caliper inside the fender

scoring and machine as necessary.

brake system for proper operation.

t'

assembly from the

—Taurus, Continental, Sable

sion service switch to the

Suspend

6.

brake fluid from a closed container.

the disc brake caliper locat-

the caliper

motion. 5.

the master cylinder reservoir

Lift

anchor plate and rotor using a rotating

rotor.

necessary, using only clean

13.

Remove

4.

lbs.

(115-142 Nm).

components

is fully

rotate the piston clockwise

seated.

Make

slots in the piston face will

is

sure one of the

positioned so

it

engage the nib on the brake pad. Install the

brake pads

in

the support

bracket. Rotate the caliper

BRAKES

A

FORD MOTOR COMPANY

H-

91 L I

assembly over

the rotor into position on the support

Make sure

bracket.

pads are

the brake

installed correctly. 1 1

Remove

.

the residue from the rear

brake pin retainer bolt threads and apply

drop of a suitable threadlock sealer.

1

Install

and torque the disc brake caliper locating pin to

23-26

brake

lbs.

ft.

(31-35 Nm).

Attach the cable end to the parking

12.

the cable retaining clip

lever. Install

on the caliper assembly. Position the brake flex

hose and bracket assembly

rail,

and

toll

lbs.

ft.

(16 Nm).

wheel and

Install the

13.

to the side

screw. Torque

install the retaining

and torque lug nuts

assembly

tire

85-104

to

ft.

lbs.

(115-142 Nm).

Pump

14. prior to

the brake pedal several times

moving

the vehicle, to position the

brake pads to the 15.

Refill

rotor.

the master cylinder reservoir

necessary, using only clean fluid

DOT 3

if

Front disc brake pads

brake

—

Escort, Tracer

from a closed container.

On

16.

Continentals, turn the

sion service switch to the

Road

17.

ON

test the vehicle

air

suspen-

moving the vehicle

prior to

and check the

Check the

13.

fluid level in the

cylinder reservoir and

Ford Escort

proper brake system operation

Road

14.

Mercury Tracer

1

the master cylinder reservoir

cap and check the

fluid level in the reser-

Remove brake

voir.

is 1/2 full.

3. 4.

fluid until the reservoir

the wheel

and

tire

assembly

the W-spring.

2 disc brake pad locating

Remove

5.

replace

To 7.

the brake

pads and shims

caliper.

if

needed.

Use a suitable

push the pis-

tool to

Apply a suitable grease between the

to

the brake caliper. Install the

locating pins. Install the

M-spring.

1 1

Install the

wheel and

Torque the lug nuts

to

tire

65-87

ft.

assembly lbs.

fluid until the reservoir

3.

If

and

ft.

Pump

13.

assem-

wheel and

tire ft

assembly. lbs

the brake pedal several times

moving

the vehicle to position the

brake pads. 14.

bly.

necessary, remove the screw plug

Check the brake

fluid level in the

master cylinder reservoir and

and turn the adjustment gear counterclockwrench

screw plug and torque

(16 Nm).

lbs.

Install the

prior to

fluid tire

15.

Road

test the vehicle

fill

if

needed

and check

lor

proper brake system operation.

to pull the pis-

ton fully inward.

4

Remove

5

Using a small prybar, pivot the

on

its If

mounting bracket

to

FRONT WITH SINGLE PISTON

access the

CALIPER

the upper lock bolt requires

lubrication or service, caliper with

Remove

6.

Mustang

the lower brake caliper bolt

remove

it

mechanics

and sus-

To

2 3.

Inspect the brake rotor. Resurface or if

9.

bolts

needed.

reservoir.

Remove the wheel and tire assembly Remove 2 anchor plate mounting

and

lift

the disc brake caliper from the

anchor plate and rotor using a rotating

install:

motion Hang the disc brake caliper from

Apply an appropriate brake pad grease

Pivot the caliper

discard Vi of the brake

from the brake master cylinder

Properly dispose of the used brake fluid

spring and guides. 7.

Remove and

1

fluid

wire.

the brake pads, shims,

on

its

the

body with

caliper

mounting

4.

bracket and position the brake pads, shims,

spring and guides to the brake

the brake pedal several times

12

then loosen the gear Vi

(88-118 Nm).

fluid level in the reser-

the wheel

rotor,

Torque the lug nuts to 65-87

between the shims and the brake pads.

(88-118 Nm).

Pump

Remove

8.

10.

12.

2.

replace

W-spring and 2 brake pad

touch the

just

of a turn. Install the

Discard the removed

full.

pend the

shims and the disc brake pad guide plates

.

Vi

brake pads.

install:

and position the brake pads and shims

9.

is

caliper

ton into the brake caliper bore 8.

for

the master cylinder reservoir

Remove brake

voir

Turn the adjustment gear clockwise

1 1

12

Remove

.

10.

Inspect the brake rotor. Resurface or

6.

and check

ft.

with an Allen wrench until the brake pads

to

wise with an Allen

pins and remove the M-spring.

from the brake

test the vehicle

cap and check the

Discard the removed fluid

Remove Remove Remove

2.

master

as needed.

REAR

FRONT Remove

fill

33-43

(45-59 Nm).

lbs.

brake system for proper operation

1

caliper bolt. Tighten the bolt to

to position the

brake pads.

position.

Do

not

let

the disc brake

Remove

the outer

and inner disc

brake pads and the anti-rattle clip from the

rotor.

disc brake caliper.

Lubricate and install the lower

5.

For Tune-up, Capacities and Firing orders, see Section

wire.

hang by the brake hose

1

of this

Clean any residue from the caliper

manual

BRAKES

4-22

FORD MOTOR COMPANY

anchor plate and disc brake pad contact

pads and the

areas

brake caliper.

6 Inspect the disc brake rotor for scoring and wear. Replace or machine, as necessary.

pads over the

1 1

caliper pin boots

for

bolts to 12.

To install: Use a

large

C-clamp and a

wood

13.

Remove

the insulators

pads,

if

the protective paper from

on the back

ft.

lbs.

of the disc brake

14.

ft.

bolts.

2

Torque the

in

tire

assembly

(115-142 Nm). oppo-

the brake pedal prior to

15.

Fill

Road

and check the

test the vehicle

FRONT WITH DUAL PISTON CALIPER 1

.

Remove and

discard Vz of the brake

from the brake master cylinder reservoir.

fluid

Properly dispose of the used brake 2.

mov-

ing the vehicle to seat the brake pads.

the inner and outer disc brake

17.

a star pattern to

for the

the disc brake calipers were replaced

If

brake system for proper operation.

brake caliper assembly.

Pump

3 brake fluid from a

or repaired, be sure to bleed the system.

(130 Nm).

the wheel and

lbs.

16.

and onto the anchor

Repeat the procedure

site disc

equipped. Install

95

Install

85-105

bore. 9.

rotor

and torque the lug nuts

into block 10. to push the caliper piston back its

the disc brake caliper and

anchor plate mounting

damage. Replace as

necessary.

8.

Install

DOT

closed container.

plate using a rotating motion. Hand-start

Inspect the piston boot and the

7.

.

voir with clean

anti-rattle clip in the disc

3.

Remove Remove

the wheel and

fluid.

assembly.

tire

the clip, washer

and disc

brake caliper locating pin.

the brake master cylinder reser-

Remove

4.

the disc brake caliper from

the brake rotor and the caliper anchor plate.

Hang

the disc brake caliper from the

with wire. 1

A

} (

Do

not

let

body

the disc brake caliper

hang by the brake hose.

Remove

5.

the outer and inner disc

brake pads from the disc brake caliper.

Clean any residue from the caliper

6.

anchor plate and disc brake pad contact areas. Inspect the disc brake rotor for scoring

7.

and wear. Replace or machine, as necessary. Inspect the piston boots and the

8.

caliper pin boots for

damage. Replace as

necessary.

To install: Use a

9.

large

C-clamp and a wood

block to push the caliper pistons back into their bores.

Remove

10.

the protective paper from

the insulators on the back of the disc brake

pads, 1

1

equipped.

if

Install the

.

pads

inner and outer disc brake

Make sure

the disc brake caliper.

in

the pads are seated properly. 12.

the disc brake caliper and

Install

pads over the

rotor

and onto the anchor

plate using a rotating motion.

Make

sure that

the guiding surfaces of the disc brake pads 1

Upper Caliper Brake Bolt

2

Front Caliper Sleeve

3

Insulator

and the anchor bracket are seating

hand

correctly.

Press the disc brake caliper

13.

down by

compress the bias spring and

to

slide

the disc brake caliper locating pin into posi-

4

Caliper Housing (Part of tion.

2B119) 5

Disc Brake Pad Anti-Rattle Clip

Caliper Piston

7

Piston Seal

fated

Install

8

Dust Boot

9

Brake Shoe and Lining

85-105 16.

washer and

the wheel and

17.

ft.

lbs.

in

clip.

tire

assembly.

a star pattern to

(115-142 Nm).

Repeat the procedure for the oppo-

site disc

brake caliper assembly.

Pump

the brake pedal prior to

mov-

10

Front Disc Brake Caliper Anchor Plate

ing the vehicle to position the brake pads.

11

Disc Brake Caliper Locating

voir with clean

Pin

closed container.

18.

Tighten to 88 N-m (65 Lb-Ft)

19. 93006G30

;

Install the

15.

Torque the lug nuts

6

A

Disc brake pads

14.

components

— Mustang with single

If

the brake master cylinder reser-

DOT

3 brake

fluid

from a

the disc brake calipers were replaced

or repaired, be sure to bleed the system.

20. piston caliper

Fill

Road

test the vehicle

and check the

brake system for proper operation.

.

BRAKES

4-23

FORD MOTOR COMPANY

REAR 1

11.

Remove and

.

discard

V2 of the brake

clips

and

12.

Remove Remove

2. 3.

the wheel and

tire

install

the screw retaining the brake

brake rotor into position on the disc support

Make sure

bracket.

the disc brake

Remove

4.

the retaining clip from the

parking brake cable

at

the disc brake caliper.

Release the tension from the parking

5.

13.

pound

Apply a suitable thread-locking comto the threads of the

1.

upper brake pin

Install the

tighten to

6.

23-26

brake pin retainer and

(31-35 Nm) while

lbs.

ft.

Remove 7.

Install the

Remove

away

on the disc brake

Install the

wheel and

Torque the lug nuts

85-105 1 7.

To

ft.

lbs. (11

in

tire

assembly

10.

Repeat the procedure

site disc

18.

T87P-2588-A, clockwise

Remove and

2.

Remove

3.

rotate the caliper piston

Vfe of

the front wheel and

tire

Remove 2

4.

disc brake caliper locating

for the

oppo-

brake caliper assembly

Pump Fill

the brake pedal prior to

DOT

rotor.

Suspend

let

the caliper

5.

Remove

6.

ing

mov-

the brake master cylinder reser-

voir with clean

not

and

the caliper inside

Do

hang by the brake hose.

the disc brake pads from the

caliper.

ing the vehicle to position the brake pads 19.

until the piston is fully seated.

properly dispose

pins and remove the caliper from the anchor

a star pattern to

5-142 Nm).

install:

Using Rear Caliper Piston Adjuster

position before

plate

Inspect the disc brake rotor for scoring

and wear. Replace or machine, as necessary.

OFF

the fender housing with a length of wire.

disc support bracket. 9.

to the

brake caliper. 16.

the inner and outer disc

right-

luggage compartment,

caliper. Install the retaining clip to the disc

rotor.

brake pads and the anti-rattle clip from the

suspension, the

assembly.

the upper brake pin retainer.

Rotate the disc brake caliper

air

the brake fluid from the master cylin-der.

parking brake cable end to

the parking brake lever

from the brake 8.

with an open-end wrench. 15.

pin hex-head with an open-end wrench.

of the

must be turned

caliper.

Hold the disc brake caliper locating

equipped with

hand side

holding the disc brake caliper locating pin

on the disc brake

lever

If

suspension switch, located on the

raising the vehicle.

brake cable and disengage the parking

brake cable end from the parking brake

FRONT air

retainer.

14.

and check the

Mercury Cougar (1998 Model)

pads and

anti-rattle clips are correctly installed.

hose bracket to the shock absorber bracket.

test the vehicle

brake system for proper operation.

Rotate the disc brake caliper over the

fluid.

assembly.

Road

21

disc brake pad anti-rattle

the inner and outer disc

brake pads on the rear disc support bracket.

fluid from the brake master cylinder reservoir.

Properly dispose of the used brake

Install the

Inspect the disc brake rotor for scor-

and wear Replace or machine as neces-

sary.

Observe the minimum thickness

specification

stamped on the

machining

required.

is

rotor

if

3 brake fluid from a

closed container.

(Ensure

that

one

of the 2 slots in the

rear brake piston face it

will

is

positioned so

engage the nib on the back

ot the

20.

If

the disc brake calipers were

replaced or repaired, be sure to bleed the

system.

inner brake pad.

1

Brake Casper Bon

2

Front Casper Sleeve

3

Insulator

4

Otac Brake Caliper

6

One Brake Pad Ann

Rattle

Clp

1

7

Caliper Housing

Front Disc Brahe Caliper Anchor Plate

e

Caliper Piston

7

Ptaton Seal

a

Oval Boor

9 2

Piston Seal (2 Req'd)

3

Caliper Piston (2

4

8

10

9

Req

Clip

d)

Washer

to

Anti-Rattle Clip and Insulator

Dust Boot (2 Req d)

11

Wheel Cylinder Bleeder Screw

5

Front Brake Locating Pin

12

Cover

6

Brake Shoe and Lining

11

Brake Shoe and l rung Front Disc Brake Celper Anchor Plate

Disc Brake CaJtper Locating

pm A

Tighten toil N-m (OOLO-Ft)

Front Disc brake pads and related

Disc brake pads and related components

— Mustang with dual piston

caliper

—Cougar

nents (15 inch wheel)

For complete service labor times, order the Chilton Labor Guide

compo

BRAKES

4-24 To

the disc brake caliper off the rotor

install:

wood

block to seat the caliper piston

Do not allow metal or sharp come into direct contact with piston surface or damage will

caliper

the

Install the correct

8.

to the caliper piston

bend the

to the caliper

marked

for left-hand or

Install the

using care not

machining

to

To outer disc brake to properly

The outer pads are

right-hand installa-

disc brake caliper over the

rotor with the outer brake

pad against the

braking surface. This prevents pinch-

rotor’s

ing the piston boot

between the inner brake

worn,

It

.

2 new locating pin

install

insulators in the disc brake caliper by fabri-

cating a tool for this purpose.

inside of the locating pin insulators with silicone dielectric grease. Install the caliper locating pins

into

assembly by

Torque the caliper locating pins

1. 14.

lbs.

ft.

Install the

85-104 15.

If

ft.

to

(61-88 Nm).

lbs.

lbs.

tire

assembly.

pattern to

in a star

(115-142 Nm).

equipped with

16.

Position Caliper Piston Tool

T87P-

the rear disc brake caliper. Be

sure the pins on the tool are

meshed

If

air

suspension, turn

ON

posi-

the brake pedal prior to

in

make sure

to bleed the

hydraulic brake system. 17.

Fill

DOT

the master cylinder reservoir with

3 brake

fluid

from a closed con-

tainer.

18.

Road

test the vehicle

and check

clockwise

until the piston is

seated

in

Lincoln Mark

the

caliper.

pads

FRONT Install the inner

in

and outer disc brake

Make sure

the support bracket.

tire

1

the

2.

Position the disc brake caliper above

the rotor with the anti-rattle spring located

.

the

3. 4.

Make sure

the inner pad

is

properly posi-

Turn the

switch to the

caliper over the rotor with a rotating motion.

Install

Remove and

discard Vz of the brake

from the brake master cylinder.

fluid

pads are on the correct sides. .

VIII

air

OFF

Remove Remove

suspension service position.

the wheel

and

tire

assembly.

the disc brake caliper pin

retainers from the locating pins

and remove

the caliper from the anchor plate and disc

assembly.

(115-142 Nm).

equipped with

air

suspension, turn

ON

posi-

tion.

Pump

the brake pedal prior to

mov-

ing the vehicle to seat the brake pads. 5.

17.

If

the disc brake calipers were

replaced or repaired be sure to bleed the hydraulic brake system. 18.

clean

Fill

DOT

the master cylinder reservoir with

3 brake fluid from a closed con-

tainer.

19.

Road

test the vehicle

and check

for

proper brake system operation.

REAR If

air

equipped with

air

suspension, the

suspension switch, located on the

hand side

of the

must be turned

right-

luggage compartment,

to the

OFF

position before

1

9

Oise Brake Caliper Housing

10

2

Caliper Piston

3

Brake Piston Seal

4

Piston Boot

Remove and

properly dispose Vz of 5

Front

Wheel Disc Brake

Shoe

Insulator (2 Req'd)

6

Brake Shoe and

7

Front Disc Brake Caliper Anchor Plate

8

Brake Shoe Hold-Down

the brake fluid from the master cylin-der.

3

Remove

the rear wheel

and

tire

assembly.

4

Release the tension from the parking

Rear Brake Pin Retainer (2 Req’d) Disc Brake Caliper Locating Pin

Caliper Guide

1

raising the vehicle.

2

Pm

Excluder

12

Wheel Cylind/r Bleeder Screw

13

Bleed Screw Cap

Lining

A

Tighten to 3 1-38 N-m (23-28 Lb-Ft)

Spring

brake cable and disconnect the parking 93006G33

brake cable from the disc brake caliper.

Remove

for

proper brake system operation.

with

a star pattern to

the air suspension switch to the

16.

mov-

was repaired

the disc brake caliper

or replaced,

clean

result.

tioned.

wheel and

Torque the lug nuts

the wheel and

ing the vehicle to seat the brake pads.

bore.

2588-A on

ft.

Pump

15.

Use a C-clamp and an old brake

9.

If

by hand. Torque the

tion.

wood block to seat the caliper piston in Do not allow metal or sharp objects to come into direct contact with the plastic caliper piston surface or damage will its

85-104

in

(26-35 Nm).

the air suspension switch to the

if

required.

on the lower adapter support arm.

hand. 13.

rotor

lbs.

Torque the lug nuts

14.

pad,

1 1

and thread them

the spindle/anchor plate

45-65

stamped on the

thickness

install:

8.

10.

Lubricate the locating pins and the

12.

is

minimum

Install

ft.

the slots on the piston. Rotate the tool

pad and the piston. 1 1

and wear. Replace or machine, as nec-

specification

tion.

10.

ing

19-26

pins to 13.

inner disc brake

making sure

the anti-rattle clip.

install

and outer disc

Inspect the disc brake rotor for scor-

7.

anti-rattle clips.

Install the correct

9.

pad

the inner

essary. Observe the

result.

pad

Remove

6.

Insert 2 disc brake caliper locating

12.

pins and thread them

brake pads.

bore.

in its

objects to

and

anchor plate using a rotating motion.

Use a C-clamp and an old brake

7 pad.

FORD MOTOR COMPANY

2 caliper locating pins.

Lift

Front disc brake pads and related

components

— Mark

VIII

yf.OC

BRAKES

**

FORD MOTOR COMPANY brake

Suspend

rotor.

the caliper inside the

fender housing with a length of wire. let

not

Remove

Do

necessary.

the inner and outer disc

not exceed the

minimum

Do

necessary.

not exceed the

minimum

allowable thickness stamped on each disc

brake

brake

To

Using a C-clamp and a block

7.

wood

of

1 1

into the caliper

housing

disc brake pads to Install

8.

brake pads

to allow for the

until

Using Caliper Piston Adjuster T87Protate the disc brake caliper piston

seated

is fully

it

pads to

braking surface. This prevents pinch-

caliper piston.

retainers to the locating pins, by

Torque the caliper pin retainers

hand

to

ft.

(22-32 Nm).

lbs.

1 1

.

Install the

Torque the lug nuts

85-105 12.

lbs

ft.

Turn the

13.

Pump

assembly

14

85-105

ing the vehicle to seat the disc brake 14.

If

movpads

15.

16.

1 7.

the brake master cylinder as

needed with clean

DOT

3 brake

fluid

Road

from a

and check

for

proper brake system operation

1

fluid

.

Verify that the parking brake control

released. 3.

switch to the 4.

5.

air

OFF

Remove Remove

the brake pedal prior to

tire

assembly

the retaining clip from the at

the disc brake

Release the parking brake cable ten-

7.

Remove

test the vehicle

and check

lor

sandpa-

C-clamp and an old brake

a

Remove

all

rust buildup

from the

Make sure

8

and

that

is installed

it

Install

Make

brake pad.

not bend the pad clips

126-169

in the

disc brake caliper over the

2 new anchor bracket

bolts.

Torque the bolts to

lbs

ft

(170-230 Nm) wheel and

Torque the lug nuts

12.

If

disc

install

Install the

85-104

piston or distortion

Install the outer

sure the clips are properly

Install the

and

mounting

holding ability or retention capability and must not be reused.

Do

can occur

rattles

10.

their torque

from the lining

the inner disc brake pad to the

during installation

rotor

•Before continuing with this procedure, make sure to have available. 2 new disc brake caliper anchor bracket mounting bolts, per caliper. Once

is

side

Ford Crown Victoria

Town Car

the anti-rattle spring

seated in the caliper lining inspection open-

seated

ft

lbs.

in

tire

assembly.

a star pattern to

(115-142 Nm).

equipped with

air

suspension, turn

the air suspension switch to the

ON

posi-

tion.

13.

Pump

the brake pedal prior to

mov-

ing the vehicle to seat the brake pads. 14.

FRONT

clean If

retainers securing the caliper to the locating

equipped with

air

Fill

the master cylinder reservoir with

DOT 3

brake fluid from a closed con-

suspension, the tainer.

air

suspension switch, located on the

hand side

Please

grit

wood block to seat the caliper piston in its bore Do not allow metal or sharp objects to come into direct contact with the plastic caliper piston surface or damage will

and

the disc brake caliper pin

pins.

Use

6.

caliper piston.

sion and disengage the cable end from the caliper lever.

medium

sure to wear an approved respira-

pad,

ing

brake fluid from a

removed, these parts lose

caliper.

is

To install:

proper brake system operation.

Lincoln

machining

If

tor.

9

DOT 3

rotor thickness speci-

when machining.

Make

per.

movpads

the brake master cylinder as

Road

minimum

Refer to the fication

11.

position.

the wheel and

faces for scoring and machine as necessary.

7

the disc brake calipers were

Fill

and outer disc

the inner

inside of the caliper legs

position.

suspension service

parking brake cable

6.

If

Remove

brake pads. Inspect the rotor braking sur-

result.

Mercury Grand Marquis

Turn the

not allow the caliper to hang from the

suspension service

discard Vi of the brake

from the brake master cylinder.

2. is

air

needed with clean

19.

Remove and

(115-142 Nm).

ON

Pump

assembly

closed container.

REAR

Do

brake hose.

brake system. 18.

test the vehicle

lbs.

tire

a star pattern to

replaced or repaired, be sure to bleed the 1.

closed container. 16.

ft.

in

ing the vehicle to seat the disc brake

brake system. Fill

the wheel and

Turn the

switch to the

the disc brake calipers were

replaced or repaired, be sure to bleed the

15.

Install

Torque the lug nuts

position.

the brake pedal prior to

lbs.

(31-35 Nm).

pattern to

suspension service

air

ft.

the

rotor

using a rotating motion. Suspend the

by hand.

in

Torque the pin retainers to 23-26

(115-142 Nm)

ON

switch to the

in a star

tire

on the support bracket.

pin retainers to the caliper

and thread them

Lift

caliper inside the fender housing with wire.

braking surfaces with

Install the caliper

locating pins

wheel and

disc brake caliper anchor

not necessary, hand-sand the glaze from the

Rotate the disc brake caliper over the

rotor into position

16-23

Check

correctly installed to the slot in the

13.

tire

assembly from the disc brake

5.

on the inner disc brake pad

that the nib

pad and the piston. the disc brake caliper pin

Be sure

with the

the rear disc support bracket.

in

is

Install

the caliper.

meshed

and outer disc brake

Install the inner

ing the piston boot between the inner brake

10.

in

be sure the pads are on the correct sides,

and

the front wheel and

Remove 2

4.

on the piston.

12.

pad against the

Remove

3.

caliper

.

slots

the disc brake caliper over the

fluid.

install:

the pins on the tool are

the caliper.

rotor with the outer brake rotor's

new

the brake rotor

the inner, then outer disc

in

Install

9.

fit

the brake fluid from

bracket mounting bolts and discard.

2588-A,

press the disc brake caliper piston

Vfe of

rotor.

To

install:

position before

assembly.

allowable thickness stamped on each disc rotor.

Remove

2.

runout and wear. Replace or machine as

ing,

OFF

Properly dispose of the used brake

Inspect the disc brake rotor for scor-

10.

to the

the brake master cylinder reservoir.

bracket.

Inspect the disc brake rotor for scor-

must be turned

raising the vehicle.

Remove

9.

runout and wear. Replace or machine as

ing,

away from the disc

rotor.

brake pads from the disc brake support

the outer, then inner disc

brake pads from the caliper. 6.

Rotate the caliper

8.

brake

hang by the brake hose.

the caliper 5.

Do

visit

of the

our web

right-

15.

luggage compartment,

site at

www.chillonsonline.com

If

the disc brake calipers were

BRAKES

4-26

FORD MOTOR COMPANY necessary, hand-sand the glaze from the

braking surfaces with

Make To

medium

grit

sandpaper.

sure to wear an approved respirator. install:

Use a C-clamp and an old brake

8.

wood block to seat the caliper piston in its bore. Do not allow metal or sharp objects to come into direct contact with the pad,

plastic caliper piston surface or

damage

will

result.

Remove

9.

rust buildup

all

from the

inside of the caliper legs. 10.

Install the inner disc

caliper piston.

Do

during installation

and

brake pad to the

not bend the pad clips in

the piston or distortion

rattles

can occur.

Install the

brake pad.

Make sure

the clips are properly

outer disc

seated.

^Make

sure the insulators are

installed on the brake pads. 1 1

Install the

.

disc brake caliper over the

disc brake rotor and install 2 caliper retain-

16-20

ing bolts. Torque to

ft.

lbs.

(22-27

Nm). 12.

Install the

wheel and

Torque the lug nuts

85-104 13.

Item i

2

2.

Description

the air

Bolt (2 Req’d)

ft.

If

lbs.

in

tire

assembly.

a star pattern to

(115-142 Nm).

equipped with

air

suspension switch

suspension, turn

to the

ON

posi-

tion.

the brake pedal prior to

mov-

ing the vehicle to seat the disc brake

3

Rivet (3 Req'd)

4

Wheel Hub

5

Washer

6

Front Disc Brake Rotor

7

Wheel Hub Without ABS

with

Pump

14.

Disc Brake Caliper

pads.

ABS

15.

(2 Req'd)

Fill

DOT

clean

the master cylinder reservoir with

3 brake

fluid

from a closed con-

tainer.

16.

If

the disc brake calipers were

replaced or repaired be sure to bleed the

8

Front Disc Brake Rotor Shield

9

Front

system.

Road

1 7.

10

Wheel Spindle

test the vehicle

and check

for

proper brake system operation.

Front Disc Brake Caliper Anchor Plate Assembly

Brake Drums 93006G83

Exploded view

of the front disc

assembly— Crown

Victoria,

replaced or repaired be sure to bleed the

system. 16.

3.

Town

REMOVAL & INSTALLATION Car,

Remove

Grand Marquis

the rear wheel and

Focus

tire

assembly.

Road

1

test the vehicle

and check

for

proper brake system operation.

4.

Remove 2

Remove

.

disc brake caliper retain-

Rear wheel

•

Wheel speed sensor,

•

Brake drum, bearing and spindle

ing bolts. 5.

REAR

Lift

the disc brake caliper off the disc

brake rotor and anchor plate using a rotat1

air

If

equipped with

suspension, the

air

ing motion.

suspension switch, located on the right-

hand side

of the

must be turned

luggage compartment,

to the

OFF

7.

ing of the brake fluid

from

the brake master cylinder reservoir. Properly

dispose of the used brake

fluid.

Remove

the inner

and outer disc

brake pads.

position before

raising the vehicle.

Remove Vz

6.

Refer to the cation

install:

2.

Install or

•

faces for scoring and

minimum

rotor thickness specifi-

when machining.

If

machining

is

not

equipped

,

connect the following:

Brake drum, bearing and spindle assembly. Tighten the bolts to 49

rotor braking sur-

machine as necessary.

if

assembly.

To

Inspect the disc brake rotor for scor-

and wear. Inspect the

or disconnect the following:

•

lbs.

(66 Nm).

•

Wheel speed sensor,

•

Rear wheel

if

equipped

ft.

1

BRAKES

4-27

FORD9. MOTOR COMPANY Ford Contour

b.

A

forward motion of the tool

wheel and allow the brake shoes to 1

Remove Remove

.

2.

the wheel and the brake

tire

drum

assembly.

retainers,

c.

5.

Grasp the brake drum and remove.

4.

If

the

light force,

be backed a.

drum

will

not slide

off

with

sure the brake

drum and shoes

6.

Position the brake

drum onto

7.

the

the parking brake control sev-

times to adjust the rear brake shoes.

Pump

10.

move 1

the brake pedal several times

good pedal before attempting

to

the vehicle.

Road

.

test the vehicle

and check

for

proper brake system operation.

the

Ford Taurus

wheel hub.

as follows:

Removelhe rubber plug on

Make

eral

to assure a

are clean of any oils or protective coatings.

then the brake shoes will need to off

retract.

the brake drum.

To install:

if

installed. 3.

Remove

Work

will

separate the quadrant from the knurled

Mercury Mystique

Install

new brake drum

retainers

if

Mercury Sable

available.

backing plate and insert a screwdriver or

8.

small brake adjusting tool into the slot to

and

Reinstall the wheel

Torque the lug nuts

to

94

ft.

tire

lbs.

assembly.

(128 Nm).

contact the brake strut and quadrant.

1

Remove Remove

.

2.

and

the wheel

tire

assembly.

the brake drum.

—If the brake drum cannot be removed easily,

remove

the brake tube-to-axle

retention bracket and pry rubber plug

from rear brake backing plate inspection hole. This will allow sufficient

room

screwdriver and disengage brake shoe adjusting lever and back off the brake for insertion of a

brake tools

to

adjuster screw.

3

Inspect the

drum

Machine or

other wear

for

scoring and/or

replace, as necessary.

To install:

Measure the brake drum inside diam-

4

D81L-1 103-A brake adjustment

eter using

gauge.

5

Using the brake adjustment gauge,

adjust the brake shoes to the

sions as the brake

6

same dimen-

drum

Position the brake

drum over

the

brake shoes on the axle hub

7 Positioning a screwdriver to release the brake

Install the

wheel and

lire

Torque the lug nuts to 85-104

shoes— Contour. Mystique

assembly ft

lbs.

(115-141 Nm).

8

Pump

the brake pedal several times

to position the brake

shoes and complete

the adjustment

9

Road

test the vehicle

and check

for

proper brake system operation.

Ford Escort

Mercury Tracer 1

2

Remove the wheel and tire assembly. Remove 2 brake drum retaining

screws 3.

necessary

mum

drum from the hub drum and refinish or replace, as

Pull the brake

Inspect the

If

refinishing,

check the maxi-

inside diameter specification.

To install: 4

If

needed, adjust the brake shoes to

fit

the brake drum.

Retracting the brake shoes to allow

drum removal

5.

Place the brake

6

Install

Torque

— Taurus and Sable

7.

Timing belt service

is

covered

in

Section

3

of this

to

89-123

Install the

manual

drum on

the hub.

2 brake drum retaining screws. inch lbs. (10-14 Nm).

wheel and

tire

assembly.

BRAKES FORD MOTOR COMPANY Torque the lug nuts

to

73-100

lbs.

ft.

(100-135 Nm). 8.

the brake

Check

system

Lower

•

Parking brake cable

cylinder and anchor block

operation.

Brake shoe hold-down springs and

•

Ford Mustang

pins 3.

1

.

2.

Remove Remove

the wheel

and

tire

Brake drum, bearing and spindle

•

assembly.

assembly. Tighten the bolts the

drum

retaining nuts,

equipped, and remove the brake drum. Inspect the brake

drum

and wear. Check the drums

for

to

49

ft.

if

(66 Nm).

lbs.

3.

return spring

Brake shoe assembly to the wheel

•

proper

for

•

•

Wheel speed sensor,

•

Rear wheel

if

equipped

scoring

for conditioning

Operate the brake pedal to adjust the

and wear. Replace or machine as necessary. If

maximum diame-

machining, observe the

ter specification.

To

install:

4.

If

a

installed,

Ford Contour

new brake drum

being

remove the protective coating

1

Remove

.

drum using Brake Adjusting Gauge D81L1103-A.

Remove

2.

the brake drum.

6.

Install

7.

Install the

8.

Complete the brake adjustment by

carefully backing the vehicle

and

tire

drum

retainers,

If

the

light force,

be backed

up several

drum

not slide

then the brake shoes

off

need

lbs.

Brake Shoe Retracting

5

Parking Brake Return Spring

6

Brake Shoe Hold Down

7

Anchor Block

8

Brake Shoe Hold Down Spring Pin

Rear Brake Backing Plate

the rubber plug on the

small brake adjusting tool into the slot to

25

93006GS0

Location ot brake components

(ill N).

test the vehicle

4

9

mum

Road

Rear Brake Shoe and Lining

to

backing plate and insert a screwdriver or

force of

Rear Wheel Cylinder

3

Spring

times while applying the brakes with a mini-

9.

and

Spring

with

will

Strut

if

off:

Remove

a.

will

Rear Brake Quadrant

2

Grasp the brake drum and remove.

4.

assembly.

the brake

equipped. 3.

tire

the rear wheel

assembly.

Adjust the brake shoes to the brake

wheel and

1

Mercury Mystique is

from the drum using brake cleaner. 5.

rear brakes.

and check the

Contour/Mystique contact the brake strut and quadrant.

brake system for proper operation.

b.

A

forward motion of the-screw-

driver will separate the quadrant from the

Brake Shoes

knurled wheel and allow the brake shoes to retract.

Remove the brake drum. Remove the brake shoe hold down springs and the brake shoe hold down pins. 6. Remove the brake shoe retracting

REMOVAL & INSTALLATION

c.

5.

Focus 1

.

Remove

or disconnect the following:

Rear wheel

•

Wheel speed sensor,

•

Brake drum, bearing and spindle

if

equipped

assembly •

springs. 7.

•

Brake shoe hold-down springs and

Disengage the parking brake cable

and conduit from the parking brake 8.

Remove

9.

Disengage the

lever.

the brake shoes. rear brake strut

and

Lubricating points on backing

quadrant from the rear brake shoe.

tour/Mystique

pins •

Brake shoe assembly from the

wheel cylinder and anchor block •

Parking brake cable

•

Lower

return spring

•

Upper

return spring

•

Primary shoe from the strut and brake shoe adjuster

•

Parking brake return spring

•

Secondary shoe from the

strut

sup-

port

To 2.

install: Install or

connect the following:

•

Secondary shoe

•

Parking brake return spring

•

support

Primary shoe to the strut and brake

shoe fully •

to the strut

PLATE

adjuster. Rotate the adjuster

93006G51

clockwise.

Upper

return spring

Removal

of

parking brake cable

— Contour/Mystique

plate— Con-

— A m 9Q “ L.*J

BRAKES FORD MOTOR COMPANY rear brake strut

Engage the

14.

adjuster assembly off the backing plate and

and

wheel cylinder assembly.

quadrant.

adjusting

spring. Reinstall the brake

16.

shoe hold down

down

spring pin and the hold

shoe

into

points.

pin and hold

down

ter— Contour/Mystique

shoe

Discard the horseshoe

retracting

To

20. Adjust the brake shoes by

where

the brake shoes contact the backing

gauge.

plate.

Insert a small screwdriver or similar

.

and quadrant

quadrant

of the

to the

brake

drum by expanding

22.

Trial

of the

of the

adjusting screw and install the socket. Turn the adjusting screw into the adjusting pivot

nut to the limit of the threads and then back

the brake drum The shoes

fit

off Vfe turn.

Assemble the parking brake

10.

properly adjusted.

Make

washer over the socket end

steel

the brake strut

should just contact the drum surface when

23.

of lubricant to the

the adjusting screw. Install the stainless

to adjust the brake

same measurement

shoes

Apply a thin coat

9.

adjuster screw threads and socket end of

brake

and quadrant.

fit

coating of disc brake

with an appropriate brake adjustment

strut

Adjusting the brake shoes to

light

caliper slide grease at the points

tool into the knurled

93006G54

Apply a

8.

first

clip.

install:

measuring the inside drum diameter

21

BEAR BRAKE STRUT AND QUADRANT

slide the lever off the

parking brake lever pin on the trailing shoe.

springs.

Measuring the brake drum inner diame-

the horseshoe retaining clip

and spring washer and

shoe hold down

spring.

Reinstall the brake

19.

93006G53

Remove

7.

rant.

Reinstall the brake

the retracting springs

from the lower brake attachments and upper shoe-to-adjusting lever attachment

the slot on the rear brake strut and quad-

18.

lever.

Remove

6.

spring.

Insert the leading brake

17

When removing

the assembly, be careful not to bend the

Reinstall the parking brake rear

15.

lever to

the trailing shoe by installing the spring

drum and

sure that the brake

brake shoes are clean of any oils or protec-

washer and a new horseshoe retaining

tive coatings.

Crimp the

the

drum— Contour/Mystique

24

Reinstall the brake

25.

Reinstall

new drum

retainers,

brake cable.

rear

may be necessary

to

back

on the park-

off

Position the leading shoe on the

12

cable and conduit to the parking brake lever It

Position the trailing shoe on the

1 1

if

backing plate and attach the rear parking

Reconnect the parking brake

26.

backing plate and attach the lower brake

ing brake cable adjustment to allow for the

shoe adjusting spring

new brake shoes.

shoes.

Reinstall the wheel

27. bly.

and

Torque the lug nuts to 62

tire ft.

13

assem-

lbs.

slots

(85

Work

28

Install the adjuster

ing shoe.

the parking brake control sev-

times to complete the brake shoe

adjustment and

to

end

ted

to the brake

end must

The narrow

fits

into the

slot

fit

in the

on

slot

into the lead-

on the dual

shoe adjusting

The single slotted side

check the parking brake

assembly

on the brake shoes. The wide

the dual slotted

Nm).

eral

clip

retains the lever to the

it

shoe securely.

drum.

available.

BRAKE

clip until

slot-

lever

of the adjuster

93006GS5

assembly must

adjustment as well. Measuring the brake shoe adjustment Contour/Mystique

Pump

29

to assure a

30. 10.

Remove

the parking brake rear

test the vehicle

for

••The adjuster socket blade

proper brake system operation.

trail-

R

is

for the right or L for the left

marked brake

assemblies. The adjuster blade must be installed with the letter R or L in the

brake cable anchor on the trailing brake

Ford Taurus

shoe.

Mercury Sable

1 1

on the

bracket

and check

cable and conduit from the parking

To

into the slots

ing shoe and the rear parking brake cable

the brake pedal several times

good pedal

Road

fit

upright position, facing the wheel

install: .

Lubricate the rear brake shoe contact

points on the backing plate with an appro-

Engage the parking brake

and conduit

13.

rear cable

into the parking brake cable

anchor on the

.

trailing

Position the trailing brake shoe on

the backing plate.

the wheel and

tire

cylinder.

assem-

bly.

3.

Remove Remove

the brake drum.

Remove

the 2 brake

springs and pins. 5.

Lift

Complete the

Pump

is

installation

brake shoes and finish the

brake shoe adjustment.

covered

in

Section

2

by revers-

the brake pedal several times

to position the

the brake shoes, springs.and

Heater Core replacement

the adjuster socket

brake lever.

ing the removal procedures.

15

shoe hold-down

Make sure

into the parking

14

the parking brake cable from

the parking brake lever. 4.

brake shoe.

Remove

fits 2.

priate grease.

12.

1

of this

manual

OH 4 “Oil

BRAKES FORD MOTOR COMPANY

1

Parking Brake Lever Pin

14

Boot

(Inner)

2

Spring Expander

3

Rear Wheel Cylinder

4

Piston and Insert

5

15

Brake Shoe Adjusting Screw Socket

16

Brake Shoe Adjusting Lever

17

Parking Brake Lever Pin

18

Leading Shoe and Lining

19

Brake Shoe Adjusting Screw

Shoe Adjustment Access Hole

6

Wheel Cylinder Retaining

7

Brake Adjusting Hole Cover

8

Brake Shoe Hold-Down

Bolt (2 Req'd)

Spring

16.

20

Cup

21

Washer

Rear Brake Backing Plate

22

Brake Adjuster Screw

Shoe and

23

Washer

24

Parking Brake Lever Retainer

25

Adjusting Pivot Nut

Spring Pin 9

10 11

Trailing

Lining

Brake Shoe Hold-Down Spring

12

Brake Shoe Retracting

13

Parking Brake Lever

Spring

A

Pm

Tighten to 12- 18 N-m

(107-159 Lb-In)

93006G56

Brake shoes and related

Road

components— Taurus and Sable

test the vehicle

and check the

brake system for proper operation.

Use a suitable high temperature

7.

grease to

Ford Escort

screwdriver into the knurled quadrant of the

To install:

lightly lubricate the

contact points on the backing plate.

Mercury Tracer

Position the trailing brake shoe on

8.

and

the backing plate 1

.

Remove

brake shoe

the wheel

and

tire

assem-

install

one

of the

brake shoe hold-down springs.

rear

quad operating

shoes

to the

2.

Remove 2 brake drum

retaining

screws and remove the brake drum. 3. 4.

Remove Remove

2 brake shoe return springs. the right-hand anti-rattle

and

install the

other brake

15.

Install the

16.

Install

right-hand anti-rattle

Install the

brake drum.

2 brake drum retaining

17.

Install the

wheel and

Torque the lug nuts

to

tire

65-87

ft.

assembly. lbs.

(88-118 Nm).

shoe hold-down spring. 10.

as the

screws.

Position the leading brake shoe on

the backing plate

and adjust the

brake drum.

bly. 9.

lever

same measurement

18.

Complete the brake shoe adjust-

ment by sharply applying the brakes sev-

spring.

spring. 1 1

5.

Push and turn

to release

2 brake

shoe hold down springs and remove the

.

12.

Install

2 brake shoe return springs.

Using a brake adjusting gauge, mea-

sure the inside diameter of the brake drum.

eral

times while driving the vehicle

alternating between forward and reverse

gears.

springs. 13. 6.

Remove

the leading

and

shoes from the brake backing

trailing

ment

plate.

14.

Compare

the brake

to the brake

drum measure-

shoes.

Adjust the brake shoes by inserting a

19.

Check

the brake

system operation by

making several stops while driving forward.

BRAKES

4-31

FORD MOTOR COMPANY

Separate the brake shoes by remov-

7.

shoe

ing the brake

Remove

8.

retracting springs.

the parking brake lever pin

and spring washer, then remove the

retainer

brake shoe adjusting lever from the adapter

To

install:

Apply a

9.

light coating of caliper slide

grease to the brake backing plate brake

shoe contact areas as well as the adjuster screw threads.

Assemble the adjuster screw and

10.

the

brake shoe adjusting screw socket and washer. Turn the brake shoe adjusting screw

socket

all

way down, then back

the

trailing

turn.

off

parking brake lever to the

Install the

11.

shoe with the spring washer and a

new parking brake

lever pin retainer.

Crimp

the retainer to securely retain the parking

brake

lever.

Place the trailing shoe on the brake

12.

backing plate and attach the parking brake 1

2

Parking Brake Link Spring

Brake Shoe

HoM-Down Spring

Pin

7

Brake Shoe Hold-Down Spring

8

Brake

Drum Screw (2

9

Brake

Drum

cable.

Req'd) 13.

Install

Rear Brake Backing Plate

10

Brake Shoe Retracting Spnng

Rear Wheel Cylinder

11

Parking Brake Lever

backing plate and attach the lower brake shoe

5

Right

12

Parking Brake Return Spnng

retracting spring

6

Rear Brake Shoe and Lining

13

Brake Adjusting Hole Cover

Hand Anti-Rank Spnng

Place the leading shoe on the brake

14

Install the

down

pin, spring

16

retainers, brake

shoe hold-down springs

Install

Remove the wheel and

tire

assem-

bly.

5.

Lift

adjuster 2.

Remove

3.

Disconnect the parking brake rear

the brake drum.

the brake shoes, springs

oft of

and

the brake backing plate as an

assembly using care not to bend the brake

cable from the parking brake lever

Remove 2 brake shoe hold-down

shoe adjusting 6.

Remove

leading brake shoe hold-

and

retainers.

the brake adjuster assembly

between the brake shoes The

brake shoe adjusting screw socket end

must

and hold-down pins.

between both brake shoes.

15.

— Escort/Tracer

Mercury Cougar (1998 Model)

4.

pin,

4

to the slots

.

hold-down

3

Brake shoes and related components

1

the brake shoe

spring and retainers on the trailing brake shoe

fit

into the slot in the leading

and the adjuster nut end must slots of the trailing brake

brake

17

fit

shoe

into the

shoe and parking

lever. Install the

brake shoe adjusting lever

lever.

the brake

shoe adjusting

screw spring.

on the pin in the

of the leading

shoe and

to the slot

brake shoe adjusting screw socket

18

Install the

upper brake shoe

ing spring in the slot

and the

on the

trailing

retract-

shoe

brake shoe adjusting

slot in the

lever Verify that the brake

shoe adjusting

lever is contacting the starwheel

on the

adjuster assembly

19

Adjust the brake shoes to the brake

drum. 20.

Install the

brake drum.

21

Install the

wheel and

tire

assembly

Using a torque wrench, torque the lug nuts in

a star pattern to

85-105

ft

lbs.

(115-142

Nm).

22

Apply the brakes several times

while backing up the vehicle. After each stop, the vehicle

23.

Road

must be moved forward

test the vehicle

and check

for

proper brake system operation by making Checking the adjustment

of the

brake shoes

— Escort/Tracer

For complete Engine Mechanical specifications, see Section

several stops from varying forward speeds

1

of this

manual

BRAKES

4-32

GENERAL MOTORS

1998-01 GENERAL 7.

Brake Caliper

Remove

the caliper

MOTORS

the rubber dust boots from

mounting

heads

bolt

Road

equipped).

REMOVAL & INSTALLATION 8. 9.

GM

C-

& H-BODIES:

the caliper

Buick LeSabre, Park Avenue

10.

Oldsmobile Eighty Eight Royale,

11.

To

Ninety Eight, Regency

12.

Pontiac Bonneville

(if

the caliper

mounting

bolts.

Remove Remove

Bosch 2U ABS system cannot

for

GM

rear).

E- K-

V-BODIES:

the caliper from the vehicle.

Cadillac Catera, deVille, Eldorado,

the brake pads.

Seville

install: Install the

brake pads. Lubricate the

mounts on

FRONT

the

1

steering knuckle with silicone grease.

increase brake pressure above master

and check

test the vehicle

proper braking performance

the park brake cable from

working on the

slides where the caliper

FRONT & REAR ^The

Remove Remove

recommended

brake system using the the22. procedure.

(if

13.

Install the caliper

over the

14.

Install the caliper

mounting

Torque the mounting bolts

to

38

Remove

%

of the

brake fluid from

the master cylinder.

rotor.

bolts. lbs. (51

ft.

Disconnect the negative battery cable.

.

2.

Remove

3.

Mark

the front wheel.

relationship between the wheel

the

and the

cylinder pressure applied by during

braking. There ize the

no need

is

system prior

depressur-

to

wheel stud

Nm). 15.

Install the

park brake cable

(if

work-

Remove brake

fluid

from the master

cylinder reservoir until the reservoir

approximately 2.

is

the front wheel.

16.

Install the

rubber dust boots over

the caliper mounting bolt heads

Mark

the

17.

prior to removal, for installation reference.

the clearance

2 lug nuts to retain the rotor

once the caliper 4.

piston

is

removed.

Using a large C-clamp, bottom the in

the caliper bore by positioning the

C-clamp on the outboard pad and on the round portion piston 5.

is

of the

brake caliper where the

housed.

Remove

the banjo bolt that fastens

the gaskets. 6.

Cap

keep the rotor

the brake line to avoid excessive

contamination.

Using a large C-clamp against the

5.

is

removal. If

too tight, check the caliper

6.

Place a catch pan under the caliper.

7.

Disconnect the brake hose from the

Cap

leading and trailing edges for build up. File

caliper.

down as

fluid loss or

18.

necessary.

Connect the brake hose

caliper. Install the

to the

brake hose banjo

using new gaskets, and torque to 33

bolt, ft.

lbs.

the lug nuts used to secure

mounting bolts

for

wear and/or damage. Replace

parts as necessary.

To

Install the

the caliper

Inspect the mounting bolts; sleeves

9.

the rotor. 20.

contamination.

and remove the caliper from the vehicle.

and boots

Remove

the lina to prevent excessive

Remove

8.

(45 Nm). 19.

the brake hose to the brake caliper. Discard

fluid loss or fluid

purposes.

into the caliper to provide clearance during

Check the clearance between the

brake caliper and caliper bracket stops.

Install

to

inboard pad, compress the caliper piston

(if

position of the wheel to the wheel studs,

3.

2 wheel nuts

in place.

equipped).

full.

Remove

for re-installation

Install

to service. ing on the rear).

1.

4.

wheel, aligning the refer-

install:

Before installing the caliper,

10.

make

ence marks made during removal, and

sure the piston

torque the lug nuts to 100

and the brake pads are properly seated.

21.

Refill

ft.

lbs.

(140 Nm).

the master cylinder and bleed

1 1

is fully

seated

the bore

in

Lubricate the mounting bolt shafts

.

and inner diameter

of the

sleeves with

sili-

cone grease. 12.

Install the caliper in the caliper

mounting bracket and bolts.

to

38

ft.

Nm).

lbs. (51

13.

mounting

install the

Torque the mounting bolts

Connect the brake hose with the

and new gaskets. Torque the brake hose to

33 14.

ft.

lbs.

Refill

bolt bolt

(45 Nm). the master cylinder and bleed

the brake system. 15.

Remove

the 2 wheel nuts securing

the rotor.

wheel and

assembly.

16.

Install the

17.

Connect the negative battery cable.

18.

Road

tire

test the vehicle for

proper

brake system operation. '

REAR—DEVILLE, ELDORADO SEVILLE 93006G60

Measuring ;he

aliper clearance

Regency, Bonneville

— LeSabre, Park Avenue, Eighty

1.

Disconnect the negative battery

cable. Eight Royale, Ninety Eight, 2.

Remove

%

of the brake fluid

the master cylinder.

from

A

BRAKES

**

GENERAL MOTORS the parking brake lever and the retaining

3.

Remove

4.

Install 2 wheel nuts to keep the rotor

the rear wheel.

21

in place.

5.

Place a catch pan under the caliper.

6.

Disconnect the brake hose trom the

Cap

caliper.

the line to prevent fluid loss or

contamination.

Remove

8.

by

lever, arid

Remove

10.

Lift

the caliper up and slide the

remove the

suitable tool in the caliper pis-

Use a

11.

ton slots to turn the piston and thread

it

the caliper. After bottoming the piston, the inner

edge

Refill

air

Remove and

into

lift

Compress

must

the boot

Inspect the pin boot, bolt boot and

Remove

6.

and replace as necessary. Inspect the bolt sleeve and pin

sleeve for corrosion or damage.

Pull the

roded or damaged sleeves; do not

14.

If

not replaced,

from the caliper and

support)

boot seats

Hold

15.

the. caliper in

sleeve.

As the

it

caliper

the caliper

of the pin

groove, then push the

in

pads

16.

•

not to

damage

down, being

the piston boot

inboard disc brake pad.

17.

boot

of the

careful

18.

20

ft.

19.

1 1

Fill

lbs.

nec-

1

the bolt to

32

ft.

to

Install the

4

Camaro

Remove

%

Matchmark

completely removing the caliper for

replacement or service, bolt inlet fitting

5

of the

tire

brake fluid from

inlet fitting to

prevent system

and torque

parking brake cable onto

for

II

the caliper it

is

must be

corroded, worn or

damaged

inlet fitting bolt for

blockage,

clear or replace as necessary. 7.

8

1

if

Check the

rotor

fluid loss.

see Section

to the

Inspect the guide pins and boots and

replace

inlet fitting to

illustrations,

damage

install:

6

replacement or service,

housing and

order to prevent

in

To

and 2 gaskets from the caliper housing Plug the openings

For Accessory Drive Belt

the caliper housing from the

caliper guide pin

brake lines

bolt, inlet fitting

in the caliper

Remove

2

and mounting bracket

hook

prevent system contamination or excessive

(43 Nm).

the

suspended trom the vehicle using a wire the relationship of the

completely removing the caliper

from the vehicle

fluid loss.

Remove

not being completely removed,

assembly. If

and

bolts

wheel and hub, then remove the wheel and

remove the

parking brake cable

lbs.

.

3.

(27 Nm).

Install the

F-BODY:

2.

and torque

If

housing and

wheel(s).

the master cylinder

If

2 wheel nuts to

2 gaskets from the caliper housing 3 Plug the openings in the caliper

second retaining pin

and bleed the brake system

Install the

Install

remove the brake hose

spring retainer.

rotor

on the bracket abutments.

Install the sleeve bolt

.

Chevrolet

moves

clips.

bracket, with the cable attached,

20.

Install the

assembly.

lire

from the vehicle

Pontiac Firebird

essary, use a small prybar to reseat or enter the pad clips

one

Install the caliper

and hub, then remove the wheel

retain the rotor.

2

Install

12.

and

fit-

Nm)

caliper retaining pin.

9.

the

damage

pad

lbs (16

ft.

Brake pads

10.

After the caliper is in position,

recheck the position

12

the relationship between

Matchmark

1

the wheel

(80 Nm).

lbs.

ft.

Torque the bolts to

Brake caliper pipe Torque the

the brake pedal

contamination or excessive

on the

Compress

sleeve boot by hand as the caliper into position to prevent

caliper.

8.

GM

Pivot the caliper

Brake

vehicle, then with the

pump

REAR

connect the following

Install or

Lower the

12.

caliper

onto the pin.

earlier

Brake caliper

ting to

boot

made

assembly.

•

pin

approaches the pin

tire

slowly and firmly 3 limes to seal then brake

59

over the end of the pin

work the large end

boot,

fully

start

and

the wheel and

install

Caliper mounting bolts

•

the position as

Align the matchmarks

1 1

•

•

sliding the caliper onto the pin sleeve.

removed and

or disconnect the following

engine running

groove. This prevents cutting the pin boot

when

the master cylinder and bleed the

Fill

Brake caliper pipe

small end

in the

10.

to

(40 Nm).

lbs.

ft.

•

over the pin sleeve (installed on caliper until the

fitting,

Brake pads

remove the pin boot

install the

the inlet

Brake caliper spring retainer

7.

away corrosion.

install

brake system.

To install:

try to

removed,

If

and 2 new gaskets. Torque the bolt

•

to the sleeves for

access

to

•

inspection or replacement. Replace cor-

polish

30

to drive the caliper

outside inward.

sleeve boot for cuts, tears or deterioration

boots

bolt

retaining pins out of the caliper from the

To install:

to gain

9.

the pistons into the

punch

down

circlip.

the bleeder screw.

a

Press the caliper housing

8.

compress the bias springs. Slide a new retainer pin into position and install a new

caliper housing to provide clearance.

Use

housing over the

bracket are seated correctly.

caliper.

Open

block-

and onto the mounting bracket. Ensure the guiding surfaces on the inboard and outboard disc brake pads and mounting

Attach a hose to the bleeder screw

4.

Install the caliper

7.

the wheel(s).

3.

inlet fitting bolt for

rotor

1.

on the

Check the

age, clear or replace as necessary.

wheel.

test the vehicle for proper

Road

to the brake

install:

6.

Connect the negative battery cable.

5.

13.

To

install the

damage

lines.

the wheel nuts retaining the

2.

flat.

12.

the master cylinder and bleed

Remove

boot next to the piston

of the

and press out any trapped lay

23.

order to prevent

in

is

must be

hook

REAR—CATERA

caliper from the vehicle.

it

suspended from the vehicle using a wire

26.

caliper inboard off of the pin sleeve to

the caliper

Adjust the parking brake cable.

brake system operation.

the caliper sleeve bolt.

If

not being completely removed,

32

(43 Nm).

25.

up and disengaging the end.

lifting

9.

remove the cable end

retainer pin.

lbs.

rotor

the parking brake cable

and

and mounting bracket.

rotor

bolt

the circlip

the caliper housing from the

22.

24

brake at the equalizer.

mounting

torque the bolt to

the brake system.

Loosen the tension on the parking

7.

and new gaskets and ft.

5.

Connect the brake hose with the

.

Remove Remove

4.

onto the parking brake cable.

clip

Install the caliper

and

into the

Install

of this manual

housing over the

mounting bracket

2 caliper guide pin bolts

start-

BRAKES

4-34

GENERAL MOTORS

9. the upper pin ing with

27

to

and torque the bolts

(37 Nm).

lbs.

ft.

Attach the brake hose to the caliper

using 2 new copper gaskets. Torque the bolt to

22

lbs.

ft.

10.

If

(30 Nm).

the hose fitting

was removed,

bleed the entire brake system. 1 1

Lower the vehicle

.

sufficiently

and COAT BUSHING ASSEMBLY WITH SILICONE GREASE

cycle the parking brake.

PLACES

2

12.

Raise and safely support the vehicle.

13.

Inspect the caliper parking brake

levers

93006G89

Caliper mounting bolt and sleeve lubrica-

and ensure they are against the stops

points— Riviera, Aurora

tion

on the caliper housing. on

If

the levers are not

Compressing the

front caliper

piston— Riv-

check the parking brake

their stops,

Aurora

iera,

14.

and

15.

brake

the 2 nuts securing the

then align the matchmarks

rotor, lier

Remove

made

the wheel assembly.

install

Lower the

Check

contamination.

the piston into the caliper

Remove Remove

the hydraulic

system

8.

the caliper

mounting

9.

remove

G-BODY:

To

FRONT

%

Siphon

3.

Remove Install

the rotor

the

tire

is

Seat the caliper piston Install the

Install the caliper

38

ft.

in

the caliper

Ver-

rotor.

and disconnect the brake

1

63

lbs.

ft.

2.

Remove

3.

Install

to

tire

and wheel assembly.

when the caliper is removed. Remove the bolt securing the brake

4.

hose

to the

the

the

2 wheel nuts loosely to secure

to the caliper

hose from the

new washers. Torque

of the brake fluid out of

the rotor

(85 Nm).

Reconnect the brake hose

caliper using

%

Siphon

.

the master cylinder reservoir.

on the anchor

Nm). Torque the mounting

lbs. (51

removed.

the bolts securing the brake

to the caliper

hose from the

pads against the

pedal.

fully in its bore.

Torque the caliper mounting bolts

13.

14.

hose

brake pads

bracket and install the mounting bolts.

and wheel assembly.

the caliper

Remove

the brake pedal several times

REAR

10.

bolts to 4.

lbs.

no hydraulic leaks and a good firm brake

ify

pads from the caliper or

the brake

11.

12.

2 wheel nuts loosely to secure

when

Pump

18.

anchor bracket.

or of the brake fluid out of

the master cylinder reservoir. 2.

being replaced

install:

Oldsmobile Aurora

.

is

ft.

anchor bracket.

Buick Riviera

1

the caliper

assembly

100

the master cylinder with fluid

Refill

to seat the brake

If

tire

to

and bleed the brake system.

the caliper from the anchor

leaks.

wheel and

Install the

(140 Nm).

for

bracket.

GM

16.

17.

bolts.

the 2 lug nuts securing the

rotor.

and torque the wheel nuts

bore to provide clearance for removal.

firmly 3 times to seat then brake pads.

16.

fluid

the brake pedal slowly 7.

and

and possible

Compress

6.

vehicle, then with the

pump

engine running

Plug the hose to prevent excessive

5.

earfluid loss

Remove

15.

adjustment.

fit-

and disconnect the brake

caliper.

Plug the hose to prevent excessive

5.

fluid loss

and possible

fluid

contamination.

caliper.

ting bolt to

33

ft.

lbs.

(45 Nm).

6. 7.

Remove the park brake cable Remove upper and lower caliper

and

bolts

To

caliper from

lift

mounting bracket.

install:

8.

Seat the caliper piston

9.

Make

fully in its bore.

sure the notches

in

the caliper

piston are at 6 and 12 o’clock. 10.

Mount

Install the

bolts to 1 1

.

63

ft.

lbs.

(85

Nm)

Reconnect the brake hose

to the

new copper washers. Torque

caliper using

the

caliper onto anchor bracket.

2 mounting bolts and torque

mounting

bolt to

12.

Install the

13.

Remove

33

ft.

lbs.

(45 Nm).

park brake cable.

the wheel nuts securing the

rotor.

14.

Reinstall the tire

and wheel assembly

and torque the wheel nuts (1)

Pin Bolts

(2)

(4)

Outboard Pad Caliper Boot inboard Pad

(5)

Piston Seal

(3)

(140 Nm). (6)

Piston

(7)

Anchor bracket

15.

(9)

Caliper Housing

16.

Anchor Bracket

-Riviera, Aurora

ft.

lbs.

the master cylinder with fluid

Pump

the brake pedal several times

to seat the brake 93006G87

Front caliper and brake pad components-

100

and bleed the brake system.

(8) Bleeder Valve

(10) Caliper

Refill

to

,

ify

pads against the

rotor.

Ver-

no hydraulic leaks and a good firm brake

pedal.

BRAKES

4-35

GENERAL MOTORS

GM

J-BODY:

Chevrolet Cavalier Pontiac Sunfire 1

.

Siphon

%

of the brake fluid out of

the master cylinder. 2.

6

Remove

3.

Compress

the

and wheel assembly

tire

the caliper piston back into

the caliper bore using a large pair of pliers.

C-clamp or special piston 4.

the caliper

If

retracting tool.

be completely

to

is

removed from the vehicle

bench service,

for

disconnect and cap the brake line from the Discard the old washers.

caliper. 5.

Remove

the caliper

mounting bolts

and sleeves. 10. 7.

Remove Remove

caliper,

the caliper from the knuckle. the brake pads from the

caliper

if

is

being replaced.

To install: brake pads in the caliper.

8.

Install the

9.

Install the caliper

on the steering

knuckle. Install

the mounting bolts and

40

sleeves and torque to 1 1

If

1

2

3 4

5

6 7

8

9

sleeve

ear

OUTBOARO SHOE A LINING INBOARD SHOE A LININC PAD CLIP WEAR SENSOR PIN BOOT

PIN BOLT

11

PIN SLEEVE

13

PISTON ASSEMBLY

14

PISTON SEAL

the mounting bolt to 12.

8LEEOCR VALVE CAP BLEEOER VALVE 17 LEVER RETURN SPRING 18 BOLT ANO WASHER 19 CABLE SUPPORT BRACKET 20 CALIPER BODY ASSEMBLY 2t caliper support

35

ft.

lbs.

(44 Nm).

master cylinder and bleed

Refill the

IS

the brake system

13

—

Install

and tighten 14

GM

Rear caliper and brake pad components

to

new copper washers. Torque

the caliper using

16

BOLT BOOT SLEEVE BOLT BOLT SLEEVE

to

12

Nm).

was discon-

uncap and connect the brake hose

nected, PISTON BOOT

lbs. (51

ft.

the caliper brake line

the

tire

and wheel assembly

to specification

Verify correct brake operation

L/N and N-BODY:

Buick Skylark Riviera. Aurora

Chevrolet Malibu

Oldsmobile Achieve. Cutlass

SHOE

Sc

Am

Pontiac Grand

PISTON SLOTS MUST BE ALIGNED AS SHOWN BEFORE INSTALLING CALIPER OVER

1

LININGS

Siphon

%

of the brake fluid out of

the master cylinder

2

Remove

3

Compress

the

tire

and wheel assembly.

the caliper piston back into

the caliper bore using a large pair of pliers.

C-clamp or 4

Plug the hose to prevent excessive

fluid loss

6

and possible

Remove

and remove the PISTON BOOT

7

PISTON ASSEMBLY

Remove

caliper,

CALIPER BODY

8 in

the piston

if

fluid

the caliper

caliper from the knuckle.

the brake

the caliper

is

pads from the

being replaced

— Riviera. Aurora

Inspect the condition of the caliper

support

for rust

and corrosion

der the travel of the caliper.

For

Tire,

Wheel and Ball Joint

contamination.

mounting bolts

To install:

ASSEMBLY Aligning the notches

the brake hose from the

and discard the copper washers.

caliper

5

special piston retracting tool

Remove

specifications, see Section

1

of this

manual

that will hin-

BRAKES

4-36

GENERAL MOTORS

9.

Inspect the caliper mounting hard-

New

ware.

bolts are usually

recommended.

Lubricate the mounting bushings and

10.

sleeves with silicone grease as required.

2 wheel nuts to retain the

4.

Install

BUSHING

a large C-clamp over top of

and against the back

the caliper housing

Install

the brake pads in the caliper.

the outboard shoe. Slowly tighten the C-

12.

Install

the caliper on the steering

clamp

13.

40 14.

mounting

the

lbs. (51

bolts

and torque

Connect the brake hose

mounting

bolt to

Refill

35

ft.

5.

to the caliper

lbs.

(44 Nm).

the master cylinder

6.

7.

the

8.

and wheel assembly.

16.

Install

Verify correct brake operation.

tire

If

the caliper

93006G61

prevent brake

the caliper

Buick Century, Regal

To

Chevrolet Lumina, Monte Carlo

10.

bolts.

is

to

Intrigue

1 1

Pontiac Grand Prix If

.

remove the brake pads from the mounting bracket.

bush-

FRONT

found, replace the slide bolts installing the brake

caliper assembly. of the brake fluid

from 12.

Before installing the caliper,

make

the master cylinder assembly.

sure the piston(s) are seated 2.

Mark a

Remove

the

tire

and wheel assembly.

and

that the brake

in

the bore,

pads are correctly

relationship between the wheel and installed.

the wheel stud for re-installation purposes. 13.

]

CALIPER SLIDE BOLT

7

OUTBOARD SHOE

3

LINING INBOARD SHOE & LINING Si

7

BUSHING ASSEMBLY CALIPER BOOT

B

PISTON

»Be sure that the insulation on the EGR tube aligns with and contacts the

ing: •

Negative battery cable

•

Engine cover from the top

insulation on the

of the

vacuum harness

at

the rear of the engine. Rotate the

intake manifold •

tube. Torque the

intake manifold

Drain the cooling system.

3.

EGR

wide-open position and reconnect the speed control and

throttle lever to the

Accelerator and the speed control

Upper intake manifold loosening and

cable from the throttle lever

ening sequence

tight-

—3.2L and 3.5L engines

throttle cables.

C-| 9

CHRYSLER CORPORATION CONCORDE •

PCV

•

Air cleaner

•

Ground wire

•

valve hose

to the intake

•

plenum

Throttle

10. •

Fill

INTREPID

hous-

the engine

Inspect the manifold for

Remove

filter.

verify correct

or disconnect the following:

To

install:

•

Exhaust system

5.

Install or

•

V-band clamps and

left

New

•

catalytic

torque to 15

Remove

4.

rotate the transaxle dip-

or disconnect the following:

2.7L Engine

RIGHT MANIFOLD

•

Oxygen (O 2 S) sensor

•

Engine

oil

ft.

ft.

(15

lbs.

•

HO 2 S

•

Negative battery cable

sensor

Nm)

connector

electrical

Operate the vehicle and inspect for

6

Front Crankshaft Seal

fold

To install:

tion.

Remove

or disconnect the following:

•

Negative battery cable

•

Air intake

plenum and

Remove

5.

•

•

filter

Exhaust manifold and new gasket

Battery cable housing tube-to-

and torque the bolts (23

Ehaust Gas Recirculation (EGR)

outward

valve and tube

Oxygen (O 2 S) sensor

•

V-band clamp from the manifold

lbs.

O 2 S sensor

•

Transaxle dipstick tube

O-ring

lbs.

for the

(12

•

traces of the old manifold

engine

dipstick

•

To

install:

4.

Install or connect the following:

(10

to

new V89 inch

Nm)

Engine wiring harness support bracket to the cylinder head

Exhaust manifold and new gasket.

Torque the bolts

17

to

Nm) working from

ft.

lbs.

utilize

in this

timing

section.

•

Exhaust system

•

Negative battery cable

belt

removed from the vehicle service.

Catalytic converter with a

lbs.

procedure later

Note that the timing

oil

band clamp and torque

faces.

engines that

chains, please refer to the applicable

3.2L and 3.5L Engines

Nm)

tube and tube

Exhaust manifold

procedures

REMOVAL & INSTALLATION

•

gasket and clean both gasket mating sur-

•

ft.

Heat shields and torque the bolts to

•

all

17

•

Heat shield

Remove

to

front crankshaft seal

are tor timing belt equipped engines

working from the center

105 inch

*»Do not reuse the V-band clamps.

•

Nm)

transaxle bolt

•The

only. For

connect the following

Install or

6.

•

•

•

traces of the old manifold

all

gasket and clean both gasket mating surfaces the air

housing

3.

to 21

Nm)

Exhaust manifold bolts and mani-

•

the precautions in the beginning of this sec-

2.

(28

exhaust leaks

fold heat shield

Before servicing the vehicle, refer to

and torque the nuts

lbs

screws toll

and mani-

dipstick tube

fold

Heat shield and torque the retaining

•

Engine wiring harness support bracket from the cylinder head

Nm)

(20

lbs.

ft.

Exhaust pipe to the exhaust mani-

•

Loosen and

3.

connect the following:

manifold gasket and exhaust

manifold to the cylinder head and

not reuse the V-band clamps.

•

1.

traces of the old manifold

all

faces.

stick tube out of the way.

REMOVAL & INSTALLATION

or

required.

Negative battery cable

converter

»Do

Exhaust Manifold

if

Remove

4.

•

engine

operation.

damage

for distortion against a

gasket and clean both gasket mating sur-

Test run the engine, check for fuel

and coolant leaks and

in

Check

manifold

the beginning of this sec-

tion. 2.

and

oil

VISION

straight-edge or thickness gauge. Replace

Before servicing the vehicle, refer to

.

•

Exhaust manifold bolts and mani-

•

3.

LEFT MANIFOLD

and bleed the cooling system.

Change

9.

•

fold

the precautions

body purge tubes

Negative battery cable

•

300M

Negative battery cable

•

1

fitting

Intake manifold plenum cover

8.

•

cracks.

Brake booster hose to intake manifold

air filter

LHS

ing

manifold

plenum •

plenum and

Air inlet

plenum and plenum hose

•

Use care

marks are

all

be sure

perform this all

valve timing

carefully aligned both before

removing the

and

to

must be

to

belt

and

after belt installation

service has been completed

It

may

be good practice to set the engine to Top

Dead Center (TOC) No.

1

cylinder compres-

(23

the center out-

3.2L and 3.5L Engines

ward. •

Heat shields and torque the bolts to

105 inch •

•

•

lbs.

(12

Nm)

New V-band clamp and torque 100 inch lbs. (11.3 Nm) O 2 S sensor EGR valve and tube using new kets, then torque to

95 inch

to

Before servicing the vehicle, refer to

gas-

Remove

lbs.

•

Exhaust pipes from the exhaust manifold

Heated Oxygen (HO 2 S) sensor electrical

and

(101

or disconnect the following:

Negative battery cable

• ft.

the beginning of this sec-

•

•

torque the bolt to 75

in

tion.

lbs. (11

Battery cable tube-to-transaxle

Nm)

.

2.

Nm) •

1

the precautions

Removing

wiring

Heat shield-to-exhaust manifold

crankshaft— 3 21 and 3.5L

engines

screws

For complete Engine Mechanical specifications, see Section

the timing belt sprocket dowel

pin Irom the

1

of this

manual

CHRYSLER CORPORATION

5-14

CONCORDE

•

LHS

300M

•

sion stroke (firing position) and aligning

all

•

INTREPID

This serves as a reference for

all

sprocket onto crankshaft.

hammer on

work

Verify that

that follows.

Before servicing the vehicle, refer to

1.

VISION

at the

the precautions

DO NOT

an equivalent setup to pull the

9.

timing marks before removing the timing belt.

•

all

Do

the sprocket.

valve timing marks are

Timing

•

belt

Properly relieve the fuel system

2.

Rotate the crankshaft 2 complete

10.

3.

Drain the cooling system.

camshafts and crankshaft. The marks must

4.

Remove

align with their respective locations.

or disconnect the following:

marks do not

•

Negative battery cable

•

Radiator and cooling fan

module

When

timing has been verified,

assembly •

Accessory drive belts

•

Crankshaft damper

•

Timing

belt front

If

cover

may be

and torque the

85

ft.

be removed. Use silicone rubber adhe-

•

crankshaft

belt

and tensioner. Refer

to

the appropriate section for the

removal and installation procedure

Assemble

4.

to

the chain on the

camshafts. Ensure the plated links are fac-

the proper tension

1.

Tensioner and chain from the

To install:

•

Radiator and cooling fan assemblies

ing toward the front. Align the plated links

•

Negative battery cable

to the dots

sealer.

Timing

tensioner as an assembly

lbs.

Accessory drive belts and adjust

•

•

Camshafts, secondary chain and

•

bolt to

the reverse order of

in

Bearing caps

•

timing

(115 Nm).

reusable and should not

sive sealant to replace any missing

Slowly loosen the camshaft bearing

the tightening sequence.

shaft damper, using tool L-3281,

cover

sealer on the timing belt front

Second chain tensioner mounting

Crankshaft damper. Hold the crank-

•

•The

•

bolts

belt covers.

bolt

Primary timing chain

cap retaining bolts

correct valve

install the

or disconnect the following:

•

3.

the

align, repeat the timing belt

installation procedure.

Remove

2.

turns and recheck the timing marks on the

pressure.

locating the

and tensioner using the

recommended procedure

tion.

first

proper crankshaft position. Failure to do so will result in piston-to-valve contact.

aligned.

beginning of this sec-

turn the crankshaft or

camshaft without

not

and bleed the cooling system.

11.

Fill

12.

Start the vehicle,

repair

if

check

for leaks

and

necessary.

on the camshaft sprockets.

'•There are 2 different styles

of

camshaft (secondary) chain tensioners

The Early Build tensioners will sepasub-components, the Later Build tensioners will not. Compress the camshaft (secondary) chain as follows: .

•

Crankshaft timing belt sprocket Locate the small dowel pin

5.

rate into

the

in

Camshaft and Valve

Lifters

crankshaft. With a small punch, carefully tap

out the dowel from the end of the crankshaft.

Remove

6.

tool

6341A, taking care not

Separate the tensioner cylinder

a.

2.7L Engine

from the tensioner housing. b.

install:

Before servicing the vehicle, refer to Inspect the crankshaft seal

7.

For early build vehicles:

5.

to nick the shaft

seal surface or seal bore during removal.

To

REMOVAL & INSTALLATION

the crankshaft seal using

sur-

lip

the precautions in the beginning of this sec-

and

face for varnish

Polish the area

dirt.

internal tensioner

tion.

using 400

grit

sandpaper

to

remove varnish

WARNING

as necessary. Install or

8.

•

Rear lower timing belt cover

•

Dowel

into the crankshaft

protrudes 0.047 •

Timing

belt

in.

so that

at

the crank-

C-4685C1,

bearing, washer and

Installing the crankshaft oil

it

(1.2mm)

sprocket

shaft using tool

and 3.5L engines

When

the timing chain

is

removed

and the cylinder heads are installed,

6342

•

12mm

thrust bolt or

seal—3.2L

oil

to

from the

remove the

components.

c.

Assemble the tensioner housing.

d.

Using hand pressure, compress

and lock the tensioner using a fabricated

connect the following:

Crankshaft seal using seal installer tool

Carefully drain the

housing using care not

lockpin. 6.

For

late build vehicles:

—

EH E ^

CHRYSLER CORPORATION CONCORDE

•

LHS

•

300M

INTREPID

•

•

VISION

PLATED CHAIN LINKS

i

Exploded view

camshaft (secondary)

of the

chain tensioner, early build— 2. 7L engine

Proper camshaft (secondary) chain alignment— 2 7L engine

•

Camshaft bearing caps and torque

••Mark the timing

the bolts gradually, in sequence, to

tion tor installation. Align the timing

105 inch •

belt sprockets with

Nm)

(12

timing belt covers before removing the

torque the bolts to 105 inch lbs

timing belt.

Nm)

•

Timing

Primary timing chain

•

Negative battery cable

Remove

tion for the removal

the lockpin from the sec-

ondary chain tensioner.

compressed— 2. 7L engine

and timing

and

installation

procedure

Fabricate a lockpin, as shown, to keep the

tensioner

belt tensioner

Refer to the appropriate sec-

belt.

10

marks on the rear

Secondary chain tensioner and

(12 •

lbs.

belt rotation direc-

•

Camshaft timing

•

Intake manifold

3.2L and 3.5L Engines

belt sprockets

assembly using the

recommended procedure Place the tensioner

a.

in

a soft-jawed

1

•

Before servicing the vehicle, refer to

.

~Be

tion.

surlaces between the exhaust manifold

vise.

Slowly compress the tensioner

b.

lockpin can be

until the fabricated

Camshafts are serviced from the

rear of

the cylinder head Although the engine

Remove

the

compressed and

locked tensioner from the vise. Insert the

7.

compressed and locked

camshaft chain tensioner

in

between the

Position the camshafts so that the

8.

and dots are facing upward

Install or

9.

•

removed

the cylinder head

for

connect the following:

The

rear timing belt cover

must be

that

allows

it

to rotate

on

its

shaft

Properly relieve the fuel system

2.

pressure.

Drain the cooling system.

3.

Remove •

or disconnect the following

Negative battery cable Radiator/cooling fan assemblies

and the accessory drive

Ensure that the rocker arms are correctly seated and in proper positions.

5

must be removed from the

have a D-shaped hole

•

** WARNING

clean the gasket mating

vehicle. Note too, that the camshaft sprockets

4

Camshafts

to

and the cylinder head.

camshaft service,

several degrees in each direction

camshafts and chain.

plated links

not need to be

sure

does

installed. c.

Exhaust manifold

the precautions in the beginning of this sec-

•

belts

Rocker arm/shatt tightening sequence

Crankshaft damper and the timing 3.2L and 3.5L engines belt

For Accessory Drive Bell

covers

illustrations,

see Section

1

of this

manual

CHRYSLER CORPORATION

a

i

5

removed

Remove

to

CONCORDE

•

LHS

•

300M

•

INTREPID

remove the cylinder heads.

the rear timing belt cover-to-cylin-

Remove

der head bolts.

the rear timing belt

•

Exhaust manifold with new gasket Intake manifold

•

Timing

•

Accessory drive belts and

belt cover

to the

set

them

•

Starter heat shield

•

3 starter-to-engine/transaxle bolts

•

and

13. oil

arm assembly

Fill

and

filter

change

is

repair

if

To

recommended. check

for leaks

2.

and

arm and

shaft

the rear camshaft cover

•

•

These engines use hydraulic up the free-play

in

Inspect camshaft journals

head

for

If

wear

is

damage. Inspect the head

oil

Measure the height Measure

a micrometer.

unworn area and

in

specification

0.001

is

2 places: the

in

wear. in.

in.

(0.254mm).

if

it

is

Nuts to the catalyst support bracket

Positive battery cable and torque

89 inch

lbs.

(10

Negative battery cable to the remote

REMOVAL & INSTALLATION 3.2L and 3.5L (VIN G) Engines 2.7L Engine

1.

1.

Remove •

•

Starter-to-engine/transaxle nut and

or disconnect the following:

Battery feed

or disconnect the following:

Negative battery cable from the

remote ground post

Negative battery cable from the

remote ground post •

Remove •

bolts

and posi-lock connec•

tors

Positive battery feed wire from the

worn beyond

To install: Lubricate the camshaft journals and

.

lobes with clean engine Install or

12. • •

oil.

connect the following:

Camshaft Camshaft cover and O-ring and torque the bolts to 21

ft.

lbs.

(28

Nm) •

Rocker arm assemblies

•

Cylinder head assembly

New head

bolts are

recommended.

•

Rear timing belt covers

•

Timing

belt sprocket,

and timing

timing belt

belt tensioner. Refer to

the appropriate section for the

removal and Installation procedure.

Be sure that once they are

all

installed, the timing of the

camshaft(s)

is

accurate.

Nm)

Posi-lock connectors

this specification.

1 1

lbs.

Starter heat shield

starter

Replace the camshaft

ft.

ground post

The standard

(0.0254mm) with

the wear limit being 0.010

•

cam using

the wear zone. Subtract

cam

the figures to get

of the

starter-to-

Nm)

the nut to

holes for

clogging. Replace the camshaft as required. 10.

•

wear or

present, inspect the cylinder

and torque the 3

necessary.

Starter Motor

for

away from the

and mount

•

nick or scratch the journals.

it

the valve train

system, therefore no lash adjustments are

remove the camshaft from the rear of the head taking care not to

rotating

roller lifters •

Carefully,

Starter

(54

to take

forward

engine/transaxle bolts 40

and

WARNING

it

engine

O-ring.

damage.

Starter by sliding

between the catalyst and the engine

necessary.

ADJUSTMENT

Remove

I:

connect the following:

Install or

•

mount and

assemblies. 8.

rearward

install:

Valve Lash the rocker

it

mount

and bleed the cooling system. An

Start the vehicle,

14.

to

component locations before disas-

Remove

toward the

it

between the catalyst and the engine

sembly. 7. 9.

Starter by rotating

engine and sliding

proper tension

Negative battery cable

•

the cylinder head bolts

^•IVIark the rocker

mount

bracket and

covers and crankshaft

Radiator and cooling fan assembly

•

pump passages. Remove

Nuts from the catalyst support

for the

cylinder head.

note

belt

•

assembly

damper

*>The right-hand side timing has O-rings located behind it

6.

VISION

•

covers.

water

•

Exploded view

of the oil

pan removal and

installation

— 2.7L and 3.5L (VIN G) engines

CHRYSLER CORPORATION CONCORDE •

2.

Starter

and position

access

to the posi-lock

connector

from the

slightly relieve the pressure

3.

pan,

left

•

Remove

the 3

left

engine

to

the starter by sliding

rear-

it

To

To install: 7.

8.

Install or

•

Starter by sliding

pan and

of sealer

pump body and 79EBOO

and torque the nut

Starter

to

(12

Install

a.

starter-toft.

b.

5

Nm)

10 inch

using the

oil

remote

ft.

40

ft.

Install the dipstick

8.

9.

Fill

amount

REMOVAL & INSTALLATION

8

grades

to

and housing and

Oil

and torque the ft.

lbs.

Crankshaft sprocket

•

Timing chain

•

Timing chain cover

9

SAE 5W-30 or SAE 10Wonly. Do not mix the two

Crankshaft damper Fill

the engine with clean engine

Start the vehicle,

10. repair

connect the following:

pan

•

•

the engine with the proper

oil

Install or

•

of clean

30 engine

new pickup tube 0-

(28 Nm).

connect the negative battery cable.

Pan

bolts

(28 Nm).

pickup tube mounting bolts to 21

(55 Nm).

lbs.

over

pump mounting

lbs.

ft.

Lubricate the

7.

Nm)

and working outward. Torque the bolts

ground post

to 21

pump

into position.

ring with clean engine oil

(55 Nm).

lbs.

and

Install the oil

6.

and torque

Install the collar-to-transaxle bolts

40

Carefully, install the oil

the crankshaft

lbs. (1.1

locations— 2. 7L

bolt

Nm)

Starting with the center vertical bolt

c.

to the

(28

nuts/bolts to 105 inch

the vertical collar to the

10. and torque to

lbs.

Nm)

Negative battery cable

lbs.

ft.

pump mounting

engine

pan mounting bolts and tighten, tem-

89

porarily to

40

M6

Oil

M8

following procedure:

Nm)

and torque the

connect the following:

Install the structural collar

7.

engine mount-to-engine bolts

engine/transaxle bolts

if

check

lor leaks

oil.

and

necessary.

of oil.

Before servicing the vehicle, refer to

1.

if

gasket sur-

(3mm) bead

in.

nuts/bolts to 21

lbs.

(54

all

pan and torque the

mount

inch lbs. (10

Oil

Oil

forward

it

Positive battery feed wire to the

•

Install or •

and the

starter

•

bolts, oil

pan and

oil

Apply a Vs

6.

Slightly, lower the engine.

•

pan mounting

between the catalyst and the engine

left

cooler line clips,

oil

at the parting line of the oil

connect the following:

Posi-lock connector

3

oil

the rear seal retainer.

•

•

cooler lines from the

oil

install:

5.

the posi-lock connector.

5-17

VISION

•

faces.

mount.

Remove

INTREPID

equipped

Clean the

4.

Remove

•

gasket

ward between th£ catalyst and the engine

6.

Oil

provide

more room. 5.

300M

necessary •

Slightly, raise the

if

Transmission

engine mount-to-

engine bolts. 4.

Engine

•

engine mount.

•

pan and transmission housing

oil

Place a support under the engine and

LHS

Structural collar from the rear of the

•

to gain

it

•

Start the engine,

check

for leaks

3.2L and 3.5L Engines

and

the precautions in the beginning of this secrepair

if

necessary.

The timing

tion.

Drain the engine

2.

and remove the

oil

Oil oil filter.

Remove

3.

access the

Pump

Negative battery cable

•

Dipstick and housing

must be removed

belt

pump

to turn the crankshaft to

REMOVAL & INSTALLATION

(TDC) No.

1

It

is

good

practice

Top Dead Center

cylinder compression stroke

(firing position)

before starting disassembly

This should align

2.7L Engine

to

located behind the

crankshaft drive sprocket

or disconnect the following:

•

oil

timing marks and be a

all

Before servicing the vehicle, refer to

1

the precautions in the beginning of this sec-

A

tion.

To ensure a proper seal, apply sealer as

shown— 2. 7L

and 3.5L (VIN

F)

2.

Drain the engine

3.

Remove •

Crankshaft damper

•

Timing chain cover

•

Timing chain

•

Crankshaft sprocket

•

Oil

pan

•

Oil

pickup tube and o-ring

•

Oil

pump

4.

Fill

the

clean engine

Tire,

Prime the

because

To install:

engines

For

oil.

or disconnect the following

Wheel and

oil

pump

pump

and cause low

rotor cavity with

1

of this

before installation,

pump oil

3.5L engines

oil.

Ball Joint specifications, see Section

oil

a dry

manual

will

wear prematurely

pressure— 3. 2L and

CHRYSLER CORPORATION

5-18 good point

CONCORDE

•

LHS

work

of reference for all

300M

•

INTREPID

•

VISION

Timing

•

to fol-

•

Refer to the appropri-

belt.

ate section for the

low. 1

•

the precautions in the beginning of this section.

Drain the engine

2.

9.

Timing

belt covers, thrust bearing,

washer

plate

and vibration dampe

using tool L-4524

oil.

8.

Apply a

light

coating of engine

the entire circumference of the

installation procedure.

Before servicing the vehicle, refer to

.

removal and

in

Connect the negative battery cable.

Drain the cooling system.

•

Accessory drive belts

1 1

Remove

•

Radiator and radiator hoses

12.

Fill

•

Negative battery cable

13.

Start the vehicle,

Negative battery cable

•

Accessory drive

•

Oil filter

•

Oil

pan

•

Oil

pump

•

Windage

•

Crankshaft damper using a suitable

belts

Timing

•

Fill

16.

Fill

amount pickup tube

pan gasket

tray/oil

and bleed the cooling system.

oil

grades of

oil.

SAE 5W-30 or SAE 10WDo not mix the two

only.

Start the engine,

17.

to aid installation. Align the

oil

check

for leaks

and

necessary.

check

for leaks

and

Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION 2.7L Engine

Rear Main Seal

matchmarks on

marks on the

the camshaft sprockets to

rear

REMOVAL & INSTALLATION

When

aligning the timing marks,

or disconnect the following: 1.

Timing

•

if

pressure.

timing belt covers before removing the timing.

Remove

repair

the transaxle with the proper fluid.

covers

belt

Place matchmarks on the timing belt

6.

.

the engine with the correct

clean

of

30 engine

proper

puller tool

5.

15.

and

transaxle.

3.

•

to

lip.

place with a plastic mallet.

Install the flexplate/flywheel

4.

or disconnect the following:

oil

seal

Place the seal over the special tool

and tap the seal 10.

oil

Before servicing the vehicle, refer to

Refer to the appropri-

belt.

the precautions ate section for the

removal and

in

the beginning of this sec-

rotate the crankshaft, not the

camshafts.

DO NOT

rotate the

tion.

installation procedure. 2.

Drain the transaxle

3.

Remove Remove

fluid.

Crankshaft sprocket using a suit-

•

able puller tool 4.

•

Oil

pump-to-engine screws and

the transaxle, inspection

cover and flywheel/flexplate.

pump Oil pump

•

the negative battery cable.

5.

cover screws and

Using a small prytool, carefully pry

out the rear

cover Oil pump rotors Wash all parts in solvent and carefully for damage or wear.

or

damage

oil seal.

Be careful not

to nick

the crankshaft flange seal surface

•

7.

or the retainer bore.

inspect

To 6.

To

install:

Place the Seal Pilot tool C-4681 on

install:

Clean

8.

no traces

parts well. There should be

all

on any com-

of old gasket/sealer

7.

Lightly coat the oil seal outside

Removing

diameter with Loctite® Stud N’ Bearing

ponents.

Assemble the

9.

the crankshaft.

oil

pump

with

Mount®

new

the crankshaft center bolt using

the Crankshaft

or the equivalent.

Damper Holder tool— 2.7L

engine

parts as required. 10.

1 1

pump

Install the oil

fasteners to

108 inch

Prime the

.

oil

cover.

Torque the

(12 Nm).

lbs.

pump

CHAIN GUIDE

prior to installa-

tion by filling the rotor cavity with clean

engine

oil

CAMSHAFT DAMPER

oil.

12.

Install

the

oil

pump and

tighten the

pump-to-engine screws as follows:

M8 screws: 21 M10 screws: 40

a.

ft.

b.

Tighten the

13. install

a

14.

new

oil

lbs.

ft.

(28 Nm).

lbs.

(55 Nm).

CHAIN GUIDE

pan drain plug and

oil filter.

connect the following:

Install or

pump

•

Oil

•

Windage

•

Oil

pickup tube tray/oil

pan gasket

pan and torque fasteners

108

to

inch lbs. (12 Nm). Pay attention to

sealing the integral •

oil

pan gasket and

windage

its

CHAIN TENSIONER

tray.

Crankshaft sprocket using tool C-

4685C1

12mm

,

thrust bearing,

bolt to

ARM

washer and

7922BG33

draw the sprocket

onto the crankshaft

Exploded view

of the timing

chain drive

assembly— 2. 7L engine

— CHRYSLER CORPORATION CONCORDE CAMSHAFT

CAMSHAFT

TIMING

TIMING

MARK

MARK

•

LHS

•

300M

•

INTREPID

•

5-19

VISION

^

TIMING

CHAIN TENSIONER

Using the Tensioner Resetting Special tool, to

purge the

oil

from the tensioner

2.7L engine

•The

camshafts

when

will rotate clockwise,

the camshaft sprocket bolts are

removed. Right camshaft sprocket mounting

•

camshaft damper and

bolts, After the timing chain

is

installed, the timing

marks should be aligned

— 2.7L engine

sprocket •

camshafts or crankshaft with the timing chain

•

damage may

Power steering pump and position it

camshaft sprocket bolts and

Lower timing chain guide, ten-

•

removed without locating

aside without disconnecting the

sioner

the crankshaft position, piston and/or

valve

Left

sprocket

arm and primary timing

hydraulic lines

chain

occur.

•

Accessory drive

•

Timing chain cover bolts

belt tensioner pulley

To install: 1

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

4.

tion,

5.

Remove

2.

or disconnect the follow-

Clean and inspect the sealing sur-

•Lubricate the timing chain and guides with clean engine oil before

Align the crankshaft sprocket timing

installation.

faces.

mark with the

oil

pump housing mark

7

ing: •

Upper intake manifold and valve

60 degrees

covers

crossmember

•

Upper

•

Fan module

•

Accessory drive belts

radiator

pump housing

is

Install the

timing chain by perform-

ing the following procedure:

Top Dead Center (TDC).

a

Verify that the crankshaft sprocket

timing mark or disconnect the followoil

aligned with the mark on

is

pump housing

ing: b.

•

the center bolt.

Damper using a 3-jaw

at

oil

the

8191, hold the crankshaft and remove

•

on the

Remove

6.

Using Crankshaft Damper Holder

3.

tool

•The mark

from the •

right cylinder

aligning the timing mark on the sprocket to the c.

left

side primary timing

head

Camshaft Position (CKP) sensor

the

left

chain sprocket onto the chain, while

and timing chain access plug from puller

Place the

Primary timing chain tensioner

2 plated

links

on the chain.

Lower the chain with the

left

sprocket

cylinder head

through the

For Wheel Alignment specifications, see Section

1

of this manual

left

cylinder head opening.

CHRYSLER CORPORATION

5-20 d.

CONCORDE

Loosely position the

LHS

•

•

300M

g.

Align the right camshaft sprocket

and loosely position the

Verify that

all

Install

the

left

lower timing chain

guide and tensioner. Torque the bolts to 21 ft.

aligns with the camshaft sprocket and

damper attaching

holes. Install the sprocket

attaching bolts and torque to 21

ft.

(28

lbs.

Turn the

14.

%

in.

left

camshaft by inserting a

square drive extension with a breaker

bar into the intake camshaft drive hub.

Rotate the camshaft until the camshaft hub aligns with the camshaft sprocket and

(28 Nm).

lbs.

POSITIONING

square drive extension with a breaker

bar into the intake camshaft drive hub.

the plated links are

aligned to their proper timing marks. 8.

in.

Nm).

sprocket over the camshaft hub. h.

Piston and Rings

Rotate the camshaft until the camshaft hub

drive sprocket.

timing mark to the plated link on the timing chain

chain tensioner into the

At the right cylinder head, insert a

13.

%

Position the timing chain around

pump

VISION

Install the

12.

Align the plated link to the crank-

the water

•

right cylinder head.

shaft sprocket timing mark. f.

INTREPID

camshaft

left

sprocket over the camshaft hub. e.

•

•Inspect the timing chain guide access plug O-rings before installing. Replace

damper attaching

holes. Install the sprocket

attaching bolts and torque to 21

(28

lbs.

ft.

Nm).

damaged

Cross-sectional view of the piston rings

O-rings as necessary. 15.

necessary, rotate the engine

If

2.7L, 3.2L Engines Install the

9.

plug to the

15

lbs.

ft.

•To

left

timing chain guide access

cylinder head and torque to

(20 Nm).

need

to

be purged from the

remove any slack

in

To arm the timing chain tensioner:

16.

reset the timing chain tensioner,

oil will first

slightly clockwise to

the timing chain.

Use a flat-bladed prytool

to gently pry the

tensioner arm towards the tensioner slightly.

Then, release the tensioner arm. Verify the

tensioner.

tensioner extends.

Purge

10.

oil

from the timing chain ten-

sioner using the following procedure:

Remove

a.

the tensioner from the ten-

sioner housing. b.

oil seal.

Apply a Va

18.

in.

(3mm) bead

at the parting line of the oil

Place the check ball end of the ten-

sioner into the shallow end of the Ten-

sioner Resetting Special tool 8186.

Using hand pressure, slowly

c.

Inspect and replace the timing chain

17.

cover gasket and

depress the tensioner

until oil is

purged

of sealer

pan and engine

block.

•When

installing the timing cover,

guide the seal over the crankshaft to prevent

damage

to the seal’s lip. - SIDE RAIL

1

from the cylinder. d.

19.

Reinstall the tensioner into the ten-

sioner housing. 1 1

Install or

9306BG04

•

Timing cover and gasket and torque the

using the following procedure: a.

M10

and the

Position the cylinder plunger into

(12

40

bolts to

M6

bolts to

Crankshaft damper

8186.

•

Accessory drive

Apply a downward force

tensioner

r-

until the

is reset.

Ensure that the tensioner

is

Nm)

3.5L Engine

lbs.

UPPER

NO. 1 RING GAP

belt tensioner pul-

Power steering pump

•

Crankshaft damper

•

Crankshaft center bolt and torque the bolt to

properly

The tensioner body must be bottomed against the top edge of the

(54

ley •

WARNING

lbs.

105 inch

SIDE RAJL

•

b.

ft.

Cross-sectional view of the piston rings—

Nm)

the deeper side of the Tensioner Resetting special tool

SPACER EXPANDER

ing:

Reset the timing chain tensioner

.

2 -

connect the follow-

125

ft.

lbs.

(170

Nm)

using tool 8191

reset.

•

Accessory drive belts

Tensioner Resetting Special tool 8186. Failure to properly perform the resetting procedure may cause ten-

•

Fan module and

•

Upper

sioner jamming.

•

Negative battery cable

electrical wiring

harness radiator

GAP AND SPACER EXPANDER GAP 9306BG03

crossmember

Piston ring gap positions— 2. 7L, 3.2L,

3.5L Engines

.

CHRYSLER CORPORATION CONCORDE

•

LHS

•

300M

•

INTREPID

•

5-21

VISION

FUEL SYSTEM Fuel System Service Precautions

At the

2.

Power Distribution Center

(PDC), remove the Fuel Safety

the

is

most important

performing not only

when

factor

system maintenance

fuel

until

man-

4.

may

ner

in

a safe

result in serious personal injury or

death. Maintenance vehicle’s fuel

and

testing of the

system components can be

accomplished safely and

effectively

ing to the following rules

and guidelines:

•

To avoid the possibility of

by adher-

fire

and per-

sonal injury, always disconnect the negative battery cable unless the repair or test proce-

dure requires that battery voltage be applied. relieve the fuel

run.

OFF

Turn the ignition switch

**

engine

CAUTION

The previous steps must be performed to relieve the high pressure fuel from the fuel rail. The following steps must be performed to remove excess fuel from the fuel rail. Do not use the following steps to relieve high pressure for excessive fuel will

(injector, fuel rail,

ulator, etc.), fitting or fuel line

skin, face

and eyes

advised that

pressure regconnection.

avoid exposing

Please be

to fuel spray.

any part

of the

body

Disconnect the

5.

from any

Connect

6.

that

it

connector

electrical

injector.

an alligator

1

1

end

of a

jumper wire (with

Connect

1

end

of a

sure.

second jumper

3.

Lower the

4

Remove

wire to the other injector terminal.

contacts.

** WARNING

Always place a shop towel or cloth

•

around the loosening spillage.

(should

absorb any excess

Ensure it

fuel

due

to

that all fuel spillage

occur)

is

quickly removed from

engine surfaces. Ensure

•

Negative battery cable

•

Purge and vent

•

Fuel line from the pressure regula-

that all fuel

age the

the jumper wire to a

9.

At the

ground

for

5.

• Do come

install the fuel

pump

fuel

spark or open

•-When

the fuel

relay

Push the

it

straight

fuel filter/regulator into the

pump module and Connect the

6

pump

and pulling the

turn to lock

it

into

position.

relay.

not allow fuel spray or fuel vapors into contact with a

it

To install:

no more

Power Distribution Center

extinguisher near the work area.

(PDC),

in the

up

Momentarily, touch the other end of

Always keep a dry chemical (Class B)

by pushing

locking tab, turning the regulator to

than a few seconds.

to

Filter/regulator

injector.

unlock

soaked

cloths or towels are deposited into a suit-

•

able waste container.

fire

lines

tor

Applying power to an injector for more than a few seconds will dam-

8.

•

fuel tank.

or disconnect the following:

connection prior to

fitting or

to

Properly relieve the fuel system pres-

2.

to the positive side of the

battery. 7.

Before servicing the vehicle, refer to the

.

precautions in the beginning of this section.

clip) to either injector terminal

and the other end

under pressure may pene-

fuel

trate the skin or

to

of the fuel tilter/pressure

regulator

Exercise extreme caution whenever relieving

system pressure,

away view

Cut

system pres-

sure prior to disconnecting any fuel system

component

fuel

until the

FUEL FLOW TO FUEL INJECTORS

continue restarting the engine

no longer

will

it

INTERNAL FUEL FILTER

Relay.

be forced into a cylinder chamber.

Always

•

Operate the engine

3.

stalls; then,

but any type of maintenance. Failure to con-

duct maintenance and repairs

Pump

fuel lines

and

install the

is

tank.

flame. •

Always use a back-up wrench when

loosening and tightening

fuel line

tion fittings. This will prevent

stress •

and torsion

where

Do

7.

repair

if

check

for leaks

and

necessary.

Pump

fuel fitting Fi-

not substitute fuel hose,

REMOVAL & INSTALLATION

Fuel Filter

fuel pipe is installed.

Before servicing the vehicle, also

sure to refer to the precautions

make

The

fuel filter

mounts

front of the fuel tank. in

the begin-

ends

ning of this section as well.

ot the filter are

inlet

marked

and

rail in

The in-tank

outlet

the fuel

for installation

purposes.

Install the fuel filter

tain that

is

it

frame

to the

The

voltage

properly orientated.

RELIEVING

is

•The in

the beginning of this section.

contains

is

pump pump

supplied through the fuel

fuel pump is serviced as part of the pump module. The fuel pump module

The fuel

Before servicing the vehicle, refer to the

pump module

pressure regulator which

relay

REMOVAL & INSTALLATION

precautions

fuel

pump and

adjusts fuel system pressure. Fuel

making cer-

Fuel System Pressure

1

Start the engine,

Fuel

to clear the DTC's.

to fuel line piping.

Always replace worn

rings with new.

connec-

unnecessary

removed, 1 or more Diagnostic Trouble Codes (DTC’s) may be stored in the Powertrain Control Module (PCM) memory. A DRB scan tool must by used

fuel filter is part of the fuel pressure regulator mounted on the fuel

installed in the top of the fuel tank

contains the electric fuel pump, fuel reservoir, inlet strainer fuel

pump module.

unit, fuel

For Maintenance Interval recommendations see Section ,

1

of this

supply and return

manual

and

pump

gauge sending line

connections

CHRYSLER CORPORATION

5-22

CONCORDE

and the pressure

The

regulator.

LHS

•

pump requires pump module.

INTREPID

VISION

•

SPECIAL TOOL

Fuel Injector

#6856

level

sensor are the only serviceable items. fuel

•

inlet

pressure regulator and

strainer, fuel

300M

•

the

If

REMOVAL & INSTALLATION

service, replace the fuel

Before servicing the vehicle, refer to the

1.

Before servicing the vehicle, refer to

1.

precautions

the precautions in the beginning of this sec-

the beginning of this section.

in

Relieve the fuel system pressure.

2.

tion.

Remove

3.

Properly relieve the fuel system

2.

•

pressure.

Remove

3.

•

or disconnect the following:

Using special tool 6856, remove the fuel

Clean the top of the tank to remove

4.

any loose

pump module

locknut

quick-connect

connect

on the ledge between the tank threads

ring

thumb and forefinger pump module electrical con-

• 'Fuel

and the pump module opening.

with

fitting

pump module

Position the fuel

8.

in

the tank. Be sure the alignment tab on the nector from the top of the fuel

Using special tool 6856, remove the

pump

pump module

underside of the

pump module fuel

in

flange sits

the corresponding notch in the fuel

tank.

locknut by turning

it

counter-

While holding the

9.

fuel

pump module

CAUTION

in

place install the locking ring and torque

to

40 inch

6856

The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir

may

spill out

when

module

the

pump and

Fuel tank

•

Fuel

is

O-ring

from the tank and discard the O-ring.

To 7.

all

Wipe

parts.

the

Fuel injectors

Lubricate the injector O-rings with

Fill

the fuel

•

connect the following:

Fuel injector and secure with retaining clips

•

Fuel

rail

press

onto cylinder head and

rail

into place.

Make sure

that

the injectors are fully seated.

pump module

electrical

con-

•

Fuel rail-to-cylinder head bolts

torque bolts to 100 inch •

the fuel tank with fuel. Install

filler

oil.

Install or

6.

rail

retainer clips

5.

using special tool

Intake

fitting’s

0-rings with clean engine

ON

the connector together until the retainer

position to pressurize

Check the

fuel

system

for

leaks.

Nm)

plenum

Lubricate the quick-connect

7.

and

lbs. (11

cap. Turn the ignition

seats and a click

oil;

then,

push

heard.

is

Connect the negative battery cable.

8.

new 0-

seal area of the tank clean. Place a

•

rail

install:

Negative battery cable

the system.

Thoroughly clean

Fuel injector-to-fuel

nector

switch to the

install:

Fuel rail-to-engine bolts and fuel

•

connect the following:

•

11.

the fuel

Nm)

lbs. (5

Install or

10.

•

Remove

Fuel injector electrical connectors

•

To

or a spanner-type tool.

removed. 6.

tabs together and pull

•

clean engine

clockwise.

I'

fitting’s retainer

the fitting assembly off of the fuel tube nipple.

pump mod-

ule by squeezing the quick-connect

5.

rail’s

then, squeeze the quick-

fitting;

dirt.

Fuel lines from the fuel

•

plenum and cover

Place a shop rag under the fuel

4.

Fuel tank

•

Intake manifold

opening with a clean cloth

Negative battery cable

•

or disconnect the following:

Negative battery cable

DRIVE TRAIN ing any repair

Transaxle Assembly

on the 42LE four-speed auto-

•

shift linkage

REMOVAL & INSTALLATION

adjustment. Also, check for

free the

The 42LE four speed transaxle uses

Use

fully-adaptive controls. Adaptive controls are those which perform their functions

based on real-time feedback sensor mation. The transaxle

is

the

in

use of hydraulically applied clutches to

However,

tronics to control virtually

all

it

MOPAR

If

the differential

requires fluid, use

Hypoid gear

shift

uses elec-

Type 7176 Automatic Trans-

the precautions

in

the beginning of this sec-

other func-

Remove

2. in

the vehicle: valve

body

assembly, solenoid pack, manual valve lever position sensor, input and output speed

sensors, transfer chain and sprockets, short (right side) stub shaft seal

side) stub shaft

the factory

and

and the long

ball bearing.

recommends

(left

Note that

that before attempt-

Strut-to-steering knuckle bolts on

both sides of the vehicle and/or rod ends, •

if

•

tie

required

Antilock Brake System (ABS) wheel

speed sensor,

Before servicing the vehicle, refer to

.

The following components are

serviceable

•

lubricant.

tion.

tions.

Front wheels

sump

80W-90 petroleum based

ties.

•

mission Fluid only. Do not substitute

1

a planetary gear train.

tool.

transaxle fluid.

infor-

conventional

scan

connector from the har-

ness, remove the wire

diagnostic trouble codes with the Chrysler

DRB

Transaxle wiring connector block located on the right shock tower. To

matic transaxle, always check for proper

if

equipped

Halfshafts

^Remove

the halfshafts by inserting a

prybar between the halfshaft and the or disconnect the following:

•

Negative battery cable

•

Engine

•

Crankshaft Position (CKP) sensor

air inlet

tube

connector and remove the sensor

from the upper

transaxle case and prying the shafts

from the transaxle housing. Swing the shafts out of the way, keeping the joints straight

and suspend using wire.

Be careful not

to

right side of the

seals. transaxle bell housing

damage

the halfshaft

COO

CHRYSLER CORPORATION CONCORDE

LHS

•

•

300M

•

INTREPID

•

O CO

VISION

Be sure the reverse lamps come on when

in

reverse.

Do not

let

the halfshafts or CV-joints

hang unsupported. Internal joint damage may result if allowed to hang free. Remove

3.

When

installing the transaxle, be

careful that the fuel tubes at the rear

engine do not contact the

of the

lowing:

or disconnect the following:

10.

REMOVAL & INSTALLATION connect the following:

Install or

** WARNING

•

Engine-to-transaxle brackets

•

Transaxle wiring harness

•

Transaxle bell housing cover

•

Driveplate and torque the fastener

Mark

4.

the ijriveplate to the torque

transaxle case bolts to 75

bolts are not to be reused. Starter

housing and allow the

starter

crossmember

motor

between the engine and the

to sit

secure

frame •

Transaxle

oil

cooler lines and plug

pushing the ends, can damage boots or CV-joints. Always support both ends of the halfshaft to prevent dam-

lbs.

Rear transaxle case mount and rear

•

bell

ft.

Nm)

(101

assembly from the

Allowing the CV-joint assemblies to dangle unsupported, or pulling or

Nm)

(101

lbs.

ft.

Transaxle and torque the engine-to-

•

The driveplate-to-torque converter

•

75

to

converter and remove the torque converter bolts.

Halfshaft

fol-

all

in

age

position and

fasteners

•

Transaxle dipstick tube

•

Exhaust pipe

——

the openings

or

disengagement

of the Tri-pot

joint.

Before servicing the vehicle, refer to

1.

engine exhaust

to

the precautions in the beginning of this sec-

manifold tion. •

•

Transaxle dipstick

•

Transaxle gear selector cable

Transaxle gear selector cable and

Remove

2 oil

ing:

Exhaust pipe from the exhaust man-

•

•

Torque the bolts

Starter.

to

40

ft.

•

ifold

and position out

^lf the clearance

will not

of the

way

starter

allow for

ground strap

is

•

Front wheels

•

Front caliper assembly from steer-

installed

correctly.

ing knuckle Align torque converter matchmarks

•

system from the vehicle. Support the transaxle using a transjack.

driveplate bolts to

Front brake rotor from the

•

Speed sensor cable routing bracket

relieve the weight off the rear transaxle

•

transaxle

mount

lbs.

(81

Nm)

strut

Hub and

assembly

bearing-to-stub axle

transaxle brackets retainer nut 1 1

While pulling the top of the steering

.

3.

mount through-bolt

knuckle outward,

Rear crossmember

•

ft.

housing cover and engine-to-

Bell

•

Engine-to-transaxle brackets and

•

60

from

Raise the transaxle slightly to

hub

•

and torque new torque converter-to5.

Negative battery cable

(54 Nm). Be sure that the

lbs.

transaxle removal, remove the exhaust

mission

or disconnect the follow-

cooler lines

onto the hub and

inner CV-joint,

install the

bearing assembly and secure

new

with

Install a puller tool

it

into place

retainer clip in place, into the

using the wheel lug nuts.

r»Pry the transaxle mount rearward

to

transaxle.

ABS

•

separate the mount from the transaxle.

4

wheel sensor

(if

removed) and

Protect wheel stud threads by

installing a

wheel lug nut onto a wheel stud.

strut-to-steering knuckle bolts

Lower the

6.

rear of the transaxle to

Front wheels and torque the lug

•

gain access to the bell housing bolts.

Remove

nuts, in a star pattern to

the bell housing bolts.

95-100

hub from turning Using the hub and bearing assembly.

•

Transaxle dipstick

the transaxle to catch transaxle fluid that

•

Transaxle wiring harness connector

will

drain out of the case.

Remove

8.

on the

or disconnect the following:

•

Transaxle dipstick tube and plug hole

•

Engine-to-transaxle bolts and

and the driveplate-to-crankshaft bolts must not be reused. Install new

whenever these

If

install:

and negative

do

this, insert

a prybar

battery

Start the

engine and allow

it

to idle

2 minutes. Apply the parking brake and

for

move tion,

the selector through each gear posi-

ending if

in

N Recheck

the fluid level

necessary. Be sure the vehicle

a light coating of grease to the

is

Fluid (ATF) only.

is

if

being replaced.

the torque

Do

not substitute transaxle

sump requires fluid, 80W-90 petroleum based Hypoid gear

fluid.

use

pilot hole of the crankshaft

converter

Air inlet tube

Irom

when refilling the transaxle. Use Mopar Type 7176 Automatic Transmission

Inspect the driveplate for cracks.

^Apply

•

sensor

joint

on the

level

cracks are present, replace the driveplate.

To

Dislodge the inner Tri-pot

transaxle To

CKP

and add

bolts are

removed. 9.

shock tower

•

12.

driveplate-to-torque converter

bolts

bolts

right

5

the stub shaft retaining snapring

cable

transaxle

'The

puller tool,

force the halfshaft outer stub axle from the

(129-135 Nm)

lbs.

flat-bladed prying tool to prevent the

ft

Place a drain pan under the dipstick

7. in

Use a

If

the differential

lubricant.

13. tion

Check the transaxle

Adjust the

Removing

or proper opera-

shift linkage,

if

For Tune-up, Capacities and Firing orders, see Section

the stub axle Irom the front

hub/bearing assembly

necessary.

1

of this

manual

—

halfshaft service

CHRYSLER CORPORATION

5-24

CONCORDE

LHS

•

300M

•

•

INTREPID •VISION stub shaft-to-hub and bearing assembly

on the intercon-

time. Take care not to pull

necting shaft to remove or separation of the

install: Install the Tri-pot joint side of the

10.

When

halfshaft by performing the following proce-

dure:

retaining circlip

and 0-ring seal on the

components

transaxle stub shaft. These are not reusable

whenever the

(163 Nm).

tightening the stub shaft

retaining nut, be careful not to

the halfshaft could result.

and must be replaced

halfshaft

removed.

is

Apply an even coat

b.

lbs.

exceed the maximum torque specifi15. cation of 120 ft. lbs. (163 Nm). If this specification is exceeded, failure of

Replace the inner Tri-pot joint

a.

ft.

WARNING

I-

To

120

retainer nut to

spider assembly will occur.

Road

grease on

of

test the vehicle to

check

for

noise or vibration.

the splines of the inner Tri-pot joint,

Be careful not

to

damage

where the 0-ring seats against the Tri-pot the threads for

CV-Joints

joint.

the axle nut 6. joint

when removing

the outer CV-

from the steering knuckle

—

through the

Install the halfshaft

c.

OVERHAUL

halfshaft

hole

in

the splash shield. Grasp the inner

service joint in in

between the transaxle case and the inner Tri-pot joint

and pry on Tri-pot

hand and interconnecting

1

shaft

Inner (Tri-pot) Joint

the other. Align the inner Tri-pot joint

spline with the stub shaft spline on the

joint.

1

Use a rocking motion with

transaxle.

Before servicing the vehicle, refer to

.

the

the precautions

i»Do not

try to

remove the inner

Tri-pot

inner Tri-pot joint to get

it

the beginning of this sec-

in

past the circlip tion.

from the transaxle stub shaft

joint

this time.

on the transaxle stub

at

Only disengage the inner

Tri-

pot joint from the retainer snapring.

shaft.

Continue pushing the Tri-pot

d.

onto transaxle stub shaft

until

it

Check

from the

WARNING strut

assembly-to-steering

where they go through the strut assembly and steering knuckle. When removing the bolts, turn the

position, the joint will not

damage

8.

joint

hand and

rotate

it

to

into the

12.

tri-pot joint

rollers in place

housing, hold the

on the trunions to pre-

vent the rollers and needle bearings

from

it

out and to the

falling

away.

Carefully, slide the shaft/spider

assembly from the

hub and bearing assembly.

Install or

Remove

tri-pot

housing.

the spider assembly-to-shaft

snapring; then, slide the spider assembly

off

connect the following: the shaft.

•

Top

of the steering

knuckle into the

assembly. Align the steering

knuckle-to-strut assembly mount-

strut.

ing holes.

assembly with

•

Strut assembly-to-steering knuckle

attaching bolts. Install the nuts to the

out and to the

attaching bolts and while holding the

rear of the vehicle, until the outer CV-joint

clears the

move

separating the spider joint

6.

one hand. Grasp the steering knuckle with the other

away

»When

rear of the vehicle. Install the outer CV-joint

Separate the top of the steering

Hold the outer

the shaft

from the

5.

strut

knuckle from the lower end of the

If

shaft.

with the other and rotate

the steering knuckle will result. 7.

position

Hold the outer CV-joint assembly

11.

down

housing.

with one hand. Grasp the steering knuckle

nuts9.off the bolt; do not turn the bolts the steering knuckle or

in

on the stub

knuckle bolts are serrated (toothed)

in

in

by grasping the inner joint and pulling. locked

The

locked

tri-pot

that the

assembly. is

and retaining

Tri-

ing knuckle attaching bolts from the strut is fully installed.

the halfshaft

Slide the boot

4.

should not be visible when the inner

inner Tri-pot joint

Remove

clamps.

the strut assembly-to-steer-

pot joint

Disconnect the negative battery cable.

3.

stops

moving. The O-ring on the stub shaft

Remove

2.

joint

bolt heads, torque the nuts to

hub and bearing assembly. lbs.

125

ft.

(170 Nm). Turn the nuts on the

DO NOT turn the bolts. New hub and bearing assembly-tobolts.

•

When removing

the outer CV-joint

stub shaft retainer nut. Tighten but

from the hub and bearing assembly, do not allow the flange disc on the hub and bearing assembly to become

•

damaged.

•

happens,

do not torque the nut

and screw

and water can enter the bearing, which wili cause premature bearing failure. If

this

Remove

at this time.

Speed sensor cable routing bracket

dirt

Brake rotor and caliper assembly; then, tighten the caliper guide pin bolts to

the halfshaft inner joint from

30

ft.

lbs. (41

1

•

Front wheels and lug nuts

•

Negative battery cable

- SNAP RING

2 - SEALING

Nm)

3 - SPIDER 4

BOOT

ASSEMBLY

- SNAP RING PLIERS INTERCONNECTING SHAFT

5 -

9306BG11

the transaxle stub shaft by grasping the inner Tri-pot joint and the interconnecting shaft

and pulling both pieces

at the

same

13.

Pump

the brakes until a firm pedal

is

obtained. 14.

Apply the brakes and torque the new

View

of the halfshaft inner tri-pot joint

snapring

and

CHRYSLER CORPORATION CONCORDE 1 1

Install

.

make sure

•

LHS

•

300M

the snapring onto the shaft:

INTREPID

•

Outer CV-Joint

If

installing a

new

boot, distribute Vz

of the grease in the service

the tri-pot housing

package inside

13.

tion.

and the other Vz inside

Carefully, slide the spider

and shaft 14. - SEALING

1

3 -

-

4

BOOT

.

assembly

15.

Position the inner boot clamp evenly

5 tool

C-4975.

of the halfshaft boot, shaft

the halfshaft and the retain-

Slide the boot

down

away

the shaft

Remove

the grease to expose the

CV-joint-to-shaft retaining ring. 6.

place the tool over the clamp bridge, tighten the tool nut until the jaws are completely

View

Remove

from the CV-joint housing.

BOOT CLAMP 9306BG12

Disconnect the negative battery cable.

3.

4.

into the tri-pot housing.

Using the Crimper

2.

ing clamps.

on the sealing boot.

INTERCONNECTING SHAFT THINNEST GROOVE INTERCONNECTING SHAFT

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

the boot.

2 -

.

the groove. 12.

5-25

VISION

that the snapring is fully seated 1

in

•

Spread the snapring ears apart and

slide the CV-joint

and boot

closed (face-to-face).

clamp

assembly

off of

the shaft.

7

Slide the boot off the shaft.

8.

Throughly, clean and inspect

parts for signs of excessive wear:

if

all

neces-

sary, replace the halfshaft.

The seal must not be dimpled, stretched or out of shape.

If

neces-

sary, equalize the seal pressure

shape

it

and

••Component

parts are not service-

able and must be replaced as an

assembly.

by hand.

To install: 16.

Position the boot onto the

tri-

pot housing retaining groove and install the retaining

clamp evenly on the

9

is

3 -

tool

C-4975.

place the tool over the clamp bridge tighten

SEALING BOOT

-

1

2 - SPECIAL

Using the Crimper

TOOL C-4975

the tool nut until the jaws are completely

CLAMP BRIDGE 93O60G13

Securing the halfshaft boot clamp

closed (face-to-face). 18.

If

visible

10

Install the halfshaft into the

on the

the CV-joint

seated

11.

If

drift;

of

7.

Slide the boot

Throughly, inspect

excessive wear;

if

off

be

the shaft. all

parts for signs

necessary, replace the

halfshaft.

'•Component

parts are not serviceable

and must be replaced as an assembly. To

install:

Slide the inner tri-pot boot clamp

9.

and boot onto the

shaft; then, position the

boot so that only the thinnest (sight) groove is

visible

on the

shaft.

Install the

shaft just far

can be

spider assembly onto the

enough so

that the

snapring

installed.

* WARNING

1

INTERCONNECTING SHAFT RETAINING SNAP RING - OUTER C/V JOINT ASSEMBLY -

2 If

necessary, tap the spider assembly

onto the shaft using a brass careful not to hit

be the outer bearings.

3

drift;

View

verify that the

of the halfshaft outer CV-joint

and snapring

For complete service labor times, order the Chilton Labor Guide

snapring

is

the shaft groove.

installing a

10. careful not to hit the outer bearings.

8.

and in

new

boot, distribute

of the grease in the service

necessary, tap the spider assembly the shaft using a brass

shaft.

Slide the outer CV-joint assembly on

the shaft, spread the snapring ears, position

fully

vehicle.

off

clamp

shaft; then, position the

boot so that only the thinnest (sight) groove

boot. 17.

Slide the outer CV-joint boot

and boot onto the

package

Vfe

into the

CHRYSLER CORPORATION

5-26

CONCORDE

CV-joint housing and the other

LHS

•

300M

•

•

INTREPID

V2 inside

k

•

VISION housing retaining groove and

WARNING

retaining

the boot.

Position the outer boot clamp evenly

12.

place the tool over the clamp bridge, tighten the tool nut until

If

shape

it

Using the Crimper

15.

neces-

14. equalize the seal pressure sary,

Using the Crimper tool C-4975,

13.

The seal must not be dimpled, stretched or out of shape.

on the sealing boot.

and

install the

clamp evenly on the boot. C-4975,

tool

place the tool over the clamp bridge, tighten the tool nut until the jaws are completely

closed (face-to-face).

by hand.

16.

the jaws are completely

Install the halfshaft into the vehicle.

Position the boot onto the CV-joint

closed (face-to-face).

STEERING AND SUSPENSION in

Bag

Air

unnecessary system repairs and/or

•

Both

personal injury.

**

bell

CAUTION

1

Some

Disconnect the negative battery cable

.

and

isolate the cable using

an appropriate

vehicles are equipped with an bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system

Always wear safety goggles when working with or around the air bag

repairs.

system.

PRECAUTIONS Several precautions must be observed

when handling

the inflator

module

to avoid

accidental deployment and possible per-

sonal injury. •

Never carry the

inflator

module by

the

wires or connector on the underside of the

module. •

When

for

2 minutes before starting any

on any

air

ponents. This

1=

bag system or related comdisable the

will

air

bag system.

be sure the bag and trim cover are pointed away from the body. In the unlikely event of an accidental deployment, the bag will, then deploy with minimal chance of injury. When placing a live air bag on a bench or other surface, always face the bag and trim cover up, away from the surface. This will reduce the motion of the module if it is accidendeployed.

tally

bag and trim cover are pointed

the steering gear under the master cylin-

bag and trim cover

With the

•

module on

»Ht may be helpful

of

•

Before servicing the vehicle, refer to

.

on each side)

Move

6.

the steering gear and interme-

diate shaft into the engine

gain access to the

•

Roll pin

to

avail-

and separate the intermefrom the steering gear

•

Right front wheel

•

Tie rod

end from the steering arm right strut

make

(If equipped with a 2.7L engine, turn left front tire towards the left as far

tion.

as possible to provide clearance.

the event

in

Turn the front wheels to the straight-

ahead position.

the begin-

DISARMING

Remove

or disconnect the following:

•

Negative battery cable

•

Wiper arms

•

Wiper module cover and cowl cover

•

CAUTION Bag system must be

compartment

roll pin.

the

3.

Reinforcement from the

strut

towers

and wiper module •

dis-

armed before repair and/or removal of any component in its immediate area including the air bag itself. Failure to do so may cause accidental

deployment

4 steering gear mounting bolts (2

the precautions in the beginning of this sec-

ning of this section as well.

Air

order

the bench,

Before servicing the vehicle, also

The

in

the clear the air conditioning lines.

REMOVAL & INSTALLATION

2.

i?

mounting

bracket to the steering gear

diate shaft

an accidental deployment.

sure to refer to the precautions

loosen the 2

bolts attaching the right

Power Rack and Pinion Steering

1

in

to

line

^Special tools are commercially able for removing roll pins.

never place anything on or close to the

module which may be thrown

to the side without

Booster vacuum

on the inflator

it

disconnecting the fluid lines

facing up. •

Master cylinder from the booster

and position

Place the inflator module on a bench

or other surface with the

fluid lines

equipped with speed proportional

steering, disconnect the wiring from

Gear

away. •

If

the solenoid control valve on the end of

carrying a live air bag,

hold securely with both hands, and ensure that the

5.

•

carrying a live inflator module,

fluid

der.

CAUTION

When

Power steering gear

•

Allow the system capacitor to dis-

repair

housing

from the reservoir

insulator (wrap with quality electrical tape).

charge

rods from the steering gear

Siphon the power steering

•

air

2.

tie

and place them on the transaxle

of the air bag, resulting

Throttle body’s intake air duct

and

resonator

Clamp

4.

position with •

the steering wheel

some

in

the center

type of holding device.

Intermediate shaft from the steering

column coupler

The steering gear

is

removed

or installed

through the right side of the vehicle

CHRYSLER CORPORATION CONCORDE

LHS

•

•

300M

•

INTREPID

equipped with Antilock Brake Sys-

** WARNING

STEERING

GEAR BOOT

5-27

VISION

•

tem (ABS)

Be sure the spacer block is

in

Brake caliper assembly. Support the

•

the rack

centered before connecting the

frame with a strong piece of wire.

rods to the steering gear.

Do Tie rods to the steering gear with

•

assembly from the vehicle

caliper

tie

and

the washers between the rods

not allow the assembly to hang

Remove

by the brake hose.

the

front brake rotor disc

SPACER the steering gear. Torque the bolts

BLOCK 10. 9300BG05

Center the spacer block

the steering

in

gear before installing the

to

tie

60

lbs.

ft.

(82 Nm).

Remaining components

•

in

the

The

reverse order of the removal steps

rods

Negative battery cable

•

Add Mopar' power and

the reservoir

let

it

go through the strut and steering

steering fluid to

2

settle for at least

it

OFF Add

fluid

knuckle. Do not turn the bolts during

removal.

minutes. Start the engine for a few seconds

and turn

damage

until the fluid level

Be sure the

tie

cedure.

shown

more than 2 as

the fluid

is

OFF

ing the

To

end

rod attaching points

tie

'•If

the

1

equipped with a 2.7L engine, turn

•

Right

tie

straight-ahead.

•

27

to

on the

tion.

on the end

use

of the coil spring requires the

of a coil

spring compressor tool.

bly.

required that 5 coils be captured

is

to half of the

specified torque, then tighten the

nuts

in

sequence again

to

95

pin •

is

roll pin.

centered

in

ft.

lbs.

•

Bracket bolts; tighten them

ened) •

to

27

lbs.

(37

ft.

lbs.

Solenoid valve,

if

(47

socket

of the strut shaft to prevent

Remove

the upper

it

strut shaft nut.

mount assem-

Remove

the coil spring

and com-

Remove

the lower spring isolator from

The suspension arms must hang

the strut

assembly lower spring seat

Remove

2.

freely.

Inspect

f.

or disconnect the following:

mal wear,

•

Negative battery cable

•

Front wheel(s)

•

Stabilizer bar attaching link at the

components

all

leakage or

oil

strut.

abnor-

for

Replace

failure.

parts as required.

To install: (58 (if

strut

Nm) tie

7.

assembly

Loosen, but do not remove the outer

3.

loos-

Nm)

Steering gear fluid lines; torque the nuts to 35

•

ft.

L-4558A

tool

10mm

supports under the suspension arms.

Be sure the

lbs.

and a

jounce bumper and seat bearing and

e.

4 steering gear mounting bolts and ft.

Rod Socket

strut shaft nut

pressor as an assembly from the

the joint.

torque the bolts to 43

the coil

the upper strut

»»Do not support the vehicle by placing

Intermediate shaft to the steering

gear using the

is off

dust shield as an assembly

(129 Nm). •

Compress

load

It

within the jaws of the compressor tool.

sequence

indexing of the

from turning. Remove the

Nm) in

all

Install Strut

c.

the precautions in the beginning of this sec-

Right front wheel. Torque the lug

nuts

for

Position the spring compressor

d.

(37

lbs.

ft.

Before servicing the vehicle, refer to

.

^Service

rod on the steering arm

and torque the nut

mount

mount assembly.

Steering gear

left front tire

strut

assembly

spring until

connect the following:

Install or

•

by performing

mark the

paint,

tool onto the strut.

the center of the steering gear travel. 9.

Using

strut

parts at

b

Position the

strut

lower spring isolator, spring and

upper

upward.

the strut from the vehicle.

Securely mount the strut assembly

a

unit,

rod hole while rais-

tie

of the steering gear

the bolts.

assembly upper

the following procedure:

install:

8. at

left

Remove

into a vise

Slide the right end of the steering

gear out through the

off

the 3 strut

Disassemble the

6.

for

a few minutes, then repeat the procedure. 7.

Remove

5.

mount-to-shock tower mounting nuts and

extremely foamy, allow

the vehicle to stand with the engine

Hold the bolt head with a

strut removal.

washers.

If

assembly-to-steering

wrench and turn the nuts

Lower the vehicle and repeat the pro-

12.

rods and the steering gear as

not hold the

at a time. Refill the reservoir

strut

knuckle bolts must not be turned during

needed.

washers between

to position the

Do

the locked position for

in

seconds 9300BG06

off the floor

engine. Turn the steering from

lock-to-lock several times.

wheel

The

4.

Raise the front wheels

start the

knuckle will

as necessary

remains constant.

and

the bolts are turned,

If

to the steering

result.

Repeat this procedure

1 1

assembly-to-steering

strut

knuckle bolts are serrated where they

end from the steering arm using

Nm)

•

speed proportional steering

tie

puller

Please

visit

MB-

stream

of fluid

strut.

site at

A

slight

between the strut,

will

rod

Speed sensor wiring harness

our web

by performing the

Inspect the strut assembly for

and dripping

mounting bracket from the

strut

signs of leakage Actual leakage

990635.

equipped with

a.

rod end-to-strut assembly steering arm

attaching nut. Then, remove the outer

Assemble the

following procedure:

if

www.chiltonsonline.com

running

off

down

the lower

amount

strut

of

be a

the side

end

of the

seepage

rod and strut shaft seal

CHRYSLER CORPORATION

9® 5 "40 is

CONCORDE

LHS

•

•

300M

•

INTREPID

not unusual and does not affect perfor-

mance

of the strut

the lower spring isolator on

Install

b.

assembly.

compressed

the strut unit. Install the

the lug nuts, in sequence, to

'•Service of the

95-100

the use of a coil spring compressor

(129-135 Nm).

lbs.

ft.

tool.

Negative battery cable

•

Rear 1

bearing into the

installed into the seat with the notches

Before servicing the vehicle, refer to

.

bly.

made

Align the paint marks

during

removal.

assembly, lower spring

Install the

e.

The

spring until

assembly and a lower

of the strut

The

strut is attached to the spindle

strut shaft, aligning

on the

mount-to-shaft

Remove

2.

retainer nut. Inspect

alignment marks

all

strut

Compress

coil spring. all

load

is off

of the

the coil

upper

mount assembly.

by a

rear spindle with a pinch

align as

or disconnect the following:

Caliper assembly and rotor from

•

required. While holding the strut shaft

10mm

from turning with a

the hub,

equipped with

if

rear disc

socket,

brakes

torque the strut shaft nut to 70

lbs.

ft.

Brake flex hose from the support

•

(94 Nm).

bracket and wheel cylinder,

com-

Equally loosen the spring tension

until all

the spring

equipped with

rear

drum

Plug the brake

flex

hose

released.

is

compressor

tool.

the rear caliper to tower. Torque the 3 upper nuts to

25

ft.

if

brakes. to prevent

system contamination. Do not allow

Install the front strut into the strut

8.

indexing of the

for

Rear wheel

•

made during removal and

Remove

strut

spring

bolt to hold the spindle to the strut.

Install the strut

pressor tool

mount

mark the isolator,

Position a spring compressor tool

b.

mount

jounce bumper and

the paint marks.

strut

paint,

parts at reassembly.

springs

onto the

bly.

g.

coil

springs are contained between the upper

split collar

f.

and upper

assemblies support the

rear strut

spring seat on the body of the strut assem-

upper mount on the

Using

tion.

positioned around the struts. The coil

and spring assem-

Securely mount the strut assembly

into a vise.

weight of the vehicle using

Lower the seat bearing and dust

d.

shield onto the strut

a.

the precautions in the beginning of this sec-

on

down.

required that 5 coils be cap-

is

tool.

bearing seat. The bearing must be

the bearings facing

It

coil spring requires

tured within the jaws of the compressor

the paint marks made during removal. Install the strut

VISION

coil

spring onto the strut assembly aligning

c.

•

7922BG48

hang by the

lbs.

brake hose. Support the caliper

off

Separate the lateral links trom the spin-

frame with a strong piece

of

dle— rear

(33 Nm). of the

strut service

Position the steering knuckle neck

9.

wire. into the strut

assembly.

Install the strut

Speed sensor cable routing bracket

•

assembly-to-steering knuckle bolts.

Install

and tube, the nuts onto the attaching bolts

• to 125 10.

lbs.

ft.

if

equipped with

ABS

and torque Lateral links to the rear spindle

(169 Nm). Do not turn the

assembly

bolts

serrated bolt heads during installation. Turn •

Rear strut assembly-to-stabilizer

only the nuts. bar attaching link at the stabilizer bar

'•Hold the hex on the attaching

The

strut assembly-to-steering knuckle bolts are serrated (toothed)

attaching link does not have to be

where they go through the strut and steering knuckle. Do not turn the bolts during removal.

turned,

damage

If

removed from the

bolts are

3.

to the steering

Remove

in

•

Brake rotor and caliper assembly

to

14

bolts to

ft.

lbs.

(19

Nm)

removed from the 4

it

to

will

Outer

tie

lbs.

(37

to

strut.

down

trailing

arm while

the strut

is

being

From inside the trunk of the remove the 3 upper strut mountbolts and remove the strut from the

5.

vehicle,

assembly onto the

assembly and torque the

attaching nut to 70

rear strut

serviced.

27

Nm)

Stabilizer link strut

arm

—

service

the end of the strut assembly. Let the

from the rod on the steering

attaching link stud at the bar

Using a hammer, tap on the top sur-

spindle and assembled components hang

if

the nut from the stabilizer-to-strut

spread

bracket onto the front strut,

off

Remove

be

and

ft.

•

jammed. This

punch

face of the spindle, driving the spindle

and torque the attaching nut

•

punch

Front speed sensor cable routing

equipped •

center

bolt. Install a

the spindle casting allowing

the adapter and torque the caliper

•

7922BG49

the hole on the spindle and tap the

into the hole until

connect the following:

strut.

the rear spindle-to-strut

assembly pinch

knuckle will result. Install or

link

stud while breaking the nut loose. The

ft.

lbs.

(95

ing

T922BG50

vehicle.

Nm)

Front wheel and lug nuts. Torque

6.

Disassemble the

the following procedure:

strut

by performing

Loosen, then remove the rear spindle-tostrut pinch bolt

— rear

strut service

CHRYSLER CORPORATION CONCORDE c.

•

300M

•

the strut shaft nut

it

paint

Remove

assembly

off of the strut shaft.

the coil spring and 7.

4558 and

Remove

compressor

an assembly from the

Insert a center

punch

into the hole

spindle and tap until the casting

spread

— rear

on the

mal wear,

all

for

pressor tool

leakage or failure. Replace

oil

parts as required.

strut service

Remove

abnor-

is

a.

Install

the lower spring isolator on

the strut unit.

If

it

is

the original isolator,

b.

Install

Install

bottom

the jounce

bumper

Install the plate

into the

on top

of the

Install the

bumper and

spindle tap

is tightly

on the

10.

d.

hammer

spindle driving the strut

— rear

it

on the surface

down and

strut service

off

of the

the end of

Install

tension

comreleased.

is

compressor

Push or

tool.

the top plate onto the strut

the notch in the

seated against the locating

assembly.

Remove

the center

in the spindle.

or connect the following:

Strut-to-spindle pinch bolt and ft.

lbs.

(55

Nm)

Lateral link-to-spindle attaching bolt

and torque

to

105

ft.

(140

lbs.

Nm)

the coil spring

and com-

•

marks on the spring

Stabilizer bar attaching link

and

torque the stabilizer link-to-stabilizer bar attaching nut to 70

to that of

ft.

lbs.

(95

the strut unit.

Access the 3 upper through the trunk

strut

mounting nuts

—

rear strut service

During reassembly, tap the spindle onto the strut until the notch in the spindle

Allow the components to hang from the trailing arm as shown

—

Timing belt service

rear strut service

is

covered

ft.

tap the spindle

strut, until

torque to 40 •

pressor tool onto the strut unit and align the paint

strut

Install

•

an assembly.

unit as

Tap with a

dust shield, jounce

(95 Nm).

lbs.

ft.

the spindle assembly onto the

of the strut.

dust shield and into the jounce bumper. c.

the spring

punch from the hole

align the paint marks.

dust shield.

until all

assembly onto the

following procedure:

70

(28 Nm). 9.

by performing the

socket tool L-

Allen wrench to pre-

Torque the 3 upper mounting nuts to 20 lbs.

strut

strut rod

8mm

Position the strut in the vehicle.

8.

To install:

Assemble the

the

Equally loosen the spring

g

components

install the strut shaft

the strut shaft nut to

strut.

Remove the plate, dust shield and jounce bumper off of the strut unit. Inspect

mount

vent the strut shaft from turning, torque

tool as

e.

f.

Using the

f.

mount

the upper strut

marks and

strut

strut shaft. Align the

retaining nut.

strut shaft nut. d.

upper

assembly onto the

from turning. Remove the

5*29

VISION

•

Install the

e.

8mm

and an

Allen wrench on the end of the strut shaft to prevent

INTREPID

rod socket tool L-

Install the strut

4558 on

LHS

•

in Section

tightly

3

of this

manual

seated against the tab

— rear

is

strut

CHRYSLER CORPORATION

5-30

CONCORDE

•

LHS

•

300M

•

INTREPID

•

VISION

WARNING

stabilizer link

Nm), while holding the

stud at the hex with a wrench

Pulling the steering knuckle out from

Rear speed sensor cable routing tube

•

and

bracket,

Rotor and caliper assembly

•

ABS

equipped with

if

the vehicle after releasing from the ball joint

(if

equipped with rear disc brakes) and torque the bolts to 16

Rear brake

•

flex

hose

ft.

lbs.

to the

(22

ft.

drum

keep the

lbs.

Loosen the pivot if

equipped

bolt

rear

lower control arm service

REMOVAL & INSTALLATION

a metal encased pivot bushing and a solid

rubber tension strut bushing. The lower

the tension strut.

arm

is

bolted to the cradle assembly

Front Refer to the front strut removal and

procedure

for coil spring service

information.

isolator bushing.

The

the lower control

arm and

able.

If

the ball joint

The

is

however,

ball joint seal,

is

tension strut from the cradle as an assembly

the

by

replaced.

ing.

Refer to the rear strut removal and instalfor coil spring service

If

replaceable

isolator bushing. Inspect the control

is

damaged, do

bushings

To

Before servicing the vehicle, refer to in

2.

ball joints

on these vehi-

cles are not serviced separately.

The

lower ball joints operate with no freedefective, the entire lower con-

arm must be replaced.

3.

Install or

8.

the beginning of this sec-

•

the ball joint stud-to-steer-

connect the following:

into bracket

bolt.

•

Carefully insert a prybar between the

sure the

ball joint

ball joint seal

first,

then

front lower control

on the cradle

bracket attaching bolt.

is

from knuckle. Be

•

does not get dam-

Washer and new nut on

BALL JOINT

STUD

SEAL

a steel

LOWER CONTROL ARM TENSION STRUT BUSHING

TENSION STRUT

NUT

TO CRADLE ISOLATOR BUSHING

WORD

“FRONT"

STAMPED

LOWER CONTROL

washer

ARM

IN

CONTROL ARM

PIVOT BUSHING

HERE

the tension strut-to-cradle nut and

— lower

control

arm service

Inspect the control

the end of

sion strut-to-cradle bracket retainer

forging with 2 rubber bushings isolating the

Remove

not

the tension strut. Torque the ten-

BALL JOINT

7922BG56

Do

tighten the bolt at this time.

aged during separation.

arm

install

Lower control arm-to-cradle

REMOVAL & INSTALLATION The

necessary.

lower control arm pivot bushing

lower control arm and the steering knuckle

and separate

Lower Control Arm

the front wheel(s).

clamp nut and

if

Tension strut and isolator bushing into the cradle

Remove Remove

ing knuckle 4.

excessive wear or deterioration

install:

tion.

Ball Joint

for

and replace these components,

or bent lower control arm.

the precautions

trol

arm

arm and

tension strut for distortion, check the rubber

not attempt to repair or straighten a broken

1.

information.

the lower control

removing the pivot bushing from the

first

cradle, then sliding the tension strut out of the

as well as the lower control arm inner bush-

Rear

assembly pivot

Separate the lower control arm and

7.

non-service-

becomes worn,

pivot bushing-to-cradle

bolt.

ball joint is built into

arm must be

entire lower control

arm

tension strut

at the

Loosen and remove the lower control

6.

using a pivot bolt through the center of the rubber pivot bushing

’»The lower

nut must be used during

'•A new tension strut-to-cradle attaching nut must be used when installing

control

Lower

A new

lower control arm from the front cradle

Coil Springs

procedure

using an open end

at the flats

installation.

to speci-

assembly. The isolator bushings consist of

installation

the nut,

wrench. Discard the tension strut-to-cradle retainer nut.

wheel toe set

When removing

from turning by holding the

and remove it—

brakes.

Have the

strut

tension strut

Nm)

Bleed the brake system,

If

the tension strut-to-cradle

the tension strut.

95

fications.

play.

Remove

5.

if

Rear wheel(s) and torque the lug

with rear

lation

can be damaged.

it

equipped with rear drum brakes

(129

12.

joint or

attaching nut and washer from the end of

nuts, in sequence, to

11.

Nm)

can separate the inner CVnot separate the inner CV-

wheel

cylinder and support plate,

•

Do

joint.

arm and tension

strut for distortion

— lower

control

arm service

1

CHRYSLER CORPORATION CONCORDE nut to 110

9.

lbs.

ft.

•

LHS

•

300M

INTREPID

•

•

5-31

VISION

(150 Nm), while

holding the tension strut

with

flat

an open end wrench. Inspect the ball joint seal and replace it

if

damaged.

Install the

lower

ball joint

stud into the steering knuckle and install the

clamp

bolt

and

nut.

Torque the bolt

to

40

ft.

(55 Nm).

lbs.

10.

Install

the front wheel and lug nuts.

Torque the lug nuts,

95-100

ft.

lbs.

in

a star pattern, to

(129-135 Nm). Lower

vehicle so the suspension

the

supporting the

is

ARBOR PRESS RAM SPECIAL TOOL 6644TOOL MB 990 799

-

1

2 -

weight of the vehicle 1 1

.

Torque the lower control arm pivot

bushing-to-cradle bracket attaching bolt to

105

ft.

lbs.

.

PIVOT BUSHING

5 -

TENSION STRUT BUSHING

6 -

LOWER CONTROL ARM

Remove

3 - SPECIAL TOOL MB990799 4 - TENSION STRUT BuSH*lG

LOWER CONTROL ARM

5 -

the nut

the lower control

arm

s tension

bushing

strut

Position Installer tool 6644-1 on top

bushing with the pivot bushing

of the pivot

and separate the ten-

Removing

pivot

bushing

8.

Remove

arm

Installing the lower control

the lower control arm/ten-

sion strut assembly from the vehicle. 2.

ARSOR PRESS RAM SPECIAL TOOL 6644-4

2 -

(142 Nm).

CONTROL ARM BUSHING REPLACEMENT 1

4 -

-

1

3 - SPECIAL

setting in the recessed area of the installer

sions strut from the lower control arm. tool. 3.

Using an arbor press, position the 9.

lower control arm with the large end of the pivot bushing inside the Receiver tool

MB-

990799. 4.

Remover

tool

6644-2 on

pivot bushing out of the lower control

6.

install:

with the word strut,

MB-

tool

arm so

that

it

ARBOR °fl£SS root b6aaj

-

10

.

lower control arm

4 - SPEClA-

Position an open end wrench on the

keep

it

arm nut

95

to

ft.

lbs.

TOOL 0644-3 TOOL U8980TW

from turn-

Torque the tension strut-to-lower con-

ing.

Using a new pivot bushing, position

the lower control

1

5 - SPECIAL

trol in

the ten-

the control

2 - special

of the tension strut to

990799.

it

away from

s -

1 1

on the Receiver

flat

7.

FRONT, stamped on

facing

arm.

Turn the lower control arm over and it

tension strut into the

Install the

lower control arm's tension strut bushing

sion

reposition

squarely bottoms

arm. 10.

Using the arbor press, press the

arm.

To

arm 7.

until the installer tool

against the surface of the lower control

Position

top of the pivot bushing. 5.

Using the arbor press, press the

pivot bushing into the lower control

arm

Installing the lower control

(130 Nm).

strut

s tension

bushing

is

square with the bushing hole.

TENSION STRUT BUSHING REPLACEMENT To install: 1

.

Remove

Thoroughly, lubricate the new tenthe lower control arm/ten-

sion strut bushing, the lower control sion strut assembly from the vehicle. 2.

Remove

the nut and separate the ten-

and the

Installer tool

Bushing

Installation

sions strut from the lower control arm.

Lube

Press the new tension strut bushing

8 3.

arm

6644-3 with Rubber

Using an arbor press, position the by hand, into the large end ot the Installer

lower control arm with the tension strut

bushing inside the Receiver

tool

6644-3 as

tool

MB-

9

lar

as

it

will

go

Position the lower control

arm onto

990799. 4

Position

Remover

tool

on the arbor press so

6644-4 on

hole top of the tension strut bushing. 5.

is

that the tension strut

centered on the Receiver tool

MB-

990799

Using the arbor press, press the tenPosition Installer tool 6644-3. with

sion strut bushing out of the lower control the bushing installed, inside the tension

ARBOR PRESS RAM SPECIAL TOOL 6644-2

arm.

•As

4 -

SPECIAL TOOL MB990799 PIVOT BUSHING

6 -

LOWER CONTROL ARM

1

-

2 3 -

strut

bushing

the lower control

Remover

tool is press through

the tension strut bushing, 9306BG25

Removing

the

arm

pivot

it

will cut the

bushing into 2 pieces. 6.

Remove

bushing hole

1 1

.

12.

the lower control arm, both

is

covered

bushing.

Using the arbor press, press the ten-

sion strut bushing into the lower control tool.

arm.

Heater Core replacement

lower control

Position Installer tool 6644-2 on top

of the tension strut

bushing pieces and the Remover

in the

arm.

in Section

2

of this

manual

CHRYSLER CORPORATION

5-32

CONCORDE

LHS

•

300M

•

*-As the bushing is being installed, a pop will be heard and Installer tool 6644-3 will move slightly up off the

•

INTREPID

the control

arm assembly

it

New hub and

•

straight off of the wheel

the

hub and bearing-to-stub

from the arbor press and remove

6644-3 from the tension

the tension strut bushing

is

Installer

bushing;

strut

now

installed.

not torque the nut

'•This hub nut

a torque prevailing

is

retaining nut

14.

Install the

tension strut into the lower

assembling the hub.

bolts to 16

ft.

Wheel and

lug nuts. Torque the lug

nuts

Remove

7.

word FRONT, stamped on the tension facing 15.

away from

the

hub and bearing assembly

to the

arm nut

95

to

Pump

12.

keep

it

from turn-

ft.

lbs.

(130 Nm).

Wheel Bearings

•If the metal seal on the hub and bearing assembly is seized to the steering knuckle and becomes dislodged on the hub and bearing during removal, the hub and bearing must be replaced.

If

ADJUSTMENT

the flinger disc

rear wheel bearings.

lubrication or

There

is

Remove

8.

the

hub and bearing assem-

bly from the steering knuckle by sliding

no periodic

maintenance recommended

straight out of the knuckle

is

and

off

the

its

from moving. Torque the hub and bearing assembly-to-stub shaft retaining nut ft.

120

to

(163 Nm).

lbs.

WARNING

When

wheel drive vehicles are

front

the brakes until a firm pedal

14.

must be replaced. These

ft.

With the weight on the vehicle on

13.

becomes

during the removal proce-

dure, the hub and bearing assembly

equipped with permanently sealed front and

95-100

wheels, apply the brakes to keep the vehicle

I:

damaged

a star pattern to

obtained.

Position an open end wrench on the

ing. Torque the tension strut-to-lower control

mount

in

(22 Nm).

lbs.

(129-135 Nm).

lbs.

steering knuckle assembly.

of the tension strut to

flat

strut,

the 3 attaching bolts that

the control arm.

time.

at this

Torque the brake caliper guide

bly.

A MUST be used when •

control arm’s tension strut bushing with the

A NEW

be used when

Brake rotor and the caliper assem-

retaining nut and can not be reused.

NEW

MUST

assembling the hub. Tighten but do

axle retainer nut. •

tool

bearing assembly-to-

stub shaft retainer nut. retaining nut

Remove

6.

Remove

the front brake rotor from

hub by pulling

mounting stud.

control arm. 13.

Remove

5.

the

VISION

•

it

ends

tightening the hub and bearing assembly to stub shaft retaining nut, do not exceed the maximum torque of 120 ft. lbs. (163 Nm). If the maximum torque is exceeded this may result in a failure of the halfshaft.

for these units.

of the stub shaft.

REMOVAL & INSTALLATION

prybar or tap

Gently pry the assembly out with a

9.

mer,

if

out with a soft-faced

ham-

Inspect the toe setting on the vehicle

and

adjust,

if

necessary.

necessary. Be very careful not to

damage

Front

it

the

hub and bearing assembly.

Rear

To install: 1.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2. 3.

Clean the hub and bearing mounting

10.

surfaces of

Remove Remove

the front wheel. the front caliper

•

away from the knuckle and

caliper off the

of the

lifting

the

machined abutment on the

steering knuckle.

Suspend

the caliper out of the

with a piece of wire.

way

•

Before servicing the vehicle, refer to

connect the following:

2.

Remove

bearing squarely onto the

•

stub shaft and the steering knuckle

•

Hub and

and tighten equally

assembly

is

until the

•

bear-

seated squarely •

knuckle. Torque the mounting bolts

•

80

ft.

lbs.

or disconnect the follow-ing:

Rear wheel

Brake caliper and

rotor,

if

equipped

Brake drum,

if

equipped with drum

brakes

against the front of the steering

to

the beginning of this sec-

with rear disc brakes

Bearing assembly mounting bolts

ing

in

tion.

Install or

11.

assembly

guide pin bolts, then rotating the top

4.

and be sure there are no

nicks present.

from the steering knuckle by removing the 2

caliper

dirt

1.

the precautions

Bearing dust cap Cotter pin, nut retainer, nut, washer

and bearing/hub assembly from the

(110 Nm).

spindle

To 3.

install: Install or

•

connect the following:

Bearing/hub assembly, the bearing/hub assembly washer and torque the nut to 124

ft.

lbs.

(168

Nm) •

Nut retainer and a new cotter pin

•

Dust cap

•

Brake drum or rotor and caliper

assembly •

Rear wheel and torque the lug nuts, in

a star pattern, to

95-100

ft.

lbs.

(129-135 Nm) 4.

Road

test the vehicle to verify

no

excessive noise from the rear wheel bearing area. Carefully pry the front bearing/hub

assembly away from the steering knuckle

CHRYSLER CORP. 1998-02 Chrysler-Sebring Coupe

DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM

6-26 6-2

F Front Crankshaft Seal

6-23

PRECAUTIONS

6-2

Removal &

Installation

Fuel Filter

STEERING AND

Removal &

SUSPENSION

6-36 6-36

Disarming

6-36

Precautions

6-36

Fuel

Installation

6-4

Removal

6-3

Pump

Removal Fuel

6-3

Alternator

Installation

Installation

System Pressure

Removal &

Lifters

Installation

6-16

Removal &

Installation

Coil Spring

Removal &

Installation

6-16

Removal &

6-28 Ignition

Timing

6-5

Intake Manifold

6-11

Cylinder Head

Removal &

6-8

Installation

D

Lower Control Arm

Installation

6-3

Removal

6-2

Removal &

&

Installation

6-5

Exhaust Manifold

6-14

Removal &

6-14

Installation

6-42

Oil

6-19

Pan

Removal & 6-5

Installation

Installation

Pump Removal &

6-19 6-21

Installation

6-21

Starter

Installation

6-22

6-39 6-18

Motor Installation

6-18 6-38

Strut

Removal

&

Installation

6-38

T Transaxle Assembly Installation

6-26 6-26

U Upper

6-41

Ball Joint

Removal & Removal &

Installation

6-41 6-41

Installation

6-41

V 6-18

Valve Lash

6-18

Adjustment

W Water

Pump

Removal &

6-7 Installation

Wheel Bearings

6-7

6-43 6-43

Adjustment

Removal &

P Piston and Ring

6-39

Shock Absorber

6-41

6-42

6-10

S

O Oil

E

Engine Assembly

Installation

Installation

Upper Control Arm 6-41

Ball Joint

Removal &

6-2

Distributor

6-11

L

Lower

Removal &

6-22

6-10

Rocker Arm/Shafts

Removal &

6-40

6-8

Installation

6-30

6-40

Installation

Removal &

Removal &

I

Removal &

6-22

Rear Main Seal

Removal &

6-30

6-36

R

6-24

6-30

Bleeding

6-31

Overhaul

Removal

Installation

Hydraulic Clutch System

6-31

CV-Joints

6-24

6-30

Halfshaft

6-28

Adjustment

6-24

6-23

Precautions

6-36 Installation

6-24

H

6-28

Clutch

Removal &

Fuel System Service

C Camshaft and Valve

Steering Gear

6-24

6-24

Relieving

Power Rack and Pinion

6-15

6-24

&

6-22

Positioning

6-15

6-24

Removal &

Bag

Installation

Fuel Injector

A Air

Dodge-Avenger

•

Installation

6-43

CHRYSLER CORP.

6-2

SEBRING COUPE

AVENGER

•

PRECAUTIONS of the following precautions,

all

which deal with personal

prevention

safety,

component damage, and important points when servicing a

of

IMMEDIATELY seek

brake fluid internally,

Before servicing any vehicle, please be sure to read

The EPA warns

•

with used engine

prolonged contact

that

may cause

oil

skin disorders, including cancer!

motor vehicle:

should make every

Never open, service or drain the radia-

system when the engine

tor or cooling

hot; serious

burns can occur from the steam

Observe

•

all

applicable safety precaufuel.

Whenever

servicing the fuel system, always work

Do

well-ventilated area. or vapors to

come

in

in

a

not allow fuel spray

contact with a spark,

open flame or excessive heat

(a hot

drop

sure to used engine

oil.

oil.

other exposed after

Soap and

expo-

water, or

waterless hand cleaner should be used. •

new

All

vehicles are

your vehicle.

If

of

becomes contaminated, completely

fluid.

Any brake

brake

the brake fluid flush the

Never reuse any brake

fluid.

fluid that is

removed from

the system should be discarded. Also,

Protective

soon as possible

fluid for

system with new

minimize your

oil.

Wash your hands and any skin areas as

when working around

effort to

used engine

to

of

You

gloves should be worn when changing

is

and hot coolant.

tions

exposure

number

a

to take into consideration

•

proper operation of the brake system. You

should always buy the correct type

medical assistance.

now equipped

come in will damage

contact with

a painted surface;

the paint.

it

Never operate the engine without the

•

proper amount and type of engine

so WILL result

Timing

•

belt

oil;

doing

severe engine damage.

in

maintenance

Many models

extremely

is

with an air bag system, often referred to as a

important!

Supplemental Restraint System (SRS) or

ence-type, non-freewheeling engine.

Supplemental

timing belt breaks, the valves

Inflatable Restraint (SIR) sys-

do not

allow any brake fluid to

utilize

an

in

interferIf

the

the cylinder

tem. The system must be disabled before

head may

extinguisher near the work area. Always

performing service on or around system

tially

keep

components, steering column, instrument

expensive) engine damage. Refer to the

light, for

example). Keep a dry chemical

fire

fuel in a container specifically

designed

for fuel storage; also,

panel components, wiring and sensors.

always

and disabling proce-

strike the pistons,

causing poten-

serious (also time-consuming and

maintenance

manual

interval charts in the front of

recommended

properly seal fuel containers to avoid the

Failure to follow safety

possibility of fire or explosion. Refer to the

dures could result

additional fuel system precautions later in

deployment, possible personal injury and

timing belt section for belt replacement and

this section.

unnecessary system repairs.

inspection.

Fuel injection systems often remain

•

in

accidental air bag

Always wear safety goggles when

•

working with, or around, the

turned OFF. The fuel system pressure must

When

be relieved before disconnecting any

sure the bag and trim cover are pointed

lines. Failure to

do so may

and/or personal

injury.

•

fuel

wash your hands thoroughly

handling brake

brake fluid

fluid.

If

you do get

with clean, running water for 15 minutes.

eye

irritation persists,

or

if

and trim cover upward, away

from the surface. This

motion

module

of the

will if

it

is

system precautions

accidentally

If

you have taken

air

bag

later in this section.

Clean, high quality brake fluid from a

•

sealed container

is

essential to the safe

for the

and

replace-

and

interval for the timing belt,

to the

Disconnecting the negative battery

cable on

some

vehicles

may

the functions of the on-board

tem^) and may

interfere with

computer sys-

require the computer to

undergo a relearning process once the negative battery cable •

When

reconnected.

is

drum

servicing

brakes, only dis-

assemble and assemble one side

reduce the

deployed. Refer to the additional

your eyes, flush your eyes

in

bag on a work surface, always

air

face the bag

ethers and polyglycols. Avoid contact with

after

carrying a non-deployed air bag, be

deployed

Brake fluid often contains polyglycol

the eyes and

bag system.

away from your body. When placing a non-

result in fire

ment

•

pressurized, even after the engine has been

air

this

at a time,

leaving the remaining side intact for refer-

ence. •

Only an MVAC-trained, EPA-certified

automotive technician should service the conditioning system or

its

air

components.

ENGINE REPAIR that serve as inputs to the

Distributor

PCM;

the

PCM

•

determines crankshaft position from these sensors, then calculates injector sequence

REMOVAL

and ignition timing, based on the 1

2.5L Engine

.

is

Disconnect the negative battery cable.

3.

Remove

or disconnect,

if

necessary

camshaft driven mechanical distributor. This engine uses a fixed ignition timing system, in

which the basic ignition timing

adjustable.

is

• 5.

The CKP sensor

is

is

mounted inside

the rotor-to-distributor

manifold bolt

•

•

Air cleaner cover to air cleaner

•

to

help with installation.

not

housing cover clamps

Rotor Distributor’s 2 electrical harness

connectors

Positive Crankcase Ventilation

•

Distributor

t

hold-down nuts and

Hall

(PCV) make-up

mounted

air

hose from the

air inlet

tube

•

Throttle

body hose clamp

•

Air cleaner cover, resonator

remotely from the distributor, while the

sensor

cap

Distributor cap

Matchmark

Air inlet resonator to the intake

•

effect devices.

Spark plug wires from the distributor

•

Crankshaft Position (CKP) sensor and

CMP

•

The Powertrain Control Module

Camshaft Position (CMP) sensor are

or disconnect the follow-

and the distributor-to-engine positioning

for access:

(PCM) determines spark advance. The

tor

Remove

the beginning of this section.

in

2.

equipped with a

4.

ing:

Before servicing the vehicle, refer to the

precautions

The 2.5L engine

data.

Exhaust Gas Recirculation (EGR) tube

washers •

Spark plug cable mounting bracket

•

Transaxle dipstick tube

•

Distributor

(if

necessary)

the distribu-

housing. Both sensors generate pulses

inlet

tube

and

CHRYSLER CORP. SEBRING COUPE TIMING DISTURBED

INSTALLATION

1

2.5L Engine

TIMING

piston

NOT DISTURBED

2.

’•Before servicing the vehicle, refer

to

the precautions in the beginning of this

.

Inspect the rotor for cracks or burned

and replace

defective. Install

it

3.

Inspect the 0-ring seal.

If

Install or

new

is

Remove •

rotor should align the No. 1 terminal of

nicked or Distributor

one. Be sure ers

the 0-ring

connect the following:

Distributor

’•'With the distributor fully seated, the

•

cracked, replace with a

hold-down nuts/wash-

and tighten the nuts

properly seated on the distriblbs.

to

108 inch

Nm)

(13

utor. •

3.

Install or

connect the following: •

•

REMOVAL 2.0L Engine

the distributor cap.

the rotor onto the distributor. 2.

of the

stroke.

Align the rotor with the distributor

•

electrodes,

Top Dead Center (TDC)

1

housing matchmark.

section. 1

is at

compression

6-3

AVENGER

Alternator

Rotate the crankshaft until the No.

.

•

or disconnect the following:

Negative battery cable

•

Right front wheel

•

Wheel

•

Auto-cruise speed control assembly

•

Alternator drive belt

well side cover

•

Alternator electrical connectors

•

Alternator bracket

•

Alternator

Spark plug cable bracket

Both distributor wiring connec-

2.5L Engine

Distributor drive with the slotted

tors

end

••When

of the

camshaft

the distributor

is

installed

properly, the rotor will be aligned with

the previously •

made mark.

Distributor

4

hold-down nuts/wash-

Distributor cap

•

Spark plug cables

•

Transaxle dipstick tube

Install or

108 inch

lbs.

EGR

Spark plug cable bracket

Both distributor wiring connec-

Throttle

Distributor cap

•

PCV hose

•

Spark plug cables

•

•

Transaxle dipstick tube

•

EGR

lbs. (11

Nm) •

Air cleaner cover, resonator

•

Throttle

•

PCV hose

•

Air cleaner

•

Air inlet resonator to intake

inlet

housing cover

Air inlet resonator to intake

mani-

fold bolt

•

and

•

A/C compressor

•

Power steering pump/alternator

Negative battery cable

Alternator bracket Intake manifold

Alternator electrical connectors

•

Alternator

housing cover clamps

mani-

Negative battery cable

5.

Generator Generator brace

Prior to installation, align the distributor

shaft with the distributor

engine

housing— 2. 5L Exploded view

ot the alternator

plenum

• •

body hose clamp

4

plenum

Intake manifold

•

tube

7922CG01

drive belt

•

fold bolt •

belt

drive belt

clamps •

tube and tighten the bolts to

95 inch

Air cleaner

Power steering pump drive cover

and

body hose clamp

•

Auto-cruise control reservoir

assembly •

tube

tors •

Wheel well side cover

if

Nm)

Air cleaner cover, resonator inlet

Right front wheel

•

•

lbs. (11

or disconnect the following:

Negative battery cable

•

tube and tighten the bolts to

95 inch •

•

connect the following,

(13

Nm) •

•

removed: •

ers and tighten to

Remove

•

and related components— 2. 0L engine

For complete service labor times, order the Chilton Labor Guide

stay

CHRYSLER CORP.

6-4

SEBRING COUPE

•

AVENGER used a

lbs.

(490-712 N)

for

belt.

k If

110-160

belt or

new

WARNING new

installing a

belt,

tension the

70 lbs. (310 N) and operate the engine for 5 minutes or more; belt to

then, apply the final tension. 3.

Torque the alternator-to-lower alterna-

tor bracket nut to

45

Nm) and

lbs. (61

ft.

alternator-to-upper bracket bolt to 40

ft.

the lbs.

(54 Nm). 4.

Install or

connect the following:

•

Auto-cruise speed control assembly

•

Wheel

•

Right front wheel

•

Negative battery cable

well side cover

2.5L Engine 1.

Pump

1.

2. 3.

4.

cover Drive belt (A/C compressor) Drive belt (Power steering oil and generator) Intake manifold plenum (Refer to GROUP 11 - Intake

5.

Generator bracket

6.

Intake manifold

Generator Generator 9. Tensioner 10. Tensioner 11. Generator

pump

7.

plenum stay

connect the following:

Alternator

•

Alternator electrical connectors

harness connector

8.

Manifold.)

Install or

•

pulley bracket pulley

Intake manifold

•

Alternator bracket. Torque the alter-

bracket

nator-to-lower alternator bracket nut to 30

Exploded view

of the alternator

and related components

—2.5L engine

16

1

.

2.

Remove • •

or disconnect the following:

Negative battery cable Drive belt

•

Alternator belt

•

Oil level

gauge

unit 2.

•

Alternator electrical connectors

•

Alternator brace

•

Install or

ft.

(22 Nm).

lbs.

plenum

•

Power steering pump/alternator

connect the following:

Attach a belt tension gauge

on the drive

Alternator

power steering pump

•

Alternator bracket

the drive belt tension to

99-121

•

Alternator electrical connectors

(440-540 N)

belt or

•

Alternator drive belt

lbs.

Attach a belt tension gauge

on the drive

belt; then,

90-110

lbs.

midway

adjust the drive belt

(400-490 N)

Alternator

for a

to

for a

(642-838 N)

3.

17 4.

pulleys; then, adjust

used

for a

new

belt.

ft.

lbs.

Install

(24 Nm). the

A/C compressor’s

Powertrain

Intermediate

Speed

module

Control switch

link

Main switch

control

assembly

Stop

light

switch

Vehicle speed

sensor |

npulspeed sensor

Reservoir assembly

Transaxle range sensor 9306CG03

View

of the auto-cruise

speed control and related components

—2.0L and 2.5L engines

lbs.

143-187

Torque the tension pulley bracket nut

belt.

control

midway

between the alternator and

belt,

•

tension to

the

drive belt 2.

1.

Nm) and

Intake manifold

2.0L Engine

tion.

lbs. (41

•

Before servicing fhe vehicle, refer to

the precautions in the beginning of this sec-

ft.

alternator-to-upper bracket bolt to

INSTALLATION

3.0L Engine

plenum stay

•

drive

CHRYSLER CORP.

6-5

SEBRING COUPE* AVENGER Attach a belt tension gauge

5.

on the drive

midway

between the crankshaft

belt,

and tension pulleys; then, adjust the drive

66-86

belt tension to

110-132

a used belt or for a

new

17

lbs.

ft.

Heater hoses

•

lbs.

•

(490-590 N)

•

Electrical

connectors from the

engine components

Brake booster vacuum hose

at the

engine

Vacuum hoses running

to the bulk-

•All wires and connectors should be labeled at the time of engine removal This will save time during assembly.

head

belt.

•

(24 Nm).

Install or

7.

Accelerator cable and bracket

•

for

Torque the tension pulley bracket nut

6.

to

(295-385 N)

lbs.

•

High pressure

fuel line

and discard

the 0-ring •

connect the following:

pump

•

Power

•

Auto-cruise control reservoir

steering

drive belt cover

ply

Right front wheel

•

Negative battery cable

belts

Do not disconnect the hoses or allow pump to hang by the hoses.

the

eidfet

•

Power steering pump move aside

rail

M Hrr

Wheel

Accessory drive

•

Fuel return hose from the fuel sup-

assembly •

•

well side cover •

Power steering pump bracket

•

A/C compressor and move aside

7.

3.0L Engine Install or

•

•

and torque the bolts

33

(44

ft.

lbs.

36

Oil level

bolt to

gauge

10

•

Alternator belt

•

Drive belt

•

unit

lbs.

ft.

(49

below the manifold and discard the

Nm)

gasket and nuts

and torque the

(15

Install the

Nm)

the engine are secure.

Exploded view

mount

ot the right-side

engine

the hoist just

— 2.0L engine

Ignition timing

is

Pow-

controlled by the

Module (PCM) and

is

86

Nm

not

adjustable.

Engine Assembly

REMOVAL & INSTALLATION 2.0L and 2.5L Engines Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section.

•The

transaxle must be removed

before removing the engine. They will not

come

out as a unit.

2.

Drain the engine coolant.

3.

Drain the engine

4.

Drain the transmission

5.

Properly relieve the fuel system

oil oil.

98-118 Nm 71-85 11 lbs.

pressure. 6.

• •

Remove Hood

or disconnect the following:

Engine mount insulator mounting Engine mount bracket 3 Engine mount stopper 1.

•

Engine under cover

•

Transaxle assembly

•

Radiator by disconnecting the

hoses

at the

bolt

2.

Negative battery cable

4.

Dynamic damper

Exploded view

ol the right-side

engine mount

— 2.5L engine

engine

Please

visit

our web

site at

enough

Draw tension on to support the

engine's weight but no more.

Timing

ertrain Control

engine hoist equipment

and make certain the attaching points on

Negative battery cable

Ignition

Exhaust system joint bolts just

•

and torque the

lbs.

ft.

hoses or discharge the system.

to

Nm)

Alternator brace bolts to

•

Do not loosen or remove the A/C

connect the following;

Alternator

www.chiltonsonline.com

Do

not dis-

CHRYSLER CORP. SEBRING COUPE

AVENGER

•

turb the placement of the vehicle on the

Check the transaxle drain plug,

i.

tightening

stands.

Rear (bulkhead side)

•

roll

stopper

stopper through-

roll

•

them

Upper (right-side) engine mount-

refill

if

•

necessary,

the cooling system.

Double check

Engine Coolant Temperature (ECT)

gauge

the

and engine

radiator

drain cocks, closing

and

bolt

refill

•

Check the

j.

Front engine

needed, and

if

transaxle.

through-bolt •

it

unit

ECT sensor connector Left

bank Heated Oxygen Sensor

(H0

2 S)

•

Brake booster vacuum hose Fuel supply and return hoses

installation items,

•

to-engine nuts/bolts, through-bolt

paying particular attention to loose hoses

•

Heater hoses

and mount assembly

or

hanging wires, loosened nuts, poor

•

Starter electrical connectors

•

k.

all

•

Support bracket below the mount

routing of hoses and wires.

•

Engine

10.

Connect the negative battery cable. engine and check

Start the

Attend to

11.

Immediately place stand or support

it

on an engine

it

with

Do not allow it to rest on the pan or lie on its side. Do not leave the engine hanging from the blocks.

for leaks.

leaks immediately.

Adjust the drive belts to the correct tension.

Adjust

wooden

all

all

cables (transaxle,

and check the

selector)

the operation of

fluid levels.

Alternator wiring

•

Drive belts

•

A/C compressor

•

Check

Power steering pressure switch Power steering

pump. Do not

oil

disconnect the hose

gauges and dashboard

all

Oil

•

7. •

throttle, shift

Pressure switch

•

•

Engine mount stay and

an

install

oil

Road

12.

hoist.

To

Installation is the reverse of the

1

removal procedure. Please note the follow-

manifold, using a

33

bolts to

lbs.

ft.

and

71-85

ft.

new

gasket. Torque the

lbs.

roll

Front

d.

mount through-bolt:

stopper through-bolt: 41

(56 Nm).

lbs.

'•Allow the mounts

to

engine weight before the front

roll

support the

final tightening of

Drain the engine

4.

Drain the cooling system.

5.

Recover the A/C

Remove

6.

Hood Negative battery cable

•

Strut tower bar

•

Air cleaner

•

Radiator reservoir tank

•

Front exhaust pipe

•

Throttle cable

•

Manifold

high pressure fuel

22 inch

Check

and secure engine.

it

lbs. (2.5

the engine if

lightly lubri-

•

lbs.

ft.

refill

(35 Nm).

Power steering

oil ft.

pump and torque (42 Nm)

lbs.

Power steering pressure switch

A/C compressor

•

Drive belts

•

Alternator wiring

•

Oil

•

Starter electrical connectors

•

Heater hoses

pressure switch

•

Fuel supply and return lines

•

Brake booster vacuum hose Left

• •

ECT sensor connector ECT gauge unit

•

Ground wire

connector

Exhaust Gas Recirculation (EGR)

•

Crankshaft Position (CKP) sensor

IAC motor

•

TPS connector

•

Control wiring/injector wiring har-

Right bank Heated

Distributor connector

•

Fuel injector connector

•

Right bank

•

CKP

•

KS connector EVAP solenoid valve connector EGR valve connector

Oxygen Sensor

•

Fuel injector connector Distributor connector •

•

Control wiring/injector wiring har•

ness combination connector • •

Throttle Position

•

Idle Air

Sensor (TPS)

(HO 2 S)

sensor connector

Control wiring harness and power steering harness combination con-

nector

Control (IAC) motor con•

the

Manifold

differential

nector •

connector

ness combination connector

(HO 2 S) •

electrical

•

connector •

2 S)

•

Evaporative (EVAP) Emission purge

Knock Sensor (KS) connector

bank (HO

•

combina-

connector

drain plug

necessary, and

the engine lifting devise

pressure sen-

•

Nm).

oil

26

Remove

•

Control wiring harness and power

tion •

connect the

and torque the

line

bolts to

•

solenoid valve connector

WARNING

Make certain each terminal is clean and the connector is firmly seated. Do not route wires near hot surfaces or moving parts.

h.

differential

steering wiring harness

nectors to the engine.

oil,

Engine mount stay and torque the

the bolts to 31

valve connector

Connect the wiring harness con-

bolts to

or disconnect the follow-

•

2.5L engine.

cated with clean engine

lbs.

refrigerant.

•

Torque the power steering

Using a new Oring

ft.

sor connector

ft.

g.

60

Nm)

oil.

•

ft.

fc

(81

3.

stopper through-bolt.

pump bracket bolts to 16 lbs. (22 Nm) for 2.0L engine or to 29 lbs. (39 Nm) for f.

to

pressure.

• e.

Engine mount bracket and stopper

ing:

stopper through-bolt: 32

roll

Engine assembly

and torque the bolts

•

(86 Nm).

(44 Nm).

lbs.

Properly relieve the fuel system

2.

(44 Nm).

(98-118 Nm).

lbs.

Rear

c.

ft.

ft.

Right-side

b.

ft.

63

connect the following:

the beginning of this sec-

in

•

to the

Right-side mount-to-engine nut bolt:

Engine assembly

install: Install or

bolts as follows: a.

•

Before servicing the vehicle, refer to

.

the precautions

Torque the engine mount nuts and

9.

Engine mount bracket and stopper

tion.

Connect the exhaust system

a.

such as

•

•

ing important steps:

Lifting Tool,

MZ203827

test the vehicle.

3.0L Engine

To install: 8.

engine

lights.

sor connector

Ground wire •

Throttle cable

Pressure sen-

CHRYSLER CORP. SEBRING COUPE •

Front exhaust pipe

•

Accessory drive

•

Radiator reservoir tank

•

Properly support the engine and

•

Air cleaner

•

Strut tower bar

•

Timing

•

Negative battery cable

•

Hood and

8.

Fill

replace the 9.

Fill

remove the

for

oil

pump

by hand to

freedom of movement.

Install

8.

tensioner and camshaft

or connect the following:

•

Rear timing

•

Camshaft sprocket(s), timing

belt

cover belt

and tensioner

adjust as needed

and

filter.

the cooling system to the proper %

Recharge the A/C system with the

10.

motor mount

right

belt,

Rotate the water

7.

check

sprockets

the engine with clean

level.

belts

6-7

AVENGER

•

With the timing belt removed, DO NOT4. rotate the camshaft or crankshaft or damage to the engine may

while the sprocket bolts are being

occur.

tightened.

DO NOT

allow the camshafts to turn

proper refrigerant. 1 1

Start the vehicle,

.

repair

if

check

for leaks

and

necessary.

•

Rear timing belt cover

•

Water

WARNING

pump

To install:

Water Pump

Do not attempt

Thoroughly clean

5.

all

sealing sur-

faces.

REMOVAL & INSTALLATION

assembly

ten-

installed in the engine.

This will cause

** WARNING

compress the

to

sioner plunger with the tensioner

damage

to the ten-

sioner and other related components.

Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough

2.0L Engine 1

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

6. turning bearings,

tion.3.

or sprocket or loose or Drain the engine coolant.

2.

Timing

•

damaged impeller damaged

•

This procedure requires removing the

timing belt and auto-tensioner. The

New

Remove

9.

connect the following

water

pump

O-ring

1 1

factory specifies that the timing

marks should always be aligned before removing the timing belt. Set the engine at Top Dead Center (TDC) on the No. 1 cylinder compression

Be sure the O-ring is properly seated in the water pump groove before

•

stroke. This should align all timing

pump and

105 inch

marks on the crankshaft sprocket and both camshaft sprockets.

lbs.

torque the bolts to

(12

or disconnect the following:

psi

•

Right inner splash shield

•

Accessory drive belts

for leaks.

If

Negative battery cable

release the pressure and continue the

•

Right inner splash shield

engine assembly process

engine and check

for

proper

if

Check and top

off

the cooling sys-

necessary

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

okay

•

and bleed the cooling system.

2.5L Engine 1.

pressurize the cooling system to 15

(103 kPa) and check

Refill

Start the

.

12.

Nm)

Using a cooling system pressure tester,

Remove

Water

the engine support.

operation.

tem,

tightening the screws.

covers

mount bracket and mount

Crankshaft damper

10

** WARNING

belt

Right engine

•

Install or

be compressed

in a vise.

sprocket flange.

•

MUST

The tensioner

2

Drain the engine coolant.

•This procedure requires removing the timing belt and auto-tensioner. Set the engine at Top

Dead Center (TDC) on

umm Ariw put*

'

2

1

Water

2.

O-nng

pump

Exploded view Exploded view

of the

water

pump mounting— 2. OL engine

Timing belt service

ing

is

covered

in

ot the

— 2.5L engine

Section 3 of this manual

water

pump mount-

CHRYSLER CORP.

6-8 the No.

SEBRING COUPE

•

AVENGER

cylinder compression stroke.

1

This should align

To

camshaft sprockets.

4.

belt

pump

Water

assemblies

connect the following:

Install or

with a

new O-ring and

Negative battery cable lbs.

Accessory drive belts and crank-

•

ft.

Support the engine and remove the

•

•

Timing

belt

covers

•

Timing

belt

and tensioner 5.

pump mounting Water pump Water

• •

Inspect the

Thermostat

Timing

•

Negative battery cable

pump

signs of coolant leakage

the cooling system to the proper

Start the vehicle, if

check

for leaks

and

necessary.

Any problems

5.

Cylinder Head

New

water

inlet

all

for flatness

using a

within 0.004

flat

cylin-

in.

(0.1mm).

REMOVAL & INSTALLATION

new pump.

Clean

parts.

gauge and a straight-edge. The

der head must be

Check the cylinder head

6.

for cracks or

other damage.

connect the following:

Install or •

require a

all

cylinder head sealing surface.

Check the cylinder head

excessive looseness or rough turning bearing.

aluminum feeler

vent and

Thoroughly clean

5.

sealing surfaces. Use care not to scratch the

or cracks,

at the

New

head bolts are recommended.

sealing surfaces.

damage

for

WARNING

Stretch-type bolts are used.

belt

level. 6.

all

install:

h

Nm)

bolts

repair

Thoroughly clean

(23

lbs.

•

Fill

To install: 4.

To

•

engine mount

right

Nm)

(23

head

ft.

Bracket and torque the bolts to 17

•

damper

shaft

Cylinder head bolts and cylinder

•

or disconnect the following:

gasket and torque the bolts to 17 •

cover

Rocker arm/rocker arm shaft

•

install:

•

Remove

camshaft sprocket and rear timing

discard the gasket

and O-ring

the crankshaft sprocket and both

3.

pump and

Water

•

timing marks on

all

new gasket and

Install a

7.

pipe O-ring.

the cylinder

2.0L Engine head.

:

Wet

WARNING

1

the O-ring with water to

installation easier;

the precautions

make

DO NOT use

oil

or

in

the beginning of this sec-

short bolts

Properly relieve the fuel system

2.

positions

New

water

pump

gasket

^Fit the pump inlet opening over the water pipe and press the assembly together to force the pipe into the water

pump. •

Water

pump and

torque the

to-engine bolts to 20

ft.

lbs.

Timing

belt

and timing

Remove

Negative battery cable

•

Air cleaner

•

All

and wiring

harness connections required

for

•

Fuel line

•

Throttle linkage

Accessory drive

•

Power steering pump and move

•

Right engine mount.

Remove

underneath the engine.

•

•

• •

Accessory drive

belts

and adjust

•

tension

•

Negative battery cable

•

Fill

Coil pack wiring connector

•

tem.

lbs.

(34 Nm).

ft.

lbs.

(68 Nm).

c.

Step

3:

Again

d.

Step

4:

Plus 14 (90 degree) turn.

pack unit

Ignition coil

belt cover,

timing

.

in

Cylinder head cover

Timing

•

Timing

•

Intake

Unstretched 3.

Remove

Negative battery cable

•

Timing

•

Thermostat and bracket

belt

cover

belt

and exhaust manifolds,

if

Ignition coil

•

Coil pack wiring connector and

pack

•

Power steering pump

•

Accessory drive

•

Throttle linkage

•

All ducts,

belts

hoses, fuel lines and

wiring harness connectors

12.

bolt

assembly

•

Air cleaner

•

Negative battery cable Fill

the cooling system.

7922CG08

'•A complete

or disconnect the following:

•

camshaft

spark plug wires

the beginning of this sec-

Drain the cooling system.

belt rear cover,

•

belt,

tion. 2.

for the

Rocker arm/rocker arm shaft

•

Threads are not straight on line Threads are straight on line

Before servicing the vehicle, refer to

(68 Nm).

if

3.0L Engine 1

wrench

•

operation.

the precautions

lbs.

ft.

removed

and exhaust manifolds,

Timing

50

connect the following:

Install or

Cylinder head cover Intake

to

not use a torque

Spark plug wires from the spark

engine and verify proper

Start the

ft.

50

sprocket and timing belt

necessary

and bleed the engine cooling sys-

25

2:

assemblies

plugs

Crankshaft damper

1:

Step

belt(s)

aside

the

and engine block from

~Do

Step

b.

•

•

covers

4

a.

11.

Timing

belt

in

4th step.

sioner. Set the timing belt tension

•

7.

lines

cylinder head removal

(27

belt ten-

assembly

vacuum hoses,

are to be installed in

9 and 10.

steps as follows:

ing: •

(110mm)

7, 8,

Torque the cylinder head bolts

10.

or disconnect the follow-

•

floor jack

6.

Drain the engine coolant.

4.

pump-

Nm) •

3.

oil.

cylinder head bolts, the

Install the

9.

pressure. •

threads with clean engine

tion.

grease.

Lubricate the cylinder head bolt

8.

Before servicing the vehicle, refer to

.

oil

and

filter

change

is

recommended. Checking the cylinder head bolts ing (stretching)— 2

.

OL engine

for neck-

13.

Run

Start the

engine and check

for leaks.

the engine with the radiator cap off so

— CHRYSLER CORP. SEBRING COUPE

AVENGER

•

surfaces of the head and block. Check the cylinder head for cracks,

Remove

coolant leakage.

compound and

damage

or engine

scale, sealing

carbon. Clean the

oil

sages thoroughly. Check the head

pas-

for flat-

ness. End-to-end, the head should be no

more than 0.008

(0.2mm)

in.

the service limit

out-of-true.

If

exceeded, correct to

is

meet6. specifications. Note

maximum

that the

amount from stock allowed

to be

removed

from the cylinder head and mating cylinder block

is

0.0079

(0.2mm).

made

If

in.

the cylinder head cannot be

serviceable by removing this amount,

replace

it.

Check

that the

head gaskets have the

proper identification marks for the engine.

Lay the head gasket with the identification Cylinder head bolt tightening

sequence— 2. OL engine

mark

the front top.

at

-»Do not apply sealant warms and

as the engine

the thermostat

bolt

5.

opens, coolant can be added to the radiator.

When

the cooling system

engine OFF,

is full,

install the radiator

cylinder head

shut the

•

cap and

With the engine cool, check

Add coolant and

levels.

Restart the engine

check

for

and

oil

all

fluid

Distributor

•

Ground

•

test drive vehicle to

proper operation.

•

Before servicing the vehicle, refer to

To

left

end

down onto

of

Cylinder head bolts: keep them

8.

Lubricate the bolts with clean engine

9.

Install the bolts

washers by hand and

in

one or 2 turns on the threads

Cylinder head and discard the gasket

•The washers must

install:

Properly relieve the fuel system

Drain the cooling system

4.

Remove

10

or disconnect the follow-

Negative battery cable

Timing

belt

lines that

may

inhibit cylinder

Water

Identification

pump

Nm).

Step 2 70

ft.

lbs (95

c.

Step 3 80

ft

lbs (108

Install or

• •

assembly

inlet

62

Stepl

b.

1 1

head removal Intake manifold

proper

in the

a

and camshaft sprockets

Wiring harnesses, vacuum hoses

and

Torque the head bolts

sequence as follows

ing:

•

be installed cor-

The rounded shoulder ot the washer denotes the lace in contact with the bolt. The flat side ot the washer contacts the head.

3.

•

each bolt

rectly.

pressure.

•

and the special

just start

numbered order

Thoroughly clean and dry the mating

•

cylinder head straight

the block.

oil.

Exhaust manifolds and crossover

tion.

•

Install the

7.

assembly

strap from the

pipe

2.5L Engine

2.

new

head bolts are recommended.

the front cylinder head

as required

the precautions in the beginning of this sec-

head gas-

cylinder head bolts are used. All

Valve covers and rocker arm

•

•

1.

to the

mating surfaces. Stretch-type

ket or

assemblies

allow the engine to cool. 14.

from the inner rear of the front

lbs (84

ft

Nm).

Nm).

connect the following

Valve cover and gasket

Exhaust manifolds and crossover pipe

pipe retaining

•

mark :p

o

o

Distributor

•

Intake manifold

•

All wiring

^o,/

harnesses,

hoses and

Transaxle side

^

•

12.

the oil

vacuum

lines

Negative battery cable Fill

and

the cooling system filter is

Changing

recommended

to elimi-

nate pollutants such as coolant in the oil.

Install the

tion

mark

engine

head gasket with the at the front facing

13.

HBCGM identifica-

upward

—2

51-

With the radiator cap

engine and check Cylinder head bolt tightening sequence

oil

2.5L engine

engine

Heater Core replacement

is

covered

in Section

2

of this

or coolant.

Check

electrical

manual

off, start

for leaks of fuel,

the

vacuum,

the operation of

all

systems as well as dash-

CHRYSLER CORP.

6-10

SEBRING COUPE

board gauges and

AVENGER

•

Add coolant as

lights.

the

engine warms.

Perform necessary adjustments

14.

to

the accelerator cable and drive belts. Allow the engine to cool

and once again check

and adjust the coolant

level.

3.0L Engine

•

Spark plug cables

•

PCV and blow

•

Breather hose

•

Water

10.

cable.

Properly relieve the fuel system

3.

pressure.

pipe

removing the

•

Exhaust manifold

•

Intake manifold

•

Alternator

upper intake manifold

•

Timing

which

•

Negative battery cable

Before servicing the vehicle, refer to

1.

inlet

Disconnect the negative battery

2.

by hoses

Fill

4.

If

right (firewall) side

rocker arm/shaft assembly, remove the

belt

the cooling system to the proper

is

(air intake

a 2-piece unit of

5.

Remove

6.

Identify the rocker

plenum),

aluminum

alloy.

the valve cover(s).

arm

shaft

assem-

the precautions in the beginning of this secblies before removal.

level.

tion.

11.

Start the vehicle,

check

for leaks

and

repair

if

MD

ers Special Tool

necessary.

auto lash adjuster retain-

Install the

7.

Relieve the fuel system pressure.

2.

998443

to

keep the

Drain the cooling system.

3.

auto lash adjusters from falling out of the

Remove

4.

or disconnect the following:

rocker arms

Rocker Arm/Shafts

Negative battery cable

•

is

•

Timing

•

Alternator

belt 8.

REMOVAL & INSTALLATION

when

the rocker

arm assembly

removed.

Remove

the rocker

arm

shaft

assem-

blies.

Intake manifold

•

’»The hydraulic automatic lash

•

Exhaust manifold

•

Water

•

Breather and blow by hoses

•

Positive Crankcase Ventilation

the precautions in the beginning of this sec-

arm

(PCV) hose

tion.

lash adjusters.

2.5L Engine

adjusters are precision units installed

pipe

inlet

1

Before servicing the vehicle, refer to

in

the

machined openings in the rocker Do not disassemble the auto

units.

Spark plug cables

•

Nm

•

Rocker arm cover

•

Timing

•

Cylinder head and discard the gas-

belt rear

3.5 2.5 ft.lbs.

cover

ket

To install: Clean

5.

all

mating surfaces

of

any

residual gasket material.

Lubricate the threads of the cylinder

6.

head bolts with clean engine Install or

7.

Cylinder head with a

•

Torque the

8.

oil.

connect the following:

bolts, in

new gasket

sequence, as

fol-

lows: a.

Step

1:

80

b.

Step

2:

Loosen

3:

80

ft.

lbs. all

(108 Nm). bolts in

sequence. Step

c.

Install or

9.

ft.

lbs.

(108 Nm).

connect the following:

•

Rear timing belt cover

•

Rocker arm cover

EXHAUST SIDE

^

FRONT OF ENGINE

1.

2.

Rocker cover Rocker cover gasket

10.

seal Oil seal

12.

11.

3. Oil 4. 5. 6.

EXHAUST SIDE

7.

8. 9346FG01

9.

Cylinder head boll torque sequence

engine

Rocker Rocker Rocker Rocker Rocker

arm and rocker arm arm and rocker arm

13. 14.

shaft shaft

15.

shaft spring

Rocker arm shaft Lash adjuster Rocker arm C Rocker arm shaft Lash adjuster Thrust case

16. O-ring 17. Camshaft

arm A arm B

— 3.0L Exploded view of the cylinder head valve

train

assembly

— 2.5L engine

CHRYSLER CORP.

6-11

SEBRING COUPE* AVENGER 4.

9.

To

To install: The rocker arm shafts are hollow and used as a lubrication

oil

duct. Ensure

Check

valve train parts are clean.

all

arm mounting portion

rocker

wear or damage. Replace

for

Check

all oil

install:

•

Rocker arms and shafts.

shaft cap to

necessary.

holes for clogging with a

23

lbs. (31

ft.

•

Rocker arm cover with a new gasket

•

rockers were removed, lubricate and install

• •

Breather hose

•

Negative battery cable

in their

any

original posi-

tions.

For the right cylinder head,

10.

the rocker the

FLAT

arm and

in

the rocker

toward the timing For the

11.

FLAT

12.

Install

air intake

hose

Vacuum connection

at

the

power

brake booster and the Positive

Crankcase Ventilation (PC V) valve •

remaining vacuum hoses and

All

pipes, as necessary. Tag for identi-

•

if

necessary, to save time

assembly.

at

arm shafts facing

shaft

Fuel line(s), the throttle control

cable and brackets

REMOVAL & INSTALLATION

assembly with the

arm

shaft facing toward

2.0L Engine This engine uses a 2-piece

the retainers and spring clips

original positions

on the exhaust

intake manifold.

aluminum

A non-reusable

gasket

joins the 2 halves.

•Be

sure to observe

tion that

sembly.

dure.

lbs. (31

ft.

•

fication,

Nm) working from the center, outward. Remove the valve lash retainer tools that may have been installed at disas23

Accelerator cable, breather hose

new gasket

and intake shafts Torque the retainer bolts to

•

Intake Manifold

the transaxle side of the engine.

in their

with a

or disconnect the following:

Negative battery cable

cylinder head, install the

the rocker

in

Remove •

install

assemblies with

belt side of the engine.

left

arm and

rocker

shaft

Drain the cooling system.

3.

and

Oil seals

them on the shafts

If

Relieve the fuel system pressure.

Nm)

•

PCV valve PCV hose

small wire and clean as required.

When

1.

2.

properly aligned, torque the rocker

the

of the shafts if

connect the following:

Install or

warnings

in

all

cautions and

the beginning of the sec-

may

be related

to this

proce-

Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only hoses and clamps specifically designed for fuel injection.

Inspect the spark plug tube seals

13.

located

on the ends

of

each tube. These

seals slide onto each tube to seal the cylin-

der head cover to the spark plug tube.

these seals

show signs

of

If

hardness and/or

cracks, they should be replaced. 14.

Install or

connect the following:

•

Valve cover(s)

•

Upper intake manifold (plenum),

if

necessary •

All

remaining electrical connectors

and tighten the

air

tube connec-

tions •

Negative battery cable

An

15.

oil

and

filter

change

is

recom-

mended. Start the

16.

engine and check

for leaks,

abnormal noises and vibrations.

3.0L Engine 1.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Relieve the fuel system pressure

1.

3.

•

Negative battery cable

•

Breather hose

•

Positive Crankcase Ventilation

Rocker arm cover

•

Rocker shaft cap

•

Rocker arms and shafts

hose

11

Generator wiring harness connection

12

PCV

2.

(PCV) hose and valve •

Air intake

Breather hose 3 Accelerator cable connection 4 Clip 5 MAP sensor connector 6 Intake air temperature sensor connector 7 Vacuum hose connection 8 TPS connector 9 Idle air control motor connector 10 Control winng harness

recommended procedure. Remove or disconnect the following:

using the

connection 16 EGR pipe connection 17 Fuel return hose connection 18 High-pressure fuel hose connection E3 use

new components

Intake manifold hose, cable and wire attachment identification

Brake service

is

covered

in

Section 4 of this manual

hose assembly

Vacuum hose 14 Vacuum hose connection 15 Brake booster vacuum hose

13

—

2 OL engine

CHRYSLER CORP.

«* 6-12

SEBRING COUPE

•

AVENGER

Alternator wiring harness

•

Manifold Absolute Pressure (MAP)

sensor and

•

Throttle Position (TP) sensor con-

nector and position the engine

rail bolt.

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

sensor connectors

(IAT)

each fuel 1

Temperature

Intake Air

>-»Use care, there are spacers under

2.5L Engine

•

tion.

Disconnect the negative battery

2.

may be necessary to remove the power steering fluid reservoir and mounting bracket to access all of the

'•Tt

lower intake manifold fasteners.

cable.

wiring harness aside

Exhaust Gas Recirculation (EGR)

•

pipe connection

Intake manifold stay

•

Properly relieve the fuel system

3.

and engine

fuel line(s)

from the

assembly. For quick-connect

To

fit-

tings,

Throttle

•

Intake manifold

•

Fuel

^Use

fitting retainer

tabs

plenum and gasket

sages

CAUTION

drop out of the fuel

as

rail

is

it

being

To prevent fuel from getting

your

in

catch any gasoline

to

0.006

Remove

or disconnect the following:

body

hose clamp

•

Throttle

cylinder head and intake manifold assembly.

•

Air cleaner cover

Check both surfaces

•

Vacuum connection from

Clean

gasket material from the

all

for cracks or other

air inlet

and

inlet

in.

(0.15mm) per 12

flat

limit is

within

(30.5cm)

in.

0.008

of

in.

(0.20mm). Properly position the

9.

hose

the

pas-

air

necessary.

if

gauge.

feeler

manifold length. The

and gasket

To install: 4.

clogging. Clean

The surfaces must be

8.

spillage. Intake manifold

cracks or other

Check upper and lower manifold

edge and

eyes, wrap shop towels around the

connection

for

gasket surfaces for flatness using a straight-

removed. •

for

7.

care since the fuel injectors can

gasket sealing surfaces.

all

damage. Check the intake manifold

assembly

rail

Clean

Check both surfaces

5. together and separate the connection.

body assembly

•

squeeze the

install:

6.

hanger Fuel injector connectors

intake manifold bolts, intake

manifold and discard the gaskets

Disconnect the

4.

fuel rail •

Lower

•

pressure.

new gaskets on

the heads and install the lower intake mani-

power

fold.

Torque the nuts as follows:

damage. Check the intake manifold water

brake booster and the Positive

a.

Front bank: 60 inch lbs. (7 Nm).

passages and

Crankcase Ventilation (PCV) valve

b.

Rear bank: 14-17

Clean

if

passages

air

clogging.

for

straight-edge and feeler gauge.

0.006

in.

(0.15mm) or

0.008

in.

(0.20mm).

New

The

pattern, starting

a crisscross

from the inside and

working outwards

17

to

ft.

lbs.

•

a

with clean engine Install or

11.

being removed or

may save time

Fuel injectors

•

Seat the injectors and torque the

Manifold Absolute Pressure (MAP) • •

injector

and pressure reg-

•

Power steering pressure switch and

Oxygen (O 2 S) sensor connectors,

assembly manifold plenum with

Plenum support bracket located the rear of the

gasket. •

body assembly

•

Throttle

•

Intake manifold stay

and engine •

MAP

Fuel injector electrical connectors Fuel line(s) to the fuel

to

sensor

Control wiring harness mounting

•

Upper

intake

plenum with new gas-

fasteners located on top of the

kets

and torque the bolts

upper plenum near the valve cover

lbs.

(18

Throttle Position (TP)

and

Idle Air

•

•

Engine control

•

Alternator wiring harness connection

•

Throttle

•

Fuel line(s)

•

Throttle cable bracket

•

Throttle control cable brackets

•

Exhaust Gas Recirculation (EGR)

•

Throttle cable bracket

•

Vacuum hose

at the

booster and the •

All

nections

valve

remaining vacuum hoses and

and •

air intake

Start the

operation.

engine and check for proper

lbs.

(18

Nm)

tube and torque the screws to

95 inch

lbs. (11

Nm)

body assembly

•

Throttle

•

TPS and

•

Plenum support bracket located

•

Control wiring harness and tighten

•

valve and transducer assembly

EGR

to

tube

7 upper intake plenum-to-lower

the •

l/^C electrical

connections

mounting fasteners

Power steering pressure switch and

manifold bolts, plenum and gasket

oxygen sensor connectors,

•

Fuel injector electrical connectors

connected.

•

4

hose

Negative battery cable

ft.

valve and transducer assembly

EGR

the rear of the

Accelerator cable, breather hose

•

EGR EGR

tube from the intake manifold

pipes •

body assembly

ft.

•

power brake

PCV

tighten to 13 •

13

Plenum support brackets and

Fuel injector connectors

Control (IAC) motor electrical con-

to

Nm)

EGR

connectors

assem-

^Exert a slight tug on the fuel line away from the fuel rail to verify positive engagement.

•

electrical

rail

bly

•

pipe connection

(12

lbs.

if

necessary •

105 inch

Nm)

(IAT) sensor connectors

rail,

oil.

connect the following:

•

sensor and Intake Air Temperature

Fuel

(20-23

lbs.

at

Lubricate fuel injector O-rings with oil

ft.

Repeat once more.

fuel rail bolts to

hanger

7.

and tag

clean engine

install the intake

new

is

14-17

Lubricate the fuel injector O-rings

10.

assembly. •

ulator

and

it

disengaged. This

Thoroughly clean the mating surfaces

6.

d.

helpful to identify

connection as

Front bank:

c.

(23

Nm) •

may be

(20-23

lbs.

Nm).

each sensor connector and vacuum

gasket and the manifold and in

necessary, to save time

if

ft.

Nm).

assembly.

at

limit is

*lt

torque the manifold

remaining vacuum hoses and

fication,

should be

connect the following:

Install or

•

less.

It

All

pipes, as necessary. Tag for identi-

manifold for flatness using a

of the intake

5.

•

necessary. Check the gasket surface

fuel rail-to-intake

and

fuel rail

manifold bolts

•

MAP

if

dis-

sensor and IAT sensor con-

nectors

CHRYSLER CORP.

6-13

SEBRING COUPE* AVENGER

19-23

Air intake

TPS

3 4 5 6

motor connector Vacuum hose connection Throttle body assembly Power steering oil pressure switch connector Heated oxygen sensor connector Intake air temperature sensor connector Injector connector Control wiring harness

10

of the

plenum and

Vacuum hose

at

booster and the •

All

connector

the

and

air inlet

hose.

Tighten the intake hose-to-throttle

1

.

repair

if

EGR EGR

check

pipe connection valve and EGR transducer

assembly 19

Intake manifold

plenum

20 Intake manifold plenum gasket

•

•

tor leaks

•

tion.

Fuel

rail,

injectors

Properly relieve the fuel system pres-

•

sure. 3.

and pressure

assembly

Insulators

Positive Crankcase Ventilation

(PCV) hose Right front upper timing belt cover

and bracket

Remove

or disconnect the following:

•

Negative battery cable

•

Intake manifold

•

Fuel injector connector

•

Fuel supply and return hoses

•

Vacuum hose

Negative battery cable Start the engine,

4.

sensor Heated oxygen sensor harness

Before servicing the vehicle, refer to

body hose clamp.

12.

MAP

3.0L Engine

2.

connectors

Air cleaner cover

•

Vacuum hose connection

the precautions in the beginning of this sec-

Remaining engine control system

•

connection 14 15 16 17 18

regulator as an

remaining vacuum hoses and

electrical

Vacuum hose connection Brake booster vacuum hose

valve

pipes •

Accelerator cable connection

manifold— 2. 5L engine

intake

power brake

PCV

11

12.

13

Idle air control

9

•

hose

1

2

7 8

Exploded view

ft.lbs.

and

necessary.

•

plenum

For complete Engine Mechanics I specifications, see Section

Intake manifold

and discard the

gasket

To install: Clean

all

mating surfaces

residual gasket material.

1

of this

manual

of

any

CHRYSLER CORP.

6-14 5.

SEBRING COUPE

Install or

•

AVENGER

•

connect the following:

new

Intake manifold with a

Nm

3.9 2.9 ft.lbs.

gasket.

Torgue the nuts as follows: a.

Right bank to 62 inch lbs. (7 Nm).

bank

16

to

b.

Left

c.

Right bank to 16

d.

Left

bank

16

to

(22 Nm).

lbs.

ft.

ft.

lbs.

(22 Nm).

(22 Nm).

lbs.

ft.

(22 Nm).

e.

Right bank to 16

•

Right front upper timing belt cover

ft.

lbs.

and bracket and torque the bolts

10

lbs.

ft.

•

PCVhose

•

Fuel

rail

bolts to •

6.

repair

assembly and torque the 102 inch

(12

lbs.

Nm)

Vacuum hose and return hoses

•

Fuel supply

•

Fuel injector electrical connector

•

Negative battery cable

Start the vehicle, if

to

Nm)

(15

check

for leaks

and

necessary.

Exhaust Manifold

REMOVAL & INSTALLATION

2.0L Engine 1

.

Before servicing the vehicle, refer to the

precautions 2.

3.

the beginning of this section.

in

Properly drain the engine coolant.

Remove

1. Air

or disconnect the following:

•

Negative battery cable

•

Air intake

hose and small

2.

intake hose

Radiator upper hose connection hose connection Control wiring harness connection Water pipe assembly

3. Air 4.

hose

air

5.

Engine oil level gauge Heat protector Engine hanger 9. Front exhaust pipe connection 10. Heat protector 11. Exhaust manifold 12. Exhaust manifold gasket 6.

connection

7.

•

Upper radiator hose from the ther-

8.

mostat housing •

Control wiring harness connection

•

Water pipe assembly and engine

oil 7922CG13

level dipstick

• •

Pulsed secondary

Heat shield and the engine hanger

•

Engine

•

Control wiring harness connection

•

Engine hanger or lower heat shield,

locknuts, separate the exhaust pipe

•

Loosen the mounting fasteners and

Clean

all

Upper radiator hose stat

To install: gasket material from the

mating surfaces and check the manifold

for

to the

thermo-

if

housing

•

hose and small

•

Air intake

•

Negative battery cable

air

hose

Fill

Start the

engine and check

Install or

•

New

•

exhaust leaks.

17

ft.

lbs.

crisscross

(23

Nm)

•

(44

if

33

Nm)

Pulsed secondary valve,

and

equipped

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

ft.

To

install:

3.

Clean

gasket material from the

2.

4.

Install or

•

Remove

or disconnect the follow-

•

Negative battery cable

•

Cooling fan assembly

for

cracks or warpage.''

New

connect the following:

gasket, manifold and stay

(brace) and torque the fasteners, in

ing: air injection

all

mating surfaces and check the manifold 1

new gasket and new

locknuts. Torque the nuts to lbs.

exhaust manifold stay

(brace), the exhaust manifold

FRONT BANK

in a

Exhaust pipe to the exhaust manifold with a

Exhaust manifold mounting fasteners, the

for

2.5L Engine

connect the following:

torque the fasteners,

•

equipped

Exhaust pipe-to-exhaust manifold

the gasket

gasket and manifold and

pattern, to

dipstick and tube

locknuts, separate the exhaust pipe

the cooling system.

7.

8.

oil level

and discard the gasket

cracks or warpage. 6.

— 2.0L engine

air injection

equipped

remove the exhaust manifold.

5.

exhaust manifold and related components

•

if

and discard the gasket 4.

of the

Exhaust pipe-to-exhaust manifold

valve, •

Exploded view

Heat shield and engine hanger

a crisscross pattern, to

22

Nm) New gasket,

exhaust pipe

ft.

lbs.

(29 •

install the

CHE U IJ

CHRYSLER CORP. SEBRING COUPE •

AVENGER

•

Battery and tray

•

Front exhaust pipe

•

Air cleaner

•

Oil dipstick

•

Strut tower bar

•

Upper and lower heat shields

•

Exhaust Gas Recirculation (EGR) pipe,

•

left

assembly guide

side only

Exhaust manifold and discard the gasket

To install: 3.

Clean

mating surfaces of any

all

residual gasket material. 4.

connect the following:

Install or •

Exhaust manifold with a new gasket

and torque the bolts (44 •

EGR

if

13

ft.

.

6.

7.

Intake manifold

4. 5.

plenum stay Heated oxygen sensor 10. Generator 11. EGR pipe assembly 12. Exhaust manifold stay 13. Exhaust manifold 14 Exhaust manifold gasket

Condenser fan motor assembly Dipstick guide assembly connection Engine hanger Exhaust manifold Exhaust manilold stay Exhaust manifold aasket

3.

lbs.

(18

Nm)

of the

ft.

lbs.

(15

9.

plenum

5.

guide

Oil dipstick

•

Air cleaner

•

Front exhaust pipe

•

Battery

Intake manifold

8.

Strut tower bar

•

and

assembly

tray

Start the vehicle,

repair

Exploded view

lbs.

Nm) •

1

ft.

Upper and lower heat shields and torque the bolts to 10

3.

2.

33

removed. Torque the

pipe,

bolt to •

to

Nm)

if

check

for leaks

and

necessary.

components— 2. 5L engine

exhaust manifold assembly and related

Front Crankshaft Seal to the

the nuts to •

33

ft.

lbs.

(44 Nm).

(13

5.

repair

ft.

lbs.

Nm)

Clean

Engine

•

Cooling fan assembly

•

Negative battery cable

dipstick

oil level

Start the vehicle,

check

and tube

4

Install or

•

for leaks

2.

•

Before servicing the vehicle, refer to the

precautions

in

Remove

or disconnect the following:

Negative battery cable

•

Intake manifold

plenum

plenum and

gasket, the manifold

ifold

brace and torque the nuts,

and man-

ft.

lbs.

stay

Exhaust Gas Recirculation (EGR)

in

a

(30

tion. 2.

Drain the engine

3

Remove

pipe assembly

leaks

equipped

oil.

or disconnect the following

•

Negative battery cable

•

Accessory drive belts

•

Crankshaft damper/pulley

•

Timing

bell

•

Timing

bell

•

Crankshaft sprocket

EGR

•

HO 2 S

ft.

lbs.

Nm)

(44

pipe assembly

cover

WARNING

sensor

Intake manifold

plenum

5.

Before servicing the vehicle, refer to

Exhaust pipe-to-exhaust manifold

Alternator

•

Alternator

if

.

using a new gasket and torque the

•

Heated Oxygen (HO 2 S) sensor

•

Manifold heat shield,

•

•

•

•

New

nuts to 33

the beginning of this section.

•

•

1

the precautions in the beginning of this sec-

Nm)

necessary.

REAR BANK .

2.0L Engine for

connect the following:

crisscross pattern, to 22

and

•

1

gasket material from the

all

mating surfaces and check the manifold cracks or warpage.

•

if

To install:

equipped and torque the lower

heat shield fasteners to 10

REMOVAL & INSTALLATION

and the gasket

fold

Engine hanger or lower heat shield, if

manifold brace, the exhaust mani-

exhaust manifold and torque

plenum and

Be careful not

stay (brace)

of the

to nick the seal

surface

crankshaft or the seal bore.

Negative battery cable

Start the engine,

and

repair

if

check

for

exhaust

•

necessary.

Front crankshaft seal using a seal puller tool

Exhaust pipe-to-exhaust manifold locknuts, separate the exhaust pipe

WARNING

3.0L Engine

and discard the gasket 1

•

Manifold heat shield,

if

.

Before servicing the vehicle, refer to the

equipped precautions

•

Exhaust manifold bolts, the exhaust 2.

in

Remove

For Accessory Drive Belt

the beginning of this section

Be careful not

or disconnect the following:

illustrations,

see Section

to

damage

the seal

contact area of the crankshaft.

1

of this

manual

CHRYSLER CORP.

6-16

SEBRING COUPE

AVENGER

•

3.0L Engine

To install: engine oil

new

Lubricate the

4.

the

oil. Install

new

seal by using oil seal installer Tool No.

1

Before servicing the vehicle, refer to the

.

precautions

Remove

2.

6780-1. Place a

new

oil

seal into

the opening •

Timing

•

Crankshaft sprocket

with the seal spring facing the inside of the

engine. Be sure the

seal

oil

installed flush

is

or disconnect the following:

Negative battery cable

• 5.

the beginning of this section.

in

6.

Crankshaft timing belt sprocket

•

Timing

Crankshaft Position (CKP) sensor

•

Crankshaft sensing blade

•

Crankshaft spacer and key

•

Front

Timing

•

Crankshaft damper/pulley

•

Accessory drive belts

belt

cover

3.

Lubricate the

engine

Change

the

oil filter

and

refill

check

Start the engine,

repair

if

and

for leaks

1

or disconnect the following:

Camshaft bearing caps

•

Camshafts

•

Camshaft followers

•

Crankshaft key and spacer

•

Crankshaft sensing blade

•

CKP

•

Crankshaft sprocket

•

Timing

•

Negative battery cable

Any components that are to be reused must be installed in their original locations. Use care to identify and mark the positions of any removed valve train components so

with Special Tool

sensor

they

may be

reinstalled correctly.

belt

Inspect the camshaft bearing

7.

Before servicing the vehicle, refer to

.

Remove •

connect the following:

New oil seal MD998717

necessary.

2.5L Engine

they are to

The

seal lip with clean

•

the

crankcase. 8.

oil

if

for later installation.

oil.

Install or

Negative battery cable

•

seal

install:

4.

7.

oil

To

at

camshafts are not interchangeable.

belt

•

Identify the camshafts,

5.

be reused,

6.

•

in

ward. Perform this step on one camshaft

belt

•

connect the following:

camshaft bearing cap retaining fasteners

the correct sequence, inside working out-

a time.

with the front cover. Install or

first

Loosen, but do not remove, the

4.

front crankshaft

Outer camshaft bearing caps,

•

seal with clean

holes

the precautions in the beginning of this sec-

in

oil

feed

the cylinder head for clogging.

Inspect the camshaft bearing journals for

tion.

Camshaft and Valve Drain the engine

2.

Remove

3.

Lifters

10.or scoring. Check the cam surface wear

oil.

or disconnect the following:

•

Negative battery cable

•

Accessory drive belts

•

Crankshaft damper/pulley

abnormal wear and damage. A

REMOVAL & INSTALLATION

groove lobes

To

2.0L Engine

•

Front timing belt covers

Timing

•

Crankshaft sprocket and key

Before servicing the vehicle, refer to

1.

belt

the precautions

in

•

Front crankshaft seal by prying out with a

flat

Properly relieve the fuel system

pressure.

Remove

3.

WARNING Be careful not

Negative battery cable

•

Spark plug wires

•

Ignition coil

Apply a

new

light

coating of clean engine

new

the

lip of

engine

pack with spark plug

pump housing

by using

MD998717. Be

Oil Seal Installer

sure the

installed flush with the oil 5.

Install or

oil

•

Ground

•

Timing

pump

seal

of the

camshafts

cam

for

followers.

cam

followers. Be sure

the

oil

cam

and properly positioned.

followers

in their

Install

original positions

K

WARNING

strap belt covers, timing belt

and

camshaft sprockets

'The

and condition

remove the camshafts

on the hydraulic adjuster and valve stem.

front crankshaft oil seal into the oil

Tool

fit

Cylinder head cover and discard

the

oil seal. Install

the

are inside the roller

the gasket

the

camshaft and

they are clean, well lubricated with clean

wires •

To install: 4.

all

The hydraulic valve lash adjusters or disconnect the following:

•

to nick the seal surface

of the crankshaft or the seal bore.

oil to

If

installation of the

tipped prytool; be

shop towel

with a

9.

it

sure to cover the end of the prytool tip

Thoroughly clean

are acceptable,

2.

cam

for replacement.

related parts.

the beginning of this sec-

tion.

the roller path or on the

cause

for

worn

install:

8.

•

in

is

visible

camshaft bearing caps are num-

To avoid valve to piston contact, be sure

NONE

of the pistons are at

Dead Center (TDC) when

Top

installing

the camshafts.

bered for correct location during instal-

is

lation.

cover.

connect the following:

•

Crankshaft timing belt sprocket and

•

Timing

belt

•

Timing

belt

•

Crankshaft damper/pulley

•

Accessory drive belts

•

Negative battery cable

key

6.

Change

the

engine with clean 7.

repair

covers

oil filter

Start the engine, if

and

fill

the 7922CG16

oil.

necessary.

check

for leaks

and

Camshaft bearing cap identification— 2. OL

Camshaft bearing cap retaining

engine

removal sequence

bolt

— 2.0L engine

CHRYSLER CORP.

6-17

SEBRING COUPE -AVENGER •Inspect the spark plug well seals for cracking and/or swelling and replace, if necessary. 16.

and

Install

Connect the negative battery cable.

19.

20. Test run the vehicle.

the cylinder head cover

Check

for leaks

proper operation.

for

2.5L Engine

assembly. 17.

Torque the cylinder head cover fasten-

ers, in

sequence, using the following 3 steps:

7922CG17

a.

Step

1:

40 inch

lbs. (4.5

b.

Step

2:

80 inch

lbs. (9

c.

Step

3:

105 inch

18.

Camshaft bearing cap retaining ening sequence

1 1

nals

•

— 2.0L engine

Nm).

and cam followers with clean engine

Nm).

Camshafts

•

Right and

•An left

connect the following:

Ignition coil

pack and torque the

Nm)

2.

Relieve the fuel system pressure.

3.

Drain the cooling system.

•

Spark plug wires

4.

Drain the engine

•

Ground

5.

Remove

•

All

caps No. 2 through No. 5 and

right

strap

vacuum

and remaining

lines

Torque the

lbs.

(12

•

Negative battery cable

•

Timing

filter

wash

change

is

recom-

may have

Upper intake manifold plenum

•

Lower intake manifold

•

Cylinder head bolts and cylinder

fallen

head

M6

fasteners to

in correct

No.

1

and

105 inch

sequence

No. 6 bearing

left-side

caps.

Bearing caps and torque the

•

fasteners to 21

lbs.

ft.

before the seals

may be

installed.

•

Camshaft end seals

•

Camshaft sprockets,

sure

M8

Nm)

must be installed

’••The end caps

•Make

(28

all

if

removed

timing marks are prop-

erly aligned, using the

recommended

procedure. •

Timing

belt

•

Timing

belt

covers

** WARNING Verify that all timing rect.

If

marks are

cor-

the timing belt or sprockets

are incorrectly installed, engine

damage

will occur.

Clean

15.

all

sealing surfaces.

Make

cer-

1

Breather hose connection

Blow-by hose Fuel hose assembly connection 4 Vacuum pipe connection 5. Spark plug cable 6. Rocker cover

2.

tain the rails are flat.

3.

•

New

cylinder head cover gaskets

DO NOT allow

oil

or solvents to con-

7.

Distnbutor

8.

Camshaft sprocket Cylinder head assembly Rocker arm and rocker assembly Camshafl Camshaft oil seal

9.

tact the timing belt as they

can dete-

and cause tooth skipping. Apply Mopar Silicone Rubber Adhesive Sealant, at the camshaft cap corners and at the top edge of the Vi round seal.

to.

riorate the rubber

For

Tire,

Wheel and

11. 12.

Exploded view

of the rear cylinder

shaft

head and camshaft mounting

Ball Joint specifications, see Section

and

•

out any sealant or

gasket material that

belt covers, timing belt

camshaft sprockets

Apply Mopar® Gasket Maker, sealer

14. to the

Nm)

and to

oil.

or disconnect the following:

into the engine.

side No. 6 13.

oil

mended

camshaft bearing

cylinder

head must be removed.

connect the following:

•

the beginning of this sec-

• For camshaft service, the

wiring Install or

in

tion.

(12 Nm).

fasteners to 105 inch lbs. (12

oil.

12.

Before servicing the vehicle, refer to

.

bolt tight-

Lubricate the camshaft bearing jour-

.

Install or

lbs.

1

the precautions

1

of this

— 2.5L engine

manual

CHRYSLER CORP.

6-18

SEBRING COUPE

•

AVENGER located on the ends of each tube. These

seals slide onto each tube to seal the cylin-

der head cover to the spark plug tube.

show signs

these seals

of

If

hardness and/or

cracks, they should be replaced.

28 - 34 21

-25

•

Cylinder head cover

•

Spark plug wires Intake manifold

•

Throttle and speed control cables

•

Air inlet resonator, air inlet

and

Nm ft. lbs.

air

remaining electrical connectors

All

•

Tighten the

•

Negative battery cable

9.

Fill

1 1

the

2.

PCV

Start the

.

air

tube connections

and bleed the cooling system.

Change

engine with clean Blow-by hose

hose

cleaner housing cover

•

10.

1.

plenum

•

oil filter

and

the

fill

oil.

engine and check

for leaks,

abnormal noises and vibrations.

valve and hose assembly

connection 3.

88 65

Nm

4.

ft.lbs.

5.

6. 7.

8. 9.

10. 11.

12.

3.0L Engine

Spark plug cable Vacuum pipe and hose asembly Rocker cover Relay box bracket assembly Control module and bracket assembly Thrust case Camshaft sprocket Rocker arm and rocker shaft assembly Camshaft Camshaft oil seal

LEFT BANK 1

.

2.

7922CG19

Exploded view

of the front cylinder

Thrust case from the

•

left

Before servicing the vehicle, refer to the

precautions

head and camshaft mounting— 2. 5L engine

in

Remove

the beginning of this section. or disconnect the following:

•

Negative battery

•

Timing

•

Thermostat housing

•

Blow by hose

belt

head

assembly •

Left

camshaft from the rear

of the

head Distributor from the right cylinder

•

head Right camshaft from the rear of the

•

head

To

3.4 ± 0.5

6.

Lubricate the camshaft journals.

7.

Install or

connect the following:

31 * 3 23 ± 2

•

Camshaft

•

Thrust case and torque the fasteners to

into the cylinder

108 inch

lbs.

^Lubricate the camshaft with clean engine •

'The

N

m

31 * 4 in-lb

install:

head

(13

Nm)

oil

seal

Nm ft-lb

lip

oil.

Camshaft seal

13 ± 2

before installing the seal. Be sure the seal

is

installed flush with the cylinder

head surface. •

Camshaft sprocket and torque ft.

lbs.

(88

to

65

Nm)

•

Cylinder head

•

Lower intake manifold using new

88 ± 10 N m 65 * 7 ft-lb

gaskets

8.

Nm

109*21

camshaft must be installed

•

Rocker arm and shaft assemblies

•

Timing

belt

Inspect the spark plug tube seals

Exploded view of the rocker arm and camshaft assembly

—3.0L engine

in-lb

.

CHRYSLER CORP. SEBRING COUPE •

Positive Crankcase Ventilation

•

Timing

(PCV) hose

•

Negative battery cable

•

Spark plug cables

•

Rocker arm cover

•

Rocker arm and shaft

•

Camshaft sprocket

• •

3.

belt

Negative battery cable

•

Engine under cover Heated Oxygen (HO 2 ) sensor elecconnector

trical

•

Front exhaust pipe

Thrust case

•

Starter

motor

Camshaft

•

Starter

motor

ADJUSTMENT The engines

in

these vehicles do not

connect the following:

Install or

3.

•

Camshaft

•

Thrust case and torque the bolt to

109 inch

65

torque to 23 •

Rocker arm cover and torque the

•

Spark plug cables

35 inch

bolts to

lbs.

lbs. (4

•

PCV and blow

•

Thermostat housing

•

Timing

•

Negative battery cable

2.0 and 2.5L Engines

precautions

Nm)

40

ft.

starter-to-

lbs.

(54

2.0L engine or 20-25

(26-33 Nm) motor

gaskets

for

electrical

when

ft.

2.5L engine

connectors

installing the

exhaust pipe.

front

Before servicing the vehicle, refer to the

1

for

Starter

~Use new

Nm)

lbs. (31

ft.

REMOVAL & INSTALLATION •

Rocker arm and shaft assembly and

motor and torque

transaxle bolts to

Nm)

(88

lbs.

ft.

Starter

Nm)

Camshaft sprocket and torque the bolt to

Starter Motor

Nm)

(13

connec-tors

or connect the following:

Install

•

lbs.

electrical

To install:

require periodic valve lash adjustment.

•

or disconnect the following:

•

•

Valve Lash

To install:

•

Remove

2.

6-19

AVENGER

•

the beginning of this section

•

Front exhaust pipe. Torque the front

Gasket

5.

Heated oxygen sensor

Catalytic converter

6.

Front exhaust pipe

Gasket Heated oxygen sensor

7.

Gasket

8 9

Protector

in

by hoses

44 33

44 33

Nm ft.lbs.

Nm ft.lbs.

belt

RIGHT BANK 1

.

Before servicing the vehicle, refer to the

precautions 2.

in

the beginning of this section

Remove

or disconnect the following:

•

Negative battery

•

Timing

•

Intake manifold

•

Breather hose

belt

plenum

•

Blow by hose

•

Spark plug cables

•

Rocker arm cover

•

Rocker arm and shaft assembly with Tool

9.4 ftlbs.

MD998443

•

Distributor

•

Camshaft sprocket with Tool

•

Camshaft

Hanger

MB990767 and MD998715 To 3.

Exploded view

of the front

exhaust pipe and related components

Install or

•

connect the following:

Camshaft and a new

oil seal,

cDOHC>

if

removed •

4.

Nm

65

ft.

(88

lbs.

Nm)

Distributor

Rotate the camshaft until the dowel

on the 5.

54

Camshaft sprocket and torque the bolt to

•

pin

— 2 5L engine

install:

end

front

Install or

is

26 - 33 Nm 20 -25 rtibi

properly positioned

connect the following:

•

Rocker arm cover and torque the

•

Spark plug cables

•

Blow by and breather hose connec-

bolts to

35 inch

lbs. (4

Nm)

54 40

Nm ft.lbs.

Removal steps 1.

•

Intake manifold

the bolts to 13

Starter terminal

2. Starter

tions

and connector

motor

plenum and torque ft.

lbs.

(18

Nm)

View

of the starter

motor— 2. OL (DOHC) engine and 2.5L (SOHC) engine

For Wheel Alignment specifications, see Section

1

of this manual

CHRYSLER CORP.

6-20

SEBRING COUPE

AVENGER

•

exhaust pipe-to-exhaust manifold nuts to 36 front

ft.

Nm) and

(49

lbs.

CHI

PAN GASKET

Oil FILTER

the

ADAPTER

exhaust pipe-to-catalytic con-

verter bolts to

36

(49 Nm).

lbs.

ft.

connector

•

H02sensor

•

Engine under cover

•

Negative battery cable

electrical

NIPPLE

3.0L Engine 1

Before servicing the vehicle, refer to the

.

precautions

in

the beginning of this section.

Remove

2.

DRAIN PLUG

or disconnect the following:

Negative battery cable from the

•

3

O-RING

shock tower FILTER

•

Air cleaner resonator

•

Starter

motor cover

Starter electrical connectors

3.

assembly

Starter

•.

Oil

PUMP BODY

To install:

7922CG21

connect the following:

Install or

4.

Torque the

Starter assembly.

•

25

bolt to

(33

lbs.

ft.

Exploded view

Nm) and

the

•

Front exhaust pipe

•

Oil dipstick

Nm).

•

Oil drain

connectors to the starter

Electrical

•

Starter cover

•

Air cleaner resonator

15 inch

and torque the

lbs. (6

components— 2. OL engine

starter

rear bracket bolt to 8 inch lbs. (1

•

to

bolt to

Nm)

Negative battery cable to the shock

•

of

the engine lubricating

•

25

ft.

and tube

plug and torque the plug lbs.

(34

the engine with clean

Fill

9.

Start the engine, if

check

pan attaching bolts

Oil

pan

To

install:

4.

Thoroughly clean and dry the

and

necessary.

Apply a continuous /ie inch (4mm)

5.

bead

of silicone

adhesive sealant to the

pan gasket surface. Be sure

2.5L Engine

mounting

Pan

within a 1

.

pan,

oil

bolt holes.

oil.

for leaks

tower

Oil

Oil

•

cylinder block ana cylinder block bolts and

Negative battery cable

8.

repair

Nm)

•

oil

to circle all

bolt holes as well. Install the oil

10-15 minute period

pan

applying the

of

Before servicing the vehicle, refer to the

gasket material to ensure proper sealing.

precautions

REMOVAL & INSTALLATION

in

the beginning of this section. 6.

2.

Drain the engine

Install or

• 3.

2.0L Engine

Remove •

the precautions in the beginning of this sec-

Negative battery cable and lower •

•

•

Center-member Engine

oil

dipstick tube

and dipstick •

Drain the engine

2.

Remove

3.

motor

Starter

•

Front and rear plates

•

oil.

or disconnect the following:

Nm)

dipstick tube and dip-

•

Transaxle inspection cover •

Center-member and torque the

•

Front plate

•

•

Front exhaust pipe

•

•

Oil

pan bolts

torque the drain plug to 29

•

Oil

pan

(40

and tube

bolts to

•

if

damage and

replace, 5.

pan

oil

if

6.

for

damage and

7.

necessary. While the pan oil

screen for clog-

8.

cracks. Clean and/or

repair

Oil

(88

Nm)

ft.

lbs.

Nm)

Negative battery cable the engine with clean

new

oil

and

oil filter.

Start the engine, if

lbs.

pan drain plug and gasket and

check

for leaks

and

necessary.

3.0L Engine

block and the to the

oil

Install or

Oil

Groove

Hole of

pan and torque the bolts

Nm)

1

bolt 7922CG22

To ensure a leak-free seal, apply sealer as

connect the following:

inch lbs. (12

'

pan.

seams between

pan and the engine block.

•

ft.

necessary.

Apply sealant

oil

65

Front exhaust pipe

Fill

install a

Thoroughly, clean the mating surfaces

of the cylinder

7.

oil

(108

Oil dipstick

removed, inspect the

the

Engine

lbs.

•

cracks; replace, is

ft.

motor

stick

To install:

ging,

80

Starter

Negative battery cable

Inspect the

53

Front and rear plates and torque the

•

4.

to

Nm)

Transaxle inspection cover

bolts to

tion. •

pan and torque the bolts

inch lbs. (6 •

Before servicing the vehicle, refer to

.

Oil

or disconnect the following:

the front exhaust pipe 1

connect the following:

oil.

to

108

shown and

tighten the bolts following the

specified sequence

—2.5L engine

.

Before servicing the vehicle, refer to the

precautions

in

the beginning of this section.

2.

Drain the engine

3.

Remove

as follows:

oil.

the engine support

module

CHRYSLER CORP.

6-21

SEBRING COUPE* AVENGER Crankshaft sprocket

•

Pump

Oil

•

Oil

pump

pickup tube and O-ring

and torque the

REMOVAL & INSTALLATION 2.0L Engine 1

•

Timing

•

Cankshaft damper

New

•

Nm)

pan

Oil

the precautions in the beginning of this sec-

pickup (28

lbs.

ft.

•

Before servicing the vehicle, refer to

.

pump

oil

tube screw to 21

belt

and covers

oil filter

the engine with clean

16.

Fill

17.

Test run the vehicle to check for

oil.

tion.

Tighten the upper

oil

pan bolts

in

2.

Drain the engine

3.

Remove

oil.

An

leaks.

sequence

or disconnect the following:

•

Negative battery cable

•

Timing

•

Oil

•

Crankshaft sprocket

•

Oil

•

Oil

belt

may be

1

Before servicing the vehicle, refer to

.

tion. 2.

Drain the engine

3.

Drain the engine coolant.

Remove

oil

pan bolts

mounting

sequence

Negative battery cable

•

Front exhaust pipe

•

Lower

oil

Remove

5.

Check

6.

•

Starter electrical connectors

•

Starter

•

Oil dipstick

To

Cover

•

Upper

Clean

block and oil

pan and discard the gas-

mating surfaces

all

of

any

install:

5.

Install or

the inner

Upper

connect the following: oil

Torque the

53 inch •

sequence,

bolts, in

lbs. (6

10

to

1 1

inch lbs. (11

Nm)

.

Starter

•

Starter electrical connectors

•

Oil dipstick

12.

O-ring and torque the bolt to 36 lbs.

•

(48

Lower

Nm)

oil

6.

pan with a new gasket to

•

Negative battery cable

Start the vehicle,

repair

if

rotors

pump

30-33

check

necessary.

the

pump

oil.

Oil

back cover and

ft.

oil

lbs.

to

oil

oil

flats of

the

11

pump

to the

•

and inspect

plunger slides

broken spring.

Be sure the

the

pump oil

using new parts

Align the marks

the

pump

lbs.

(10 Nm).

relief valve,

and valve cap. Torque the

30-33

ft.

lbs.

pump

(41-44 Nm).

before installation by

Install the

O-ring into the counter-

pump body the pump onto

discharge passage.

Position

the crankshaft until

teners to 10

ft.

fasteners to

30

14.

front oil seal

1

oil.

bore on the

seated on the block. Torque the size

(23-28

For Maintenance Interval recommendations, see Section

pump

Apply gasket maker sealer on the

pump.

rotor

on

back cover and

the rotor cavity with clean engine

filling

connect the following:

lbs.

rotors

surfaces are clean and free

Prime the

12.

body.

engine block.

ft.

for a

Reinstall the

valve cap to

before installa-

pump

dam-

for

and outer rotors when assembling

spring, gasket

pump-to-engine block bolts and

Nm) New

pump

parts well.

all

pump

Install

13.

oil

case

torque the screws to 89 inch

body.

pump

pump

that the oil relief

Assemble

10.

(10 Nm).

relief valve,

ring into the discharge

torque to 17-21

for leaks

Clean

the inner

on the crankshaft as you

Install or •

Check

9.

oil.

flats

the

as required with clean

when assembling

pump

pump

Align the

14.

oil

of old sealer.

using new parts

the engine

of the

pump

Remove

8.

Align the marks on

oil.

(41-44 Nm).

with the

Oil

Inspect the

6.

tion by filling the rotor cavity with clean

15.

the engine with clean

and

lbs.

upper and lower covers

To install:

lbs.

install the

Front exhaust pipe

•

96 inch

Nm)

•

Fill

pump

the

and outer

Prime the

engine

and torque the bolts (11

ft.

Crankshaft sprocket

block and

Install

13.

•

7.

Apply gasket maker

passage

and guide with a new

belt

the inside of the case for excessive wear.

Be sure the

block mounting surface of the

•

and inspect

surfaces are clean and free

Reinstall the

96

belt

Timing

age and remove the rear cover.

broken spring.

for a

parts well

all

pump

valve cap to to

Timing

•

•

dam-

spring, gasket and valve cap. Torque the

Nm)

Cover and torque the bolts

•

5.

rotors

torque the screws to 88 inch

pan with a new gasket.

Crankshaft damper

smoothly and check

Install the

9.

•

for

that the oil relief plunger slides

as required with clean

residual gasket material.

To

pump

the

Assemble

8.

Clean

case

of old sealer.

ket 4.

pump

install:

7.

•

oil

smoothly and check

and guide

Drive belts and accessories

•

loca-

the inside of the case for excessive wear.

ket

•

tag the front cover

age and remove the rear cover

pan and discard the gas-

or disconnect the following:

bolts.

Inspect the

4.

•

in their original

Remove and

In

and must

oil.

Negative battery cable

•

pump mounting

different sizes

be reinstalled Tighten the lower

pressure.

the precautions in the beginning of this sec-

pump pick-up tube and O-ring pump and front crankshaft

front cover/oil

tions.

oil

2.5L Engine

4.

bolts

engine

pan

seal

The

pressure gauge should be

oil

installed to verify proper

lbs. ft.

(14

Nm) and

lbs. (41

M8

size

fas-

M10

Nm).

connect the following:

Install or

•

Timing

belt

and crankshaft sprocket

•

Timing

belt

cover

•

Crankshaft damper

•

Drive belts and accessories

of this

manual

CHRYSLER CORP.

6-22

SEBRING COUPE

•

AVENGER •

New

•

Negative battery cable

oil filter

the engine with clean

7.

Fill

8.

Start the vehicle,

repair

if

check

oil.

for leaks

and

necessary.

Rear Main Seal REMOVAL & INSTALLATION 2.0L and 3.0L Engines

**Be sure to observe all cautions and warnings in the beginning of the section that

may be

related to this proce-

dure. 1

Remove

.

or disconnect the following:

•

Transaxle

•

Flexplate/flywheel

•

Rear crankshaft

'•Pry the

oil

seal

seal from the housing

using a suitable

To

oil

flat

bladed prying

tool.

install:

"•When

installing the

new

seal there

is

no need to lubricate sealing surface. 2.

connect the following:

Install or

•

housing using a

Oil seal into

suit-

able installation tool 1. Oil

2. Oil

11. Plug 12. Relief

pressure switch pressure gauge unit

4. Oil filter

5. Oil filter

15. Oil

6. 7.

bracket bracket gasket Drain plug Drain plug gasket

18. Oil

9. Oil

screen screen gasket

19. Oil

of the oil

pan and pump assembly

pump cover pump outer pump inner

rotor

Fill

the cooling system.

16.

Fill

the engine with clean

install

a

new

Road

17.

oil

—2.5L engine

and

oil filter.

test the vehicle.

Check

for

proper operation as well as leaks.

Transaxle

68

ft.

lbs.

(92

Nm)

2.5L Engine

rotor

1

.

4.

•

Oil

•

Oil

•

Oil

•

Oil

Clean

Before servicing the vehicle, refer to the

precautions 2.

15.

•

16. O-ring

17. Oil

pan

7922CG20

Exploded view

Flexplate/flywheel and torque the bolts to

pump case

8. Oil

10. Oil

•

spnng

13. Relief plunger 14. Crankshaft oil seal

3. Oil filter

pump pump pump pump

•

case

Flexplate/flywheel

5 rear seal housing-to-engine bolts

•

Oil seal

•

Rear crankshaft

case

any

or disconnect the following:

Transaxle

•

outer and inner rotors

of

the beginning of this section.

•

cover

mating surfaces

all

in

Remove

housing oil

seal

from the

oil

residual gasket material.

3.0L Engine 1

.

3.

5.

Prime the

6.

Install or

pump

oil

Before servicing the vehicle, refer to the

precautions 2.

To install:

in

the beginning of this section.

Drain the engine

Remove

the engine support

•

Negative battery cable

•

Oil filter

•

Oil

•

Inner and outer rotors

•

Oil

module

Oil filter

pump

cover and torque the

•

lbs. (10 Nm) pump case assembly New front crankshaft oil seal

•

Relief plunger

•

Baffle plate

•

Oil

•

Baffle plate

bolts to

pressure switch

89 inch

Oil

bracket

•

Lower and upper

•

Baffle plate

oil

pan

screen and gasket

•

Baffle plate

•

Relief spring

•

case

Oil

•

•

Oil

pump

• oil.

as follows:

•

before installation.

connect the following:

oil

screen with a new gasket Fig. 1

-

pan and cover

2

-

pan

3 -

•

Upper

oil

•

Lower

oil

•

Oil filter bracket with a

and plunger

Front crankshaft

and spring

93

install

Crankshaft Rear Oil Seal

SPECIAL TOOL MD-99871 SEAL

HOUSING 9346FG05

seal

new gasket Install the

•

Oil

pressure switch

new

rear

main seal

CHRYSLER CORP. SEBRING COUPE* AVENGER seal

housing using a suitable

to the

To 3.

5.

install:

»»When

installing the seal there is no

need

Apply a

light coating of

engine

bolts to

connect the following:

Install the seal into the

housing using

and torque the (92

lbs.

Nm)

Piston and Ring

to lubricate sealing surface.

MD998718.

ft.

Transaxle

•

oil to

68

seal lip circumference.

oil

Install or •

Tool

Flexplate/flywheel

mating surface of the seal housing.

the entire 6.

•

Apply silicone rubber adhesive sealant

4.

flat

bladed prying tool

6-23

and housing and torque

Oil seal

the

mounting

(11

Nm)

bolts to

Identification

96 inch

mark

“1

lbs.

POSITIONING

R"

Chrysler engine connecting rod and cap installation

— ensure

and rod prior

to

matchmark

the cap

disassembly

to

Chrysler piston ring identification mark

Piston ring orientation

locations

2.5L (VIN N) engines

NO

SIDE RAIL

side

rail

^

-

NO

1

ring

gap

Y)

and

1

RING GAP

UPPER of

lower/^-

Gap

— 2.0L (VIN

\

ff Front of engine

J

\

No. 2 ring gap and spacer expander gap

Gap

of

upper side

The small arrows on

Piston positioning

the crown ot the pistons

Piston ring end-gap spacing

— 2.0L (VIN Y)

Piston ring end-gap

spacing— 2. 5L and

the front ol the engine

3.0L engines

engine

must point toward

— 2 OL and 2.51

engines

FUEL SYSTEM Fuel System Service Precautions Safety

is

the

most important

performing not only

nance but any type to

fuel

of

factor

maintenance. Failure

conduct maintenance and repairs

safe

manner may

injury or death.

in a

of

system components can be

accomplished safely and

effectively

to the following rules

by

and guide-

lines.

•

spillage Ensure that

applied.

(should

•

Always

relieve the fuel

fire

and per-

occur)

is

all

fuel spillage

quickly removed from

engine surfaces. Ensure

system pres-

that all fuel

soaked

cloths or towels are deposited into a suit-

component

able waste container

(injector, fuel rail,

pressure reg-

•

connection

Exercise extreme caution whenever relieving fuel

system pressure,

and eyes

to

avoid exposing

to fuel spray.

Please be

advised that fuel under pressure

may pene-

skin, face

trate the skin or

any part

of the

body

that

to

•

Always keep a dry chemical (Class B)

extinguisher near the work area.

fire

• Do not allow fuel spray or fuel vapors come into contact with a spark or open

flame. •

it

Always use a back-up wrench when

loosening and tightening

contacts.

To avoid the possibility of

it

sure before disconnecting any fuel system

ulator, etc.), fitting or fuel line

result in serious personal

Maintenance and testing

the vehicle’s fuel

adhering

when

system mainte-

dure requires that battery voltage be

Always place a shop towel or cloth

sonal injury, always disconnect the negative

around the

battery cable unless the repair or test proce-

loosening to absorb any excess fuel due to

fitting

or connection prior to

For Tune-up, Capacities and Firing orders, see Section

fuel line

tion fittings. This will prevent

stress •

1

and torsion

to fuel line piping.

Always replace worn

of this

manual

connec-

unnecessary

fuel fitting

0-

CHRYSLER CORP.

6-24

SEBRING COUPE

rings with new.

where

fuel

pipe

Do

•

AVENGER

not substitute fuel hose,

Separate the

5.

the bottom of the

is installed.

Remove

6.

fuel filter

Fuel System Pressure

connection

flare nut

at

mounting bolts and the

the

Do

not use conventional fuel

the injection system and could

from the vehicle.

CAUTION

servicing the vehicle, refer to

Before

1.

the precautions

in

the beginning of this sec-

tion.

Remove

2.

the fuel

filler

cap

to release

Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and

3.

Remove

4.

At the fuel tank, disconnect the fuel

injury or

harness connector.

only hoses and clamps specifically

pump

Start the vehicle

5. until

the rear seat cushion.

it

to the

stalls

OFF

from lack

and allow

it

to run

To

Install

7.

pump

connector.

Tighten the

flare nut fitting

before mounting the

attachment of the

Use

27

Negative battery cable

•

Rear seat cushion

panel on the far right side

on the bracket. bracket only

its

filter

Access cover

•

Fuel

•

Return hose and high pressure fuel

•

bolt.

While holding

housing, torque the eye bolt

lbs.

(29 Nm). Torque the flare nuf fo

ft.

lbs.

(36 Nm).

Tighten the

filter

to

To

Install the intake air

11.

hose,

replaceable fuel

filter is

located

in

Start the vehicle,

13.

if

and

Pump

air intake

hose

fuel filter

housing securely

for access.

with a wrench. Cover the hoses with

shop

torque

lbs. (2.5

Nm)

High pressure hose, return hose fuel

pump

wiring

Negative battery cable

Check the

fuel

pump

Apply sealant

for

proper pres-

access cover and

to the

Install the rear seat

Pressurize the fuel system by turning

9.

pump 1

cushion.

7.

8.

the ignition key to the

Disconnect the negative battery cable

Hold the

22 inch

sure and inspect the entire system for leaks. 6.

REMOVAL & INSTALLATION

and remove the 4.

for leaks

Properly relieve the fuel system

pressure.

pump assembly and

install the cover.

Fuel

tion.

3.

check

necessary.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

2.

5.

for leaks.

brake booster. repair

1.

Fuel

and •

system and check

pump assem-

if

the ize the fuel

pump

position projections

the nuts to

position to pressur-

engine compartment, on the bulkhead, next

nuts and

connect the following:

Install or

Connect the negative battery cable,

ON

pump

bly

removed. 12.

to the

Fuel

with the holes In the fuel

•

turn the key to the

wiring

install:

"Align the seal

4.

mounting bolts

pump

hose

ease

of the filter will

•

A

the

•

fully.

REMOVAL & INSTALLATION

is for

pump.

by hand

ft.

10.

Fuel Filter

the seat cushion by pulling

lower cushion upward. There are 2

fuel lines.

pressure hose and eye the fuel

22

or disconnect the following:

•

access covers underneath the seat. The

Using new gaskets, connect the high

9.

Always wrap shop towels around a fitting that is being disconnected to absorb residual fuel in the lines.

on

Movement

fuel filler cap.

CAUTION

filter

Install the filter

8.

finger-tight.

K

Remove

3.

install:

7.

the rear seat cushion and the

specifically

Relieve the fuel system pressure.

2.

fuel

position.

then reconnect the fuel

to the vehicle.

causing

for fuel injection.

^Remove

designed for fuel injection.

Disconnect the negative battery cable,

6.

damage

fail,

to the vehicle.

the stopper outward and lifting the

Turn the key

of fuel.

designed

the high pressures in fuel injection

systems, and could cause substandard parts to fail, causing personal

fuel tank pressure.

damage

Use only hoses and clamps

RELIEVING

fuel injec-

They are not compatible with

tion systems.

personal injury or •:

filters,

hoses or clamps when servicing

filter.

engine

Start the

ON

position.

to verify

proper fuel

performance.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

Fuel Injector

tion.

towels and remove the eyebolt. Discard the

REMOVAL & INSTALLATION

gaskets.

2.0L Engine 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

3.

Position the fuel

Exploded view nection

of the fuel line-to-filter

con-

pump

Relieve the fuel system pressure.

Remove

or disconnect the following:

•

Battery

•

Air intake

•

High pressure

hose fuel

hose connection

and discard O-ring for installation

by •

Fuel injector harness connector

•

Fuel injector electrical connectors

aligning the seal projections (arrows) with the fuel

pump

holes

COUPE*

CHRYSLER CORP.

SEBRING

6-25

AVENGER

*

2.5L Engine Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section.

Relieve the fuel system pressure.

2.

Remove

3.

•

or disconnect the following:

Power steering

oil

pressure switch

connector •

Heated Oxygen (HO 2 ) sensor connector

•

Intake Air Temperature (IAT) sensor

connector

6.

connectors

•

Injector

•

Control wiring harness

plenum

•

Intake manifold

•

Fuel injector electrical connectors

•

High pressure

•

O-ring from the high pressure fuel

fuel

hose connection

hose connection • •

Fuel

rail

and injectors as an assem-

bly •

Fuel injector-to-fuel

rail

Air intake

•

Battery

repair

rail

and injectors as an assem-

check

for leaks

and

•

Fuel injector retaining clips

•

Fuel injector(s) and discard the 0rings and

necessary.

if

Fuel bly

hose

Start the vehicle,

retaining

clips

•

grommet

Fuel injectors and discard the 0-

•

rings

To 4.

5.

install: Install or

connect the following

•

New

•

Fuel injectors

fuel injector

O-rings

Lubricate the O-rings with clean

engine fuel rail

oil;

then, install the injectors into the

by twisting them

make sure

that they turn

(left

and

right) to

smoothly

in

the

seat.

WARNING Do not allow engine the fuel •

oil to

get into

rail.

Fuel injector-to-fuel

rail

retaining

clips •

Fuel injector electrical connectors

•

Fuel

•

Fuel injector harness connector

•

New

rail

high-pressure

fuel

hose 0-

ring lubricated with clean engine oil

** WARNING Do not allow engine the fuel •

1

oil to

get into

tion

fuel

hose connec-

and torque the

fuel rail bolts to 1.8

Nm)

fuel ft.

oil

pressure switch

High-pressure 9 O-nng 8.

fuel

10 Fuel

3. Intake air

5.

temperature sensor connector Injector connectors Control wiring harness

11. Insulators

4.

12 Injector supports 13. Insulators 14 injectors

6.

Intake manilold

rail.

High pressure

Power sleenng connector

Heated oxygen sensor connector

2.

7. Injector

plenum

connectors

15.

hose connection

rail

O-nngs

16 Grommets

hose-tolbs. (2.5

swear Exploded view

ot the fuel injector, tuel rail

and related components

For complete service labor times, order the Chilton Labor Guide

— 2.5L engine

CHRYSLER CORP.

6-26

SEBRING COUPE

•

AVENGER

4.

To

install:

•

Negative battery cable

Lubricate the O-rings and grommet(s)

•

Intake manifold

•

Fuel injector electrical connector

with clean engine tors into the fuel

and

•:

in

by twisting them

rail

make sure

right) to

smoothly

then, install the injec-

oil;

•

the seat.

WARNING

the fuel

rail.

oil to

New

connect the following:

fuel injector

O-rings and

grommet(s) Fuel injectors Fuel injector-to-fuel

Vacuum hose

High pressure

fuel

hose connection

•

Fuel pressure regulator

fuel hose-to-fuel rail

•

Fuel

bolts to 1.8

lbs. (2.5

•

Insulators

•

Fuel injectors and discard the O-rings

ft.

Nm)

plenum

Intake manifold

•

Control wiring harness

To install:

•

Injector connectors

4.

•

IAT sensor connector

•

HO 2 S

•

Power steering

sensor connector oil

Start the vehicle,

retaining

rail

repair

if

Fuel

rail

and torque the

for leaks

•

Insulators

•

Fuel

and

lbs.

New

•

ft.

(10-13 Nm)

necessary.

•

.

the3.precautions

high-pressure

fuel

hose 0-

ring

oil.

of this

80 inch

Nm)

lbs. (9

Vacuum hose

•

Fuel return and supply hoses

•

Fuel injector electrical connector

•

Intake manifold

•

Negative battery cable

sec-

plenum

tion. 2.

Lubricate the O-ring with clean

the beginning

13

to

Nm)

•

Before servicing the vehicle, refer to in

oil

Fuel pressure regulator and torque the bolts to

1

new O-ring

and torque the bolts

rail

inch lbs. (12

fuel rail-to-

intake manifold bolts to 7.2— 9.4

Fuel injector with a

lubricated with clean engine

pressure switch

check

connect the following:

Install or

•

3.0L Engine •

with the injectors

rail

•

Fuel injector electrical connectors

•

engine

Fuel supply and return hoses

•

and torque the

connector

•

•

clips

6.

•

7.

get into

plenum

rail.

Install or •

the fuel

get into

oil to

that they turn

Do not allow engine

5.

(left

Do not allow engine

Properly relieve the fuel system pres-

3.

Start the vehicle,

5.

sure.

Remove

or disconnect the following:

repair

if

check

and

for leaks

necessary.

DRIVE TRAIN •

Transaxle Assembly

REMOVAL & INSTALLATION

•

Back-up

light

position

it

lower arm and lower

switch harness and

Speedometer

•

electrical connector,

from the transaxle assembly •

Manual 2.0L

•

Starter

Rear

•

Transaxle mount bracket

the precautions in the beginning of this sec-

•

Upper transaxle mounting bolts

tion.

•

Front wheels

•

Undercover

.

Before servicing the vehicle, refer to

• 2.

Drain the transaxle fluid.

Remove

or disconnect the following:

•

Battery and battery tray

•

Battery brace

•

Air cleaner

•

Select and shift cable cotter pins

•

rod end from the

and intake hoses

Stabilizer bar link

from the damper

fork •

and the cable ends from the

Damper control

Engine front

roll

stopper through-

Centermember

Support the transaxle, using a trans-

mission

jack,

and remove the transaxle

lower coupling

steering knuckle •

Bell

•

•

tie

housing cover

•

bolt

4.

Cotter pin and

Clutch release cylinder connection

necting the hydraulic line

stopper mounting bracket

•

1

and

and move aside without discon-

support the engine assembly. roll

Halfshafts from the transaxle

secure aside

Using Special Tool 7137 or C-4852,

AND 2.5L ENGINES

ball joints

from the steering knuckle

aside

bolt.

^•The coupling

bolt threads

from the

engine side, into the transaxle, and fork

from the

lateral

lower

is

located just above the halfshaft open-

arm ing.

transaxle

•

Lateral lower arm,

compression Slide the transaxle rearward and care-

5.

fully

7137

or

C-4852

lower

To 6.

it

from the vehicle.

install: Install or

•

connect the following:

Transaxle and torque the transaxle-

to-engine bolts to 70

lbs.

ft.

(95

Nm) •

Bell

housing cover and torque the

bolts to •

84 inch

mounting bolts

For transaxle removal, properly support

Also, use a transmission jack to support

the engine assembly as

the transaxle assembly

shown

Nm) and (73 Nm) •

lbs. (9

Nm)

Centermember and torque to

65

ft.

the rear bolt to

Front engine

roll

the front

lbs.

54

(88 ft.

lbs.

stopper through-

— CHRYSLER CORP. SEBRING COUPE and

bolt

Once

lightly tighten.

weight of the engine

full

mounts, torque the bolt

is

the

on the

42

to

ft.

(57 Nm).

lbs.

Battery

•

Air cleaner

•

Front exhaust pipe

•

•

Clutch release cylinder

•

Halfshafts using

new

and

•

tray

assembly

When

keep

installing the halfshaft,

avoid damaging the

to the axle, to

seal

—

ing knuckle. Torque the ball joint

48

Nm). Torque the

rod end nut to

21 a •

(28

lbs.

ft.

new

Nm) and

Damper 65

secure with

(88

•

Vehicle Speed Sensor (VSS) con-

•

Battery and tray

•

Starter

5.

Clutch release cylinder connector

•

Transaxle assembly upper coupling

•

Centermember

•

Rear

•

Transaxle

(39

lbs.

•

Undercover

•

Wheels

•

Transaxle

ft.

roll

fork

4

to the

when

light

Air cleaner

•

Battery tray

•

Battery stay

Upper

•

Bell

Battery and battery tray

•

Battery brace

•

Air cleaner

•

Shifter lever-to-transaxle nut, cable

and intake hoses

pan bolt

oil

and cable from the

housing cover

Transaxle assembly lower coupling

mounting bracket

•

Shifter cable

•

Speedometer, solenoid, neutral

Transaxle assembly safety switch (inhibitor switch), the

connect the following

Install or

•

lbs.

(48

ft.

Bell

•

Transaxle

•

Transaxle dipstick and tube

•

Starter

housing cover and torque the

cover— to—engine bolt to 80 lbs. (9 Nm) and the cover— to ft.

lbs.

•

Upper

pan

oil

or

Rear

•

Transaxle

•

Upper transaxle mounting bolts

Driveshaft connection

Clutch release bearing engagement

new

Lower arm and torque the nut ft.

lbs.

(108

mount

bracket

to

80

•

Front wheels Left side

•

Tie rod

Nm)

undercover

end from the steering

knuckle

end and torque the nut

Tie rod

21

hose

to

ft.

lbs.

Nm)

(28

Stabilizer bar link

from the damper

fork •

and battery

Mopar

roll

•

• air intake

stopper mounting bracket

•

bolt

•

•

and

and using Special Tool 7137

C-4852. support the engine

assembly

(26

•

•

cooler lines

oil

inch

Nm).

Nm)

temperature sensor

connectors

lbs.

Nm)

transaxle bolt to 19

ft.

oil

Transaxle assembly and torque the

(48

Wheel speed sensor connector,

if

•

Damper

fork from the lateral lower

equipped control is level,

and

•

refill

•

number 4773167.

and torque the nut

33

Nm)

ft.

lbs.

•

come ON

(45

Tranasxle

42

lbs.

ft.

ENGINE

Rear to

33

roll ft.

arm and compression

Lateral lower

lower arm, lower ball joints from the steering knuckle

Nm) •

Halfshafts from the transaxle

mount stopper and

torque the nut to 60

reverse.

(57

arm

to

Transaxle mount bracket and torque the nut to

the transaxle for proper operalights

Stabilizer link

•

MS9417 MTX

•

3.0L

fluid.

or disconnect the following:

electrical

switch and

Be sure the vehicle

in

Remove

Driveshaft connection

lower coupling bolts to 36

Select and shift cables and

Check

Drain the transaxle

3.

Clutch release bearing engagement

•

Nm)

Be sure the reverse

tion.

Lower arm

•

cotter pins

fluid, part

2.

switch and

speedometer connector

9.

Tie rod

•

Upper transaxle mounting bolts and

the transaxle with

equipped

end

•

stopper mounting bracket

torque them to 35

8.

Brake hose clamp

if

pulse generator, kickdown servo

mount bracket

stopper through-bolt.

•

•

•

roll

•

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

bolts

lbs.

Back-up

and

bracket and stopper

Wheel speed sensor,

ft.

Starter

mount

Stabilizer link

•

to

Remove the engine support Tighten mount through-bolt to 51 (69 Nm) and tighten the front engine

•

for leaks

transaxle

7.

•

check

necessary.

Automatic

•

Nm)

the transaxle

•

if

To install:

(43

lbs.

Rear

Start the vehicle,

6.

repair

retaining clip

damper

transaxle and torque the nuts to 32

•

the transaxle fluid to the proper

stopper

roll

•

•

Nm)

and torque the self-locking nut ft.

Fill

level.

•

•

the through-bolt to

Stabilizer link to the

29

assembly

Air cleaner

light

•

fork to the lower control

lbs.

ft.

Front exhaust pipe

•

up

tion.

(65

lbs.

cotter pin.

arm and torque •

tie

ft.

•

bolts

ball joints to the steer-

self-locking nuts to

up light switch connector and selection cable connec-

tions

1

and

Tie rod

Shift

switch connection

oil

rated part of the halfshaft. •

•

connector

—

Back

the transaxle, with the ser-

lip of

Back

•

nector

the inboard joint straight in relation

VSS

and selection cable connec-

Shift

tions

circlips

•

•

6-27

AVENGER

•

ft.

lbs. (81

and

secure aside

Nm)

housing cover

•

Bell

•

Engine front

stopper and torque the nut lbs.

(45

Nm)

roll

stopper through-

bolt 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

•

Centermember

•

Clutch release cylinder and torque to

tion.

13

ft.

lbs.

(18

Nm)

•

Centermember

•

Flexplate-to-torque converter bolts.

Rotate the crankshaft to bring the 2. 3.

Drain the transaxle

Remove

•

fluid.

Starter

motor and

electrical

connecbolts into a position for removal,

tors

or disconnect the following:

Please

one

visit

our web

site at

www.chiltonsonline.com

at a time.

OQ “£0

CHRYSLER CORP. SEBRING COUPE

AVENGER

•

^*To make installation easier, use

Damper

•

make matchmarks on

chalk or paint to

the torque converter and flexplate.

These marks

65

be used at assembly assembly, keeping these

29

WARNING

K

Left side

•

Wheels

•

Transaxle

removing the bolts, push the torque converter toward the •

damaging the

roll

•

Support the transaxle using a trans-

coupling

NOT

•

bolt.

Nm) and

(69

lbs.

coupling bolt

inserted from

is

(43

51

torque the front

35

ft.

lbs.

Nm)

(48

Dipstick tube and dipstick

•

Shifter cable

mounting bracket

•

Shifter lever

and torque the nut

•

Oil

(19

lbs.

ft.

a.

b.

to

carefully lower

Nm)

After the torque converter

6.

mounted on assembly

70

lbs.

ft.

10.

(95 Nm).

clutch pedal clevis pin play to agree with

pulse generator, kickdown servo

the standard value and secure the

switch and

pushrod with the locknut.

oil

temperature sensor

connectors

electrical

and

•

Air cleaner

•

Battery tray Refill the

torque the torque converter-to-flexplate bolts to

55

lbs.

ft.

Install or

8. •

Bell

’•AA/hen adjusting the clutch pedal

air intake

connect the following:

108 inch

lbs.

Nm)

(12

Centermember and torque the

Nm) and lbs.

to

65

lbs.

ft.

fluid. Start the

2 minutes.

to idle for

Recheck

fluid level

and add

if

neces-

marks

bolt full

and

ft.

for

weight of the engine

mounts, torque the bolt lbs.

•

Once is

to

proper oper-

With the pedal

Clutch

When

Pedal Height and Free-Play

WARNING

the inboard joint straight to the axle to avoid lip of

1.

keep

damaging the

lbs.

(28

tie

Torque the

Compare

cotter pin.

48

ft.

lbs.

the

measured value with

desired distance of 7.0-7.09

in.

(6-1 3mm).

disengaged, check the

the

The measurement should

(70mm)

or more.

measurements are not within

system. still

If

after

bleeding the measurements

not within specified range, there

(65

in

the system, which

is

a

must

the

be replaced.

REMOVAL & INSTALLATION

Measure the clutch pedal

clevis pin

play at the face of the pedal pad. Press the

pedal lightly until resistance

measure

this distance.

vis pin play

is

2.0L and 2.5L Engines

met, and

The clutch pedal

cle-

should be within 0.040-0.120

ft.

secure with a new

component

in.

(175-1 80mm).

ball joint

rod end nut to 21

Nm) and

If

faulty

oil

Tie rod and ball joints to the steer-

Nm), the

Measure the clutch pedal height from

are

2.

self-locking nuts to

measurement should

specification, bleed the clutch hydraulic

relation

the transaxle with the

ing knuckle.

to

the face of the pedal pad to the bulkhead. in

splined part of the halfshaft. •

in.

circlips

installing the halfshaft,

fully

of the pedal pad.

5. I-

OFF.

distance between the bulkhead and the top

be 2.760

new

to

and the pedal resting point

be between 0.240-0.510

ADJUSTMENT

Halfshafts using

ON

determine the clutch pedal free-play. The

ft.

(56 Nm).

is

the clutch pedal until the resis-

clutch pedal free-play

the

on the

42

Move

4.

this point

range on the dipstick.

Check the transaxle

lightly tighten.

the clutch pedal

the way, the interlock

all

tance begins to increase; measure between

should be between the

HOT

the

in

stopper through-

roll

when

switch switches over from

N.

(69-78 Nm).

Front engine

that

selector through each gear position, ending

ation. •

Check

d.

front

(88

51-58

the rear bolts to

play, be careful not to push the pushrod toward the master cylinder.

MOPAR®

depressed

sary. Fluid level

mounting bolts

it

height or the clutch pedal clevis pin

Apply the parking brake and move the

in

•

transaxle with

engine and allow

hose

and battery

ATF PLUS transmission

(75 Nm).

housing cover and torque the

bolts to

Turn the pushrod to adjust the

c.

safety switch (inhibitor switch), the

mounting

to the engine. Install the to

equipped with cruise control sys-

by tightening the locknut.

Align the balance matchmarks and

7.

seal

If

has been

the transaxle, install the transaxle

and tighten

so the pedal

standard clutch pedal height. Then, lock

Speedometer, solenoid, neutral

To install:

bolt

the standard value, then tighten

nector and turn the switch to obtain the

cooler lines and secure with

from the vehicle.

it

is

tem, disconnect the clutch switch con-

clamps •

not equipped with cruise control,

the locknut.

Slide the transaxle rearward and

5.

bolts

If

and adjust the stop

turn

height

•

14

standard values,

play, is not within the

adjust as follows:

Starter

located just above the halfshaft

opening.

Clutch pedal height and tree-play adjust-

ment measurements

to

stopper bolt

roll

tighten to

the engine side into the transaxle and is

mount through-bolt

9.

^The

lbs.

Upper transaxle mounting bolts and

•

at

remove the transaxle lower

the pan)', and

ft.

stopper mounting bracket

Transaxle

engine the side ot the case,

32

to

9300CG01

Rear

ft.

(at

mount bracket and torque

and remove the engine support

converter. 4.

to

Nm)

transaxle. This will prevent the converter from remaining in contact with

mission jack

fork

undercover

mounting nuts

the

Clutch pedal clevis pin play

Nm)

(39

lbs.

ft.

•

After

the engine, possibly

damper

and torque the self-locking nut

parts in balance.

Clutch pedal height

to

Nm)

(88

lbs.

ft.

Stabilizer link to the

•

will

to realign the

fork to the lower control

arm and torque the through-bolt

in.

(1-3mm). 3.

If

the clutch pedal height or clevis pin

1

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

Remove

or disconnect the following:

C OQ U L.V

CHRYSLER CORP. SEBRING COUPE* AVENGER

Apply multi-purpose grease to the

8

clutch release bearing. Pack the bearing

inner surface and the groove with grease.

Do

not apply grease to the resin portion of

the bearing. Place the bearing in position

and

install

the return clip.

Apply a coating

9.

of

grease to the

clutch disc splines, then use a brush to rub it

the grooves. Using a clutch disc align-

in

ment

tool, position the clutch disc

flywheel. Install the retainer bolts tighten a

little

at a time, in

on the

and

a diagonal

sequence. Install the transaxle

10.

check the

assembly and

fluid level.

1 1

Connect the negative battery cable.

12.

Verify proper clutch operation.

3.0L Engine 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Remove

Negative battery cable

•

or disconnect the following:

Negative battery cable

yUiiiltml

•

Transaxie

•

Pressure plate-to-flywheel bolts,

When

pressure plate and clutch disc

grease to each part, but be careful not to apply excessive grease. Exces-

Valve and spring

sive grease will cause clutch slip-

Clutch release cylinder

page and shudder.

Clutch cover and disc

Clutch fluid line bracket

’Hf the pressure plate loosen the bolts

one or 2 turns

in a

is to

be reused,

diagonal pattern,

time. This will pre-

at a

installing the clutch, apply

Insulator,

vent warping the clutch cover assembly.

Remove

3.

the return clip

sure plate release bearing.

Do

19 ± 3 N-m 14 ± 2 ft-fb

and the presnot use sol-

vent to clean the bearing. Inspect the clutch release fork and

4.

damage

fulcrum

for

remove

the release fork

or wear.

If

necessary,

and the fulcrum

from the transaxle. Carefully inspect the condition of the

5.

clutch

components and replace any worn

or

damaged parts. To install: Inspect the flywheel for heat

6.

damage

or cracks. Resurface or replace the flywheel

as required. Install or

7.

connect the following:

•

Flywheel using new bolts

•

Fulcrum,

•

Release fork

^Apply grease

if

removed, and tighten

a coating of multi-purpose

to the point of contact with the

fulcrum and the point of contact with the release bearing. Apply a coating of

multi-purpose grease to the end

of the

release cylinder's pushrod and the

pushrod hole

in

the release fork.

Exploded view

Timing belt service

is

ol the clutch

covered

in

assembly-3. 0L engine

Section

3

of this

washer and clutch tube

Union, union bolt and gasket

manual

CHRYSLER CORP.

6-28

SEBRING COUPE* AVENGER

**To make installation easier, use

Damper

•

make matchmarks on

chalk or paint to

the torque converter and flexplate.

These marks

will

fork to the lower control

arm and torque 65

be used at assembly

•

the through-bolt to

Nm)

(88

lbs.

ft.

damper

Stabilizer link to the

fork

to realign the assembly, keeping these

and torque the self-locking nut

parts in balance.

29

WARNING

U

•

Left side

•

Wheels

•

Transaxle

removing the bolts, push the torque converter toward the After

•

Rear

verter from remaining in contact with

damaging the

•

Support the transaxle using a transthe side of the case,

NOT

coupling

ment measurements

to 51

torque the front

stopper bolt

roll

tighten to •

bolt.

Nm) and

(69

lbs.

Clutch pedal height and tree-play adjust-

35

ft.

lbs.

standard values,

play, is not within the

adjust as follows:

Upper transaxle mounting bolts and

•

at

and remove the transaxle lower

the pan),

(43

lbs.

mount through-bolt

Transaxle ft.

(at

ft.

stopper mounting bracket

roll

engine 4.

32

to

and remove the engine support

converter.

mission' jack

mount bracket and torque

Nm)

transaxle. This will prevent the conthe engine, possibly

undercover

mounting nuts

the

to

Nm)

(39

lbs.

ft.

Nm)

(48

a.

If

height

Starter

•

Dipstick tube and dipstick

•

Shifter cable

mounting bracket

•

Shifter lever

and torque the nut

not equipped with cruise control,

and adjust the stop

turn

is

bolt

so the pedal

the standard value, then tighten

the locknut.

9.

(••The coupling bolt

inserted from

is

the engine side into the transaxle and is

14

located just above the halfshaft •

opening.

Oil

(19

lbs.

ft.

b.

to

Nm)

standard clutch pedal height. Then, lock

clamps

by tightening the locknut.

Speedometer, solenoid, neutral

•

carefully lower

After the torque converter

mounted on

safety switch (inhibitor switch), the

clutch pedal clevis pin play to agree with

pulse generator, kickdown servo

the standard value and secure the

switch and

pushrod with the locknut.

has been

the transaxle, install the transaxle

•

70

to

lbs.

ft.

temperature sensor

connectors

'When

mounting

to the engine. Install the

and tighten

oil

10. electrical

assembly

(95 Nm).

and

Air cleaner

•

Battery tray

air intake

Refill the

torque the torque converter-to-flexplate

55

bolts to

lbs.

ft.

Install or

8.

•

Bell

engine and allow

connect the following:

108 inch

lbs.

Nm)

(12

Centermember and torque the

fluid. Start the

2 minutes.

to idle for

Nm) and

to

65

lbs.

ft.

51-58

the rear bolts to

marks

if

neces-

in

bolt full

and

roll

for

proper oper-

weight of the engine

mounts, torque the bolt lbs.

•

is

to

Clutch

When

Pedal Height and Free-Play

WARNING

seal

lip of

1.

keep

the inboard joint straight in relation to the axle to avoid

lbs.

(28

tie

48

ft.

cotter pin.

lbs.

rod end nut to 21

Nm) and secure

faulty

measured value with the

(65

(6-1 3mm).

the

The measurement should

(70mm)

or more.

measurements

are not within

If

after

bleeding the measurements

not within specified range, there

component

in

the system, which

is

a

must

REMOVAL & INSTALLATION

Measure the clutch pedal

clevis pin

play at the face of the pedal pad. Press the

pedal lightly until resistance

measure

this distance.

vis pin play

new

in.

disengaged, check the

be replaced.

is

2.0L and 2.5L Engines

met, and

The clutch pedal

cle-

should be within 0.040-0.120

ft.

with a

measurement should

in.

(175-1 80mm).

ing knuckle. Torque the ball joint

still

the face of the pedal pad to the bulkhead. the

If

system. are

2.

Nm), the

the clutch pedal height from

desired distance of 7.0-7.09

Tie rod and ball joints to the steer-

to

specification, bleed the clutch hydraulic

oil

the transaxle with the

self-locking nuts to

Measure

Compare

damaging the

splined part of the halfshaft. •

in.

circlips

installing the halfshaft,

fully

of the pedal pad.

5.

C

OFF.

distance between the bulkhead and the top

be 2.760

new

to

and the pedal resting point

With the pedal

ADJUSTMENT

Halfshafts using

ON

determine the clutch pedal free-play. The

ft.

(56 Nm).

is

the clutch pedal until the resis-

be between 0.240-0.510

the

on the 42

Move

clutch pedal free-play

stopper through-

Once

4.

this point

range on the dipstick.

Check the transaxle

lightly tighten.

the clutch pedal

the way, the interlock

all

tance begins to increase; measure between

should be between the

HOT

the

ft.

(69-78 Nm).

Front engine

when

switch switches over from

N. Recheck fluid level and add

ation. •

that

selector through each gear position, ending front

(88

Check

d.

depressed

sary. Fluid level

mounting bolts

push the pushrod

Apply the parking brake and move the

in

lbs.

play, be careful not to

toward the master cylinder.

housing cover and torque the

bolts to •

it

adjusting the clutch pedal

height or the clutch pedal clevis pin

MOPAR®

transaxle with

ATF PLUS transmission

(75 Nm).

hose

and battery

Align the balance matchmarks and

7.

Turn the pushrod to adjust the

c.

from the vehicle.

it

To install: 6.

equipped with cruise control sys-

nector and turn the switch to obtain the

cooler lines and secure with

Slide the transaxle rearward and

5.

bolts

If

tem, disconnect the clutch switch con-

in.

(1-3mm). 3.

If

the clutch pedal height or clevis pin

1.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

Remove

or disconnect the following:

CHRYSLER CORP.

fi.OQ U LXJ

SEBRING COUPE* AVENGER

Apply multi-purpose grease to the

8.

clutch release bearing. Pack the bearing inner surface and the groove with grease.

Do

not apply grease to the resin portion of

the bearing. Place the bearing

and

install

Apply a coating

9.

in

position

the return clip. of grease to the

clutch disc splines, then use a brush to rub it

the grooves. Using a clutch disc align-

in

ment

tool, position the clutch disc

flywheel. Install the retainer bolts

tighten a

at a time, in

little

on the

and

a diagonal

sequence. 10.

Install

check the

the transaxle assembly and

fluid level.

11.

Connect the negative battery cable.

12.

Verify proper clutch operation.

3.0L Engine 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

•

Negative battery cable

•

Transaxle

•

Pressure plate-to-flywheel bolts,

When

pressure plate and clutch disc

grease

loosen the bolts

in a

is to

be reused,

diagonal pattern,

one or 2 turns at a time. This will prevent warping the clutch cover assem-

not to

installing the clutch, apply

each

the return clip

sure plate release bearing.

Do

Insulator,

be careful apply excessive grease. Excesto

part, but

Valve and spring

Clutch release cylinder

page and shudder.

Clutch cover and disc

19*3 N-m 14*2 ft-fb

and the presnot use sol-

vent to clean the bearing. Inspect the clutch release fork and

4.

damage

fulcrum

for

remove

the release fork

or wear.

If

necessary,

and the fulcrum

from the transaxle. Carefully inspect the condition of the

5.

clutch

components and replace any worn

or

damaged parts. To install: Inspect the flywheel tor heat

6.

damage

or cracks. Resurface or replace the flywheel

as required. Install or

7.

connect the following:

•

Flywheel using new bolts

•

Fulcrum,

•

Release fork

if

**Apply a coating grease

removed, and tighten

of

multi-purpose

to the point of contact with the

fulcrum and the point

of contact

with

the release bearing. Apply a coating of

multi-purpose grease to the end

of the

release cylinder’s pushrod and the

pushrod hole

in

the release fork.

washer and clutch tube

Union, union bolt and gasket

sive grease will cause clutch slip-

bly.

Remove

or disconnect the following:

Negative battery cable

Clutch fluid line bracket

'Hf the pressure plate

3.

Remove

Exploded view

Timing belt service

is

of the clutch

covered

assembly-3. OL engine

in Section

3 of this manual

CHRYSLER CORP.

6-30

SEBRING COUPE

AVENGER

•

•

Release fork shaft

•

Left

•

Release fork

•

Clutch release bearing

•

Release fork boot and fulcrum

•

Release fork boot and maintenance

Tighten the bleed screw, then release

4.

Cotter pin, halfshaft nut and washer

•

Loosen the bleed screw, then have the

3.

clutch pedal pressed to the floor.

support spring

•

Front wheel

•

Tie rod

Repeat the procedure

5.

MB991113

until the fluid is

free of air bubbles. i-

cover

suggested that a hose be attached to the bleed screw with the

Install or

•

connect the following:

other end

Release fork boot and maintenance

•

Release fork

(19

lbs.

ft.

Valve and spring

•

Union, bolt and gasket and torque

Insulator,

17

ft.

•

of joint

damage

lbs.

to

assembly

Check

3.

the clutch for proper operation.

•

Lateral

(23

Nm)

the

compression

Halfshaft from the hub/knuckle by

REMOVAL & INSTALLATION

setting

to 11

ft.

up a puller on the outside

wheel hub and pushing the half-

lbs.

shaft from the front

hub

Halfshaft from the transaxle by

and torque the (19

arm and

using a joint separation tool •

•

lbs.

fork lower through-bolts,

upper pinch bolt and damper fork

2.0L and 2.5L Engines

ft.

damper

arm from the steering knuckle

Nm)

Fluid line bracket

bar link from the

Damper

the reservoir with clean brake

washer and clutch tube

inserting a prybar between the

Nm)

transaxle case and the halfshaft

Negative battery cabie If

Check and top

4.

in

fork

Halfshaft

and torque the fastener

14

Refill

7.

•

the bolt to

Sway

•

fluid.

Nm)

Clutch release cylinder

bolt to

improper methods

the joint, leading to possible failure.

• 6.

•

•

of

support spring and release fork

Clutch disc and cover and torque

(15

Use

separation can result

bleeding.

the bolts to 14

•

container at

reservoir to run out of fluid during

shaft •

in a

bleeding operation. Do not allow the

Clutch release bearing

Left

immersed

least half full of brake fluid during the

cover •

•

WARNING

’»lt is

To install: 3.

end from the steering

knuckle using joint separation Tool

the clutch pedal.

off the fluid level,

if

necessary.

the vehicle

is

going to be rolled

equipped with a center bearing on

remove the center bear-

the right halfshaft,

vehicle, obtain 2 outer CV-joints or

ing bracket-to-chassis bolts; then, tap

proper equivalent tools and

Hydraulic Clutch System

If

while the halfshafts are out of the

the hubs.

the vehicle

If

is

install to

rolled with-

lightly

on the center bearing bracket

sep-

to

arate the inner shaft from the transaxle.

out the proper torque applied to the

BLEEDING

front will

1.

wheel bearings, the bearings

no longer be usable. Before servicing the vehicle, refer to

1.

the precautions in the beginning of this sec-

the precautions tion. 2.

DOT

Fill

the reservoir with clean

4 brake

DOT

Do not

pull

damages

Before servicing the vehicle, refer to in

the beginning of this sec-

on the shaft. Doing so

the inboard joint.

Do not

insert the prybar too far or the oil

seal

in

the case

may be damaged.

tion.

3 or

Remove

2.

or disconnect the following:

fluid.

•

To install:

Negative battery cable

4.

Inspect the halfshaft boot for

Check

or deterioration.

damage

the ball joints

and

splines for wear. 5.

Replace the circlips on the ends

of

the halfshaft(s). 59 - 71

6.

Nm

43-52 ft.lbs.

Insert the halfshaft into the transaxle.

Be sure 7.

If

it

is fully

seated.

equipped with a center bearing on

the right halfshaft, install the center bearing

196-255 Nm 145-188 ft.lbs.

bracket-to-chassis bolts and torque to 30 lbs.

8.

Removal steps 1.

2. 3.

Cotter pm Drive shaft nut Tie rod end connection

4. Stabilizer link 5.

Damper

and

Pull the knuckle

install the

assembly outward

other end of the halfshaft into

10 Drive shaft and inner shaft (R.H.) .

n.

the hub.

Drive shaft

9.

connection 12 Circlip .

fork

7.

arm connection Compression lower arm connection

7

8.

Harness

'

9.

Bolt

6. Lateral

lower

Install the

washer so the chamfered

edge faces outward*

Install the halfshaft

clip

Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.

10.

Connect the

lateral

arm and

the

com-

pression arm to the steering knuckle.

Torque the self-locking nuts lbs.

of the left

and

right halfshaft

nut

and tighten temporarily.

Caution

Exploded view

ft.

(40 Nm).

assemblies' mounting

to

43-52

(59-71 Nm).

1 1

.

Install or

connect the following:

ft.

CHRYSLER CORP. SEBRING COUPE •

Damper

•

Halfshaft snapring

Nm)

•

Tri-pot spider

and the upper pinch lbs.

(24-33 Nm) and •

ft.

17-25

to

install a

new

Sway

Do not disassemble the spider assembly.

lbs.

ft.

cot-

The

bar link to the

damper 29

to

ft.

fork

(39

lbs.

Birfield joint assembly, located on the wheel side of the halfshaft, is not to be disassembled; repair of this

joint is only by

*

Nm)

Lockwasher and axle

replacement

** WARNING If

torque the axle nut with the Special

MB990767

from turning

to

to

the boot

145-188

ft.

lbs.

2.01 (DOHC) ENGINE

4.

(200-260 Nm) 1

^•Before securely tightening the axle

make sure

nut,

there

is

the precautions in the beginning of this sec-

no load on the

New

soft

cotter pin

•

Negative battery cable

12.

jawed

halfshaft

and place

•

in

slide the

damper from

the halfshaft.

If

removed,

install the

a

damper by performing

dynamic

the following proce-

vise.

Tri-pot boot

dure:

Tri-pot case

Slide the damper onto the halfshaft new bands. b Position the damper so the dis-

a.

bands and remove any grease

from the case

level.

necessary, remove the dynamic

damper bands and

5. it

Disassemble or remove:

•

the transaxle to the proper

Fill

Remove

3.

Front wheel

If

damage.

To install: 2.

•

be reused, wrap plas-

tion.

wheel bearings. •

Before servicing the vehicle, refer to

.

is to

tape around the shaft splines to

protect the boot from

Tri-Pot Joint

hold the hub

Tri-pot boot

of the

halfshaft.

nut; then,

•

tic

Tool

assembly

** WARNING

pin

and torque the nut

•

76

bolt to

to the steering knuckle

end

and torque the nut

ter

(88

Nm)

(103

Tie rod

lbs.

ft.

6-31

AVENGER

fork then torque the lower

through-bolt to 65

•

•

with

tance from the front of the birfield joint to Test drive the vehicle

13.

and check

for

proper operation.

3.0L Engine 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Remove •

or disconnect the following:

Negative battery cable

•

Front wheel

•

Vehicle Speed Sensor (VSS) cable,

•

Brake hose

•

Driveshaft nut

if

equipped clip

and

cotter pin

•

Lower arm

•

Tie rod

•

Stabilizer link

•

Driveshaft and circlip

ball joint

connection

end

To install: 3.

Install or

connect the following:

•

Driveshaft

•

Stabilizer link

and torque the nut

33

Nm)

•

ft.

lbs.

Tie rod

21

ft.

(44

end and torque the nut

lbs.

(28

•

New

•

Lower arm

to

to

Nm)

cotter pin to the tie rod

end

ball joint

•

Driveshaft nut and torque

•

maximum of 167 New cotter pin to

ft.

lbs.

Brake hose clip

•

VSS

•

Front wheel

•

Negative battery cable

if

to a

Nm)

the driveshaft nut

•

cable,

it

(226

5.

Snap nng

10.

equipped

8

J

asscnnWy 9Q0GCG06

Exploded view

Heater Core replacement

of the halfshatt

is

covered

in

assemblies— 2. OL (DOHC) Engine

Section

2 of this manual

CHRYSLER CORP.

6-32

SEBRING COUPE

•

AVENGER Remove

2.

soft

jawed

halfshaft

and place

it

in

a

vise.

Disassemble or remove:

3.

bands

•

Tri-pot boot

•

Tri-pot case for

left

halfshaft or

tri-

pot case/inner shaft assembly for

9.

right halfshaft

^Wipe

the grease from the tri-pot

case. 10.

Distribute a portion of the 3.7 oz. Positioning the dynamic

damper on

(105 g) specified repair

the

assemblies— 2. OL (DOHC) Engine Install the tri-pot

edge

14.60-14.84

of the in.

damper assembly

(371-377mm)

is

1.

(191-1 97mm)

7.52-7.76

for the left halfshaft.

Tighten and secure the damper

Position the boots large end on the

•

WARNING

Position the large and small boot If

Adjust the boot so that the bands

are spaced at 3.03-3.27

WARNING

d.

plastic tape

in.

(77-83mm).

Tighten the band securely.

dam-

4.

2.5L (SOHC) ENGINE

age.

Before servicing the vehicle, refer to

newsmall boot clamp onto

7.

Apply the specified repair

8.

Install

the tri-pot spider

kit

is

If

working with the

necessary

right halfshaft

and

to replace the tri-pot case,

To

install:

tion. 5.

the halfshaft followed by the tri-pot boot.

between the spider axle and the

be reused, wrap plas-

press the case from the inner shaft assembly.

the precautions in the beginning of this seca

is to

tape around the shaft splines to protect the boot from damage.

it

Install

the boot

tic

around the shaft

splines to protect the boot from

6.

Tri-pot boot

clamps onto the boot. c.

Wrap

Do not disassemble the spider assembly.

tri-pot case.

bands. :

WARNING

in.

b. c.

boot by performing

assembly

the following procedure:

for the a.

right halfshaft or

Tri-pot spider

assembly and

add the remaining grease. the front

Halfshaft snapring

•

grease into the

kit

tri-pot case, insert the spider halfshaft

•

If

installing a

new

tri-pot

case onto

grease

roller.

assembly

onto the shaft from the spline beveled section direction

and secure with the snapring.

12

Lubricating the tri-pot spider assembly

5 (R H. only)

\

“

fMT

Iff T.J.

boot repair

1

kit

T.J.

2. T.J.

3. T.J. 4. T.J.

T.J. repair kit

boot band boot band

Seal plate 6 Inner shaft 7. Bracket assembly 8. Dust seal outer

9306CG11

^%> 'U

Bearing repair

dust

9.

shaft

assembly

11.

Bracket

assembly

repair kit

Dust seal inner Center bearing Center bearing bracket

12. Circlip

13

Snap nng

14.

Spider assembly

15. T.J. boot 16 B.J. assembly

Lubricating the tri-pot case assembly installed

seal f

kit

10.

case and inner case

5.

5

9306CG12

Exploded view

ot the haltshaft

assemblies— 2. 5L (SOHC) Engine

CHRYSLER CORP. SEBRING COUPE

•

AVENGER

6-33

the right halfshaft, perform the following

procedure: Lubricate the inner shaft splines

a.

with Multi-Mileage Grease No.

2525035.

Press the inner shaft assembly into

b.

tri-pot case.

Secure the

c.

tri-pot

MB991248 on

Tool

case with special

a hydraulic press

with the case facing upward. d.

Position's

new

036023

seal plate in the

Installing the inner dust seal to the center

center of the tri-pot case.

Place a 1.18

e.

the seal plate

in.

Removing

(30mm)

and press the

pipe on

seal into the

shaft

the tri-pot case from the inner

assembly

— Right

halfshaft with 2.5L

bearing bracket

— Right

halfshaft with 2.5L

(SOHC) Engine

(SOHC) Engine

tri-pot case.

T'

Wrap

WARNING

plastic tape

around the shaft

splines to protect the boot from

dam-

age. Install a

6.

new small boot clamp onto

the halfshaft followed by the tri-pot boot.

Apply the specified repair

7.

between the spider axle and the

grease

onto the shaft from the spline beveled section direction

Installing the outer dust seal to the center

Removing

spider assembly

Install the tri-pot

8.

kit

roller.

and secure with the snapring

bearing bracket the center bearing bracket from

the inner shaft assembly

— Right

— Right

halfshaft with 2.5L

(SOHC) Engine halfshaft

with 2.51 (SOHC) Engine

Distribute a portion of the 4.23 oz.

9.

(120 g) specified repair

kit

grease into the

tri-pot case, insert the spider

MB990938

assembly and

add the remaining grease. Install the tri-pot

10.

boot by performing

the following procedure:

Position the boots large end on the

a.

tri-pot case. b.

Position the large and small boot

i.*~M

clamps onto the boot. are spaced at 3.03-3.27 d.

in.

(77-83mm).

Tighten the band securely.

Removing

the center bearing Irom the

center bearing bracket— Right halfshaft

2.5L (SOHC) ENGINE

it

in

Remove

.

the right halfshaft

Installing the inner shaft into the center

bearing bracket— Right halfshaft with 2.5L

(SOHC) Engine

with 2.5L (SOHC) Engine

Center Bearing

1

MB991172

Adjust the boot so that the bands

c.

MB990938 and place

a soft-jawed vise.

Remove

2.

from the

Remove

3.

the tri-pot spider

assembly

tri-pot case.

the tri-pot case by perform-

ing the following procedure: a.

Position the inner shaft/tri-pot case

assembly on by Tool

a hydraulic press

MB991248

supported

with the tri-pot case

facing upward. b.

WJ6CG22

Position a bar inside the tri-pot

case, on the end of the inner shaft and

press the case from the inner shaft

Installing the center bearing to the center

Installing the inner shaft

bearing bracket— Right halfshaft with 2.5L

tri-pot

(SOHC) Engine

is

covered

— Right

(SOHC) Engine

assembly.

Brake service

case

in

Section 4 of this manual

assembly

into the

halfshaft with 2.5L

CHRYSLER CORP.

6-34

SEBRING COUPE

AVENGER

•

9306CG16

Positioning the birfield joint boot’s small Installing the seal plate into the tri-pot

case— Right

halfshaft with 2.5L

Measuring the small band's crimp

diameter

(SOHC)

Engine

Place the inner shaft assembly

4.

in

MB991561

a

soft-jawed vise.

Using a wheel

5. ter

puller,

press the cen-

bearing bracket from the inner shaft.

Using a hydraulic press,

6.

Adapter Tool

MB990938, press

Tool

Installer

MB990932 and Snap-in

Bar

the center bearing

and inner dust seal from the center bearing bracket.

9306CG14

9306CG17

To install: Positioning the birfield joint boot's large

Using a hydraulic press,

7.

Adapter lool

MB990938, press

Tool

Installer

MB990932 and Snap-in

View

of the

band crimper

tool

diameter 8.

Bar

the center bearing

into the center bearing bracket.

Using a hydraulic press,

8.

Adapter Tool

MB990938, press

Tool

Installer

MB990933 and Snap-in

Bar

the inner duct seal 9.

into the center bearing bracket.

Using a hydraulic press,

9.

Installer

MB990931 and Snap-in Bar MB990938, press the outer duct seal

Adapter Tool Tool

9306CG18

into the center bearing bracket.

Using a hydraulic press and Adapter

10. 1.

MB991 1 72,

Tool

press the inner shaft into

Positioning the birfield joint boot’s large

the center bearing bracket. 1 1

Install

.

band

band

the tri-pot case onto the right

halfshaft by performing the following proce-

Using a Band Crimper Tool

Disassemble or remove:

2.

dure:

Lubricate the inner shaft splines

a.

Tri-pot joint

•

Dynamic damper,

with Multi-Mileage Grease No. 2525035.

tri-pot case.

Secure the

c.

tri-pot

MB991248 on

Tool

case with special

To

Birfield joint

boot bands

•

Birfield joint

boot

new

•

seal plate in the

•

or install:

4.

boot

Birfield joint

boot small band

Place a 1.18

in.

(30mm)

pipe on

Place the halfshaft

so that the

the seal plate and press the seal into the 5.

birfield joint is

in

standing

vertically.

12

Assemble the

13.

Install the right halfshaft.

tri-pot joint

assembly. 6.

Birfield Joint

in.

Boot

soft

jawed

vise.

halfshaft

and place

it

in

a

is

exposed on the

shaft.

Adjust the Band Crimper Tool

MB991561 so

that the

jaw opening

is

until the is

grease

oz. in

is

install a

not correct,

new

one.

(155g) specified

the repair

kit,

pack the

10.

(0.1-1

Position the'boot so 0.004-0.061

.55mm)

of clearance exists

in.

between

the boots large diameter end and the birfield

0.114

Position the small band so there

joint

housing shoulder.

11. is

clearance between the boot and the bands

mating edge.

of

band crimp

birfield boot.

(2.9mm). 7.

Remove

groove

the crimp dimension

amount

Position the boots small diameter so 1

of the

(2.4-2.8mm).

Using 5.47

a soft jawed vise

tri-pot case.

that only

in.

remove the band

Birfield joint

center of the tri-pot case. e.

0.094-0.110

If

Assemble

the small

measurement

internal

install:

3.

Position a

eguipped with a

•

a hydraulic press

with the case facing upward. d.

if

2.0L (DOHC) engine

Press the inner shaft assembly into

b.

MB991561, crimp

•

Adjust the Band Crimper Tool

MB991561 so in.

(3.2mm).

that the

jaw opening

is

0.126

CHRYSLER CORP. SEBRING COUPE 12.

and position the large boot

Install

band so

that

6-35

AVENGER

•

rests against the boot(s) pro-

it

and a gap exists between the clamp

jection

and the boot. Using a Band Crimper Tool

13.

MB991 561, crimp

the small band until the

measurement

internal

0.094-0.110

of the

crimp

is

(2.4-2.8mm).

in.

3306CG13

If

the crimp dimension

remove the band 14.

If

is

not correct,

new

install a

Measuring the small band

diameter

s

crimp

equipped with a 2.0L (DOHC)

engine, install the dynamic

damper by per-

forming the following procedure: Slide the

a.

3306CG16

Positioning the birfield joint boot's small

one.

damper onto

MB991561

the halfshaft

new bands.

with b.

damper so

Position the

the dis-

tance from the front of the birfield joint to the front

assembly

(371-377mm) 7.52-7.76

edge

of the

14.60—14.84

is

in.

damper

in.

for the right halfshaft or

(191-197mm)

for the left

halfshaft. c.

Positioning the birfield joint boot s large

Tighten and secure the damper

View

of the

band crimper

tool

diameter

bands. 15.

the tri-pot joint.

Install

3.0L ENGINE Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section.

Remove

2.

halfshaft

and place

it

in

a 11

soft

jawed

vise.

Disassemble or remove:

3.

•

Tri-pot joint

•

Dynamic damper

•

Birfield joint

boot bands

•

Birfield joint

boot

To

10.

install:

Assemble

4.

Positioning the birfield joint boot’s large

band

or install:

MB991561, crimp

•

Birfield joint

boot

•

Birfield joint

boot small band

5.

Positioning the birfield joint boot s small

band

Place the halfshaft

in

vise so that the birfield joint

0 094-0.110

a soft jawed is

standing ver-

the small

measurement

internal

in.

of the

(2.4-2

band crimp

MB991561 so

is

8mm)

in

Position the boots small diameter

so that only

1

groove

is

If

exposed on the

is

install a

not correct,

new

MB991561 so in.

that the

jaw opening

is

0.1

14

(2.9mm). 8.

amount

of

grease

oz.

one.

Position the boot so 0.004-0 061

is

.55mm)

mating edge.

the boots large diameter

Using a Band Crimper Tool

joint

of

end and the

0 126

rests against the boot(s) pro-

exists

between the clamp

Using a Band Crimper Tool

internal

in

birfield

housing shoulder.

For complete Engine Mechanical specifications, see Section

the small

measurement in.

(2

of the

band crimp

until the is

4-2 8mm).

** WARNING

clearance exists between

(0.1-1

is

and position the large boot it

and a gap

0094-0 110

clearance between the boot and the bands

9.

pack the

birfield boot.

Position the small band so there

that

MB991 561, crimp

(155g) specified

in the repair kit,

jaw opening

and the boot. 14.

Using 5.47

Adjust the Band Crimper Tool

Install

jection

shaft. 7.

that the

2mm).

band so

the crimp dimension

remove the band

(3

13

** WARNING

tically.

6.

Adiust the Band Crimper Tool

12

until the

If

the crimp dimension

remove

1

of this

is

the band install a

manual

not correct,

new one.

CHRYSLER CORP.

6-36

SEBRING COUPE

•

AVENGER

STEERING AND SUSPENSION 9.

ment on

Bag

Air

CAUTION

:

Some

or near

tion:

SRS Use a

vehicles are equipped with an

bag system, also known as the Supplemental Inflatable Restraint (SIR) system or Supplemental Restraint System (SRS). The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.

the inflator

module

multi-meter for which

2 miliamp (mA)

test current is

minimum range

measurement

for

of resistance

SRS

use with the Chrysler

Check Harness when checking the SRS

diate inspection

DRB

11.

air

III

diagnosed and serviced.

of the air

12.

Air

Bag Control Unit (SRS-ECU)

13.

Air

Bag Modules

14.

If

resulting in unnecessary system

repairs and/or personal injury.

are diag-

in

sonal injury. Along with the precautions

DISARMING

LOCK

the

The system consists

following:

ules,

Never carry the

inflator

module by

on the underside

the wires or connector

of

carrying a live inflator module,

hold securely with both hands, and ensure

Place the inflator module on a bench

or other surface with the bag

4.

and trim cover

inflator

module on the

module which may be thrown

Disconnect the negative battery

5.

Do

connectors or wires are

6.

Air

If

System bag

the clock spring

before drying or baking the vehicle after i

painting. After air

bag system service, check

SRS warning

is in

operation to be sure

system functions properly.

that the 8.

light

Make

the

OFF

when

a scan tool

connected or disconnected.

DO NOT

use any

air

bags, the

G sensor and

bag modules

electrical test

tem to

is

designed

deploy the

air

to retain

bag

air

bag sys-

enough voltage

for a short period of

time even after the battery has been dis-

connected.

SRS-ECU

the sating

to ignite

from the

REMOVAL & INSTALLATION

G sensor

2.0L and 2.5L Engines

and deploy.

CAUTION

vehicle equipped

the air bag or to the driver by rendering the air

bag system inoperative.

is

air

can provide diagnostic infor-

bag system,

it

mation. The

SRS-ECU monitors

the air bag

position, the

minate

for

is

in

the system.

turned to the

SRS

warning

When

ON

or

If

key.

the

SRS

(air bag system) clock spring under the steering wheel and render the Security Restraint System (SRS)

START 1

light

may damage

injury.

the

should

about 7 seconds, then turn

operating condition.

and pinion unit, center the front wheels and remove the ignition

inoperative, risking serious driver

system and stores data concerning any detected faults

Prior to removal of the steering rack

Failure to do so

The SRS-ECU not only controls the

That indicates that the

equip-

one minute before

Power Rack and Pinion Steering

with an air bag system, to avoid injury to

ignition key

certain that the ignition switch

position

at least

Gear

the technician by inadvertent deployment of

air

Wait

c.

working on the vehicle. The

Service technicians should use care

bag components should not be

modules themselves and

A

located

to the output signal

when working around any

Bag Control Unit (SRS-ECU), the

7.

air

faulty,

the Supplemental Restraint

is

must be ON. The SRS-ECU, then causes the

subjected to heat over 200°F (93°C).

Remove

light is

cates the status of the air bag system.

analog

not attempt to repair any of the

replace that harness.

the

console assembly monitors the system

must respond

bag system wiring harness connectors. of the

high-quality electrical tape or similar

non-conductive wrapping.

located under the

SRS warning

cable and insulate the cable end with

bag

bag Electronic

air

(SRS-ECU)

To deploy the

the

in

the key

within the steering column.

event of an accidental deployment.

Air

The

clock spring interconnection

With the

Remove

located on the instrument panel which indi-

bench, never place anything on or close to

any

inflator unit.

air

and which contains a sating G sensor and

facing up.

air

the center of the steer-

analog G sensor. An

3.

bag mod-

air

and another located above the

Control Unit floor

bag and trim cover are pointed

away.

the

in

2

of

glove box, which contains the folded

and an

When

that the

one located

ing wheel

the module. 2.

position.

from the ignition lock cylinder. b.

.

the

in

the beginning of this section, observe the

1

in

straight-ahead position and place the key

to avoid

accidental deployment and possible per-

bag system using the

Position the front wheels

a.

replaced.

air

following procedure:

they should only be

faulty,

Disarm the

1.

components

may cause

accidental deployment of the air bag,

NEVER ATTEMPT TO REPAIR THE FOLLOWING COMPONENTS:

of these

CAUTION

:

nents. Failure to do so

bag diagnostic codes.

any

bag during vehicle servicing,

Air Bag system must be disarmed before removing many compo-

and

for reading

the vehicle’s

The

and may be used.

scan tool

If

the

refer to all service precautions.

other factory special tool wiring adapters

erasing

required.

if

imme-

SRS warning light is in any of these 3 conditions, the SRS system must be inspected,

SRS Check Harness acts like a “break-out box” for checking SRS wiring. There are that are available

is

or

while driving,

To avoid injury from accidental deploy-

MB991613

Chrysler Special Tool

10.

more than 7 seconds

light illuminates

ment

electrical circuitry.

nosed as

when handling

digital

maximum

or less at the

PRECAUTIONS Several precautions must be observed

does not illuminate as described or

light

stays on for

the

air

SRS components

any

except those specified by Chrysler corpora-

.

Before servicing the vehicle, refer to the

illu-

precautions

in

the beginning of this section.

off.

SRS system is in the SRS warning

2.

Drain the power steering fluid using

the following procedure:

CHRYSLER CORP. SEBRING COUPE

1.

Joint

assembly and gear box

connecting 2. 3. 4.

bolt

5.

a.

of the

* should be temporarily tightened before they are finally tightened once the total weight of the engine has been placed on the vehicle body.

power rack and pinion steering gear mounting

Disconnect the power steering

return (low side) hose. b.

Connect a suitable container

wheels, several times, from side-to-side,

In

Disarm the SRS system.

4.

Remove

the

Both front wheels

•

Lower steering column

between the jack and the

Cotter pins and

tie

Both triangular braces near the

Support the center crossmember.

round

the through-bolt from the front

roll

stopper and remove the 3 bolts

securing the center crossmember. •

Nm) and

Center crossmember and properly

•

Rear

roll

torque

fluid lines;

ft

lbs.

secure the low side

stopper through-bolt and

torque to 32

lbs (43

ft.

Nm)

the 2 rack assembly-to-chassis bolts

and the

Rack and pinion steering assembly

(69-78 Nm)

•

its

•

rubber mounts

Front

rear bolt to

roll

the nut to

•When

removing the rack and pinion assembly, tilt the assembly to the inner side of the compression lower arm. and remove from the left side of the

Use caution

to

For Accessory Drive Belt

bolts to

•

Tie rod

20

•

1

stopper bolt and torque

32

ft.

lbs.

(43

Nm)

Stabilizer bar

ft.

50-56

ft.

lbs

(69-78 Nm)

ends and torque the nuts

lbs.

(27

to

Nm)

Solenoid's wiring harness connector,

see Section

lbs.

•

•

illustrations,

ft.

Both triangular braces and torque the

install:

Align the rack assembly so the

51-58

•

avoid damaging

the boots.

To

Nm)

Crossmember and torque the front bolts to 58-65 ft. lbs. (78-88 Nm)

and

vehicle.

(18

lbs.

Power steering

engine into position

tit-

Rack assembly clamp bolts and

•

•

equipped with Electronic

Nm)

hose with the clamp and raise the

pressure pipe

vent excessive fluid leakage

rod ends from

crossmember 5.

fluid

lbs (69

the high side fitting to 11

pan.

tings; then, plug the fittings to pre-

joint-to-

Control Power steering (EPS)

Remove

oil

and return hose from the rack

Solenoid’s wiring harness connec-

•

Power steering

•

the steering knuckles

if

ft.

•

ft.

Pinch bolt and torque the bolt to 13

(15

and washer tank

Stabilizer bar

•

Steering rack and torque the mounting bolts to 51

•

damage to the when supporting and jacking engine, place a block of wood

rack and pinion input shaft bolt •

or connect the following:

Install

•

order to prevent

or disconnect the following

•

tor,

shaft

removed.

3.

•

7.

engine,

While cranking the engine, turn the

until the fluid is

umn

slightly

6.

ignition coil. d.

splines are inserted into the steering col-

rear roll stopper through-bolt.

** WARNING

Properly disable the ignition sys-

tem by removing the connector from the

support the engine and remove the

Lower the engine

to the

hose. c.

Clamp Gear box assembly

The fasteners marked

Stay (L.H.) Stay (R.H.)

Exploded view

Center

8.

Caution

tion 6.

member assembly

7.

9.

Power steering pipe connection Cotter pin Tie rod end and knuckle connec-

6-37

AVENGER

•

if

equipped with EPS

Front wheels

of this manual

CHRYSLER CORP.

6-38 8.

Refill

ing fluid

SEBRING COUPE ‘AVENGER power

the reservoir with

steer-

and properly bleed the power

steering system. 9.

Perform a front end alignment.

3.0L Engine 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Drain the power steering

3.

Remove •

fluid.

or disconnect the following:

Negative battery cable from the

left

shock tower •

Front exhaust pipe

member

•

Center

•

Steering shaft assembly

•

Tie rod

3.

end from the steering

knuckle •

Return hose and pressure tube 9346FG07

connections Exploded view

•

Cylinder clamp

•

Steering gear from the vehicle

To install: 4.

connect the following:

Install or

•

Steering gear to the vehicle

•

Cylinder clamp and torque the bolts to 51

•

(69

To

ends

Tie rod

(15

lbs.

ft.

Strut

•

Upper mounting bolts

•

Strut

to 21

ft.

•

Strut

to

33

ft.

lbs.

(44

•

Strut

assembly

to the lower control

ft.

lbs.

(300

bar link and torque the nut to

33

lbs.

ft.

(44

Nm)

Front speed sensor harness clamp,

•

Brake hose clamp

•

Front wheel

•

Negative battery cable

if

equipped

Nm) •

Stay and torque the bolts to 55 lbs.

•

(74

5.

ft.

Nm)

Steering shaft assembly and torque the bolt to 13

ft.

lbs.

(18

Center

•

Negative battery cable

Fill

Nm)

member

•

and bleed the power steering sys-

tem. 6.

repair 7.

Start the vehicle, if

check

for leaks

and

necessary.

Perform a front wheel alignment.

Strut

REMOVAL & INSTALLATION 3.0L Engine 1

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

Remove

or disconnect the following:

®

Negative battery cable

•

Front wheel

•

Brake hose clamp

•

Front speed sensor harness clamp, if

•

•

equipped

Sway

2

BRAKE HOSE CLAMP FRONT SPEED SENSOR HARNESS CLAMP

1.

3.

STABILIZER LINK

4.

BOLTS

5

NUT STRUT ASSEMBLY

6.

9346FG08

bar link

Lower control arm

Exploded view

of

the front strut

assembly—3. OL

Nm)

Sway

•

assembly and torque the

Nm)

knuckle (29

•

connect the following:

upper bolts

lbs.

the bolts to 221

assembly

install:

Nm)

to the steering

and torque the nut

arm and steering knuckle. Torque

from the steering knuckle

•

Install or

Nm)

Pressure tube and return hoses and torque to 11

•

lbs.

ft.

assembly— 3. OL

gear

of the steering

— 4.

ment,

Check and adjust the

if

CHRYSLER CORP. SEBRING COUPE* AVENGER

C OQ U 03

end align-

front

needed.

Shock Absorber REMOVAL & INSTALLATION

front

2.0L 1

.

AND 2.5L ENGINES Before servicing the vehicle, refer to the

precautions 2.

3.

in

Remove

the beginning of this section. or disconnect the following:

Negative battery cable

•

Wheel

•

Sway bar link from the damper fork Damper fork lower through-bolt, upper pinch bolt and damper fork

•

98 71

•

assembly •

1

4.Stff-toctang

7 Jppsr bu*vng 6 srw t*; 6 Cup 9 Burnp rufib* 10 Oust cow*

w

nut

2

Shock absorber

3 4

Upp* bu*tvng A Upp* brack* a**krrtky Upp* spring pad

5 6 Coksr

CAUTION Do Not remove the large center

spring

12 Shock bso'twr

Exploded view

nut.

Co4

11

of the front

Msomety

shock absorber

Exploded view

To install: Install or

•

connect the following:

ft.

Shock absorber and torque

the

upper mounting nuts

ft.

(44 •

Nm) and

to

32

fork then torque the lower

through-bolt/nut to 65

ft.

lbs.

(103

•

Nm) 4

to

29

ft.

(39

lbs.

Use a

jack to raise or lower the lower

control arm, so that the top shock absorber

Nm)

plate studs align through the body. Raise

Wheel

the jack to hold the shock absorber

assem-

bly in position.

Perform a front end alignment

(88

shock absorber

ot the rear

assembly mounting

76

bar link and torque the link-

to-damper fork nut

lbs.

Nm)

Damper

lbs.

Sway

•

the upper pinch bolt to

5.

Install or

connect the following:

Rear

~The

shock absorber assembly

is a

load bearing component; therefore, the

vehicle chassis and axle weight must

be supported separately, requiring the use of 2 separate lifting devices.

The

rear

package shelf

must be removed

to

front cover(s)

access the top mount-

Most connections are

ing nuts.

plastic clips.

Use care when removing these components to

avoid unnecessary damage. 1

Remove

or disconnect the following:

•

Rear shelf speaker covers

•

Rear shelf top assembly

•

Front cover(s) to access the shock

absorber top mounting nuts 2.

Raise and support lower control arm

assembly •

slightly.

Shock absorber upper mounting nuts

7922CG31

Exploded view

of the front

shock absorber

•

Shock absorber lower mounting

•

Shock absorber

bolt

1. Self-locking

3.

5. 6.

Upper bushing B

12 Shock absorber assembly

4.

Position the shock absorber assembly

7. Collar

8 Cep 9 Dus’ cover 10 Bump rubber

3.

To install:

nut

Washer Upper bushing A Braoei Spnng pad

2.

11

Cotl

7922CGM

so that the lower mounting bolt can be

assembly mounting

installed

For

Tire,

and

Wheel and Ball Joint

Exploded view

lightly tightened.

specifications, see Section

spnng

1

of this

ot the rear

manual

shock absorber

CHRYSLER CORP. SEBRING COUPE

•

AVENGER Carefully release the spring

9.

com-

pressor, watching the spring position as seats.

When

the spring

it

properly seated,

is

release/remove the compressor tools. Reinstall the

10.

ENGINES

3.0L 1

shock absorber assembly.

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Disassemble as follows:

3.

Remove

and place 4.

it

in

Install

the strut/shock assembly

compressor

a suitable

Special Tool

tool.

MB991 176

to

secure the strut and remove the dust cover

and jam

10. 11.

COIL SPRING

12.

SHOCK ABSORBER ASSEMBLY

JAM NUT

7.

2.

WASHER

8.

UPPER BUSHING A UPPER BRACKET ASSEMBLY UPPER SPRING PAD COLLAR

9.

3.

4. 5. 6.

5.

UPPER BUSHING B CUP ASSEMBLY BUMP RUBBER DUST COVER

1.

6. 7.

cover.

9346FG09

Exploded view

shock absorber

of the

Remove the coil spring. Remove the lower spring To assemble: 8.

9.

10. •

Top

and torque the

plate nuts

mounting nuts •

•

32

to

ft.

lbs.

Lower mounting

bolt

and torque

the bolt to 71

lbs.

(98

Interior trim

ft.

in

Compressor Tools MB991237 and

MB991238

Nm)

compress the spring

pieces

compressor

3.0L ENGINE

precautions

in

Make

certain

or disconnect the following:

absorber

been removed from

Negative battery cable

and washer from the top

•

Rear shelf trim

absorber assembly

•

Cover from the upper shock tower

•

Upper mounting nuts

release the tension on the spring compressor.

•

Shock from

Allow the spring

•

Shock assembly

If

the spring

of the

shock absorber

To install:

may remain connect the following:

Install or

3.

•

Shock absorber and torque shock ft.

•

to steering

lbs.

(98

lbs.

(45

73

Nm)

Upper shock nuts and torque ft.

to

32

Nm)

•

Upper tower cover

•

Rear shelf trim

•

Negative battery cable

in

expand

to is

the

absorber shield. ring, the spring,

to

lator

fully.

If

only the

components

6.

REMOVAL & INSTALLATION

sor.

Remove the upper insulator the bumper and lower insuto

each

8.

shield,

in

the beginning of this sec-

lbs.

Before servicing the vehicle, refer to the beginning of this sec-

in

Disassemble as follows:

3.

Remove

4.

5.

6.

7.

the rear shock from the

Install the

assembly

in

a spring

com-

Remove

the jam nut,

washer and

Remove

the upper bracket

assembly

is

correctly

or 16

ft.

lbs.

strut to

(22

rear strut. Install the dust cap.

18

Nm) on

the collar the cup,

and bushing.

bump

rubber and

9.

Remove

the coil spring

To assemble: 10.

Smoothly compress the washer and piston rod

Remove Remove

dust cover.

Install

the coil spring to the shock

absorber using Compressor Tools

MB991237 and MB991239. nut.

ft.

the

bump

Install the

dust cover and

12.

Install the

cup and bushing

13.

Install the collar,

1 1

Nm)

the strut/shock to the vehicle.

2.

8.

spring compres-

certain the spring

Install the

(25

tools.

Install

pressor tool.

mount and washer.

Torque the nut on the front Before servicing the vehicle, refer to

(64 Nm).

dust cover and remove the

tion.

lower insulator, the shock

spring.

AND 2.5L ENGINES

lbs.

ft.

Install the

and spring pad.

Install or align the

insulator rings.

Front

nut.

upper bushing.

positioned relative to the upper and lower

tion.

1.

location for proper reassembly.

Install the

Make

47

and jam

properly aligned, torque the

the precautions

absorber bumper and the uncompressed

7.

to

seat.

compress the spring and

vehicle.

install:

shock absorber

Coil Spring

the precautions

16.

compressor assembly.

spring. Install the upper spring insulator,

2.0L

15.

being replaced, the spring

from the spring. Take notice

To

When

rubber.

upper spring pad and

install the insulator

absorber bearing, washer, mount and shock

the

knuckle bolt

Carefully

to be replaced, slowly

By hand, remove the upper shock

5.

13.

14.

bump

the dust cover and

Install the

Rear is

1.

the rear steering knuckle

Install

shock

•

4.

.

12.

compressor

assembly and shock

remove the piston rod nut

plate,

lower spring pad and coil

Install the

jam nut

After tension has

3.

the shock absorber

the beginning of this section.

Remove

2.

slowly.

properly engaged before

is

tightening.

Before servicing the vehicle, refer to the

.

compressor and

pad.

spring. 1 1

spring compressor assembly or

equivalent. Tighten the

the

1

Place the shock absorber assembly

2.

Nm)

(44

nut.

Remove the strut insulator. Remove the upper spring seat and pad. Rempve the bump rubber and dust

.

rub-

ber.

and bracket assembly.

supper spring pad

CHRYSLER CORP. SEBRING COUPE 14.

the upper bushing and

Install

86

trol

Nm

When

15.

Remove

install the

the upper

properly aligned, install the

jam nut and torque 16.

arm mounting

and using the

washer.

the

17

to

(23 Nm).

lbs.

tt.

nuts.

Remove

the nuts

joint separation tool, separate

arm

shafts from the

shock

absorber tower.

compressor tools and

Remove

5.

shock absorber.

or disconnect the following:

Upper control arm assembly

•

Upper arm

•

Upper

6-41

AVENGER

•

shaft assembly-to-upper

arm nuts/bolts and

control

Ball Joint

the

shaft(s)

REMOVAL & INSTALLATION The upper

install:

6.

Install the

and bolts

2.0L and 2.5L engines, and cannot be seror

damaged

28

ball

—

Nm

/ —t-J

20 1Ub*r

Upper arm

1.

ball joint

2.

8.

Self-locking nut for

4

Upper arm

REMOVAL & INSTALLATION suspension on the 2.0L and called a Multi-Link

arms used

9. of the

suspension; a curved arm called the

called the Lateral

arms contain lower

straight

Lower Arm. Both since there

are 2 sockets in the steering knuckle. Ball joints

and lower arms are removed and

A

replaced as an assembly

ment

is

(86 Nm).

knuckle and torque

front

end align-

ft.

lbs.

(28

Nm)

Check the wheel alignment and if

necessary.

3.0L Engine c.

If

the ball joint stud

is

out of speci-

fication (turns too easily or is too

continue with the

1

.

stiff),

ball joint/control

tion.

assembly replacement.

-The

upper

ball joint boot

removed and replacement

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

arm

can be

the joint greased. ball joint boot is

A new

Remove

Rear wheel

•

Upper control arm from the

recom-

shock absorber

tower, locate the

at

steer-

ing knuckle

mended. Inside the engine compartment,

or disconnect the following:

•

•

Upper control arm assembly

•

Upper control arm bracket

•

Upper control arm

required after these procedures.

Upper Control Arm

20

mounting

2. ball joints

with

Front wheel

upper control arm

Suspenin this

Compression Lower Arm and also a

arm

lbs.

Ball joint to the

•

adjust,

front

it

or connect the following:

the locking nut to

assembly

4.

Exploded view

is

ft.

Install

• shaft

7922CG35

sion. There are 2 lower

shafts to

upper a/m

mstalation

2.5L engines

arm

and secure

3 Upper arm assembly

Ball Joint

front

(57 Nm).

mounting nuts. Torque the mounting

nuts to 62

and knucxle

connection

The

lbs.

the shock absorber tower

1

the

arm assembly.

Lower

ft.

Align the upper control

1

replacement of the upper con-

joint requires trol

A worn

to 41

for the 7.

viced separately.

upper arm shaft assemblies

upper control arm and torque the nuts

to the

an integrated part

ball joint is

upper control arm assembly

of the

To

the

upper con-

REMOVAL & INSTALLATION 2.0L and 2.5L Engines 1

.

Before servicing the vehicle, refer to the

precautions 2.

the beginning of this section

in

Remove

or disconnect the following:

•

Front wheel

•

Ball joint stud

from the steering

knuckle, using the joint separation Tool 3.

The

MB991113

ball joint

can be checked using

the following procedure: a.

An adapter (MB 990326)

able that

adapts If

to

fits

onto the

ball joint

is

avail-

stud and

an inch-pound torque wrench.

this tool is not available, a

shop-made

substitute can be fabricated. b.

Turn the

ball joint

1,

stud with the 2.

torque wrench. The factory standard for

breakaway torque (0.34-1.45 Nm).

is

3-13

UPPER ARM AND KNUCKLE CONNECTING BOLT UPPER ARM ASSEMBLY MOUNTING BOLTS

3

4 5

UPPER ARM ASSEMBLY UPPER ARM BRACKET UPPER ARM JGtl

inch lbs.

Exploded view

ol the

upper control arm assembly

For Wheel Alignment specifications, see Section

1

of this

manual

CHRYSLER CORP.

6-42

SEBRING COUPE

«

AVENGER

3.

connect the following:

Install or

•

Upper control arm and brackets and torque the bolts (57

•

to

42

ft.

torque the bolts to 29

ft.

lbs.

•

(39

Nm) •

•

Upper control arm

to the steering

knuckle and torque the bolt 73 lbs. •

(98

ft.

MB991113

50-56

fork-to-lower control arm

•

arm mounting

Lower control arm

(98-118 Nm).

install:

3.

When

6.

installing the control arm,

tem-

bolt nut to

Check the

front

71-85

ft.

lbs.

end alignment and

'adjust as required.

arm

ing the control

Compression Lower Arm

suspension

to the

the vehicle

is sitting

Install or

on

its

only after

fully

.

precautions

connect the following:

Damper

•

REMOVAL & INSTALLATION

fork

and torque the fork-to-

lower control arm through-bolt to

64

Lower Arm

•

ft.

lbs.

(88

(88-108 Nm).

Ball joint stud

from the steering

MB991113 •

Install a

new

Lower control arm-to-crossmember

cotter

To

install:

Tension rod to the control arm and

•

3.

torque the nuts to

Stay bracket from the crossmember

•

bolt

or disconnect the following:

•

Front wheel

lbs.

ft.

pin.

Front wheel

or disconnect the following:

•

knuckle and

65-80

tion.

•

the beginning of this section.

knuckle, using Joint Separator Tool

Ball joint stud to the

the precautions in the beginning of this sec-

in

Remove

Nm)

torque the nut to

Before servicing the vehicle, refer to

Before servicing the vehicle, refer to the

wheels. 2.

Remove

is

bolt

To

4.

2.

weight of the vehicle

full

on the suspension, torque the inner lower

1

.

the

Lower control arm-to-crossmember

crossmember. Tighten them

1

Front wheel

Once

5.

to

(69-78 Nm)

lbs.

ft.

porarily tighten the nuts and/or bolts secur-

Nm)

Rear wheel

Lower Control Arm

Lateral

crossmember

and torque the mounting bolts

through-bolt

Upper control arm assembly and

Stay bracket to the

knuckle, using Joint Separator Tool

Damper

•

lbs.

Nm)

•

from the steering

Ball joint stud

•

To install:

80-94

ft.

connect the following:

Install or

lbs.

•

(108-127 Nm)

Control arm to the crossmember

and torque the bolts (83 •

9871 -

to

60

lbs.

ft.

Nm)

Ball joint stud to the

knuckle and

torque the nut to 43-51

ft.

lbs.

(59-71 Nm) • 4.

front

end alignment and

adjust as required.

Nm ft.

Front wheel

Check the

lbs.

3.0L 1

.

ENGINE Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

Remove

or disconnect the following:

•

Front wheel

•

Lower control arm from the steer-

•

Lower control arm mounting

ing knuckle bolt

and clamp cover

• 3.

If

Lower control arm replacing the bushing, perform the

following:

Apply soapy water between the

a.

shaft

bushing

Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent

1.

2. 3.

and old bushing and pry the old out.

To

install:

4.

Apply soapy water

new bushing and

Compression lower arm ball joint and knuckle connection Compression lower arm mounting

4.

Stay

5.

bolt

6.

Shock absorber lower mounting bolt and nut Lateral lower arm ball joint and

•

7.

knuckle connection Lateral lower arm mounting bolt

and

•

Compression lower arm assembly

8.

nut Lateral lower

to the shaft

install the

and

new bushing,

if

removed. 5.

Install or

arm assembly

connect the following:

Lower control arm Lower control arm clamp and torque the bolts

to

60

ft.

lbs. (81

Caution Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. 7922CG36

Exploded view

of the lateral

lower arm and the compression lower arm mounting

Nm) •

Lower control arm

to the steering

knuckle and torque the bolts to 80 ft.

lbs.

(108

Nm)

CHRYSLER CORP. SEBRING COUPE Front wheel

•

Check and adjust the

6.

6-43

AVENGER

•

front toe,

if

needed.

Rear 1

Before servicing the vehicle, refer to

.

the precautions in the beginning of this section.

Remove

2.

or disconnect the following:

•

Rear wheel

•

Stabilizer Jink

Wheel Speed Sensor (WSS),

•

if

equipped

Lower control arm assembly

•

to

steering knuckle

Lower control arm

•

3.

To install: Install or

3.

connect the following:

Lower control arm and torque the

•

bolt to

55

ft.

lbs.

(74

Lower control arm

•

Nm)

to the steering

knuckle and torque the bolt to 80 lbs.

• •

•

WSS,

if

SZ?CGJ7

equipped

Exploded view

Stabilizer link

and torque the

29

Nm)

lbs.

ft.

ft

Nm)

(108

(39

of the front

hub assembly mounting and related components

bolt to

Remove

knuckle and torque the self-locking

or disconnect the follow-

Rear wheel nut to 21

ing:

Wheel Bearings

•

Front wheel

•

Vehicle Speed Sensor (VSS),

couple of lug nuts and

if

Caliper and brake pads; then, sup-

•

port the caliper out of the

play,

remove the

caliper

and

rotor.

a dial indicator to bear against the

back and in.

forth.

If

(0.05mm), replace the

front

guide pins Once the caliper

•

Upper

secured, the lug nuts can be

is

rear

hub and wheel bearing assem-

designed

for the life of the vehicle

maintenance. The bearing with the wheel

is

leading to possible failure.

hub and can only be unit.

REMOVAL & INSTALLATION

VSS.

•

Front wheel

•

New

•

is

cotter pin

and bend

to

secure

(halfshaft)

hub

side

is installed

hub.

Install

outward, away from the

the washer and

hub nut Tighten

145-188

ft

lbs

(200-260 Nm).

** WARNING

bearing assembly from the

knuckle

•The

equipped

the axle nut with the brakes applied. Torque

4 hub-to-steering knuckle bolts

Hub and

if

Examine the driveshaft

the nut to •

is

washer Locate the chamfered side This

and

a sealed unit

removed and/or replaced as one

•

6

Never use wedge-type tools or the ball joint can be damaged.

requires no type of adjustment or periodic

install the

removed.

knuckle outward

of

joint,

Rear The

from the steering

improper methods of joint separation can result in damage to

bearing assembly.

bly

ball joint

** WARNING Use

in the holder. Slide the caliper

Brake rotor from the hub assembly

pull the

hub and

pads

•

knuckle using a press type tool and

end-play exceeds 0.002

Caliper holder and place the brake

over the brake pads and

hub hub

•

way

Position

flange near the center ridge. Wiggle the

lightly tighten to

using wire

Front To check hub and bearing assembly end-

Nm)

hold the rotor on the hub.

equipped

ADJUSTMENT

(28

lbs.

ft

Position the rotor on the hub. Install a

5.

Pump

the brake pedal until hard,

before attempting to

hub and wheel bearing assembly

move

the

vehicle.

not serviceable and should not be

disassembled.

Rear To install:

Front

4 1

.

Before servicing the vehicle, refer to the

precautions 2.

in

Remove

and washer.

Install or

•

the beginning of this section.

Hub

WITH

connect the following:

to the steering

knuckle and

torque the bolts to 65

ft.

lbs.

1

(88

•

Upper

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

Nm)

the cotter pin, halfshaft nut

.

DRUM BRAKES

tion. ball joint to the steering

For Maintenance Interval recommendations, see Section

2.

1

Remove

of this

or disconnect the following:

manual

CHRYSLER CORP.

6-44

SEBRING COUPE

cVehicles with

•

AVENGER

drum brakes>

74 - 88 54 - 65

ABS

•

VSS,

•

Rear wheel and lower the vehicle

if

equipped with

WITH DISC BRAKES

Nm ft.lbs.

1

Before servicing the vehicle, refer to

.

the precautions in the beginning of this section.

Remove

2.

or disconnect the follow-

ing: •

Rear wheel

•

Vehicle Speed Sensor (VSS),

if

equipped with Anti-lock Brake Sys-

tem (ABS) Caliper and brake pads; then, sup-

•

port the caliper out of the

way

using wire Brake rotor

•

Remove

3.

the parking brake shoes as

follows: a.

Upper shoe-to-anchor springs.

b.

Lower shoe-to-shoe spring.

c.

Brake shoe hold-down springs.

d.

Parking brake cable from the actu-

ating lever.

Remove Remove

4. 5.

the 4 hub-to-knuckle bolts. the

hub and bearing assem-

bly from the knuckle.

"The

hub assembly is not serviceable and should not be disassembled. 6.

Rear speed sensor cVehicles with

1.

7. 8.

ABS-rotor cVehicles with

ABS> 2.

Caliper assembly

3.

Brake drum Brake disc Clip mounting

4. 5.

Shoe and

assembly

Rear hub assembly

6.

lining

ABS>

If

Socket

Caution

Do

To

Press the wheel sensor rotor onto

the hub.

not disassemble the rear hub assembly. 8.

of the rear

hub assembly mounting

Install the

hub

Rear wheel

•

Vehicle Speed Sensor (VSS),

3. if

equipped with Anti-lock Brake Sys-

If

Socket

replacing the hub, use special

MB991248 and

To install:

•

Brake drum

4.

•

4 hub to the knuckle bolts

•

Hub and knuckle

’"The hub assembly is not serviceable and should not be disassembled.

a press, to

remove

the wheel sensor rotor from the hub.

tem (ABS)

bearing assembly from the

to the

54-65

ft.

knuckle and lbs.

(74-88

Nm) 9.

•

remove

install:

torque the bolts to Exploded view

a press, to

the wheel sensor rotor from the hub.

7.

bolt

replacing the hub, use special

MB991248 and

Install the

hold rotor on hub. Install

brake pads

the caliper holder and place

in holder.

brake pads and Install or

•

Hub

connect the following:

to the

bolts to •

knuckle and torque the

54-65

Brake drum

ft.

lbs.

(74-88 Nm)

parking brake shoes.

Position the rotor on the hub. Install

a couple of lug nuts and lightly tighten to

11.

Press the wheel sensor rotor onto the

hub. 5.

10.

caliper

is

Slide the caliper over

guide pins. Once

install

secured, lug nuts can be

removed.

VSS,

12.

Install the

13.

Install the rear

if

equipped

wheel.

CHRYSLER CORPORATION 1997 Eagle-Talon

7-17

DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM

7-14

PRECAUTIONS STEERING AND SUSPENSION Air

Removal &

7-25

Installation

Pump

Removal &

Installation

Fuel System Pressure

7-25

Disarming

7-26

Precautions

7-25

Fuel

&

Installation

Removal &

Lifters

Installation

Steering Gear

7-15

Removal &

7-15

Rear Main Seal

7-15

Removal

7-14

Halfshaft

7-9

Hydraulic Clutch System

7-20

Removal &

Adjustments

7-18

Removal &

7-18

Installation

7-28

Coil Spring

Installation

7-20

Removal &

Installation

7-20

Overhaul

Ignition

Removal &

Installation

7-5

7-3

&

Removal &

Installation

Lower

Installation

Lower Control Arm

Removal & 7-25

Oil

Removal &

7-3

Installation

Oil

7-12 7-12

Removal &

Installation

7-12

7-8

Pinion Seal

7-9

Piston and Ring

Removal &

F

Removal &

Installation

7-9

Removal &

Installation

Positioning

7-25 Installation

7-27

T Transaxle Assembly

Transfer

Installation

Case Assembly

Removal &

Installation

Removal &

7-17 7-17

7-19 7-19 7-6

Turbocharger

Upper

Installation

7-6

7-29

Ball Joint

Removal &

Installation

Upper Control Arm

Removal &

7-29 7-29

Installation

7-29 7-1

Valve Lash

W Water

Pump

7-4

&

Installation

Wheel Bearings

7-25

Adjustment

7-13

Removal &

7-13

1

7-11

Adjustment

Removal

P

Removal &

7-11

7-27

Strut

V

Installation

7-8

Front Crankshaft Seal

7-30

Pump

Exhaust Manifold Installation

7-29

7-12

Pan

Removal & 7-3

Installation

U

7-30

Installation

7-6 7-11

Starter

0

E

Engine Assembly

7-7

7-29

Ball Joint

Removal &

7-13 7-6

Installation

L

7-25

Installation

7-7

Intake Manifold

D Differential Carrier

7-3

Timing

Adjustment

7-5

Cylinder Head

&

Removal &

7-20

CV-Joints

Removal

7-19

7-19

Bleeding

7-28

7-13 Installation

Rocker Arm/Shafts

Removal &

7-18

Clutch

&

S 7-14

7-2

7-26

R

7-15

H

7-9

7-26 Installation

System Service

Precautions

C Camshaft and Valve

Power Rack and Pinion

7-14

7-14

Relieving

7-2

Alternator

Removal

Installation

Fuel Injector

Fuel

Bag

Removal

Removal &

7-2

A

7-14

Fuel Filter

7-2

7-4 7-31 7-31

Installation

7-32

CHRYSLER CORP.

7-2

TALON

PRECAUTIONS

sure to read

of the following precautions,

all

which deal with personal of

to

prevention

safety,

component damage, and important points take into consideration when servicing a Never open, service or drain the radia-

•

cooling system

when

the engine

Observe

tions

applicable safety precau-

all

when working around

fuel.

Whenever

servicing the fuel system, always work

Do

well-ventilated area. or vapors to

open flame

oil

to

changing

come

in

in

a

not allow fuel spray

Soap and

exposure

to

becomes contaminated, completely

used engine

new

All

hand cleaner

so WILL result

Timing

The system must be

head may tially

keep

and sensors. Failure

fuel in a container specifically

designed

for fuel storage; also,

to follow safety

disabling procedures could result

always

an interfer-

strike the pistons,

in

If

the

the cylinder

causing poten-

serious (also time-consuming and

expensive) engine damage. Refer to the

and acci-

in

extremely

is

utilize

ence-type, non-freewheeling engine.

umn, instrument panel components, wiring

fire

maintenance

timing belt breaks, the valves

around system components, steering col-

example). Keep a dry chemical

belt

doing

oil;

severe engine damage.

in

Many models

important!

extinguisher near the work area. Always

light, for

will

it

Never operate the engine without the

•

•

now equipped

vehicles are

removed

come in condamage

fluid to

proper amount and type of engine

oil.

should be used. •

fluid that is

the paint.

soon as pos-

used engine

Any brake

fluid.

from the system should be discarded. Also,

tact with a painted surface;

disabled before performing service on or

drop

brake

flush the

Never reuse any

fluid.

do not allow any brake

oil.

worn when

water, or waterless

with an air bag system.

contact with a spark,

or excessive heat (a hot

sible after

of brake

the brake fluid

system with new

a

Wash your hands and any

oil.

If

prolonged con-

number of skin disorders, including canYou should make every effort to mini-

mize your exposure

your vehicle.

may cause

other exposed skin areas as

and hot coolant. •

that

used engine

Protective gloves should be

is

burns can occur from the steam

hot; serious

The EPA warns

•

tact with

should always buy the correct type fluid for

medical assistance.

cer!

motor vehicle:

tor or

IMMEDIATELY seek

brake fluid internally,

Before servicing any vehicle, please be

maintenance

manual

interval charts in the front of

recommended

properly seal fuel containers to avoid the

dental air bag deployment, possible per-

this

possibility of fire or explosion. Refer to the

sonal injury and unnecessary system

ment

additional fuel system precautions later in

repairs.

timing belt section for belt replacement and

Fuel injection systems often remain

•

pressurized, even

OFF. The

turned

engine has been

after the fuel

working with, or around, the

system pressure must

be relieved before disconnecting any fuel lines. Failure to

do so may

and/or personal

injury.

•

Brake

fluid often

brake fluid

in

fluid.

If

with clean, running water for 15 minutes.

eye

irritation persists, or

if

you have taken

a non-

vehicles

may

interfere with

computer sys-

require the computer to

bag on a work surface, always

undergo a relearning process once the neg-

and trim cover upward, away

ative battery cable

air

module

of the

reduce the

will if

it

is

sealed container

is

reconnected.

drum

brakes, only disat a time,

leaving the remaining side intact for refer-

bag

ence.

later in this section.

essential to the safe

is

servicing

assemble and assemble one side

accidentally air

When

•

Clean, high quality brake fluid from a

• If

some

tem^) and may

system precautions

you do get

Disconnecting the negative battery

•

cable on

away from your body. When placing

deployed. Refer to the additional

your eyes, flush your eyes

to the

inspection.

bag system.

the7.functions of the on-board

motion

replace-

and

interval for the timing belt,

sure the bag and trim cover are pointed

from the surface. This

contains polyglycol

air

carrying a non-deployed air bag, be

face the bag

and wash your hands thoroughly

handling brake

after

When

deployed

result in fire

ethers and polyglycols. Avoid contact with the eyes

Always wear safety goggles when

•

this section.

for the

and

proper operation of the brake system. You

Only an MVAC-trained, EPA-certified

•

automotive technician should service the conditioning system or

its

air

components.

ENGINE REPAIR Alternator

To

install;

4.

Install or

REMOVAL & INSTALLATION Non-Turbo .

ft.

lbs.

Nm).

(61

•

Alternator

•

Alternator bracket

•

•

Alternator electrical connector

•

Under cover side panel

•

Alternator drive belt

•

Right wheel

•

Negative battery cable

connect the following:

Install or

Adjust the alternator drive belt deflec-

5. 1

alternator-to-lower bracket nut to 45

connect the following:

Speed control assembly

Before servicing the vehicle, refer to

and tension

tion

to the following

speciTca-

the precautions in the beginning of this sec-

Turbo

tions: tion.

Used

a.

2.

Disconnect the negative battery

belt deflection:

0.35-0.47

in.

1.

(9.0—1

2.0mm)

cable. 3.

Remove •

b.

(7.5-1 Right wheel

belt deflection:

0.30-0.41

Under cover side panel

•

Speed control assembly

•

Alternator drive belt

2.

Used

belt tension:

90-110

lbs.

3.

Disconnect th# negative battery cable.

Remove •

d.

Alternator electrical connector

•

Alternator bracket

New

belt tension:

6.

110-160

ft.

lbs.

(54

Right wheel

lbs.

•

Under cover side panel

•

Alternator drive belt

•

Power steering pump

•

Power steering pump

Torque the alternator-to-upper

bracket nut to 40 Alternator

or disconnect the following:

(400-490 N) (490-712 N)

•

the beginning of this sec-

0.5mm)

-

•

in

in.

tion.

c.

•

New

or disconnect the following:

Before servicing the vehicle, refer to

the precautions

Nm) and

the

drive belt

CHRYSLER CORP.

7-3

TALON Ignition

Timing

ADJUSTMENT Ignition timing is controlled ertrain Control

ment

is

by the Pow-

Module (PCM). No

adjust-

necessary or possible.

Engine Assembly

REMOVAL & INSTALLATION The following procedure can be used on all

vehicles. Slight variations

to extra 4

etc.,

may occur due

but the basic pro-

Generator

cedure should cover

5 Generator brace

1

Exploded view

connections,

of the alternator

models.

all

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

and related components— Non-turbo

tion.

0 *

Nm

20-25 14 — 18

2.

Relieve the fuel system pressure.

3.

Drain the cooling system and the

crankcase.

ft.lbs.

Remove

4.

rf.

or disconnect the following:

•

Negative battery cable

•

Engine undercover,

•

Hood assembly. Matchmark hood hinges

if

prior to

equipped the

removal to

ease alignment during installation. •

Air cleaner

assembly and

air intake

ducts 1 Drive belt (Generator) 2 Generator harness connector 3 Generator 4 Drive belt (power steering) 5 Water pump pulley 6 Power steering pulley 7 Generator brace

•

of the alternator

•

6.

(12-15 Nm) and the

above the engine without disconnecting

bot to 8.7-1

the hoses.

alternator-to-lower bracket nut/bolt to

14-18

•

Alternator electrical connector

•

Alternator

7.

To 4.

5.

ft.

(20-25 Nm).

lbs.

ft.

lbs.

Adjust the power steering drive belt

deflection

and tension

•

Accelerator cable

Install or

•

Heater hoses

Brake vacuum hose

•

Connection

•

High pressure

a.

•

Alternator electrical connector

•

Alternator drive belt

Fuel return line

Oxygen (O 2 S) sensor connection

b

a.

c.

belt deflection:

0 35-0.45

New

0.30-0.35

Used

(245-490 d.

New

(490-686

55.1-110.2

New

(490-686 8.

belt tension:

0.18-0.22

•

belt tension:

• in.

55.1-1 10.2

belt tension:

belt tension:

110.2-154.3

for

thermo switch sen-

110.2-154 3

Transaxle assembly

•

lbs

Idle

•

Motor Position (MP) sensor con-

•

Throttle Position (TP) sensor con-

connect the following:

•

Under cover side panel

•

Right wheel

•

Negative battery cable

lbs

speed control connection

nector

N).

nector •

N).

N).

Connection

• lbs.

N).

Install or

Coolant Temperature Sensor (CTS)

sor

in

(7-9.0mm). c.

in

connector

belt deflection:

Used

(245-490 d.

belt deflection:

0.22-0.32

in.

(9-1 1.5mm). b.

belt deflection:

(4.5-5.5mm).

to the following specifications:

Used

New

Coolant temperature gauge connection

(5.5-8 mm).

Adjust the alternator drive belt deflection

and tension

Used

fuel line

•

•

to the following

vacuum hoses

tor

•

specifications:

connect the following:

Alternator

if

Wheel Drive

•

install:

•

All

(AWD)

Torque the alternator-to-upper bracket 1

Transaxle and transfer case,

equipped with

and related components— Turbo

^Support the power steering pump

and

intercooler

93Q60GQ?

Exploded view

Radiator, coolant reservoir

Exhaust Gas Recirculation (EGR) temperature sensor connection on

lbs

California vehicles only •

Fuel injector connectors

For complete service labor times, order the Chilton Labor Guide

CHRYSLER CORP.

7-4

TALON transistor connector

Power

• •

Ignition coil connector

•

Condenser and noise

filter

Accelerator cable

for

•

Transaxle and torque the upper

tion.

mounting bolts

connec-

Nm) and

tor •

Crankshaft Position (CKP) sensor

•

Camshaft Position (CMP) sensor

lbs.

•

Manifold

differential

pressure sen-

sor connector

and control harness

•

Distributor

•

Alternator and

pressure switch

oil

connectors Drive belt and compressor and wire

•

the

compressor aside,

DO NOT

equipped.

if

discharge the system or

lbs.

ft.

any brackets to

22

ft.

Nm)

Radiator and intercooler

•

Air cleaner

•

Control brackets

To

•

Hood

5.

•

Negative battery cable

•

Water pump, gasket and 0-ring.

Engine mount

Torque control brackets

8.

Fill

the engine with clean

9.

Fill

the cooling

system

oil.

to the

Start the engine, allow

1 1

it

and check

test the vehicle

for

all

not allow

(roll

stop-

Water pump, using a new gasket. Torque bolts

before removal.

assembly

1

.

Before servicing the vehicle, refer to in

the beginning of this sec-

2.

Drain the cooling system.

3.

Remove •

6.

or disconnect the following:

Timing

belt.

Refer to the timing belt

unit repair section in this

lbs.

ft.

(69

manual

belt rear cover,

Timing

belt

•

Remaining components

•

Negative battery cable

Fill

Start the engine,

7.

repair

if

necessary.

on the

mount. Exhaust pipe and torque the nuts to ft. lbs. (49 Nm) Vacuum hoses

•

Water hoses

•

Fuel return and high pressure hoses

36

vacuum hose

•

Brake booster

•

Wiring harness connections

•

A/C compressor

electrical

connec-

tors •

CKP

•

CMP

•

Ignition coils

sensor sensor connector

and

fuel injector

con8.7-11

It.lbs.

nectors •

Manifold

differential

pressure sen-

4

sor connector •

Capacitor

•

TP sensor connector

•

Ignition

•

ECT sensor

•

power

transistor connector

Engine coolant temperature gauge

Removal slaps 1.

Generator brace

2 Water 3.

pump

Water pump gasket

4. O-ring

connector •

Oxygen (O 2 S) sensor connection

Water pump mounting and

bolt locations

to

17

ft.

if

removed

the cooling system to the proper

Nm)

•

(13 Nm).brace.

(24 Nm).

Timing

lower mount through-bolt

is

lbs.

pump

•

nut should not be tightened until the

weight of the engine

ft.

•

Engine and torque the engine

50

10

level.

install:

connect the following:

to

Alternator-to-water

Torque the brace pivot bolt

REMOVAL & INSTALLATION

tion.

certain to note the orientation

•

other grease to

oil or

contact the O-ring. •

the precautions

full

pipe 0-ring

to reach

Do Road

.

Make

front

inlet

coolant.

bracket

bolts to

connect the following:

water

level.

i**Some engine mount pieces have arrows on them for proper assembly.

'•The

New

lbs.

mount

if

bolts

*»Coat the O-ring with water or proper

pers)

•

pump

Install or

•

•

Install or

necessary

Water

Water Pump

•

7.

to the rear cover.

belt rear cover,

functions for proper operation.

port the engine weight.

To

access

•

•

leaks.

the engine

for

Timing

Discard the gasket and 0-ring.

aside

Remove

brace

install:

Attach a hoist to the engine and sup-

6.

pump

•

assembly

normal operating temperature and check

discard the gasket 5.

Alternator-to-water

Unfasten the retainers, then remove

4.

ft.

Nm)

and torque the bolts

(30

•

(69

32

Power steering pump and wire Exhaust manifold-to-pipe nuts and

•

to 51

the lower bolts to

•

10.

disconnect the refrigerant lines •

(44

Starter lbs.

connectors •

timing belt removal and installa-

•

—2.0L (VIN

F)

engine

check

for leaks

and

CHRYSLER CORP.

7-5

TALON

—

Front of engine (Timing belt side) 1

3

1

5

10

8

2

0

0

O

0

0

0

0

0

7

9

6

4 "322DG04

Cylinder head bolt removal sequence 2 OL (VIN F

and Y) engines

V*

Front of eng me (Trning belt sde)

6

1

3

,

0

0

O

0

o

0

0

0

0

10

4

2

5

7

8

r ^10.

Cylinder Head

•

Engine center cover

•

Spark plug wires

Brake booster vacuum hose

•

Fuel lines from the fuel supply

•

Bypass hose and water hose con-

Engine

Drain the cooling system and

crankcase

Remove

•

Accelerator cable and mounting

Power steering pump

•

Cylinder head cover and semi-cir-

•

Idle Air

Knock

•

Heated Oxygen (HO 2 S) sensor

•

Engine coolant temperature gauge

(ks)

lbs. d.

Heat protector

•

Thermostat housing and O-ring

•

Intake manifold stay

(35

in

•

To

bolts to 17

•

Ignition

module (power

of the •

Throttle Position (TP) sensor

•

Condenser

•

Manifold Differential Pressure

for

(MDP) sensor •

head bolts from below the head

•

Ignition coil

•

Camshaft Position (CMP) sensor

the bolt

(99.4 •

Crankshaft Position (CKP) sensor

•

Air conditioning

•

Engine control wiring harness

to the end;

measures more than 3.91

mm),

a

new

Install the

9.

engine

oil to

retainer

together •

Power steering pump

•

Timing

install

them

our web

site at

Refer to the appropri-

www.chiltonsonline.com

and

installation procedure. •

PCV, breather and vacuum hoses

•

Water hose and bypass hose

fin-

ger-tight.

visit

belt.

ate section for the removal

cylinder head. Apply clean

and

oil seal

and the cylinder head come

in.

cylinder head gasket,

the bolts

packing

at the front of the

cylinder head where the camshaft

or disconnect the following

Please

Apply sealant

with identification mark facing upwards

compressor

Rocker arm cover and apply sealant to the semi-circular

replace the bolt.

Install

8.

Remove

the length of the cylinder

Nm)

Heat protector

12.

lbs

Nm)

•

the cylinder

warpage.

Measure

Fuel injectors if

5.

Check

ft

and torque the

(23

Radiator and water hoses

•

engine block and the sealing surface

7.

lbs.

bolts to 16ft. lbs (22

of the cylinder head.

head

ft.

•

Thoroughly, clean the deck surface

transistor)

25

Thermostat housing and torque the

Cylinder head and discard the gas-

install:

6.

new gasket

to

Nm)

Intake manifold stay

steps, using the specified

ket

sensor

15

connect the following:

and torque the bolts

•

Engine Coolant Temperature (ECT)

to

* turn (90

Turbocharger, using a

•

sender •

Tighten the bolt

Install or

1 1

sequence •

sequence

Tighten the bolt an additional V*

e

Cylinder head bolts gradually,

2-3

in

(20 Nm).

turn (90 degrees).

Turbocharger assembly from

sensor

58

degrees) from the mark.

Water and radiator hoses

•

•

ft.

exhaust manifold

Control (IAC) motor

to

bolts completely in the

Tighten the bolts

c.

•

•

sequence

belt

•

Label and disconnect the following:

4.

in

(78 Nm).

Loosen the

b.

Timing

body

sequence, using

reverse order

•

Intake air duct (hose) from the

throttle

lbs.

cular packing

bracket

•

ft.

•

or disconnect the following:

Negative battery cable

in

Tighten the bolts

a.

hoses, breather hose and

(PCV) hose

tion.

•

Tighten the bolts

the following procedure:

Positive Crankcase Ventilation

the precautions in the beginning of this sec-

3.

rail

nections

Vacuum

Before servicing the vehicle, refer to

2.

2.0L (VIN F and Y) engines

•

•

1.

3220005

Cylinder head bolt tightening sequence

REMOVAL & INSTALLATION

2.01 (Vin F)

1

CHRYSLER CORP.

7-6 •

TALON

Fuel lines to fuel supply a

new

engine

of

oil

to the

new

using

rail,

O-ring. Apply a small

•

Spark plug wires and center cover

•

All

•

Intake air hose, at the throttle

body

•

them

oil filter

and

refill

the

be stretched, replace

appears

engine and check

for fuel,

To remove the arms, the camshaft must

new head gasket and

Install a

the

be removed.

clean engine

is

It

recommended

first

that all

rocker arms and lash adjusters be replaced of the bolts with

Coat the threads

7.

Start the

a bolt

If

it.

cylinder head

crankcase. 15.

for stretching.

engines do not use rocker arm shafts; the valves are directly actuated by rocker arms.

to

6.

Replace the

REMOVAL & INSTALLATION The Dual Overhead Camshaft (DOHC)

Clean the cylinder head bolts and

inspect

the cooling system to the proper

level.

14.

Rocker Arm/Shafts

the deck and the cylinder head for

5.

Negative battery cable Fill

and

Thoroughly clean the cylinder head

4.

adjust

13.

install:

warpage.

Accelerator cable, connect and

for coolant leaks

proper operation.

and engine block sealing surfaces. Check

removed connectors

engine and check

Cylinder head

•

To

Brake booster vacuum hose

the proper

in

sequence

0-ring.

•

•

Cylinder head bolts,

•

amount

and

oil

together. Refer the camshaft procedure for

install the bolts finger-

details.

coolant and

tight in the

leaks.

oil

in

2.01 (Vin Y) Engine

engine block. The short bolts go

the corners.

Tighten the cylinder head bolts

8.

proper sequence,

the

in

in

Before servicing the vehicle, refer to

1.

the precautions

25

ft.

lbs.

Outer bolts 7 through 10: 20

ft.

lbs.

Center bolts

a. in

Turbocharger

the following steps: 1

through

6:

REMOVAL & INSTALLATION

the beginning of this sec-

(33 Nm). tion. b.

Drain the cooling system and

2.

(27 Nm).

crankcase.

•

and

d.

Air cleaner

Air conditioning

air intake

Power Steering Pump (PSP) switch Heated Oxygen (HO 2 S) sensor

Engine coolant temperature gauge g.

Engine Coolant Temperature (EOT)

lbs.

Outer bolts 7 through 10: 20

ft.

lbs.

Manifold Absolute Pressure (MAP)

1

through

6:

4.

Remove

Turn

fasteners

all

•

Throttle Position (TP) sensor

•

Idle Air

more

•

Injector harness

in

Ignition coil

•

Camshaft Position (CMP) sensor

•

Wastegate vacuum hose

•

Air outlet

•

Upper and lower heat shield

new gasket

Refer to the timing belt

belt.

for timing belt

Purge

•

•

Water hose

•

Overflow tube

•

Brake booster vacuum hose and

purge •

hose and brake booster •

Overflow tube connection

•

Upper radiator hose and water hose

belt.

rail

•

•

connectors

•

Exhaust pipe nuts and discard the

Air intake duct

Exhaust manifold Exhaust manifold-to-turbocharger through-bolts/nuts

and

air

•

cleaner

assembly •

under the turbo has a

gasket

Heater hose

necessary

timing belt removal and instal-

line

using

All electrical

•

Water cooling lines

'"The water

new gasket

Accelerator cable and adjust as

manual

feed line-to-turbo eyebolt and

threaded connection.

•

Refer to the timing belt

unit repair section in this

hose

•

connections.

Oil

gaskets •

Fuel lines-to-fuel supply a

vacuum hose connections

Timing

air

water pipe

rail

•

Triangular engine hanger bracket

•

at the

aside.

Exhaust manifold self-locking nuts

Upper

hose

pump

•

Intake manifold stay radiator

Power steering pump and bracket nected and wire the

instal-

•

engine

•

removal and

hose connections

assembly. Leave the hoses con-

•

Heater hoses from the rear of the

Fuel lines from the fuel supply

•

manual

lation.

body

and tube

Front exhaust pipe-to-exhaust

Timing

Oil return line

ket •

Oil filter

capscrews and gas-

from r/nder the turbo

Turbocharger

lation. •

Intake manifold stay

•

Intake

•

and exhaust camshafts

Exhaust pipe from the exhaust manifold

10.

Fill

the engine with clean

11.

Fill

the cooling system to the proper

oil.

^Both water

pipes and

oil

feed line

can remain attached.

level.

12.

Turn the ignition to the

and check

for fuel leaks.

Then,

ON

position

start the

if

Oxygen (O 2 S) sensor Oil dipstick

•

Accelerator cable from the throttle

•

•

Air intake bellows hose

Camshafts

solenoid valve

Condenser fan/radiator assembly,

•

•

Exhaust Gas Recirculation (EGR)

Radiator

equipped with A/C

sequence. Do

unit repair section in this

•

Negative battery cable

•

connect the following:

manifold using a

Control (IAC) motor

•

through 10: 14

1

or disconnect the follow-

•

Install or

Intake Air Temperature (IAT) sensor

air

oil.

ing:

not use a torque wrench for this step. 9.

•

for

Drain the cooling system.

•

turn (90 degrees)

sensor

•

ft.

Drain the engine

3.

(27 Nm).

sensor

•

50

2.

(67 Nm).

sender

•

lbs.

Center bolts

e.

f.

•

ft.

tion.

(27 Nm).

•

•

Outer bolts 7 through 10: 20

6:

duct

compressor

•

•

lbs.

through

(67 Nm).

Negative battery cable

•

•

ft.

1

or disconnect the following:

•

•

50

Center bolts

c.

Remove

3.

Before servicing the vehicle, refer to

1.

the precautions in the beginning of this sec-

Inspect the following items:

5.

•

Turbine (hot side) and compressor

CHRYSLER CORP.

7-7

TALON Intake Manifold

28-34 Nm 20-25 ft**.

REMOVAL & INSTALLATION 2.0L (VIN F) Engine Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section.

Relieve the fuel system pressure.

2.

10-12

3.

Drain the cooling system.

4.

Remove

Nm

^^7-9ftJb.

or disconnect the following:

•

Negative battery cable

•

Accelerator cable, breather hose

and •

air intake

Upper

hose

radiator hose, heater

hose

and water bypass hose 1

Oil return

.

pipe

•

Gasket Turbocharger Eye bolt s Gasket 2

.

3. 4

Water pipe B

.

Eye bolt Gasket

7.

8

Eye bolt Gasket

.

.

13.

line

High pressure

and

fuel line

fuel

hose

Label and disconnect the following

5.

Exhaust fitting 6.

14.

Brake booster vacuum

•

the electrical connectors:

pipe

12. Oil

•

return

8-10 Nm 8-7 ft. m

Water pipe A

9

1

necessary vacuum hoses and

pipes

.

6

10

All

•

Gasket •

Oxygen (O 2 S) sensor Engine Coolant Temperature (ECT) sensor

Exploded view

assembly— 2 OL

turbocharger

of the

(cold side) wheels for cracking or

other

damage

installing the threaded

water

Turbine and compressor wheels for

•

ease of movement

inlet pipe,

leakage

Oil

•

Wastegate valve operation.

problem

is

If

Install or

any

Pressure

test the

wastegate valve by

•

actuator to

make sure

the rod moves.

Water

Water cooling lines and torque to

•

Thermostat housing,

Nm)

•

Power brake booster and Positive

if

may be damaged. >"»The wastegate actuator should main-

vacuum; fc*

if

not, replace

it.

WARNING to adjust the

waste-

gate valve.

To

(49

ft.

ft.

to

36

ft

Nm) (42

lbs.

and torque the bolts

(19

lbs.

10

ft.

(15

lbs.

vacuum •

To

Nm) bracket,

oil

Replace

sages

hose

Air outlet

•

Wastegate hose

•

Air intake bellows

•

Oil dipstick

•

O2S

•

Radiator assembly

for

il

connected

•

tube and dipstick

in

a crisscross

from the inside and

pattern, starting

working outwards,

to

11-14

10.

Fill

the cooling system to the proper

oil.

•

Fuel

rail,

check

if

for leaks

and

lightly with oil.

bolts to

necessary.

locking nuts. Before

Timing belt service

Nm).

is

covered

in Section

lbs.

with injectors and pres-

sure regulator, lubricate Start the vehicle,

ft.

(15-19 Nm).

the engine with clean

.

new gas-

Torque the manifold-to-cylin-

der head bolts

Negative battery cable

pas-

connect the following:

Intake manifold, using a ket.

sensor

air

clogging

Install or

7.

return line with clean all

lines,

Intake manifold

damage and water passages and

Heat shields

Fill

repair oil.

necessary

Inspect the intake manifold's mount-

install:

Prime the

if

install;

6

level.

engine

and heater connections

ing surfaces for cleanliness, cracks or other

removed

9.

1 1

body water hose

inlet

Crankcase ventilation (PCV) valve

to

Nm)

•

•

Do not attempt

with injectors and pres-

rail,

•

and torque the bolts

Power steering pump and

•

Fuel

Intake manifold bracket

to •

Spark plug wires

sure regulator attached

Engine hanger and torque the bolts

•

Do not apply more than 10 psi (71 kPa) for the wastegate diaphragm

•

Throttle

14

WARNING

tain

temperature sensor

connect the following

Oil feed line

applying approximately 9 psi (62 kPa) to the

speed control

•

31

deposits, clean as required

Exhaust Gas Recirculation (EGR)

•

lbs.

•

Idle

•

•

Exhaust manifold using a new gasket

for restriction or

Thermo switch

•

the inner

•

found, replace the

passages

oil to

Turbocharger

part. Oil

apply light

for the

•

7.

•

connection

pipe flange surface. 8.

•

•

(VIN F) engine

3 of this manual

all

seals

Torque the retaining

84-108

inch lbs. (10-13

CHRYSLER CORP.

7-8

TALON

Thermostat housing,

•

Intake manifold brace bracket

•

Throttle

•

All

if

•

removed

•

(34

body bracket •

hoses, cables and electrical

•

connectors •

Run

9.

opens,

check

refill

plenum using a new gasket to

25

cooling system

the radiator completely and •

for leaks.

Adjust the accelerator cable. Check

•

lbs.

Fuel

body using a new gasket and engine

(23

to

•

Nm)

rail fuel

in

EGR pipe Vacuum hoses and PCV hose

to-turbocharger nut/bolts to ft.

•

•

Engine control wiring harness and

•

•

2.

Nm)

and torque the bolts (44

•

Vacuum hose at throttle body MAP and CT sensors

•

Condenser cooling

•

Accelerator cable at the bracket and

•

Power steering pump

•

O 2 S sensor harness

•

Oil level indicator

Properly relieve the fuel system presthrottle

4.

(10

AIS motor and TP sensor

body

33

to

lbs.

ft.

Nm) fan

10.

sure. 3.

lbs.

Exhaust pipe using a new gasket

•

the beginning of this sec-

oil lines

Heat shields and torque the bolts to

•

tion.

40-47

the turbocharger

89 inch

ets/clips

ft.

(55-65 Nm).

lbs.

Engine hanger, water and at

reposition and secure with brack-

Before servicing the vehicle, refer to

18-22

(25-30 Nm) and the manifold-

lbs.

level.

in

a crisscross pattern to

rings

Alternator wiring harness

the precautions

Exhaust manifold and new gasket.

Torque the manifold-to-head nuts

new 0-

lines using

•

1.

for

connect the following:

Install or

6.

17

vehicle has cooled, recheck the coolant

2.0L (VINY) Engine

gasket material from the

all

damage.

assembly

and adjust the ignition timing. Once the

Clean

mating surfaces and check the manifold

Intake manifold stay

ft.

•

the engine until the thermostat

install:

5.

Nm)

Throttle

To

lbs.

ft.

hanger and torque the bolts

Negative battery cable Refill the

8. 10.

Intake

and torque the bolts

•

Breather and

•

Vacuum

•

Negative battery cable

Drain the cooling system.

Remove • •

air intake

reservoir,

if

hoses

and tube using a

new O-ring

equipped

or disconnect the following: •

Negative battery cable

Negative battery cable

Vacuum

6.

reservoir,

if

Fill

the cooling system to the proper

7.

Fill

the engine with clean

8.

Fill

the

oil.

equipped with level.

coding system

to the

proper

cruise control 7.

Adjust the accelerator cable.

level.

and breather hoses

•

Air intake

•

Accelerator cable from the bracket

Operate the engine

9.

Exhaust Manifold

•

Engine harness retaining clips

•

Manifold Absolute Pressure (MAP)

Coolant Temperature (CT) sensor connector

•

1

Before servicing the vehicle, refer to

1.

motor

Air Injector Service (AIS)

the precautions in the beginning of this section.

tion. 2.

Drain the cooling system.

3.

Remove

Drain the cooling system.

•

Negative battery cable

Remove

•

Air intake

•

Upper

Alternator wiring harness

Pollution Control Valve

4.

(PCV) hose

•

Vacuum hoses

•

Exhaust Gas Recirculation (EGR)

or disconnect the following:

Negative battery cable

•

Condenser cooling

•

fan,

if

equipped

A/C

Power steering pump and move

•

Intake manifold stay

rail

and engine

hanger •

Throttle

•

Intake manifold

•

Injector connectors

•

Fuel

•

Intake manifold

rail

it

Air

Engine control wiring harness from

Water pipe assembly

Dipstick tube

•

Oil dipstick

•

Exhaust pipe-to-turbocharger nuts,

•

Upper heat shield

separate the exhaust pipe and dis-

•

Engine hanger

card the gasket

•

•

•

and torque the retainers

in

rail

bolts to

ft.

lbs.

Injector connectors

and vacuum hose con-

lbs.

a criss-

(23

(10

Nm)

Heat shields

•

at

exhaust manifold

Lower heat shield

•

Exhaust manifold and discard gasket

Exhaust manifold-to-turbocharger

4.

and nut

Install or

•

Engine hanger, water and if

oil

lines

(23 •

Exhaust manifold and discard gasket

connect the following:

Exhaust manifold with a new gasket

and torque the bolts

neces-

sary •

•

To install:

from the turbocharger,

Nm)

Front exhaust pipe from the manifold

and turbocharger

bolts

assembly and torque the

89 inch

Air intake

nections

with injectors

cross pattern to 17

the rear of the engine

•

•

new gasket

hose connection

•

•

•

plenum and gasket

connect the following:

hose from water

Oxygen (O 2 S) sensor harness

body

Intake manifold using a

hose

radiator

•

install: Install or

or disconnect the following:

outlet

aside

Fuel lines from the fuel

Fuel

oil.

•

with

•

•

Before servicing the vehicle, refer to

3.

aside

•

•

.

move

it

leaks.

the precautions in the beginning of this sec-

Drain the engine

•

•

and exhaust

2.

pipe

5.

for fluid

the engine coolant.

Engine control wiring harness and

assembly

To

off

thermo-

2.0L (VINY) Engine

Throttle Position (TP) sensor con-

connector •

Top

until the

2.0L (VIN F) Engine

nector •

opens.

Check

REMOVAL & INSTALLATION

sensor •

stat

17

ft.

lbs.

Lower heat shield and torque the bolts to

•

to

Nm) 10

ft.

lbs.

(15

Nm)

Front exhaust pipe using a

new

CHRYSLER CORP.

7-9

TALON gasket and torque the bolts to 33 (44

lbs.

•

MB995022 /

Engine hanger and torque the bolts to

10

ft.

lbs.

(15

Nm)

•

Upper heat shield and torque the

•

Oil dipstick

bolts to 10

•

ft.

Nm)

ft.

lbs.

(15

Nm)

and water pipe

Engine wiring harness

to the rear of

the engine

Z)

hose and upper radiator hose

•

Air

•

Air intake Tiose

7922D619

• 5.

7922DG17

Negative battery cable

Fill

To prevent damaging the end of the crank-

the cooling system to the proper

level.

6.

repair

shaft, use the proper sprocket

tool— 2.0L (VIN Start the vehicle, if

check

for leaks

removal

To avoid damaging the front seal, use the front oil seal installer Tool

MB995022—

2.0L (VIN Y) engine

Y) engine

and

necessary.

Front Crankshaft Seal

REMOVAL & INSTALLATION 2.0L (VIN 1

.

Before servicing the vehicle, refer to the

precautions 2.

Engine

F)

the beginning of this section.

in

Remove

or disconnect the following:

•

Negative battery cable

Installing the front crankshaft sprocket

•

Timing

using the Crankshaft Sprocket Installer

belt.

Refer to the timing belt

unit repair section in this

3.

for

manual

timing belt removal and instal-

Using the special tool crankshaft

to

seal— 2.0L

remove

the front

(VIN Y) engine

Tools

MB995035 and MB995026— 2 OL

(VIN Y

|

engine

lation.

2.

•If reusing the timing belt, be sure mark the direction of rotation on the belt.

This will ensure the

same

Remove

direc-

•

Negative battery cable

•

Timing

belt.

Refer to the timing belt

unit repair section in this

life.

for timing belt •

Crankshaft pulley

•

Timing

•

sprocket

is difficult to

may

Crankshaft seal by prying

remove,

it

out

New

Crankshaft

oil

shaft oil seal

• Be

seal using Crank-

2

Removal Tool

oil

seal

bore or the crankshaft sealing surface.

tool

To

install:

Crankshaft sprocket

3.

Apply clean engine

•

Timing

4

Install or

unit repair section in this for timing belt

manual

removal and instal-

•

•

•

Accelerator cable Irom the throttle

•

oil to

the

MB995035 and MB995026 belt.

for

•

Refer to the timing belt

manual

3.

Rocker cover

•

Timing

for

•

in

Section

Dead

Refer to the timing bell

2 of this manual

manual

timing belt removal and instal-

Camshaft sprockets

tion.

covered

belt

lation.

Negative battery cable

the precautions in the beginning of this sec-

is

piston at Top

unit repair section in this

timing belt removal and instal-

Heater Core replacement

1

Center (TDC) on the compression stroke.

Before servicing the vehicle, refer to •

Valve (PCV) hose, from the

Position the No.

lation. 1

Breather hose and Pollution Con-

rocker cover

using a seal driver

unit repair section in this

2.0L (VINY) Engine

Spark plug cables

trol

Crankshaft sprocket using special

Timing

Engine center cover

• •

oil seal.

Cable bracket from intake plenum

•

connect the following:

Oil seal

Tools

lation.

Negative battery cable

or disconnect the following

Negative battery cable

•

crankshaft seal using a driver

Refer to the timing belt

Remove •

body careful not the scratch the

connect the following:

belt.

Before servicing the vehicle, reler to

tion.

•

•

1

MB995020

install:

•

2 OL (VIN F) Engine

the precautions in the beginning of this sec-

Removal Tool

MB995027

using a suitable prytool

Install or

instal-

be used. •

•

manual

removal and

Crankshaft sprocket using Crankshaft Sprocket

an appropriate puller

REMOVAL & INSTALLATION

lation.

belt crankshaft

•If the sprocket

Camshaft and Valve Liners

ing:

tion of rotation, thereby extending belt

To

or disconnect the follow-

to

CHRYSLER CORP.

7-10

TALON Remove

2.

Dowel pins

or disconnect the following:

•

Negative battery cable

•

Ignition coil

•

Pollution Control Valve (PCV) hose

pack

and breather hose from cylinder head cover Semi-circular packing from the rear

•

of the

Exhaust side

Intake side

head

•

Camshaft Position (CMP) sensor

•

Timing

Refer to the timing belt

belt.

unit repair section in this

manual

7922DG08

for

Tap the camshaft with a plastic loosen the bearing caps

hammer

—2.0L (VIN

For installation, position the camshafts

to

lation.

with the dowels facing up, as

F)

shown Camshaft sprockets

•

2.0L (VIN

engine

F)

engine

~Use 5.

Exhaust side

Intake side

bearing caps and torque

Install the

the bolts evenly,

in

2-3

steps to 14

ft.

lbs.

to

Lubricate the seal

7.

Install or

Front

lip

with engine

bracket

Outside camshaft bearing cap

•

seal using Seal Installer

Bearing caps. Gradually, loosen the

•

MB998713

camshaft bearing caps

•

Camshaft sprockets

•

Timing

unit repair section in this for timing belt

Identifying the rocker in

arm

shafts

— notice

•

8. 4. (Use

a

of the

camshaft

wrench on the hex shaped part to hold the

cam when

front

Cylinder head by applying sealant

in

2-3

steps.

^If the bearing caps are hard to remove, tap the rear of the camshaft

hammer.

with a plastic

Apply sealant

and

•

Bearing caps. Loosen the bearing

cap bolts

instal-

one camshaft

^Keep

the bearing caps in order. They must be installed in the location from which they were removed.

packing

•

Camshafts

rear bearing

caps where they meet

^The able.

Rocker cover using a new gasket

•

PCV hose and

•

Spark plug wires

•

Center cover

•

Accelerator cable and adjust

•

Negative battery cable

camshafts are not interchange-

Mark the camshafts

breather hose

To 3.

it

install: Install or

2.0L (VIN Y) Engine

Bearing caps and rocker arms must be installed

in

the

same

Camshafts, lubricate with engine

•

Bearing caps and torque the bolts

in

(28

sequence

them with oil

Loctite

seal

location

Camshaft(s) and seals

Install or

connect the following:

Camshafts, lubricate with engine

oil

and position with the dowels facing up :

If

WARNING

new camshaft(s) are being remove the rocker arms

installed,

and

camshaft(s) and bearBe sure the camshaft(s) can

install the

ing caps.

n

be turned by hand. After checking, remove the camshafts and install the rocker arms.

nij 7922DG03

Camshaft bearing cap

bolt tightening

sequence—2. OL

ft.

Camshaft

To install: •

21

•

from which they were removed. •

to

Outside camshaft bearing caps, lubricate

the beginning of this section.

in

Nm)

•

Before servicing the vehicle, refer to the

precautions

connect the following:

•

evenly and

WARNING 1

for later

identification.

lbs. '

at a time.

to the lower part of the

the cylinder head.

removing the sprockets. •

removal and

to the semi-circular

the

manual

lation.

the intake side

in

reverse of the tightening sequence,

Refer to the timing belt

belt.

bolt.

Rear timing belt cover and

oil.

connect the following:

oil

MB990767 and MB998719,

removing the sprocket mounting •

6.

•

tool

secure the camshaft sprockets when

(20 Nm).

the slits

timing belt removal and instal-

(VIN Y) engine

518®

oil

CHRYSLER CORP.

7-11

TALON •

Rear timing belt cover and bracket

•

Camshaft sprockets

•

Timing

belt.

54 40

Refer to the timing belt

unit repair section in this

manual

Nm ft. lbs.

for

timing belt removal and installation. •

Semi-circular packing, lubricate with

5699

Loctite •

CMP

Install the

4.

.

at rear of cylinder

head

sensor cylinder head cover. Torque

the bolts in the proper sequence, evenly as «

follows: a.

Step

1:

40 inch

lbs. (4.5

Nm).

b.

Step

2:

80 inch

lbs. (9.0

Nm).

c.

Step

3:

106 inch

connect the following:

Install or

5.

(12 Nm).

lbs.

breather and

PCV hoses

•

Air,

•

Coil pack

•

Negative battery cable

Valve Lash

ADJUSTMENT Valve clearance valve clearance

is

is

not adjustable. Proper

maintained by the

hydraulic lash adjusters.

Exploded view

Starter

of the starter

and related components— Non-turbo

REMOVAL & INSTALLATION

Nm ft.lbs.

Non-Turbo Before servicing the vehicle, refer to the

1.

precautions

in the

Remove

2.

beginning of this section

or disconnect the following

•

Negative battery cable

•

Starter electrical

•

Starter bolts

and

connectors starter

To install: connect the following:

Install or

3.

•

and torque the

Starter

transaxle bolts to

40

starter-tolbs.

ft.

(54

Nm)

Starter electrical

•

Negative battery cable

30 22

Turbo 1.

Nm ft.lbs.

2 A09X0122

Before servicing the vehicle, refer to the

precautions 2.

\ \

connectors

•

in

the beginning of this section

Remove

or disconnect the following:

•

Battery

•

Air

•

Starter electrical connectors

•

Starter bolts

hose "C"

Removal steps Air

1

and

starter

hose

C

2 Starter terminal and connector .

To install: 3.

Install or

•

Starter

3. Starter

motor

connect the following:

and torque the

transaxle bolts to

22

9M6DG01

starter-to-

ft.

lbs.

(30

Exploded view

of the starter

and related components— Turbo

Nm)

Brake service

is

covered

in Section

4 of this manual

CHRYSLER CORP.

7-12

TALON

•

Starter electrical

•

Air

•

Battery

•

connectors

hose “C" •

cylinder

shaft

compression

Exhaust pipe using a new gasket.

should be aligned

Torque the exhaust pipe-to-manifold 9.

Oil

flange nuts to

Pan

2.0L (VIN F) Engine

33

ft.

the precautions

the beginning of this sec-

in

at this point.

Using the proper equipment, support

Remove

or disconnect the following:

Front engine

mount bracket and

accessory drive belts

oil.

for leaks.

2.0L (VINY) Engine

•

Timing

belt

upper and lower covers

•

Timing

belt

and crankshaft sprocket

•

Oil

pressure sending unit electrical

connector

tion.

1

2.

Drain the crankcase.

3.

Remove

Before servicing the vehicle, refer to the

.

precautions

or disconnect the follow-

ing: •

Negative battery cable

•

Exhaust pipe, lower

it

Remove

on

Using the appropriate equipment,

Turbocharger return pipe from the

pan

Oil

cracks. Replace

Tap a thin prytool

faulty.

if

damage and

all

and

MD998162

pan and discard the gasket

all

oil

for

While the pan for

cracks. Replace

Install or

6.

pan so

that

Oil

Oil

80

tool,

ft.

(108

^lf necessary, the

•

Dipstick and tube assembly

come

•

Negative battery cable

Start the

Oil

oil.

engine and check

oil

pan

for leaks.

• 6.

clean

such a manner that

in

bolt holes are circled

and there

is

oil

cover

Oil

After all

pump

a con-

drive

7.

in.

•

(4mm)

•

connect the following:

48-72

inch lbs. (6-8 Nm).

Oil return pipe,

using a new gasket

and torque the retainers inchlbs. (7-10 •

•

to

72

Left

lbs.

ft.

62-88

Nm)

Crossmember and torque to

resid-

from the mating sur-

Assemble

the

oil

pump it

to

gears into

ensure smooth

movement and no looseness. Be sure

there

diameter.

in

applying sealant. Torque bolts

after

to

should

pan. Install within 15 minutes

Oil

pump, all

bead approximately

in a

Install or

8.

of sealer

oil

components and remove

the front case and rotate

be applied

and driven gears

faces.

pan.

"•The continuous bead

at the rear of the

disassembling the

ual gasket material

tinuous bead of sealer around the entire perimeter of the

pump

engine front cover.

oil.

faces of the

silent shaft can

out with the cover assembly. •

the engine with clean

8.

pump

Nm)

Front exhaust pipe

Fill

oil

assembly

•

7.

of

lbs.

proper

for

Front case cover and

•

Front plate and torque the bolts to

faulty.

removed

installation.

Nm)

(12 •

position.

lengths of the mounting

bolts as they are

lbs.

in

driven gear-to-silent shaft

Front cover mounting bolts

’•‘'Note the

connect the following:

pump

bolt

pump.

pan using a new gasket and

is

loose mate-

all

oil

torque the bolts to 107 inch

clogit

pan and engine

oil

the point where the

at

engine block meets the

damage and

screen

(8mm)

in.

traces of the old gasket or

Apply sealant around the gasket sur-

7.

Plug on the side of the engine block. Insert a suitable tool with a

•

gasket surfaces of the cylinder oil

Oil

the engine front cover,

pan bolts

Apply sealant

oil

removed. Clean sealing surfaces

rial is all dirt

Oil

•

Using a wire brush or other

block and the

Front plate

in

using special plug removal Tool

block mating surfaces.

install:

6.

Plug cap

•

pan

pan

oil

removed, inspect the

To

Dipstick and tube assembly

•

Clean

to break the seal.

Inspect the

5.

•

sealer material from the

between the engine block and pan

Front exhaust pipe

install:

5.

bolts.

screen and discard gas-

the silent shaft

•

oil

and bracket oil

shaft diameter of 0.32

To 4.

Crossmember side of the

pan,

into the plug hole. This will hold

engine.

of the

•

•

Negative battery cable

•

•

support the weight

Oil

or disconnect the following:

•

•

models 4.

•

oil.

•

Wheel Drive (AWD)

All

Oil filter

•

from the

Transfer assembly and right driveshaft,

Oil

•

ket

engine manifold •

pressure sensor

•

the beginning of this section.

in

Drain the engine

2. 3.

0.16

oil.

the weight of the engine.

Before servicing the vehicle, refer to

1.

its

4.

•

engine and check

Start the

all

to

of

The timing marks

stroke.

Drain the engine

5.

the engine with clean

Fill

clean

(60 Nm).

is at

3.

Negative battery cable

•

ging,

lbs.

ft.

Nm)

(42

lbs.

43

plug and torque

Oil drain

•

10.

REMOVAL & INSTALLATION

Top Dead Center (TDC)

Transfer assembly and right drive-

member and

the

oil

bled or the cover

pump is

gear cavity must be

leum

jelly.

is disassemremoved, the

filled

This seals the

acts like a primer so the

draws

oil

turns.

Do not use grease.

with petro-

pump and oil pump

as soon as the engine

the bolts 1

Nm)

(100

Whenever

torque the forward

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec7922DG21

retainer bolts to

Nm) and bolts to

72

ft.

the rearward

58

ft.

lbs.

(80

lbs.

(100

member Nm) left

tion. 2.

Using the special Tool

Disconnect the negative battery

cable. Rotate the engine so that the No.

1

tighten the plug

MD998162

cap— 2.0L

to

(VIN F) engine

CHRYSLER CORP.

7-13

TALON is

2.0L (VIN Y) Engine

no ridge wear on the contact surface

Rear Main Seal

between the front case and the gear surface of the oil

1

pump

the precautions

pump, by aligning

Oil

the

pump

oil

drive gear with the driven gear tim-

engine

Drain the engine

3.

Remove

New

oil.

1

or disconnect the following:

•

Negative battery cable

•

Rear plate

•

Oil filter

•

Oil

pan

•

Oil

pick-up tube

•

Timing

cover and torque the

bolts to 13 •

REMOVAL & INSTALLATION Before servicing the vehicle, refer to the

.

precautions

ft.

Nm)

(18

lbs.

crankshaft seal using an

New

and adapter

belt.

MD998285, on

seal guide Tool

end

for

the

•

Transaxle

•

Transfer case,

•

Drive plate,

from damage. Apply a

tect the seal

new •

new

a

25

•

Nm)

(34

lbs.

ft.

pump

drive gear onto

Secure the

oil

silent shaft

by installing and tighten-

ing the driven gear bolt to Install or

.

•

cap

lbs.

(40 Nm).

MD998162,

20

to

lbs.

ft.

oil

oil

•

Oil

•

Oil

in

the

4

5.

Install or

•

•

oil

•

pan

The width

the bolt holes.

applied

is

to

of the sealant

be about 0.16

in.

(4mm)

•

bead

wide.

•

inch lbs. (12

to

108

•

Electrical

•

Oil ft.

•

oil

•

14.

lbs.

fill

the crankcase

Negative battery cable Start the engine. Verify oil pressure

and inspect

for leaks.

Oil

belt.

If

removed, drive the

oil

case so the

separator

its oil

hole

is

6

Refer to the timing belt

manual

Install or

•

17

connect the following:

Seal case using a

new

gasket,

if

removed

7

•

Flywheel or drive plate

•

Transfer case,

•

Transaxle

•

Negative battery cable

Refill

and check

if

equipped

the crankcase Start the engine

lor leaks

Piston and Ring

pickup tube

pump meets

oil

Oil

at

the point

the engine block

pan using a new gasket and

Nm)

Oil filter adapter

lbs.

Nm)

and

pump

connect the following:

using a new 0-

and torque the assembly

harness

(45

without

in

ring. Align the roll pin with the hole

cooler and torque the bolt to 33

Oil filter

way

torque the bolts to 108 inch lbs

oil

pressure switch •

the

timing belt removal and instal-

(12

pressure gauge unit and

all

facing downward.

Apply Loctite' 18718,

pressure switch Oil

oil

5.

into the oil seal

Crankshaft sprocket using the

where the

Nm)

pressure gauge unit and

Oil

6.

connect the following

pan and torque the bolts

Oil

on the

new 0-

lation

sealant application. Install or

install a

pump and torque the bolts to ft. lbs. (23 Nm) New crankshaft oil seal in the oil pump

Timing

the seal

it.

of sealant to the sealing

pump and

unit repair section in this

pan within 15 minutes

oil

—Press

Oil

for

—Install the

MD998376

proper installation tools

flange groove, keeping towards the inside of

Oil seal in the crankshaft rear oil

seal case using Seal Installer Tool

tilting

oil

oil.

connect the following:

Install or

•

seal using crankshaft

MB995020 pump mounting bolts pump

Apply a bead

pan and cylinder block the

oil

discharge passage.

new gasket in

seal with clean engine

seal tool

surface of the

tighten the

mating surfaces. Apply sealant

•

engines have a separator that

Lubricate the inner diameter of the

3.

new

To install:

(27 Nm).

screen using a

Oil

Crankshaft

ring into the counterbore

case groove. Using the spe-

Clean the

12.

ft.

connect the following:

Tool

cial

•

29

Plug cap using a new O-ring front

•

if

oil seal.

should also be removed.

4

silent shaft in place.

•

—Some

surface or the seal bore.

side of the engine block to lock the

left

•

seal case,

oil

To install:

Insert a suitable tool into the hole in

9.

13.

Crankshaft rear

leaking: otherwise, the

bracket gasket and torque

the bolts to

ot

•

Do not nick the crankshaft sealing

Nm)

(24

lbs.

ft.

on the bracket using

Oil filter oil filter

1 1

if

equipped with a manual transaxle

Crankshaft sprocket using the

and torque

front case gasket

the bolts to 17

left

equipped

Front case assembly, through a

•

the

if

equipped with an

housing cover and flywheel,

Bell

timing belt removal and instal-

MB995027

ference of the seal pilot tool.

10.

•

crankshaft sprocket Removal tool

thin coat of oil to the outer circum-

if

automatic transaxle

manual

lation.

crankshaft to pro-

of the

•

the

or disconnect the following:

Negative battery cable

Refer to the timing belt

unit repair section in this

front case gasket. Position

front

the beginning of this section.

•

appropriate driver •

in

Remove

2.

oil.

pump

Oil

the beginning of this sec-

2.

ing marks. Lubricate the gears with

•

in

tion.

connect the following:

Install or

•

Before servicing the vehicle, refer to

front cover.

To install: 8.

.

to

40

ft.

(55 Nm).

•

New

•

Rear plate

•

Negative battery cable

oil filter

the engine with clean

7.

Fill

8.

Start the

Chrysler engine connecting rod and cap oil.

installation

engine and check

For complete Engine Mechanical specifications, see Section

1

—ensure

to

matchmark

for leaks

of this

and rod prior

manual

to

disassembly

the cap

CHRYSLER CORP.

7-14

TALON

R”

mark

identification

‘‘1

of rail

lower/^-

Gap side

.» Gap

No. 2 ring gap'

of

upper side rail

Piston ring end-gap

Piston ring orientation— 2. OL Engine

locations

gap

of engine F Front

and spacer expander gap

Chrysler piston ring identification mark

1

ring

\

(t m

No.

spacing— 2. OL

(VIN Y)

engine

NO. RING GAP

SIDE RAIL

1

UPPER

Timing

c=>

belt side

Piston positioning 7922AG06

Piston ring end-gap

spacing— 2. OL

—2.0L (VIN

Y) engine.

The small arrows on the crown

of the pis-

tons must point toward the front of the

(VIN F) Piston positioning

engine

—2.0L (VIN

F)

engine

engine

FUEL SYSTEM Fuel System Service Precautions Safety

is

an important factor when ser-

may

in

a safe

tenance and testing of the vehicle’s

Main-

fuel

effectively

by adhering to the

of fire

soaked cloths or towels

to fol-

Do

•

come

and per-

loosening and tightening

fuel line

stress

relieve the fuel

system pres-

and torsion

pipe

Do

connec-

(injector, fuel rail,

ulator, etc.), fitting or fuel line

pressure reg-

fuel

system pressure,

skin, face

and eyes

to avoid

to tuel spray.

any part

of the

Protector

•

Rear seat cushion

Fuel Filter

REMOVAL & INSTALLATION

not substitute fuel hose where fuel

On most in

vehicles, the fuel

Fuel System Pressure

On some non-turbo

fuel filter is

mounted under

filter is

located

mounted on

the engine compartment,

firewall.

the

engines, the

the vehicle near

the fuel tank.

RELIEVING

may pene-

body

that

1

Be sure

.

warnings

in

to

observe

all

cautions and

the beginning of the section

it

that

fitting

connector

•

!:

Always place a shop towel or cloth

around the

connect the following:

pump

Fuel

CAUTION

Please be

contacts. •

position.

is installed.

exposing

advised that fuel under pressure trate the skin or

Install or

•

connection.

Exercise extreme caution whenever relieving

OFF

Disconnect the negative battery cable.

fuel fitting Fi-

sure prior to disconnecting any fuel system

component

to run

unnecessary

to fuel line piping.

Always replace worn

•

rings.

Always

it

Always use a back-up wrench when

battery cable unless the repair or test proce-

•

5.

flame.

tion fittings. This will prevent

applied.

engine and allow

stops, due to lack of fuel. Turn the

After relieving fuel pressure:

spark or open

sonal injury, always disconnect the negative

dure requires that battery voltage be

4.

not allow fuel spray or fuel vapors into contact with a

Start the it

ignition switch to the

extinguisher near the work area.

•

To avoid the possibility

fuel

Always keep a dry chemical (Class B)

• fire

sys-

lowing rules and guidelines. •

all

all

are deposited into a suitable waste container.

tem components can be accomplished and

3.

until

manner

result in serious personal injury.

safely

fuel spillage is

Ensure that

vicing the fuel system. Failure to conduct

maintenance and repairs

Ensure that

quickly removed from engine surfaces.

spillage.

or connection prior to

loosening to absorb any excess fuel due to

may be related to this procedure. Remove or disconnect the following:

2.

•

Rear seat cushion

•

Protector

•

Fuel

pump

connector

Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only

CHRYSLER CORP.

7-15

TALON hoses and clamps specifically designed for fuel injection systems.

•

Main pipe

loosen

flare nut,

holding the fuel

filter

it

while

nut securely

with a back-up wrench 1

Properly relieve the fuel system pres-

.

•

sure. 2.

On non-turbo

engines, raise and

6.

safely support the vehicle to gain access to

the

filter,

filter.

3.

Flare nut connection from the

filter

and discard gaskets If

•

Before servicing the vehicle, refer to the

precautions

in

the beginning of this section.

equipped with a

fuel tank

mounted

remove or disconnect the following: Eyebolt, gasket and connector

•

Pressure regulator

•

Fuel

filter

bolts

•

Fuel

filter

bracket,

and

filter

To service the fuel

•Wrap that is

shop towels around the fitting being disconnected to absorb

residual

Pump Locking MB991480 is needed

To install: 7.

Install or •

4.

pump on AWD

Cover the hose connection with shop

Fuel

vehicles,

necessary Ring Removal tool

a Fuel

the lines.

fuel in

if

connect the following:

filter in its

bracket and finger-

Fuel

tighten at this time

Pump

towels to prevent any splash of fuel that

could be caused by residual pressure fuel

pipe

5.

•

the

or disconnect the following:

**

Negative battery cable

Eye

bolt,

by holding the

fuel filter

nut securely with a back-up wrench •

'•Movement attachment

line.

Remove •

in

High-pressure ter

fuel line

from the

of the filter will

ease

REMOVAL & INSTALLATION

of the fuel lines.

CAUTION

1

Be sure new O-rings are installed prior to assembly. •

•

Main pipe

•

Fuel

at the filter.

in the

main

filter nut.

Manually, •

pipe's flare nut.

ft.

lbs.

25 •

ft.

Fuel

Nm) and

(30

lbs.

•

filter

ft.

mount-

If

22

lbs.

(14

ON

to

for leaks

Fuel lines

•

Fuel

pump assembly from

MB991480. All

lift-

the tank

install:

5

Install or

release the fuel pres-

to

remove the locking

ring

Wheel Drive (AWD) model.

To

sure before opening the fuel system.

engine

Harness connector

•

on the

repairs of a leak are required,

remember

and

Use Fuel Pump Locking Ring Removal

Tool

position to pres-

and check

Rear seat cushion, by pulling the

•

4

Nm)

Negative battery cable

Turn the key to the

7W2DG10

to

the flare nut to

mounting bolts and

surize the fuel system

F)

or disconnect the following:

Negative battery cable

ing the cushion up

(35 Nm).

torque to 10

— 2.0L (VIN

beginning of this section.

seat stopper near the floor

Using a back-up

wrench, torque the eyebolts

ing

Remove

3.

screw

ol the fuel tilter

in the

Relieve the fuel system pressure.

2.

fil-

and discard gaskets

Exploded view

Before servicing the vehicle, refer to the

.

precautions

8.

connect the following

pump

•

Fuel

•

Fuel hoses

•

Harness connector

in the

tank

•

Rear seat cushion

•

Negative battery cable

Fuel Injector

REMOVAL & INSTALLATION 2 OL (VIN Y) Engine Before servicing the vehicle, refer to the

1

precautions in the beginning ol this section.

29 22

2

Relieve the fuel system pressure

3.

Remove

Nm ft. lbs.

or disconnect the following:

•

Battery

•

Air intake

•

High pressure fuel rail

Exploded view

of the fuel filter

mounting— 2. OL

(VIN Y) engine

For Accessory Drive Belt

illustrations,

see Section

1

of this

hose fuel

hose from the

and discard the O-ring

•

Fuel injector harness connector

•

Fuel

•

Fuel injector electrical connectors

•

Fuel injector-to-fuel

•

Fuel injectors

manual

rail

rail

relainer(s)

and discard the O-rings

CHRYSLER CORP.

7-16

TALON

To

install:

4.

Install or

connect the following:

•

New

«

Fuel injectors

fuel injector

O-rings

^Lubricate the O-rings with clean engine

oil;

then, install the injectors

by twisting them

into the fuel rail

(left

and right) to make sure that they turn smoothly in the seat.

WARNING

C

1.

High-pressure luel hose connection

2.

O-ring

3. Injector 4.

Do not allow engine the fuel

oil to

get into

6.

rail.

8. 9.

Fuel injector-to-fuel

•

Fuel injector electrical connectors Fuel ft.

harness connector

rail

connectors Retainers

7. Injectors

•

•

Fuel

5. Injector

rail

and torque the bolts

to

2

Nm)

lbs. (3

O-rings O-rings

refainer(s)

rail

Exploded view

•

Fuel injector harness connector

•

New

of the fuel injector, fuel

high-pressure fuel hose O-ring

12

Nm

8.7

ft.

lbs.

^Lubricate the O-ring with clean engine C

oil.

WARNING

Do not allow engine the fuei •

oil to

get into

rail.

hose connection

High pressure

fuel

and torque the

fuel hose-to-fuel rail

bolts to 1.8

lbs. (2.5

•

Air intake

•

Battery

ft.

Nm).

hose

2.0L (VIN F) Engine 1

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

3.

Relieve the fuel system pressure.

Remove

or disconnect the following:

•

Negative battery cable

•

Spark plug cables

3.

High-pressure fuel hose connection O-ring Fuel return hose connection

4.

Vacuum hose connection

5.

6.

Fuel pressure regulator O-ring

7.

PCV

1.

2.

•

High pressure from the

•

fuel line

connection

fuel rail

O-ring and discard

it

•

Fuel return line connection

•

Vacuum hose connection

•

Fuel pressure regulator

•

O-ring and discard

•

Positive Crankcase Ventilation

it

13. O-rings 14.

of the fuel injector, fuel rail

Fuel injector connectors

PCV hose New O-ring

WARNING

•

Insulators

•

Fuel injector(s)

fuel rail.

•

O-rings and discard them

turns smoothly.

•

Grommets and

Do not allow the

oil to

Make sure

get into the

•

Do not allow the

Fuel injector(s)

•

New

insulators

•

Fuel

rail

ft.

lbs. (3

and torque the bolts

Nm)

"Lubricate the O-ring with clean engine oil.

the fuel injector

discard them

connect the following:

engine

•

rail

New grommets New O-rings

F)

•

oil.

Fuel

•

and related components— 2. OL (VIN

engine

Fuel injector connectors

Install or

Grommets

'Lubricate the O-rings with clean

•

To install:

connectors

rail

10. Insulators 11. Insulators 12. Injectors

•

*

Fuel

93060G05

Exploded view

•

•

9.

hose

(PCV) hose

4.

8. Injector

fuel rail. to 2

oil to

Make sure

get into the

the fuel pressure

regulator turns smoothly.

CHRYSLER CORP.

7-17

TALON Fuel pressure regulator and torque

•

to

7

ft.

lbs. (9

'•Lubricate the O-ring with clean

engine

Nm)

•

Vacuum hose connection

•

High pressure

(2.5

•

Fuel return line connection

•

New

0-ring

Do not allow the

oil

bolt to 1.8

ft.

lbs.

Nm)

•

Spark plug cables

•

Negative battery cable

to get into the

connection

fuel line

and torque the

oil.

fuel rail.

DRIVE TRAIN •

Transaxle Assembly To 6.

REMOVAL & INSTALLATION

mount and

Transaxle

Install or •

connect the following:

Transaxle and

Manual

Nm) and bolts to

1

.

Before servicing the vehicle, refer to the •

2.

Center

equipped.

Remove

or disconnect the following

•

Battery

•

Air intake

lbs.

ft.

•

Negative battery cable

•

Battery

•

Control actuator and bracket,

(30-34 Nm)

58

ft.

lbs.

(78

•

battery tray if

Air cleaner assembly, intercooler

and

Nm)

4

ft.

and

equipped with auto-cruise

housing cover and slave cylin-

Bell

lbs

Nm)

(12

•

assembly

the transaxle

22-25

(69

lbs.

ft.

der and torque the bolts to 9

Mark

air

hose, as required

the shift cable’s location.

•

Adjusting nut and

•

Dipstick

•

Solenoid connector

shift

cable

and tube assembly

hoses •

•

50

fluid.

or disconnect the follow-

ing:

.

member assembly and

Drain the transaxle and transfer case if

Remove

right-hand stay and torque the

• 3.

Drain the transaxle

3.

the beginning of this section.

in

bolts to fluid,

2.

mount and torque

the through-bolt to

precautions

transaxle

install:

Halfshafts

•

Neutral safety switch (inhibitor

Battery tray and support

Auto-cruise actuator and bracket,

if

-Be

sure to install the washer

switch) connector

the

in

•

proper direction.

equipped with cruise control

Pulse generator kickdown servo switch connector

•

Charcoal canister and bracket

•

Shift

•

and select cables from the

transaxle •

Back-up

•

Vehicle Speed Sensor (VSS)

• 4.

• light switch

•

•

Starter •

stopper bracket mounting

roll

•

•

Transaxle mounting bracket nuts

•

Engine undercover Transfer case assembly,

with All

if

equipped

Wheel Drive (AWD)

Do not remove

or install the axle

when the damage to

shaft nut floor or

Transfer case assembly,

vehicle

is

Slave cylinder from the

and torque

to

54

lbs.

ft

ing.

Do

line

and position

•

Bell

housing cover

•

Right-hand center

hous-

not disconnect the fluid it

aside.

Center

Tie rod

• •

ft.

(48

lbs.

VSS and back-up

•

Cruise control actuator,

•

Battery tray support

•

Charcoal canister bracket and can-

light

ends and

from

Exhaust pipe and transfer case, on

Wheel Drive (AWD) vehicles

connectors

•

Lower

removed

•

Flexplate-to-torque converter spe-

and

il

tray

bell

housing cover

cial bolts

•To remove

the bolts, turn the engine

Air duct

and

air

cleaner assembly

Refill the transaxle. fill

with gear

crankshaft with a box wrench and bring the bolts into a position appropriate for

On turbocharged

removal, one

Refill

85W

or

the transfer case with gear

GL-4

at a time.

oil ol classification

or higher,

** WARNING After

removing the

bolts,

push the

torque converter toward the transaxle

oil of

SAE 75W-

so

75W-90.

it

doesn't stay on the engine,

allowing

oil to

pour out

verter hub or cause

member

ball joints

Halfshafts

All

(support) •

Sheet metal undercover

•

Nm)

35

or higher, SAE 75W-85W or 75W-90. On non-turbocharged models, fill with Mopar MS9417 MTX Fluid P/N 4773167 9.

stay

•

the engine support fixture.

•

classification

member

Transaxle mounting bracket sup-

steering knuckle

GL-4 bell

Upper transaxle-to-engine bolts

•

Transaxle assembly mounting bolts to

Starter

porting the transaxle

(74

Starter

models, •

roll

bolts

cooler

•

stopper bracket mounting

Rear

•

•

8 Halfshafts

•

lbs

ft

oil

ister

the bearings will

•

70

to

temperature sensor connector

lines

Nm)

Remove

on the

occur.

removed

if

Transaxle mounting bracket nuts

and torque 7.

•

Speedometer cable and

Nm)

bolts

5.

Oil

•

(95

Transaxle mounting bolts

Rear

•

and torque the bolts

Attach a support fixture to the engine •

Engine undercover and lower the vehicle

Automatic

of the

damage

con-

to the

converter.

Place a transmission jack under the transaxle and support •

1

Before servicing the vehicle, refer to the

•

it.

precautions

Transaxle mounting bolt

For

Tire,

in

Wheel and Ball Jo ini

the beginning of this section.

specifications,

see Section

Lower transaxle-to-engine bolts

and transaxle

1

of this

manual

-HI 7#”80

CHRYSLER CORP. TALON

To

install:

5.

Install

•

pedal lightly until resistance

measure 5.

or connect the following:

Transaxle and torque the transaxle-

vis pin play

to-engine bolts to 35

(1-3mm).

Nm) and

lbs.

ft.

(48

the torque converter-to-

driveplate bolts to

34-38

ft.

If

housing cover and torque the

Bell

•

Transfer case and exhaust pipe,

lbs. (5

new

using a els

ft.

Nm)

AWD mod-

gasket, for

to 51

•

Circlips

and halfshafts

•

Tie rods

and

the castle nut to

25

lbs.

ft.

(34

35

ft.

lbs.

Nm)

•

Speedometer cable and

•

Solenoid connector

•

Neutral safety switch (inhibitor

Clutch release fork

•

Return clip

for

Oil

temperature sensor connector

remaining components

AWD, check

equipped with

fluid level

engine and allow

N

in

(neutral).

and add,

’»lf the vehicle

if

it

to idle

Lubricate the clutch release bearing.

6.

Lightly apply multi-purpose grease to

push the pushrod

7.

Install or

•

connect the following:

Clutch disc using a suitable guide

that

when

all

the clutch pedal

is

the way, the interlock

ON

to OFF.

on the

fly-

wheel •

Pressure plate

•

Clutch release (slave) cylinder and torque the bolts to 13

ft.

lbs.

(18

2.01 (VIN F) Engine 1

Before servicing the vehicle, refer to the

.

• •

Recheck the

ADD mark on the Do not add fluid unless the or below the ADD mark.

above the

the beginning of this section.

or disconnect the following:

Transaxle

Clutch

oil

tubes by unscrewing the

fittings

necessary.

warm and should

in

Remove

2.

has run for less than 15

considered

5.

the clutch disc splines.

REMOVAL & INSTALLATION

be

dipstick.

chamber

•

Clutch

•

Clutch release (slave) cylinder

•

Valve plate and valve plate spring

union

minutes but more than one minute, the fluid is

Check

precautions

the selector through each gear posi-

ending

to the clutch release

Mopar ATF Plus ATF automatic

2 minutes. Apply the parking brake and

move

Apply grease

Nm)

the transfer case.

Start the

tion,

adjusting the clutch pedal

switch connector

If

4.

fork boot

fork contact areas.

height or the clutch pedal clevis pin

depressed

transaxle fluid.

7.

Turn the pushrod to adjust the

to position the disc

All

with

connect the following:

•

switch changes from

with Dexron®ll,

Install or

ening the locknut.

d.

•

it

Release fork boot and fulcrum

Fulcrum and release

toward the master cylinder.

•

to

install:

•

Pulse generator kickdown servo

Refill

•

3.

play, be careful not to

type 7176, Mitsubishi Plus

cause damage

clutch pedal height. Then, lock by tight-

c.

cooler

to

other direction or removing

turn the switch to obtain the standard

*»When oil

away from

force.

equipped with cruise control,

pushrod with the locknut.

Under-guard

fill

If

the standard value and secure the

Starter

it

the clip by pushing the fork in any

To

switch) connector

and

the standard value, then tighten

clutch pedal clevis pin play to agree with

lines

6.

is

Nm) •

•

bolt so the pedal

and adjust the stop

b.

(48

•

Release fork by sliding

Be careful not

not equipped with cruise control,

detach the clutch switch connector and

Transaxle mounting bracket and

torque the bolts to

•

ing the return clip

in.

the locknut.

ft.

and torque

ball joint

Clutch release bearing by unfasten-

the fulcrum

If

height

Nm)

(69

should be within 0.04-0.12

•

cle-

the clutch pedal height or clevis pin

a.

turn

and torque the bolts

lbs.

met, and

adjust as follows:

(46-53 Nm) bolt to 4

is

The clutch pedal

play are not within the standard values,

lbs.

•

•

this distance.

•

oil fluid

bolt,

gaskets and union

Clutch release (slave) cylinder, without disconnecting the fluid line

level is at •

Pressure plate

•

Clutch disc

Clutch

ADJUSTMENTS

Clutch Pedal Free-Play 1

.

Before servicing the vehicle, refer to the

precautions 2.

in

the beginning of this section.

Measure

the clutch pedal height from

the face of the pedal pad to the firewall. 3.

Compare

the

measured value with the

proper distance of 6.93-7.17

in.

(176-1 82mm). 4.

Measure the clutch pedal

7922DG15

Slide the release fork in the direction of

clevis pin

play at the face of the pedal pad. Press the

the arrow to disengage ball

it

from the pivot

Lubrication points for the clutch release lever and bearing

CHRYSLER CORP.

7-19

TALON Hydraulic Clutch System

2.

Drain the transfer

3.

Remove •

BLEEDING

•Do

Negative battery cable

•

Front exhaust pipe

•

Transfer case assembly and torque

not allow the reservoir to run out

44

the bolts to

during bleeding, otherwise the entire procedure must be repeated.

oil.

or disconnect the following:

ft.

lbs.

(59

Nm)

of fluid

•Be

damage

careful not to

case's output housing

oil

the transfer

seal.

Do

not

Before servicing the vehicle, refer to

1

the rear driveshaft hang; suspend

let

the precautions in the beginning of this sec-

from the body with a piece

it

of wire.

tion.

Cover the opening 2.

Cross-sectional view of proper clutch disc fluid

Fill

meeting

and pressure plate alignment, showing the 3.

transfer case to keep

DOT

Attach a hose to the bleeder valve on

the slave cylinder with the other

hose submerged Valve plate spring and valve plate

•

Gasket, union, gasket and union

•

Clutch

oil fluid

to 11 •

tubes, then

oil

them and tighten the

attach

ft.

lbs.

4

chamber. Uncap or

unplug the clutch

fresh

DOT

in a

container

end

and

of the

at least half

3 brake fluid from a sealed

fittings 5.

floor,

6.

install:

oil

•

then loosen the bleed

Before servicing the vehicle, refer to

Tighten the bleed screw and have

transfer extension

Repeat the procedure

oil.

connect the following:

Transfer case assembly and torque

to

40-43

ft.

lbs.

(55-60 Nm) on

manual transaxle or 43-58

transaxle.

Transfer Case Assembly

care

when

installing the rear

driveshaft to the transfer case output shaft.

Remove

•

or disconnect the follow-

Front exhaust pipe using a

new

gasket and torque the bolts to 33

ing: 1

•

Transaxle

•

Clutch

Before servicing the vehicle, refer to the

precautions oil

in

lbs (44

Nm)

the beginning of this section

tube by unscrewing the

fitting

'•Plug or cap the ends

to

prevent con-

tamination from entering the

line.

•

Release (slave) cylinder

•

Pressure plate and clutch disc

•

Clutch release bearing

•

Clutch release lever

•

Boot

To

install:

3.

Apply a suitable grease

to the clutch

release lever. Lightly apply multi-purpose grease to

the clutch disc splines. 5.

lbs.

REMOVAL & INSTALLATION

tion.

4.

ft.

(60-80 Nm) on automatic

until the fluid is

the precautions in the beginning of this sec-

2.

on the

the transfer case-to-transaxle bolts

•Use 1.

seal lip

Install or

5.

free of air bubbles.

2.0L (Vin Y) Engine

from dripping

Lubricate the driveshaft sleeve yoke

your helper release the clutch pedal

Transaxle

oil

dirt out.

4.

screw on the slave cylinder.

(15 Nm).

keep

To and

Have an assistant press the clutch

pedal to the

to

housing with clean engine

container.

on the release cylinder

bolt,

full of

the transaxle and

3 specifications.

alignment tool

•

in

the reservoir with clean brake

Install or

Boot assembly

•

Clutch release lever

•

Clutch release bearing

•

54-59 40-44

connect the following:

•

Nm ft. lbs.

^

Clutch disc and pressure plate

assembly •

Clutch release (slave) cylinder and torque the bolt to 14

ft.

lbs.

(19

Nm) •

Clutch lbs.

•

oil

(15

tube and torque to 11

ft.

Nm)

Transaxle

Exploded view

ol the transfer

case assembly mounting— Vehicles with manual transaxle

For Wheel Alignment specifications, see Section

1

of this

manual

ft.

CHRYSLER CORP.

7-20

TALON 4.

6.

Fill

the transfer case with gear

classification

85W

GL-4

SAE 75W-

or higher,

fluid level in the

75W-90. Check the

or

•

connect the following:

Install or

oil of

Toe control arm,

Circlips

•

Halfshaft into the transaxle

arm nut

(-Be sure

seated.

is fully

it

(1

Halfshaft into the

•

Center bearing bracket,

and torque the bolts

REMOVAL & INSTALLATION

(45

to

equipped

if

Before servicing the vehicle, refer to the

2.

h

33

Nm)

lbs. (71

Halfshaft nut, temporarily tighten

•

Tie rod end

to 21

is

going to be rolled

Also,

if

proper torque

to the front

Remove

•

lbs.

the

tie

lbs.

ft.

1

or disconnect the following:

New

Cotter pin, halfshaft nut and washer

•

Speedometer drive from the extension housing

.

2.

right

removing the

if

Tie rod from the steering knuckle

•

Stabilizer link

•

Damper

from the damper fork

Lateral lower

rod

in

connect the following:

The

Rearwheel(s)

•

Wheel speed sensor,

if

with Anti-Lock Brake

System (ABS)

equipped

•

Brake caliper and rotor or brake drum

•

Parking brake shoes (disc brakes) or

•

Parking brake cable from the back-

•

Wheel cylinder brake

WARNING

•

improper methods

of joint

damage

in

•

to •

removed

•

Remaining brake components

•

ABS

wheel speed sensor,

if

•

Rear wheel

•

Brake drums,

if

equipped

Shock absorber from

All

•

equipped with an inner shaft

if

Halfshaft by pressing

•

Halfshaft/inner shaft

tapping plastic

it

from the hub

it

line,

if

1

the steering

Halfshafts by prying

transaxle on

FWD

it

•

from the

3.

WARNING it

from the transaxle; doing so damages the inboard joint. Do not insert

ma y

oil

Before servicing the vehicle, refer to the

seal in

be damaged.

it

from the

splines for wear.

Check

damage

the ball joints

and

halfshaft

and place

it

in

a soft

vise.

Disassemble or remove the following: •

Tri-pot boot

•

Tri-pot case

bands

hub assembly

install: Install or

Tri-pot spider

assembly

WARNING

Do not disassemble the spider assembly.

connect the following:

hub assembly

•

Halfshaft in the

•

New

•

Halfshaft into the differential

•

Differential

mount support

•

Washer on

the halfshaft

•

Halfshaft nut

in

the cor-

ft.

h

If

and torque lbs.

it

to

WARNING

the boot

tic

is to

be reused, wrap plas-

tape around the shaft splines to

damage.

protect the boot from

(196-255 Nm)

’If the cotter pin hole does not align, tighten the nut to 188 ft. lbs. (255 Nm) and install the cotter pin in the first hole that aligns.

Tri-pot boot

on the inner shaft

circlip

rect direction

•

Halfshaft snapring

•

h

Halfshaft from the

the grease from the tri-pot case.

•

•

Inspect the halfshaft boot for

the beginning of this section.

dif-

housing

145-188

install:

or deterioration.

in

Remove

(Wipe

mount support.

Halfshaft by prying ferential

To

vehicles

the prybar too far or the

3. 4.

Cotter pin, nut and washer from the

•

vehicles

not pull on the shaft to dislodge

2.

Toe control arm from the steering

Differential

assembly by

AWD

.

precautions

jawed

•

from the transaxle with a

hammer on

Tri-Pot Joint

halfshaft

Wheel Drive (AWD) vehicles

•

assembly, located

halfshaft.

arm and lower arm from

Trailing

Birfield joint

knuckle

Center support bearing bracket bolts,

To

if

on the wheel side of the halfshaft, is not to be disassembled; repair of this joint is only by replacement of the

the steering knuckle

the joint, leading to possible failure.

the case

line,

FRONT WHEEL DRIVE— (FWD)

ing plate

arm from the steering

3. separation can result

Do

Parking brake cable

the beginning of this section.

knuckle

[:*

Wheel cylinder brake

•

(200-260 Nm)

equipped with drum brakes

•

•

Bleed the brake system.

to

shoe/lever assembly (drum brakes)

knuckle

on

ft.

removed

(24-33 Nm)

•

fork from the lateral lower

arm

•

52

cotter pin

Install or

right halfshaft •

of

to

Nm)

Before servicing the vehicle, refer to the

precautions

•

!'

to the steering

Rear

Negative battery cable.

•

ft.

Nm)

(98

lbs.

wheel bearings, the bear-

ings will no longer be usable.

•

trail-

with the brakes applied

not applied

is

Nm) and

(28

17-25

145-188

the hubs.

in

ball joint to the

Wheel and torque the axle nut

•

with the halfshafts removed, install 2 outer CV-joints tools

and

lbs.

ft.

nut to

Use

4.

steering knuckle and torque the nut

WARNING

ft.

knuckle and torque the bolt

lbs.

ft.

•

the beginning of this section.

the vehicle

(28 Nm),

lbs.

ft.

Lower shock mount

•

outward

in

20

to

arm nut to 85-99 ft. lbs. 1 8-1 37 Nm) and lower arm nut

to 71

Washer, face the chamfered edge

•

Front

If

hub

•

Halfshaft

precautions

arm and

ing

transaxle and add, as required.

1

trailing

lower arm. Torque the toe control

on the halfshaft ends

•

Dynamic damper bands from halfshaft,

if

the

necessary

To install: If

removed,

install

the

dynamic damper

by performing the following procedure:

CHRYSLER CORP.

7-21

TALON

Lubricating the tri-pot case assembly installed

1 T.J. boot band 2 T.J boot band 3. T.J case

4

Circlip

5

Snap

10 B J

(large)

(small)

B B B

11

12 13

(105 g)

assembly

Do not disassemble the BJ assembly e*cepi replacement of the B J boot.

Dynamic damper

9

of the front halfshaft

assemblies

(120 g)

for

tri-

9

— Front wheel

Install the tri-pot

boot by performing

the following procedure:

9306GG

Exploded view

oz.

grease into the

add the remaining grease.

Caution

6 Damper band

kit

pot case, insert the spider assembly and

ring

bool

T.J

non-turbo or 4 23

turbo specified repair

J boot band (large) J boot

6 Spider assembly 7.

for

J bool band (small)

Position the boots large end on the

a.

drive

tri-pot case.

Wrap

Position the large and small boot

b

** WARNING

A

clamps onto the boot Adjust the boot so that the bands

c.

around the shaft protect the bool Irom dam-

plastic tape

splines lo

are spaced at

3.03—3 27

in.

age.

ALL WHEEL DRIVE (AWD) 5.

Install a

Apply the specified repair

between the spider axle and the 7.

Install the tri-pot

kit

front halfshaft

damper on

the

assemblies— Front wheel

tion direction

grease

tion.

roller

Remove

2.

spider assembly soft

and place

it

in

drive

bands

•

Tri-pot boot

•

Tn-pot case (right halfshaft) or

Distribute a portion ol the 3.7 oz

pot case/inner shaft assembly Slide the

a.

damper onto

halfshaft)

the halfshaft

new bands.

with b.

••Wipe

Position the

damper so

the dis-

the grease from the tri-pot

case.

tance from the front of the Birfield joint to the front

bly

edge

of the

14.60-14.84

is

in.

damper assem-

(371-377mm)

for the right halfshaft (non-turbo)/left

halfshaft (turbo) or

(191-197mm)

7.52-7.76

c.

•

Halfshaft snapring

•

Tri-pot spider

assembly

** WARNING

in.

for the left halfshaft

Do not disassemble the spider assembly.

(non-turbo, M/T). Tighten and secure the damper

bands.

•

For Maintenance Interval recommendations, see Section

1

a

Disassemble or remove the following:

3

and secure with the

halfshaft

jawed vise

snapring. 8.

Before servicing the vehicle, refer to

1

the precautions in the beginning of this sec-

onto the shaft from the spline beveled sec Positioning the dynamic

— FRONT

new small boot clamp onto

the halfshaft followed by the tri-pot boot 6.

(77-83mm).

Tighten the band securely.

d

of this

Tri-pot boot

manual

tri-

(left

CHRYSLER CORP.

7-22

TALON Install a

6.

new small boot clamp onto

the halfshaft followed by the tri-pot boot.

Apply the specified repair

7.

between the spider axle and the

grease

spider assembly

Install the tri-pot

8.

kit

roller.

onto the shaft from the spline beveled section direction

and secure with the snapring.

Distribute a portion of the 3.70 oz.

9. 10.

(105 g) specified repair

kit

grease into the

tri-pot case, insert the spider

assembly and

add the remaining grease. Install

the tri-pot boot by performing

the following procedure:

Position the boots large end on the

a.

tri-pot case.

Position the large and small boot

b.

clamps onto the boot. Adjust the boot so that the bands

c.

are spaced at 3.03-3.27

in.

(77-83mm).

Tighten the band securely.

d.

ALL WHEEL DRIVE

(AWD)—REAR

Before servicing the vehicle, refer to

1.

the precautions

in

the beginning of this sec-

tion.

Remove

2. 8 Dust seal (outer) 9. Dust seal inner) 10 Center bearing 11 Center bearing bracket 12 Circlip

Caution

Do nof disassemble the men °' lhe B J b °°''

B.J.

soft

assembly except replace-

’

If

the boot

of the front halfshaft

is to

it

—AWD

•

Tri-pot boot

bands

be reused, wrap plas-

tape around the shaft splines to

tic

damage.

protect the boot from 4. is

and place

If

working with the

left

necessary to replace the

halfshaft

tri-pot case,

and

it

press

the case from the inner shaft assembly.

To the

install: installing a

5.

If

left

halfshaft,

new

tri-pot

case onto

perform the following pro-

cedure: Lubricate the inner shaft splines

a.

with Multi-Mileage Grease No. 2525035.

Press the inner shaft assembly into

b.

tri-pot case.

Secure the

c.

tri-pot

MB991248 on

tool

case with special

the case facing upward. d.

Position a

new

e.

Place a 1.18

boot band (targe) boot band (small)

3. T.J.

case

A

in.

(30mm)

and press the

T.J.

Snap

ring

Spider assembly 6 T.J boot 7 B.J boot band (large) 8. B.J. boot band (small) 9. B.J. boot 5.

seal plate in the

center of the tri-pot case.

the seal plate

2. T.J.

1.

a hydraulic press with

pipe on

10. B.J. assembly 11. Circlip

seal into the

tri-pot case. Caution

h

Do

WARNING

not disassemble the B.J. assembly.

Wrap

plastic tape around the shaft splines to protect the boot from dam-

age.

9306DG10

Exploded view

of the rear halfshaft

assemblies

— AWD

in

a

Disassemble or remove the follow-

3.

assemblies

halfshaft

vise.

ing:

9306DG07

Exploded view

jawed

CHRYSLER CORP. TALON c.

Adjust the boot so that the bands

are spaced

MB990938

at:

Conventional: 2.99—3.23

•

7I 09 tw

in.

(76-82mm) Limited

•

(81 d.

slip:

3.19—3.43

in.

-87mm)

Tighten the band securely.

Center Bearing Positioning the tri-pot boot bands halfshaft

assemblies with t

Tri-pot case

•

— Rear

AWO

ALL WHEEL DRIVE (AWD) 1

and clean the case

Before servicing the vehicle, refer to the

.

precautions

thoroughly •

Halfshaft snapring

•

Tri-pot spider

in

the

left

halfshaft

and place

Remove

from the

left front

halfshaft

AWD

assembly

MB990938

tri-pot case.

Remove

4.

—

it

with

the tri-pot spider

the center bearing from the

center bearing bracket

a soft-jawed vise. 3.

assembly

Removing

the beginning of this section.

in

Remove

2.

the tri-pot case by perform-

ing the following procedure:

Do not disassemble the spider

a.

assembly.

Position the inner shaft/tri-pot case

assembly on a hydraulic press supported •

by Tool

Tri-pot boot

MB991248

with the tri-pot case

facing upward. i'

WARNING

b.

Position a bar inside the tri-pot case

on the end If

the boot

is to

be reused, wrap plas-

tape around the shaft splines to

tic

damage.

protect the boot from

of the inner shaft

and press the

case from the inner shaft assembly

Remove and disconnect

5.

•

Bearing

the following

Inner shaft assembly, place

it

in a

Installing the center bearing to the center

soft-jawed vise

To

bearing bracket— left front haltshatt with

install: •

:*

Wrap

WARNING

plastic tape

Center bearing bracket, press

it

from

AWO

the inner shaft with a wheel puller

around the shaft

splines to protect the boot from

MB990938

Inner dust seal

dam-

age. Install a

4.

new small boot clamp onto

the halfshaft followed by the tri-pot boot.

Apply the specified repair

5.

between the spider axle and the Install the tri-pot

6.

kit

grease

roller.

spider assembly

onto the shaft from the spline beveled section direction

Distribute a portion of the specified

7.

repair

kit

grease into the tri-pot case, insert

the spider

Installing the inner dust seal to the center

bearing bracket— left tront haltshatt with

and secure with the snapring.

assembly and add the remaining

Removing shaft

the tri-pot case from the inner

assembly— left

AWD

tront haltshatt with

AWO

grease.

Conventional type

8.

(95

of grease:

3.35 oz

g).

Limited slip type of grease: 3.70 oz.

9.

(105

g).

Install the tri-pot

10.

boot by performing

the following procedure: a.

Position the boots large end on the

tri-pot case. b.

Position the large and small boot

clamps onto the boot. Be sure the boot • •

band

identification

to

check

numbers:

Large band: 20-98 No. BJ 82

Small band: 20-83 No. BJ 82

Removing

the center bearing bracket trom

the inner shaft assembly shaft with

—

Installing the outer dust seal to the center

bearing bracket

left tront hall-

AWD

For Tune-up, Capacities and Firing orders, see Section

AWD

1

of this

manual

—

left front

haltshatt with

CHRYSLER CORP.

7-24

TALON Inner shaft into the center bearing

•

bracket using a hydraulic press and

MB991172

Adapter Tool 7.

Install

the tri-pot case onto the

half-

left

shaft by performing the following procedure:

Lubricate the inner shaft splines

a.

with Multi-Mileage Grease No. 2525035.

Press the inner shaft assembly into

b.

tri-pot case.

Secure the

c.

case with special

tri-pot

MB991248 on

Tool

a hydraulic press

with the case facing upward. Installing the inner shaft into the center d.

new

Position a

9306CG13

seal plate in the

Positioning the Birfield joint boot's small

bearing bracket— left front halfshaft with

center of the tri-pot case.

AWD

diameter Place a 1.18

e.

(30mm)

in.

pipe on

the seal plate and press the seal into the tri-pot case. 8.

MB991561 connect the following:

Install or

assembly

•

Tri-pot joint

•

Left halfshaft

Boot

Birfield Joint

FRONT Before servicing the vehicle, refer to

1.

Installing the inner shaft tri-pot

case

—

left front

assembly

9306CG14

the precautions in the beginning of this secinto the

halfshaft with

AWD

View

of the

band crimper

tool

tion.

Remove

2.

the halfshaft

and place

in

it

a soft jawed vise.

Disassemble or remove the following:

3.

6.

•

Tri-pot joint

•

Dynamic damper,

for Front

Wheel

(FWD)

Drive •

Birfield joint

boot bands

•

Birfield joint

boot

To install:

Assemble

4.

Installing the seal plate into the tri-pot

case— left

front halfshaft with

AWD

5.

or install the following:

•

Birfield joint

boot

•

Birfield joint

boot small band

Place the halfshaft

in

a soft jawed

band vise so that the Birfield joint

is

standing

vertically. •

6.

Center bearing and inner dust seal

from the center bearing bracket

7.

using a hydraulic press, Installer

MB990932 and SnapMB990938

Adapter Tool in

Bar Tool

in.

•

shaft.

that the

jaw opening

is

0.114

Position the small band so there

mating edge. 9. Using a Band Crimper Tool MB991561, crimp the small band until internal measurement of the crimp is

Adapter Tool

MB990932 MB990938

Inner duct seal into the center bear-

0.094-0.110

ing bracket using a hydraulic press, Installer

Adapter Tool

and Snap-in Bar Tool

MB990933 MB990938

Outer duct seal into the center

is

clearance between the boot and the bands

ing bracket using a hydraulic press,

and Snap-in Bar Tool

•

exposed on the

is

Center bearing into the center bear-

Installer

•

groove

(2.9mm). 8.

connect the following:

1

Adjust the Band Crimper Tool

MB991561 so

To install: Install or

Position the boots small diameter so

that only 10.

h

in.

the

(2.4-2.8mm).

Measuring the small band’s crimp

WARNING of

If

the crimp dimension

remove the band

is

install a

not correct,

new

one.

bearing bracket using a hydraulic press, Installer Adapter Tool

MB990931 and Snap-in MB990938

Bar Tool

grease

11.

(0.1-1

Using 3.88

(FWD), 4.59

oz.

3.35 oz. (95 g)

oz.

(130 for

(110 g)

for

g) for turbo

AWD,

in

the repair

kit,

pack the

Birfield

boot.

Position the boot so 0.004-0.061

,55mm)

of clearance exists

in.

between

non-turbo

the boots large diameter end and the Birfield

(FWD)

joint

specified

or

amount

housing shoulder.

12.

Adjust the Band Crimper Tool

CHRYSLER CORP.

7-25

TALON b.

damper so

Position the

the front edge of the

14.60-14 84

in.

damper assembly

(371-377mm)

1

from the drive pinion. •

is

Pinion

seal

oil

To install:

for the

right halfshaft (non-turbo)/left halfshaft

connect the following:

Install or

3.

(turbo) or 7.52-7.76 in. (191-197mm) 16. for the left halfshaft (non-turbo. M/T).

•

New

pinion

oil

drive the

new

Use an

sea

Oil

MB995020

Seal Installer tool

Tighten and secure the damper

c.

companion flange

puller to pull the

the dis-

tance from the front of the Birfield joint to

to

seal into the axle

housing

bands. Install

•

the tri-pot joint.

Grease

oil

and companion

seal lip

flange. Lubricate with Multi9306CG1

REAR

Mileage grease No. 2525035. •

Before servicing the vehicle, refer to the

1

Align the

companion

Positioning the Birfield joint boot's large

precautions

diameter 2.

soft

3.

B.J. boot

band

drive pinion

the beginning of this section.

Remove

jawed

Projection

in

the halfshaft and place

it

in

•

a

Disassemble or remove the following:

flange-to-drive

tool

MB990850

Tri-pot joint

•

Birfield joint

boot bands

•

Birfield joint

boot

lbs.

•

(186

secure the

137

ft.

Nm)

Driveshaft and torque the bolts to

22-25

Assemble

to

flange and torque the nut to

•

To install: 4

New companion

pinion nut. Use an End Yoke Holder

vise.

(large)

D

flange-to-

matchmarks

ft.

lbs.

(29-34 Nm)

or install the following:

•

Birfield joint

boot

•

Birfield joint

boot small band

Differential Carrier

9306CG18

Positioning the Birfield joint boot's large

band

5.

Position the large and small boot

clamps onto the boot. Be sure

to

REMOVAL & INSTALLATION

check the

boot band identification numbers:

MB991561 so

that the

jaw opening

is

0.126

•

(3.2mm).

in.

13.

Install

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

Small band: 20-83 No. BJ 82

tion. 6.

Install the tri-pot joint.

Remove

2.

band so 15. jection

•

and position the large boot

1

Large band: 20-110 No. BJ 87

that

and

a

it

rests against the boot(s) pro-

gap exists between the clamp

Pinion Seal

Halfshafts

•

Driveshaft

and the boot. Using a Band Crimper Tool

14.

MB991 561, crimp

the small

measurement

internal

0.094-0.110

in.

of the

band

•Support

REMOVAL & INSTALLATION until the

crimp

is 1

(2.4-2.8mm).

•

Before servicing the vehicle, refer to in the

2.

•

the crimp dimension is not correct, remove the band install a new one.

If

Remove

or disconnect the follow-ing

•

Driveshaft

•

Companion

flange nut.

Yoke Holder Tool MB990850, install

the

3

Raise the carrier into position. Install or

•

to

a.

with

Slide the damper onto new bands.

the halfshaft

the

companion flange

connect the following:

and torque the

Differential carrier

mount-to-rear crossmember bolt to

secure the companion flange.

~Matchmark

Differential carrier

install:

dynamic damper by performing the following procedure:

bolt

To 4

Use End

mount-to-rear

Differential carrier

crossmember

beginning of this sec-

tion.

equipped with FWD,

the differential carrier with a

jack.

the precautions

If

or disconnect the following

•

72

ft.

lbs (98

Nm)

to •

Driveshaft

•

Halfshafts

the drive pinion. •

Companion

flange

Use a bearing

STEERING AND SUSPENSION Air

** Some

abled before performing service on or

Bag

CAUTION vehicles are equipped with an

bag system, also known as the Supplemental Inflatable Restraint (SIR) or Supplemental Restraint System (SRS). The system must be disair

PRECAUTIONS

around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system

accidental deployment and possible per-

repairs.

module.

Several precautions must be observed

when handling

the inflator

module

to avoid

sonal injury. •

Never carry the

inflator

module by

the

wires or connector on the underside of the

For complete service labor times, order the Chilton Labor Guide

CHRYSLER CORP.

7-26 When

•

TALON

carrying a live inflator module,

hold securely with both hands, and ensure that the

bag and trim cover are pointed away

Place the inflator module on a bench

or other surface with the

bag and trim cover

With the

module on

inflator

the bench,

that

at least

to retain

one minute before workair

bag system

enough voltage

to

is

deploy

may be thrown

in

the event of

.

in

the

Reconnect the negative battery cable,

turn the ignition switch to the

bag warning

air

ON

position

LOCK

position.

Remove

and insulate the cable end with high-quality non-conductive

proper operation.

aside;

DO NOT

Stabilizer bar

Joint assembly and gear

Power steering pipe connection

•

Tie rod

end from the steering

knuckle

4.

and

•

Left

•

Center

•

Center

right side stays

member assembly member

Power steering gear

1

.

Before servicing the vehicle, refer to the

precautions 2.

in

•

the beginning of this section.

To

Drain the power steering fluid into a

Install or

suitable container.

Remove

Power steering gear assembly

or disconnect the following:

connect the following:

•

Power steering gear assembly

•

Power steering gear

.

5 Cotter pin 6 Tie-rod end and knuckle connection 7 Stay (L.H.) .

.

Stay (R H.)

9 Centermember assembly 10 Clamp 11 Gear box assembly 12 Return tube

28

Nm

21

ft. lbs.

.

.

.

69

Nm

51 ft lbs.

NOTE The fasteners marked

5

* should be temporarily tightened before tightened once the total weight of the engine has been placed on the vehicle body.

are

finally

7922DG14

Exploded view

o.

retaining

install:

.

tfrey

retainers

clamp

1. Brake fluid reservoir assembly 2 A/C compressor 3 Joint assembly and gear box connecting bolt 4. Power steering pipe connection

.

body con-

•

18 Nm 13 (Llbe.

8.

disconnect

•

•

3.

wrapping.

it

•

the

Disconnect the negative battery cable

electrical tape or similar

Air conditioning compressor. Posi-

fluid reservoir

fluid reservoir

necting bolt

REMOVAL & INSTALLATION

key from the ignition lock cylinder. 2.

•

light for

straight-ahead position and place the ignition key in the

Brake

the refrigerant lines

Gear

Position the front wheels

•

tion

Power Rack and Pinion Steering

1

Negative battery cable

Windshield washer

To arm:

an accidental deployment.

DISARMING

• •

the battery has been disconnected.

and check the

never place anything on or close to the

module

designed

4.

facing up. •

Wait

on the vehicle. The

the air bag for a short period of time after

from you. •

3.

ing

power steering gear assembly and related components

retaining

CHRYSLER CORP. TALON clamp and torque the bolts

Nm) member member assembly

ft.

(69

lbs.

•

Center

•

Center

and torque the bolts

•

to 51

7-27

lbs.

(78-88 Nm)

Left

and

to

51-58

lbs.

ft.

ft.

and torque

right side stays

the bolts to

retainers

58-65

(69-78

Nm) •

end

Tie rod

to the steering

and torque’the nut

to

21

knuckle lbs.

ft.

(28

Nm) Power steering pipe connection and

•

torque the nuts to 13

ft.

lbs.

(18

Nm) •

assembly and gear body con-

Joint

necting bolt and torque the bolt to 11

5.

lbs.

ft.

(15

Nm)

•

Stabilizer bar

•

Air conditioning

•

Brake fluid reservoir

•

Windshield washer

•

Negative battery cable

Fill

compressor

the reservoir with

fluid reservoir

power steering 1.

and bleed the system.

fluid

2.

6.

Check

adjust,

if

end alignment and

the front

mounting nut

Stabilizer link

Shock absorber upper mounting

5.

Damper

6.

Shock absorber assembly

lork

nuts 3.

necessary.

Shock absorber lower mounting bolt

4.

Damper

fork

mounting

bolt

Strut Exploded view

of the front strut

mounting

REMOVAL & INSTALLATION •

Upper

strut

.

compartment 1

and torque 1

assembly-to-chassis

nuts, in the engine

Front 4

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

if

to

32

Check and adjust

lbs.

ft.

(44

Nm)

the front alignment

2

necessary.

tion. 2.

Remove •

or disconnect the following

Upper

strut

Rear

assembly-to-chassis 1

nuts, from the engine •

Front wheel

•

Stabilizer link nut

•

Strut

compartment

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

assembly lower mounting

Remove •

bolts

To 3.

Damper

•

Strut

fork •

Install or

Damper (88

and torque the damper

fork

arm

nut/bolt to

64

ft

Nm)

assembly lower mounting

bolts

and torque the fork bolt to

3.

strut-to-

65-87

ft.

lbs.

ft.

Strut

lbs.

and torque the

(39

Install or

Nm)

Strut

connect the following:

and torque the upper

chassis nuts to 32 4.

Stabilizer link nut

nut to 28

Strut-to-steering knuckle bolt

•

•

(88-118 Nm)

•

•

To install:

Strut

damper •

large nut in the

center of the strut assembly.

fork-to-lower

•

Upper mounting bracket-to-body

• Do not remove the

connect the following:

Strut

lbs.

the luggage compart-

cap and flange nuts

install:

•

lid in

ment

•

•

or disconnect the following

Service

ft.

lbs.

strut-to-

(44

5.

Please

7S22QCi?6

adjustable stand to align the strut lower

mounting holes.

Front wheel

Nm)

Raise the suspension with a jack or

visit

Install or

our web

Exploded view

connect the following:

site at

www.chiltonsonline.com

ot the rear strut

mounting

CHRYSLER CORP.

7-28

TALON Lower

•

strut

mounting

torque to 71

lbs.

ft.

Cap and service

•

bolt

(97

and

Nm)

lid

Coil Spring

REMOVAL & INSTALLATION

Front 1

Before servicing the vehicle, refer to the

.

precautions

Disassembly steps

-

1.

Self-locking nut

7.

2.

Washer

8.

Upper bushing B Cup assembly

3.

Upper bushing A Upper bracket assembly Upper spring pad

9.

Bump

4. 5.

10.

of the front strut

the strut assembly.

CAUTION

Do not use air tools to tighten the compressor tool bolt.

rubber Dust cover

Shock absorber assembly

Compress

3. 7922DG28

Exploded view

the beginning of this section.

11. Coil spring

12.

6. Collar

in

Remove

2.

the coil spring, using

Spring Compressing tools

MB991237 and

MB991239.

assembly

:

WARNING

Be sure

to install the tools

maximum

the

evenly so

length will be attained

within the installation range. 4.

Remove

or disconnect the following:

•

Self-locking nut, by holding the

•

Washer

•

Upper bushing

•

Upper bracket assembly

•

Upper spring pad

•

Collar

•

Upper bushing B

•

Cup assembly Rubber bumper

piston rod

• •

Dust cover

•

Coil spring

A

To assemble: 5.

Use the compressor tools

press the coil spring, then strut.

install

to it

comto the

Align the edge of the coil spring to the

stepped portion of the strut spring seat. 6.

Disassembly steps 1.

Self-locking nut

7.

Collar

2.

Washer

8

Cup assembly

Upper 4. Upper 5. Upper 6 Upper 3.

bushing A bracket assembly spring

pad

bushing B

.

Dust cover 10. Bump rubber 9.

assembly

•

Rubber bumper

•

Cup

•

Upper bushing B

•

Collar

•

Upper spring pad

•

Upper bracket assembly

*»lnstall the

assembly so the position

of the 3 bolts are in the

tion with the

damper

proper orienta-

fork.

•

Upper bushing A

•

Washer and

.

7922DG27

strut

assemble the following:

Dust cover

11. Coil spring

12 Shock absorber

assembly Exploded view of the rear

Install or

•

self-locking nut.

Tem-

porarily, tighten the self-locking nut, then

remove

the spring

com-

CHRYSLER CORP.

7-29

TALON pressor tools and tighten the nut to

14-18

ft.

Lower

torque wrench.

Front wheel(s)

•

Ball Joint

(20-25 Nm) using a

lbs.

Upper

•

REMOVAL & INSTALLATION

Do not use

air tools to tighten the

ball joint is

the lower control

self-locking nut!

Upper

Strut

control

Check and adjust the

7. if

an integral part of

arm assembly, and cannot replacement of the lower

arm assembly. 3.

front alignment,

at the

Upper Control Arm

bolts

Rear .

Upper arm-to-shafts through-bolts

Assemble the upper arm

Before servicing the vehicle, refer to

and nuts

precautions 2.

• •

the beginning of this section.

in

or disassemble the following

Remove

ft.

lbs.

(57 Nm). The

84-86 degrees.

After the

measure dimensions A and B

to

insure correct assembly.

Before servicing the vehicle, refer to the

tion.

Remove

to 41

is

the shafts are connected at the cor-

rect angle, 1

to the shafts

proper angle. Tighten the through-

arm and

the precautions in the beginning of this sec-

2.

Upper arm

•

proper angle

REMOVAL & INSTALLATION 1

•

To install:

«

necessary.

mounting nuts from the

shaft

body

be serviced separately. A worn or damaged ball joint, requires

•

from the steering

MB991113 •

The lower

ball joint

knuckle using special tool

or disconnect the following:

•

A

•

B

— —

11.8 9.2

in.

in.

(299.9mm)

(234.0mm)

Strut

Compress

the spring using a coil

spring compressor •

86

Self-locking nut by holding the pis-

Nm

ton rod •

Upper bracket assembly and spring pad

•

Collar

•

Upper bushing

•

Cup assembly

•

Bump

•

Dust cover

•

Coil spring

rubber

To assemble: 3.

Align the end of the coil spring with

the stepped part of the spring seat the

compressed 4.

coil

spring on the

and

install

strut.

assemble the following:

Install or

•

Dust cover

•

Bump

•

Cup assembly

•

Upper bushing

rubber

Removal steps 1.

Upper arm

Pall joint

and knuckle

Collar

•

Upper spring pad

•

Bracket assembly

•

Upper bushing and washer

•

New

2.

Upper arm

Exploded view

4

of the

upper control arm and related components

self-locking nut on the piston

Carefully,

A B

remove the spring com-

:

299 9 234 0

mm mm

(11 .8 in.)

(9.2 m.)

pressor from the spring. Tighten the selflocking nut to 16 6.

ft.

lbs.

(25 Nm).

Install the strut.

Upper

Ball Joint

REMOVAL & INSTALLATION The upper

Upper arm assembly upper arm shaft assembly

self-locking nut

rod and temporarily tighten the nut 5.

3.

connection

•

ball joint is

the upper control arm.

If

an integral part

of

the upper ball joint

is to

be serviced, the upper control arm

have

to

will

Be sure

to install the shafts

on the control arm

at the correct

be replaced.

Timing belt service

is

covered

in Section

3 of this manual

angle

CHRYSLER CORP.

7-30

TALON

Install or

4.

connect the following:

2.

Control arm assembly and torque

•

the self-locking nuts to

(86

ft.

lbs.

Nm)

Upper

•

62

ball joint-to-steering

ft.

lbs.

(28

adjust,

Compression lower arm

if

•

.

•

2.

install: Install or

•

(81 •

mounting bolts

to

60

ft.

to •

Before servicing the vehicle, refer to the beginning of this sec-

To 3.

knuckle assembly

•

Lateral lower

4.

43-51

ft.

lbs.

arm and

Lateral lower Lateral

arm mounting

install: Install or

connect the following:

Lateral lower

arm and temporarily,

mounting

front

on the

wheel

floor at

height

necessary.

Lateral lower

removal steps

removal steps

Compression lower arm ball joint and knuckle connection Compression lower arm mountinq

arm assembly

4.

Stay

5.

Shock absorber lower mountinq bolt

bolts 3.

arm

6.

Lateral lower

7.

knuckle connection Lateral lower arm mounting Lateral lower arm assembly

Compression lower arm assembly 8.

ball joint

and bfclt

Caution ' :

Indicates parts which should be temporarilly tightened, fully tightened with the vehicle on the ground in the unladen condition.

and then

9300DG03

Exploded view of the lower arms and related components

bolts;

do not

tighten the bolt until the vehicle

Compression lower arm assembly

2.

bolts

arm

Specified grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent

1

ball joint at

assembly

•

install the

(59-71 Nm)

Check and adjust the if

mounting bolts

•

•

Wheel

alignment,

tion.

j

Strut lower

lbs.

and torque the new self-locking nut

Compression Lower Arm

in

Stay (bracket)

•

the knuckle

Nm)

Ball joint to the

or disconnect the following:

Wheel

•

connect the following:

Compression lower arm and torque the 2

REMOVAL & INSTALLATION

the precautions

Remove •

Compression lower arm

3.

the beginning of this sec-

in

tion.

Both compression lower arm

To

Lower Control Arm

1

Before servicing the vehicle, refer to

bolts

necessary.

Lower Arm

the precautions

MB991113

tool

Nm)

ball joint

knuckle with special

at the steering

to

Perform a front wheel alignment and

5.

Lateral 1

Wheel

•

Front wheel(s)

•

or disconnect the follow-

•

knuckle

and torque the new locking nut

20

Remove

ing:

normal riding

is

CHRYSLER CORP.

7-31

TALON •

knuckle assembly

Ball joint to the

and torque the new self-locking nut to •

43-51

lbs.

ft.

Strut lower

•

lbs.

to

lateral

71-85

lower arm through-

alignment,

(97-118 Nm).

lbs.

ft.

Check and adjust the

5.

51-58

Wheel

and nut

bolt

Nm)

(88

lbs.

(69-78 Nm)

Torque the

4.

ft.

Stay and torque the bolts to ft.

Nm ft.lbs.

mounting bolts and

torque to 64 •

74-88 54-65

(59-71 Nm)

front

wheel

necessary.

if

Nm

49-59 36-43

Wheel Bearings

ftlbs.

ADJUSTMENT

Front

The

front

wheel bearing

is

sealed and not

the wheel bearing

shows signs

adjustable.

If

of play, the

hub assembly must be replaced

Rear The wheel bearing play If

the wheel bearing play

cations, the

is

is

not adjustable.

1.

7. Clip

ABS>

3.

Brake drum Shoe and lever assembly

4.

Caliper assembly

2

hub assembly must be replaced

FRONT WHEEL DRIVE (EWO)

8 Parking brake cable 9 Rear hub assembly 10. Brake pipe connection IV Dus; seal

5 Brake disc 6.

1

Rear wheel speed sensor

4 Caliper assembly 5. Brake disc 1.

6.

Upper arm

ball Joint

is at

the limit value. Specification

(18

kg) or less.

ALL WHEEL DRIVE

and knuckle

(

AWD

conneclion

2.

3.

hub

3.9 lbs

7

Front

hub assemoly

1

Before servicing the vehicle, refer to the

precautions

2

in the

Remove

beginning

the caliper

of this section.

assembly and the

I9H0G2S

brake disc (rotor). Exploded view

ol the front

hub assembly

3.

Place a dial gauge against the hub

surface, then

Heater Core replacement

is

covered

in

Section

2

of this

manual

move

the

hub

in

the axial

7I ~ 0 Q9 £ direction

CHRYSLER CORP. TALON

and check whether or not there

is

ball joints

from the steer-

•

Damper

•

REMOVAL & INSTALLATION

and

fork

lateral

lower con-

tem (ABS)

the steering knuckle

•

4.

install or

'•The front hub assembly is a sealed unit and should not be disassembled. 1

•

the beginning of this sec-

in

"»Do

connect the following:

Remove

2.

or disconnect the following:

•

.

Wheel

•

Halfshaft cotter pin

Lateral

and compression lower

control

arm

•

•

Halfshaft nut by holding the rotor in

•

place with a suitable tool

•

•

Front wheel speed sensor,

17-25

it

•

tem (ABS)

•^o

it

out of the

to ball joint

from

lbs.

(88

Nm)

ft.

(33

lbs.

torque to 43

Front hub assembly

•

Nm)

lbs.

ft.

(59

Nm)

•

order to keep the clearance between

off

ABS

the

145-188

shaft.

If

Install or

lbs.

(196-255 Nm).

'•Tf the cotter pin holes

Be careful not to damage the ball If equipped with ABS, be

joint boot.

careful not to

damage

maximum. the

first

the rotor.

•

Install a

ft.

new

(225

lbs.

(88

Nm)

on

AWD

Parking brake shoe and lining if

equipped with disc

brakes

do not align, lbs.

ft.

assembly,

•

tighten the nut to 188

rotor.

Parking brake cable and retaining clip,

•

ABS

install the

connect the following:

Rear hub and bearing and torque to

65 •

ft.

removed,

4.

•

position while torquing the nut to

press

to

rotor.

5.

Halfshaft nut. Hold the rotor in

the front hub mounting bolts and half-

vehicles equipped with ABS,

To install:

if

equipped

'•Shift the knuckle to the outside in

FWD

use a suitable inner shaft remover

ball joint to the

Front wheel speed sensor,

On

3.

AWD

Rear hub and bearing assembly

•

Brake disc (rotor) and caliper and

•

fhe steering knuckle •

25

equipped with disc

Parking brake cable clip and cable

on

steering knuckle and torque the nut

not disconnect the fluid line.

Upper control arm

ft.

Upper control arm

•

3.

•

•

to

Nm)

lbs. (8.5

65

if

brakes

connect the following:

bolts to

with a piece of wire.

Parking brake shoe and lining

assembly,

Front hub assembly and torque the

•

Caliper and suspend

way

•

Dust shield and torque the bolt

Install or

5.

Brake shoe and lining assembly, on

(24-33 Nm)

lbs.

on Front Wheel

bolt,

(FWD)

AWD

ball joint to the steering

cotter pin

78 inch

if

equipped with Anti-lock Brake Sys-

•

New

ft.

mounting

Clip

Drive

ball joints into the

end

Tie rod

equipped with drum

if

brakes

knuckle and torque the nut to

and discard

Brake drum,

•

steering knuckle

tion.

rear disc

not disconnect the fluid line.

the bolt and nut

Before servicing the vehicle, refer to

.

was removed,

Steering knuckle and hand-tighten

•

equipped with

a suitable piece of wire

the steering knuckle

If

if

brakes and suspend the caliper on

To install: Front

Caliper,

Steering knuckle

•

if

equipped with Anti-lock Brake Sys-

arm from

trol

the precautions

Rear wheel speed sensor,

ing knuckle

(0.05mm).

in.

arm

trol

end-p!ay. End play should not exceed 0.002

Nm)

Shoe and

lining assembly,

on

AWD

cotter pin in

mounting

•

Clip

•

Brake drum,

matching holes. Wheel

if

on

bolt,

FWD

equipped with drum

brakes and torque

to

60

ft.

lbs. (81

Nm) If

necessary

to

remove the steering

Rear

•

knuckle, remove or disconnect the follow1

ing: •

Dust shield

•

Tie rod end from the steering

•

.

Before servicing the vehicle, refer to the

precautions 2.

in

•

or disconnect the following:

•

Wheel

Compression and

•

Halfshaft,

lower con-

(AWD)

on

All

vehicles

if

equipped with

Nm)

Rear wheel speed sensor,

equipped

knuckle and discard the cotter pin lateral

(59

the beginning of this section.

Remove

Rotor and caliper,

disc brakes and torque to 43

on

•

Halfshaft,

•

Front wheel

Wheel Drive

AWD

if

ft.

lbs.

CHRYSLER CORPORATION 1998-02

Dodge/Plymouth-Neon

8-25

DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM

8-2

8-22

PRECAUTIONS STEERING AND SUSPENSION

8-2

Removal &

Fuel Injector

Bag

8-36

Fuel

Disarming

8-36

Precautions

8-36

Alternator Installation

8-2

C Camshaft and

Removal &

Lifters

Installation

Installation

Fuel System Pressure

Removal And

Installation

8-42

8-6

Cylinder Head Installation

Installation

Installation

Removal &

8-2

Exhaust Manifold

8-14

Removal &

8-14

Oil

8-44

Ball Joint

Installation

Oil

Installation

Pump Removal &

Rocker Arms/Shafts

Removal &

Installation

Installation

8-21

8-10 8-10

S 8-18

Motor

Removal &

Installation

8-18 8-40

Removal &

Installation

8-40

T Removal &

8-43 Installation

Transaxle Assembly

Removal

&

Installation

8-43 8-25

8-25

V 8-18 8-18

Adjustment

W Water

8-19

8-36

8-36 8-21

Installation

8-44

8-19

Pan

Removal &

Removal &

Valve Lash

0 8-2

Rear Main Seal

8-11

L

8-6

Engine Assembly

Installation

8-11

i

Removal &

Installation

Tension Strut

8-2

Adjustment Intake Manifold

Lower

Removal &

8-32 8-2

Timing

Removal &

Rack and Pinion Steering Gear

Strut

i

Ignition

8-22

Positioning

Starter

8-32

Halfshafts

E

Installation

8-23

8-22

8-33

Overhaul

8-23

H Removal &

8-22

Piston and Ring

8-23

Relieving

8-33

CV-Joints

8-24

Fuel System Service

8-42

Coil Spring

Removal &

Installation

Precautions

8-31

8-23

8-23

8-31

Adjustment

Removal &

Installation

Pump

8-15 8-15

8-15

8-24

Removal &

8-31

Clutch

Installation

Removal &

8-2

8-15

8-23

Removal &

8-36

Removal &

Installation

Fuel Filter

A Air

P

F Front Crankshaft Seal

Pump

Removal &

8-6 Installation

Wheel Bearings

8-20

Adjustment

8-20

Removal &

8-6

8-45 8-45

Installation

8-45

7/ Q9 direction

CHRYSLER CORP. TALON

and check whether or not there

Damper

•

REMOVAL & INSTALLATION To

install:

4.

If

1

•

Remove

or disconnect the following:

•

•

Wheel

•

Halfshaft cotter pin

•

Halfshaft nut by holding the rotor in

•

place with a suitable tool

•

•

Front wheel speed sensor,

was removed,

'•Do

tem (ABS) •

Caliper and

Lateral

and compression lower

arm

way

New

it

•

from

the steering knuckle

^Shift the knuckle

25

ft.

lbs.

(33

lbs.

torque to 43 •

(88

Nm)

Nm)

lbs.

ft.

(59

•

On

3.

Nm)

off

To

145-188

lbs.

Install or

•

Be careful not to damage the ball If equipped with ABS, be

joint boot.

careful not to

damage

maximum. the

first

the rotor.

•

Install a

new

(225

ft.

lbs.

(88

Nm)

on

AWD

Parking brake shoe and lining

assembly,

if

equipped with disc

brakes

do not align, lbs.

rotor.

Parking brake cable and retaining clip,

•

ABS

install the

connect the following:

Rear hub and bearing and torque to

65

• ft.

removed,

If

5.

(196-255 Nm).

'•If the cotter pin holes

tighten the nut to 188

press

to

install:

•

ft.

vehicles equipped with ABS,

rotor.

4.

Halfshaft nut. Hold the rotor in

shaft.

FWD

ABS

the

if

position while torquing the nut to

the front hub mounting bolts and half-

AWD

use a suitable inner shaft remover

ball joint to the

Front wheel speed sensor,

to the outside in

equipped with disc

Rear hub and bearing assembly

•

equipped

order to keep the clearance between

if

Parking brake cable clip and cable

on

Brake disc (rotor) and caliper and

•

Front hub assembly

•

to

Nm)

steering knuckle and torque the nut

fluid line. ball joint

assembly, brakes

Upper control arm

•

Parking brake shoe and lining

(24-33 Nm)

Front hub assembly and torque the

to

•

AWD

connect the following:

ft.

Wheel

Brake shoe and lining assembly, on

•

lbs. (8.5

65

equipped with drum

(FWD)

Drive

ball joint to the steering

lbs.

if

Clip mounting bolt, on Front

•

cotter pin

bolts to

3.

Upper control arm

ft.

Install or

out of the

with a piece of wire.

'•Do not disconnect the •

end

Brake drum,

•

ball joints into the

Dust shield and torque the bolt

•

suspend

not disconnect the fluid line.

brakes

control

78 inch 5.

rear disc

connect the following:

17-25

if

equipped with

if

a suitable piece of wire

Tie rod

it

equipped with Anti-lock Brake Sys-

Caliper,

brakes and suspend the caliper on

knuckle and torque the nut to

and discard

if

tem (ABS) •

steering knuckle

tion. 2.

Rear wheel speed sensor,

lower con-

the bolt and nut

the beginning of this sec-

in

lateral

the steering knuckle

Steering knuckle and hand-tighten

•

Before servicing the vehicle, refer to

.

and

fork

the steering knuckle

install or

hub assembly is a sealed and should not be disassembled. front

the precautions

•

Steering knuckle

•

Front

unit

from the steer-

equipped with Anti-lock Brake Sys-

arm from

trol

(The

ball joints

ing knuckle

(0.05mm).

in.

arm

trol

is

end-play. End play should not exceed 0.002

Nm)

Shoe and

lining assembly,

on

AWD

cotter pin in

mounting

•

Clip

•

Brake drum,

matching holes. Wheel

if

on

bolt,

FWD

equipped with drum

brakes and torque

to

60

ft.

lbs. (81

Nm) If

necessary

to

remove the steering

Rear

•

knuckle, remove or disconnect the follow1

ing: •

Dust shield

•

Tie rod

•

.

Before servicing the vehicle, refer to the

precautions

end from the steering

2.

in

•

or disconnect the following:

•

Wheel

Compression and

•

Halfshaft,

lower con-

(AWD)

on

All

vehicles

if

equipped with

Nm)

Rear wheel speed sensor,

equipped

knuckle and discard the cotter pin lateral

(59

the beginning of this section.

Remove

Rotor and caliper,

disc brakes and torque to 43

on

•

Halfshaft,

•

Front wheel

Wheel Drive

AWD

if

ft.

lbs.

CHRYSLER CORPORATION 1998-02

Dodge/Plymouth-Neon

DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM

8-25 8-2

8-22

PRECAUTIONS STEERING AND SUSPENSION

8-2

Removal &

8-36

Disarming

8-36

Precautions

8-36

Removal &

Installation

8-2

C Camshaft and

Removal &

Lifters

Installation

Pump

Fuel System Pressure

Installation

8-42

Coil Spring

Removal And

Installation

8-42

Installation

8-6

Cylinder Head Installation

Removal & Lower

Removal &

8-2

Exhaust Manifold

8-14

Removal &

8-14

Oil

Installation

Oil

Installation

Installation

Installation

8-21

8-10

8-10 8-18

&

Installation

8-18

Removal &

Installation

8-40

Removal

8-40

T Removal &

8-43 Installation

Transaxle Assembly

Removal &

Installation

8-43 8-25 8-25

V 8-18

Valve Lash

8-18

Adjustment

W

8-44 Water

8-19

8-36

S Motor

8-11

8-19

Pump Removal &

Installation

Tension Strut

8-44

Pan

Removal &

Installation

8-32

0 8-2

Removal &

8-36 8-21

Strut

8-11

Ball Joint

Removal &

Removal &

Installation

Rocker Arms/Shafts

Starter

L

8-6

Engine Assembly

Installation

8-23

8-2

Intake Manifold

E

Installation

8-23

8-2

Timing

8-33

Overhaul

Rear Main Seal

8-32

Adjustment

8-33

CV-Joints

&

8-24

I

Ignition

Rack and Pinion Steering Gear

Removal

H Halfshafts

Removal &

8-22

Positioning

8-24

8-22

Precautions

8-31

8-23

System Service

8-15 8-15

8-22

Piston and Ring

8-23

Relieving Fuel

8-15

8-23 Installation

8-31

Adjustment

Removal &

Installation

Removal &

8-31

Clutch

Removal &

Fuel

8-2

Alternator

Installation

Fuel Injector

Removal &

Bag

8-15

8-23

Fuel Filter

A Air

Installation

Removal &

8-36

P

F Front Crankshaft Seal

Pump

Removal &

8-6 Installation

Wheel Bearings

8-20

Adjustment

8-20

Removal &

8-6

8-45 8-45

Installation

8-45

^* CHRYSLER CORPORATION

8-2

NEON

PRECAUTIONS

of the following precautions,

all

which deal with personal of

prevention

safety,

IMMEDIATELY seek

brake fluid internally,

Before servicing any vehicle, please be

sure to read

component damage, and important points when servicing a

•

The EPA warns

with used engine

prolonged contact

that

may cause

oil

skin disorders, including cancer!

motor vehicle:

should make every

Never open, service or drain the radia-

system when the engine

tor or cooling hot; serious

burns can occur from the steam

Observe

•

all

applicable safety precaufuel.

Whenever

servicing the fuel system, always work

Do

well-ventilated area.

come

in

not allow

fuel

a

in

spray

contact with a spark,

open flame, or excessive heat

(a hot

effort to

used engine

drop

oil.

oil.

other exposed

Soap and

expo-

water, or

waterless hand cleaner should be used. •

All

new

vehicles are

your vehicle.

If

becomes contaminated, completely

fluid.

Any brake

brake

of

the brake fluid flush the

Never reuse any brake

fluid.

removed from

fluid that is

the system should be discarded. Also,

when changing after

fluid for

system with new

Protective

soon as possible

sure to used engine

of

You

minimize your

oil.

Wash your hands and any skin areas as

when working around

or vapors to

to

gloves should be worn

is

and hot coolant.

tions

exposure

number

a

to take into consideration

•

proper operation of the brake system. You

should always buy the correct type

medical assistance.

now equipped

a painted surface;

it

Never operate the engine without the

•

proper amount and type of engine

so WILL result

Timing

•

belt

doing

oil;

severe engine damage.

in

maintenance

Many models

extremely

is

with an air bag system, often referred to as a

important!

Supplemental Restraint System (SRS) or

ence-type, non-freewheeling engine.

Supplemental

timing belt breaks, the valves

Inflatable Restraint (SIR) sys-

do not

come in contact with will damage the paint.

allow any brake fluid to

an

utilize

interferIf

the

the cylinder

in

tem. The system must be disabled before

head may

extinguisher near the work area. Always

performing service on or around system

tially

keep

components, steering column, instrument

expensive) engine damage. Refer to the

example). Keep a dry chemical

light, for

a container specifically

fuel in

designed

fire

for fuel storage; also,

panel components, wiring and sensors.

always

and disabling proce-

strike the pistons,

causing poten-

serious (also time-consuming and

maintenance

manual

interval charts in the front of

recommended

properly seal fuel containers to avoid the

Failure to follow safety

possibility of fire or explosion. Refer to the

dures could result

additional fuel system precautions later in

deployment, possible personal injury and

timing belt section for belt replacement and

this section.

unnecessary system

inspection.

Fuel injection systems often remain

•

•

accidental air bag

in

repairs.

Always wear safety goggles when

this

ment

•

for the

some

working with, or around, the

turned OFF. The fuel system pressure must

When

be relieved before disconnecting any

sure the bag and trim cover are pointed

tem^) and may

away from your body. When placing a non-

undergo

lines. Failure to

do so may

and/or personal

injury.

fuel

result in fire

wash your hands thoroughly

handling brake

after

brake fluid

in

fluid.

If

irritation persists, or

if

bag on a work surface, always

from the surface. This

motion

you do get

of the

module

will if

it

If

you have taken

•

away

is

accidentally air

bag

later in this section.

Clean, high quality brake fluid from a

sealed container

is

essential to the safe

vehicles

may

interfere with

the functions of the on-board

require the

•

When

is

and

to

process once the neg-

a relearning

ative battery cable

computer sys-

computer

reconnected.

drum

servicing

brakes, only dis-

3. assemble and assemble one side

reduce the

deployed. Refer to the additional

system precautions

your eyes, flush your eyes

with clean, running water for 15 minutes.

eye

air

face the bag and trim cover upward,

ethers and polyglycols. Avoid contact with the eyes and

carrying a non-deployed air bag, be

deployed

Brake fluid often contains polyglycol

•

bag system.

to the

Disconnecting the negative battery

cable on

pressurized, even after the engine has been

air

replace-

and

interval for the timing belt,

at

a time,

leaving the remaining side intact for refer-

ence. •

Only an MVAC-trained, EPA-certified

automotive technician should service the conditioning system or

its

air

components.

ENGINE REPAIR »»The alternator spill shield does not need to be removed.

Alternator

REMOVAL & INSTALLATION

•

1998-99 Models

3 pivot bracket-to-engine bolts

•

Pivot bracket

•

Alternator, by sliding

bolt 1

.

Before servicing the vehicle, refer to

the precautions

in

*lt is not necessary to

the beginning of this sec-

off

it

the “T”

and out through the wheel well

remove the “T”

bolt.

tion. 2.

Remove

To install:

or disconnect the following:

•

Negative battery cable

•

Alternator's

adjustment

Install or

nut,

•

loosen

connect the following:

Alternator, **Be sure to

rocker

arms and spacers

indicated by

when

there

is

locations

in their original

merge

wear on the

roller or

damage

the rocker

rocker

arm

lubrication

shaft oil

if

is

duct.

to the shafts for

damaged

or worn.

hollow and

Check

clogs with a small piece

wear or

is

REMOVAL & INSTALLATION

into

travel is not reduced, replace the

rocker

damage. Replace

arm assembly

to the rocker

damage. Check the location where the

taken up.

SOHC If

are serviced as an

Engine —Except High Output Engines

assem-

The hydraulic lash adjuster and

arm

assem-

1

Before servicing the vehicle, refer to

the precautions in the beginning of this section

bly.

The

used as a

the oil holes for

of wire,

and clean

as required. Lubricate the rocker arms and spacers. Be sure to install

in their original

locations.

To

install:

Set the crankshaft to 3 notches before Top Dead Center (TDC) before installing the rocker arm shafts, otherwise valvetrain damage may occur

when

the mounting bolts are tight-

ened. 4.

Set the crankshaft sprocket to

aligning the

arrow on the off to

5.

TDC

by

mark on the sprocket with the oil

pump

housing, then back

3 notches before TDC. Install the

INTAKE MANIFOLD TO

WATER

INLET

SUPPORT

rocker arm/hydraulic lash

adjuster assembly

making sure

that the

Intake manifold bolt torque

Brake service

is

covered

in

(valve) cover.

Intake Manifold

and pump the plunger

until the lash adjuster travel is

bly.

arms mount

oil

arm

Install the

Connect the negative battery cable.

depressed

is

for scoring,

arm; replace any components showing

rocker

full of oil.

no plunger

the lash adjuster

clean engine

arm

or

excessive plunger travel, sub-

for installation.

Inspect the rocker

little

rocker

7.

8.

sequence— 1998-99

2 OL (VIN C)

Section 4 of this manual

SOHC

engine

8-12

CHRYSLER CORPORATION NEON 2.

Knock Sensor (KS)

•

Properly relieve the fuel system pres-

3.

Remove

• • •

•

Fresh

air inlet

duct from the

air

Clean

4.

Fuel supply line from the fuel tube

To

assembly

5.

SOHC

engine

of

any

install: Install or

connect the following:

•

New

•

Fuel

assembly

•

Intake manifold

•

Brake booster vacuum hose

retainers, in

•

Positive Crankcase Ventilation

lbs. (11

rail

•

(PCV) hose

C)

mating surfaces

all

Fuel injector cover

Fuel

Manifold Absolute Pressure (MAP)

sensor

and discard the

residual gasket material.

•

•

2000-02 2.0L (VIN

Intake manifold

gasket

Negative battery cable

cleaner

sequence—

Starter wiring connectors

•

or disconnect the follow-

ng:

Intake manifold bolt torque

con-

electrical

nector

sure.

electrical

17

connector on 1999

models 6.

ft.

gaskets and seals

and torque the new

sequence,

to

95 inch

Nm)

rail

and torque the screws

lbs.

(23

to

Nm)

•

PCV hose

•

Brake booster hose

Inspect the fuel line quick-connect

tings for

Apply a

fit-

damage and replace necessary. small amount of clean engine oil to if

the fuel inlet tube. •

Fuel supply hose to the fuel

rail

assembly. Ensure the connection

is

fastened securely by pulling on the connector. •

Fuel injector cover

•

MAP

•

KS sensor connector

•

Air inlet duct

•

Negative battery cable

View

of the

sensor wiring

Manifold Absolute Pressure

(MAP) sensor— 2000-02 SOHC engines

- BOLT 2 - BRACKET 3 - BRACKET 1

4 -

1

- KNOCK SENSOR

2 -

BOLT

STARTER MOTOR 9306EG23

9306EG21

View View

of the intake manifold

lower supports

—2000-02 SOHC engines

of the

Knock Sensor (KS)

SOHC engines

— 2000-02

OH OO

CHRYSLER CORPORATION

O

neon 7.

repair

Start the vehicle, if

check

and

for leaks

•

MAP sensor connector MTV actuator connector

•

Oil dipstick

•

Inlet air

•

necessary.

High Output Engine 1

.

Before servicing the vehicle, refer to

Heater hose from the intake manifold

•

Heater tube from the bottom of the

•

Upper

radiator

and coolant recov-

ery hoses

body

•

PCV

•

Fuel injector connectors and har-

the precautions in the beginning of this sec-

•

intake manifold

duct to the manifold and

the throttle

I

•

hose

Fuel

rail

assembly

tion. 2.

ness

to the fuel rail

•

Fuel

rail

•

Fuel supply line

•

Negative battery cable

Properly relieve the fuel system pres-

cover

sure. 3.

Remove

or disconnect the follow-

ing:

t •

6.

check

for leaks

and

Negative battery cable repair

•

Start the vehicle, if

necessary.

DOHC

injectors to rest on

may damage them.

•Cover

the injector openings to pre-

vent debris from entering the ports.

Throttle body-to-intake manifold air

duct

Do not allow the their tips as this

•

Engine

Accelerator,

kickdown and cruise

control cables, 1

Wrap towels around

the precautions

the fitting to

Fuel supply line quick-connect

tube assembly

from the

fuel

•

Fuel

cover from the engine

•

Fuel injector connector and harness

rail

from the injectors and •

•

in

the beginning of this sec-

•

fuel rail

Relieve the fuel system pressure.

3.

Remove

•

or disconnect the following

•

Negative battery cable

•

Air inlet duct fold

connector

Throttle

body vacuum hoses

•

Throttle

body

•

Manifold Absolute Pressure/ldle Air

cal

Wrap towels around

Lower intake manifold support

catch any spilled fuel.

•

the fitting to

Manilold Absolute Pressure (MAP)

models •

Oil dipstick

•

Manifold Absolute Pressure (MAP)

Manifold Tuning Valve (MTV) actu-

•

Fuel supply line quick-connect

from the •

sensor wiring

Knock Sensor (KS) nector.

fuel rail

Intake manifold-to-cylinder

bolts

Engine Coolant Temperature (ECT)

Irom the tab located on the heater tube

for-

ward •

Knock (KS) Sensor wiring

•

Brake boosfer hose

•

Intake manifold

and discard the

gasket

To

install:

4

Clean the mating surfaces of any

residual gasket material. 5.

Install or

•

connect the following:

ifold with a

to the upper mannew gasket and torque

the bolts to

105 inch

Lower manifold

lbs.

(12

Nm). •

Intake manifold

on the cylinder

head with a new gasket •

Engine wiring harness between the middle intake runners

•

KS

•

Brake booster hose and torque the

wiring connector

intake manifold bolts, in sequence, to •

105 inch

lbs.

(12

Nm)

Lower manifold support bracket bolt

and torque the

lbs.

(28

bolt to 21

con-

sensor connector

head

and move the manifold

electrical

Detach the wiring harness

ator wiring •

electri-

connector on 1998 models

sensor electrical connector on 1999

bracket bolt •

•

Throttle Position (TP) sensor elec-

Temperature (TMAP) sensor

(PCV) hose

electri-

•

** CAUTION

Positive Crankcase Ventilation

motor

connector

trical

from the intake mani-

equipped, from

and bracket

Idle Air Control (IAC)

cal

2.

if

the throttle lever

tion.

catch any spilled fuel. •

Before servicing the vehicle, refer to

ft.

Nm) For complete Engine Mechanical specifications, see Section

1

of this

manual

CHRYSLER CORPORATION

8-14

NEON •

MAP

sensor electrical connector on

1999 Models

1999 models •

IAC sensor

connector on

electrical

1999 models

7922EG16

Intake manifold bolt torque sequence

DOHC

2.0L (VINY)

•

KS and

•

Wiring harness to the heater tube tab

•

TP sensor Throttle

•

engine

connectors

starter electrical

•

1

.

electrical

connectors

tion. 2.

Release the

3.

Remove •

body vacuum hoses

Accelerator,

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

kickdown and speed

control cables,

Fuel supply line from the fuel

•

Air cleaner

•

bracket and throttle lever •

EGR

•

tube and torque to 95 inch

torque to 95 inch •

BOTTOM VIEW

INTAKE MANIFOLD

lbs.

•

Intake manifold side retainers

Air duct to the air

filter

•

DOHC

2.0L (VIN Y)

sequence—

•

•

Right side splash shield

•

Alternator drive belt

•

Alternator spill shield

•

Exhaust pipe from the manifold.

Negative battery cable

engine

Low Emission

Exhaust Manifold Starter electrical connectors

equipped, discard the manifold-to-

•

Exhaust Gas Recirculation (EGR)

flex joint gasket.

•

REMOVAL & INSTALLATION

•

1998 Models

kets 1

^If necessary, separate the upper and lower manifolds.

.

all

of the gasket

mating surfaces.

To install: Install or •

lbs.

ft.

lbs.

•

•

Air cleaner

•

Power steering pump

Fuel

(28

to 21

DO NOT

Upstream Heated Oxygen Sensor

to

ft.

• •

Fuel supply hose to the fuel

outward

if

•

Exhaust manifold and discard the

•

4.

Thoroughly clean the mating surfaces.

Install the

is

fastened

securely by pulling on the connector.

the fasteners to 17

ft.

(23 Nm), starting at the center and

working outward

the fuel inlet tube.

’•Ensure the connection

exhaust manifold with a

new gasket and torque lbs.

oil to

manifold

Upper

radiator

and coolant recov-

in

both directions

’•-Repeat this procedure until

•

ECT sensor

•

Throttle

tener to •

TMAP

electrical

connector

body and torque the 16 ft. lbs. (22 Nm)

sensor

electrical

both directions. Repeat

procedure

until all

Lower heat shield

fasteners

to the

Exhaust pipe

5.

Install or

to the

exhaust

manifold with a

all fas-

21

lbs.

ft.

gasket,

if

fasteners

(28 Nm).

Alternator spill shield

•

Alternator drive belt

•

Right side splash shield

•

HO 2 S

•

Upper heat shield

sensor connector to the

exhaust

manifold

teners are tightened to specifications.

Power steering

reservoir

and

connect the following: bracket

•

Alternator bracket bolt,

•

Exhaust manifold heat shield

•

ery reservoir hoses

and working

•

•

Heater tube and hose to the intake

in

(23 Nm),

lbs.

new manifold-to-flex joint LEV equipped. Torque the

fit-

necessary.

ft.

remove the

to

replace,

17

are tightened to specifications.

To install:

damage and

to

manifold

3.

Apply a small amount of clean engine

•

Exhaust manifold with a new gasket

this

rail

Inspect the fuel line quick-connect

connect the following:

gasket

starting at the center

gasket

assembly

•

New

and torque

lbs.

•

Nm) PCVhose

Install or

•

loosen the

outer exhaust manifold bolt.

17

install:

(HO 2 S) connector

alternator bracket bolt to

to

5.

disconnect

•

•It may be necessary

ft.

Thoroughly clean the mating sur-

•

onto the intake manifold

rail

4.

To

reservoir,

Exhaust manifold heat shield

(23

tings for

aside.

Exhaust manifold and discard the

faces.

assembly and bracket

Nm)

and torque the screws

6.

it

.

•

new gasket

Intake manifold using a

and torque the fasteners

Upper exhaust manifold fasteners

•

the fluid lines.

the bolts to

Lower exhaust manifold fasteners

•

gasket

or disconnect the following:

Negative battery cable

move

Nm)

(28

the exhaust

•

the beginning of this section.

Remove

Upper and lower manifolds with

21

in

•

connect the following:

new gaskets and torque •

Before servicing the vehicle, refer to the

precautions 2.

Thoroughly clean

Lower heat shield from manifold

Upper and lower intake manifold assemblies and discard the gas-

5.

If

Vehicle (LEV)

•

tube

4.

Upstream Heated Oxygen (HO 2 S)

lbs. (3

Nm) Intake manifold bolt torque

Upper heat shield from the exhaust

sensor connector

housing and

torque the clamp to 25 inch 7922EG15

Power steering reservoir bracket

manifold

and

Nm)

lbs. (11

rail

assembly and bracket

and move the reservoir aside

Nm)

(11

Negative battery cable

•

equipped, to their

if

fuel pressure.

or disconnect the following:

HO 2 S

•

Air cleaner bracket

•

Exhaust pipe

(28 •

assembly and bracket

•

Air cleaner

•

Fuel supplyjine to the fuel

•

Negative battery cable

rail

sensor

to the

and assembly

2000-02 Models

manifold and

torque the fasteners to 21

connector

on 1998 models

loosened

Power steering pump reservoir

•

fas-

if

Nm)

Negative battery cable

ft.

lbs.

1.

Before servicing the vehicle, refer to

the precautions tion.

in

the beginning of this sec-

O O

CHRYSLER CORPORATION NEON

-

C U

1I

3.

•

support bracket

bolt,

if

ULEV

equipped. Torque the bolts to 40

Wiring harness heat shield-toif

ULEV equipped

bolt, •

Lower

(15)

Connect negative cable

vehicle.

if

front crankshaft oil seal, using

•

Crankshaft key

•

Crankshaft sprocket using Installer

Wiring harness heat shield-to-

6792

Tool

exhaust manifold support bracket

(14)

New

Crankshaft Installer Tool 6780-1

exhaust manifold, •

or connect the following:

Install •

ft.

(54 Nm).

lbs. •

To install:

Cylinder head-to-exhaust manifold

Make

LEV equipped

sure the word

crankshaft sprocket

Front Crankshaft Seal

Exhaust manifold tightening

•

Timing

•

Crankshaft damper using thrust

belt

bearing washer and bolt from Installer Tool

REMOVAL & INSTALLATION

put Engines

damper or disconnect the following:

•

Negative battery cable

•

Wiring harness heat shield-to-

1

exhaust manifold support bracket if

Low Emission

Vehicle (LEV)

Wiring harness heat shield-toexhaust manifold,

if

Ultra

Low

Emission Vehicle (ULEV) equipped •

Exhaust manifold support bracket

•

if LEV equipped Make up air hose Speed control vacuum

bolt,

•

reservoir,

• • •

clip

in

•

•

Negative battery cable

•

Accessory drive belts

•

Crankshaft damper, using Puller Tool

1026 and

1

Insert Tool

6827-A

•

Timing

•

Crankshaft sprocket using special

•

Tools 6793 and C-4685-C2

•

Timing

Crankshaft sprocket key

•

Crankshaft sprocket with special

Crankshaft

oil seal,

puller Tool

6771

belt

Tools 6793 and insert

using a seal •

Crankshaft

Install or

•

connect the following:

Front crankshaft cial

Exhaust manifold and discard gasket

Tool

6792

Exhaust manifold with a new gasket

Make

and torque the

crankshaft sprocket

16

ft.

lbs.

bolts, in

(23

sequence,

(23

if

ULEV

FRONT

on the

facing outward.

to

16

ft

Removing the

front crankshaft oil seal

•

Timing

Crankshaft damper using thrust

belt

bearing washer and bolt from Installer Tool

damper

lbs. (11

•

if

6792 and torque

bolt to

105

ft

lbs

the

(142

Nm)

Negative battery cable

Camshaft and

Cylinder head cover,

Lifters

ULEV

REMOVAL & INSTALLATION

equipped

Speed control vacuum

reservoir,

if

equipped

SOHC

•

Make up

•

Exhaust manifold support bracket if

is

•

Nm)

Nm) O 2 S sensor connector and harness

M10 M12

sure the word

Nm)

shield,

Upper and lower heat shields and

bolt,

seal with spe-

oil

Tool 6780-1

Crankshaft sprocket with special

•

connect the following:

Upper heat

C-4685-C2

seal with special

oil

install:

3

clip

•

Crankshaft damper with special Tools 1026 and 6287-A

ULEV

if

torque the bolts to 95 inch

•

or disconnect the following:

Negative battery cable

•

belt

the beginning of this section.

in

Remove

2.

Tool 6771

Cylinder head cover,

lbs.

•

Engine

Before servicing the vehicle, refer to the

.

To

equipped and torque bolts

•

Negative battery cable

precautions

Exhaust manifold bolts

to •

•

Upper heat shield

Install or

(142

or disconnect the following:

To install: 3.

lbs.

ft.

Accessory drive belts

the beginning of this sec-

equipped •

105

1

•

DOHC Remove

•

Oxygen (O 2 S) sensor connector

lbs.

tion.

•

and harness

for

Before servicing the vehicle, refer to

if

equipped •

.

Engine

the precautions

2.

equipped •

SOHC

6792. Torque the

bolt to

998—99 models or 100 ft. (136 Nm) for 2000-02 models.

Nm)

bolt,

on the

9306EG25

sequence-2000-02 models and High Out-

Remove

FRONT

facing outward.

Negative battery cable

to battery.

m

2.

is

air

LEV equipped. Torque

1998-1999

the

new

Installing a

bolt to bolt to

40 70

ft.

ft.

lbs.

lbs.

(54 Nm), (95

6780-1: proceed with caution

if

ft.

lbs.

Nm) and

illustrations,

shafts

see Section

in

an aluminum cylinder head. Rocker arm

using sub-

mount

(28 Nm).

For Accessory Drive Bell

MODELS

This engine uses a camshaft running

seal using seal installer

stitute tools

the nut to 21

Engine

hose

1

of this

manual

directly to the cylinder head.

CHRYSLER CORPORATION

8-16

NEON VALVE RETAINING

ROCKER SHAFT RETAINING BOLT

VALVE

RETAINER

SPACER

EXHAUST ROCKER ARM/ HYDRAULIC LASH ADJUSTER ASSEMBLY

4.

INTAKE ROCKER ARM/HYDRAULIC LASH ADJUSTER ASSEMBLY

Exploded view

of the cylinder

Care must be taken to ensure ing

marks align

after cylinder

head and valvetrain assembly

all

valve tim-

head and val-

vetrain service. Please note that the cylinder

head must be removed from the vehicle

to

service the camshaft.

'•After

all

components are

the engine, a

DRB scan

installed on

tool is neces-

To

— SOHC engine camshaft and check the cylinder head

install:

damage. Replace the cylinder head

'•The cylinder head bolts should be checked for stretching before reuse. If the thread area of the bolt is necked down the bolts must be replaced with new. New head bolts are recom-

or

5.

Clean

Before servicing the vehicle, refer to

all

roller for

parts well. Inspect the

feed holes

in

for scoring.

Check

the head for blockage.

of pitting

the

oil

Check

the precautions in the beginning of this sec-

the camshaft bearing journals for scoring.

tion.

light

scratches are present, they

may

2.

Relieve the fuel system pressure.

removed with 400

Remove

deep scratches are present, replace the

•

Negative battery cable

•

Cylinder head cover

show signs

grit

abrasive paper.

If

wear or damage. Replace rocker

If

if

the camshaft lobes

worn

or

show signs

on the nose, flank or base

If

serviced,

the rocker

circle,

arms and

shaft are to be

mark the rocker arms so any

that

are to be returned to service will be installed in their original

arms

off

locations. Slide the rocker

the shaft.

rocker arms

in

the

Keep the spacers and

same

location for

reassembly.

EXHAUST ROCKER ARM ASSEMBLY

7.

'•Mark the rocker arm shaft assemblies to identify them for later installa-

Inspect the rocker

arms

for scoring,

tion. •

Rocker arm shaft bolts

•

Rocker arm assemblies

•

Timing

•

Camshaft sprocket

•

Rear timing belt cover

•

Cylinder head

•

Camshaft Position (CMP) sensor

•

Camshaft from the

belt

der head

of

arm

replace the camshaft. 6.

If

be

3.

or disconnect the following:

the camshaft lobes

damaged. camshaft journals

.

If

arms/hydraulic lash adjuster

sary to perform the camshaft and

1

damaged.

wear, check the corresponding rocker

mended.

crankshaft timing relearn procedure.

for

worn

if

and tensioner

7922EG10

rear of the cylin-

Rocker arm shaft identification— SOHC

Rocker arm shaft notch location— SOHC

engine

engine

O O

CHRYSLER CORPORATION NEON

I

engine

Rocker arm shaft retainers,

•

7I

belt side

up and toward the timing of the

i

original positions

bolts to

17

•

Timing

belt

•

All electrical,

ft.

in their

and torque the

lbs.

(23

Nm)

and tensioner

vacuum and

fluid

connections Negative battery cable.

•

••An

and

oil

filter

change are recom-

mended. Use a DRB scan

16.

tool to perform the

camshaft and crankshaft timing relearn procedure, as follows:

Connect the scan

a.

tool to the

DLC

(located under the instrument panel, near

the steering column). b.

Turn the ignition switch

ON

and

access the "miscellaneous" screen. Select the “re-learn cam/crank"

c.

option, then follow the instructions on

the scan tool screen.

wear on the

damage

roller or

on the end

to the shaft.

screw

Replace parts as necessary.

The rocker arm

8.

used as a lubrication the shaft

oil

duct.

a small wire

all oil

Check

holes on the camshaft.

that

install

fit

It

.

and clean as required.

rearward as

as

To

Move

Read the end-play on the

dial indi-

0 005—0 013 inch

•

oil.

Install the adjuster into the

b.

arm making sure

the adjuster

to

rocker •

least

is at

Submerge

c.

oil

and

the rocker

pump

lash adjuster travel

is

arm

•

clean

in

Install the

Camshaft

lbs. (9.6

taken up.

It

•

travel

rocker

arm on

ft.

lbs.

(115

Throttle cables

•

Throttle Position (TP) sensor

•

Nm)

Cylinder head

the crankshaft sprocket

Tire,

Wheel and

Control (IAC) valve from

Idle Air

Air

body make-up hose from

the air

Air cleaner

•

Timing

•

Camshaft sprocket

•

Cylinder head cover and mark the rocker

belt

arm

shaft assemblies to ease

installation

Rocker arm and shaft assemblies.

•

Rocker arm shaft assembHes

•

Engine Coolant Temperature (ECT)

Position the rocker shafts pointing

Ball Joint specifications, see Section

housing

•

3

Camshaft end-play can be checked,

For

from the intake

cleaner

13.

camshaft target magnet

connector

Air intake duct

•

•

seal flush with the cylin-

notches before Top Dead Center (TDC) on

•

tray

Temperature (IAT) sensor

the throttle

shaft.

Install the

Inlet Air

Nm)

shaft assemblies, set the crankshaft to

using the following procedure:

and

•

Ireely.

Before installing the rocker arm and

15.

the rocker

85

or disconnect the following:

Battery

manifold

arm

a.

Remove •

electrical

Camshaft sprocket and torque the bolt to

the plunger until the

not reduced, replace the adjuster.

d

Drain the cooling system.

der head

partially filled with oil.

engine

3

•

sensor and torque the screws

85 inch

of this section.

Relieve the fuel system pressure.

connect the following

Camshaft, lubricate the bearing

CMP

beginning

in the

2

4

Lubricate the lash adjuster thor-

a.

is

will go.

••Be sure the camshaft turns

oughly with clean engine

Before servicing the vehicle, refer to the

journals thoroughly

fol-

lowing procedure:

.

precautions

the camshaft as far forward

Install or

•

installed on

tool is neces-

crankshaft timing relearn procedure. 1

e.

14.

DRB scan

contact with the

Zero the dial indicator.

it

components are

sary to perform the camshaft and

Be sure the

(0.13-0.33mm).

Replace worn or defective

use the

is in

cator. Specification is

to their origi-

install a lash adjuster,

probe

will go.

d.

f.

all

the engine, a

camshaft

lash adjusters. 12.

touch on

Using a prybar, move the camshaft

dial indicator

rocker arms should be cleaned and checked. Lash adjusters removed from a

nal locations.

the

2000-02 MODELS

dial indicator to

it

the thermostat opens,

drive vehicle to check for proper operation. in

far

the vehicle exhibited a tappet-like

arm should be returned

4 Nm). Be sure

magnet

c.

as

all

warms and

coolant can be added to the radiator. Test

••After

noise, the valve lash adjusters built into the

rocker

the engine

Tighten the

for leaks.

the engine with the radiator cap off so as

of the camshaft.

nose

the

holes for clogging with

original locations. 1 1

Setup a

b.

arm components and spacers, then them on the rocker arm shaft in their

rocker

lbs. (3

to

To assemble, thoroughly lubricate

10.

30 inch

to

the dowels on the

hollow and

clean inside and out.

is

Check

9.

shaft

is

of the camshaft.

engine and check

Start the

17.

Run

sensor electrical connector

1

of this

manual

CHRYSLER CORPORATION

8-18

NEON

•

Heater supply and return tioses

•

•

Heater tube support bracket

•

•

Power Distribution Center (PDC) screws aside

and the

Camshaft Position (CMP) sensor

magnet

and camshaft target

Camshaft from the

•

rear of the cylin-

der head 7922EG19

To install: Lubricate the camshaft journals with

5.

clean engine

oil.

Camshaft and reposition the

•

30 inch

the screw to

CMP

•

Cylinder head cover

•

Negative battery cable

belt

Use a DRB scan

tool to perform the

cedure, as follows:

engine

Connect the scan

tool to the

•

Front camshaft seal,

(located under the instrument panel, near

crankshaft timing relearn procedure.

the steering column). b.

Remove

Turn the ignition switch ON, and

or disconnect the follow-

access the “miscellaneous” screen.

•

Timing

c.

• if

•

Cylinder head cover

•

Timing

•

Both camshaft sprockets

the scan tool screen.

Camshaft sprocket and torque

belt

85

to

7.

Nm)

(115

lbs.

option, then follow the instructions on

cover

belt rear

Timing

•

Rocker arms

belt

to 21

ft.

Cylinder head cover Ignition coil

lbs.

camshaft

Nm)

(28

-The

and spark plug cables

inch lbs. (12

in

sequence, one

the proper order

•

to

bearing caps are identified for

location.

caps

105

Nm)

Valve Lash

at a time.

Remove

If the bearing caps are diffiremove, use a plastic hammer

first.

cult to

Heater tube bracket bolt

to gently tap the rear part of the

Heater tubes

camshaft.

•

ECT sensor

•

Air cleaner

•

Throttle

in

these vehicles do not

Starter Motor

connector

electrical

•

attaching screws

and

The engines

require periodic valve lash adjustment.

•

Battery

ADJUSTMENT

the outside bearing

•

PDC

engine and check for proper

Camshaft bearing caps, loosen the bearing caps

in

•

•

Start the

operation and leaks.

and tensioner

•

•

Select the “re-learn cam/crank”

Negative battery cable

removed

and torque the fasteners

Intake

and exhaust camshafts

To

install:

3.

Before installation, clean the cylinder

REMOVAL & INSTALLATION

tray

housing

head and cover mating surfaces. Make cer-

body connections tain that the rails are

1998-99 Models

flat.

IAT sensor

•

4. Fill

the cooling system to the proper

Lubricate the bearing journals and 1

cam

followers with clean engine

.

2. 5.

Use a DRB scan

tool to

Install or

Remove

oil.

level.

connect the following:

perform the

If

the negative battery cable.

equipped with A/C, perform the

lowing procedure:

camshaft and crankshaft timing relearn procedure, as follows:

Connect the scan

a.

tool to the

DLC

Remove outside bearing caps

first

(located under the instrument panel, near the steering column).

Turn the ignition switch

b.

ON, and

access the “miscellaneous” screen. Select the “re-learn cam/crank"

c.

option, then follow the instructions on

the scan tool screen. 9.

Run

engine and check

Start the

for leaks.

the engine with the radiator cap oft so as

the engine

warms and

the thermostat opens,

coolant can be added to the radiator. Test

check

drive vehicle to

DOHC 1

DLC

sary to perform the camshaft and

sensor

and torque

8.

Timing

DOHC

2.

Nm)

lbs. (3

Camshaft sprockets

•

camshaft and crankshaft timing relearn pro-

•

7.

lbs.

ft.

ing:

•

ft.

fasteners to 18

fas-

Nm)

Identifying the camshaft bearing caps

Camshaft target magnet and torque

•

M8

•

a.

PDC

and heater tubes •

6.

connect the following:

Install or

6.

M6

(24 Nm).

removal •

Bearing caps. Torque the

teners to 105 inch lbs. (12

ease the camshaft

to

Camshafts

for proper operation.

Engine

Be sure

to

observe

all

precautions

in

the beginning of this section.

'After

all

components are

the engine, a

DRB scan

7922EG20

installed on

tool is neces-

Bearing cap removal

sequence— DOHC engine

fol-

CHRYSLER CORPORATION

8-19

NEON Support the engine/transaxle

a.

assembly with a b.

Remove

jack.

mount

the tront engine

Follow the proper tightening

bolt

sequence 9.

from the mount/crossmember bracket.

Lower and

c.

damage

rotate the

engine/transaxle assembly forward to

for the structural collar or

to the collar or oil

pan may

occur.

provide starter clearance. Install the structural collar

»»Do not remove the wiring 3.

Remove

at this time.

or disconnect the following:

•

Both starter-to-transaxle bolts

•

Starter electrical connectors

•

Starter by positioning

and lowering

(54 Nm), Exploded view

of the structural collar

— 1998-99 models

install:

connect the following:

•

Starter

•

Starter electrical connectors

•

Starter-to-transaxle bolts

2.

Drain the engine

3.

Properly support the engine and

Remove

4.

ft.

lbs.

(54

Fill

1 1

Start the

.

.

Front engine

•

Negative battery cable

equipped with A/C, perform the

fol-

mount bracket

•

Powertrain bending strut

•

Oil pan-to-transaxle structural col-

ft.

lbs.

•

(54

bolt

•

Remove

1. •

or disconnect the following

on high output

•

Starter electrical connectors

•

Starter-to-engine bolts

•

Starter

install:

2.

Install or

•

Starter lbs.

Apply silicone sealer

6.

Install or

7.

Remove

and torque bolts

to

40

•

Negative battery cable

•

Oil filter

•

Oil filter adapter

•

Structural collar

bending brace

•

Lateral

•

Transaxle lower dust cover

•

Oil

pan

to the oil

•

New

•

Oil

oil

pan gasket

pan and torque the retainers

Starter electrical connectors

Intake manifold

(12

lbs.

and adapter,

removed

•

Oil filter

Transaxle lower dust cover

•

Power

•

Front engine

train

to

Nm)

•

bending

if

strut

mount and bracket

Torque the front engine mount

8.

Nm)

•

line

ft.

on high output

retainers as follows:

Engine mount bracket bolt

a.

20

1

inch lbs. (3 Nm).

engines

Engine mount bracket bolts

b.

Negative battery cable

and Oil

oil.

or disconnect the following:

connect the following:

105 inch

•

•

the beginning of this section.

Drain the engine

pan

Oil

connect the following:

(54

in

equipped

if

pump-to-engine block parting

engines only

To

for leaks:

and add as nec-

To install:

Negative battery cable Intake manifold

oil.

engine and check

4.

surfaces.

•

lbs.

3.

Thoroughly, clean the gasket mating

5.

2000-02 Models .

ft.

with air conditioning

and

Nm)

and adapter,

Oil filter

engine mount-to

mount/crossmember bracket

40

Raise and safely support the vehicle.

Transaxle lower dust cover

•

engine/transaxle assembly.

1

bolts:

2.

lar

Raise and support the

torque to 40

lbs.

Before servicing the vehicle, refer to the

precautions

Install the front

ft.

2000-02 Models

or disconnect the follow-

ing:

lowing steps:

b.

80

essary.

oil.

transaxle assembly.

and

Nm)

a.

pan

the engine with clean

10.

1

If

lbs.

final torque.

then, recheck the fluid level

Install or

30 inch

lines

mounting

•

Collar-to-oil

c.

torque the bolts to 40

5.

bolts:

Collar-to-transaxle bolts:

b.

aside.

4.

pan

(108 Nm).

it

^lt equipped, move the A/C

To

Collar-to-oil

a.

(3 Nm).

vertically

it

and

torque the retainers as follows:

4:

c.

Pan

1:40 d.

REMOVAL & INSTALLATION

80

ft.

lbs.

2,

(108 Nm).

Engine mount bracket bolts 5 and ft.

lbs.

(54 Nm).

A

Engine mount bracket-to-insulator

assembly through-bolt: 40

ft.

lbs.

(54

e.

f.

the precautions in the beginning of this sec-

LATERAL bend *g brace

2

-

STRUCTURAL COLIAR OUST COVER

Insulator-to-lower radiator cross-

member nuts: 40 Mass damper ft.

Before servicing the vehicle, refer to

-

3 -

Nm).

1998-99 Models

1

lbs.

bolt:

(54 Nm).

40

ft.

lbs.

Exploded view tural collar

(54

models

Nm).

tion.

For Wheel Alignment specifications, see Section

1

of this

manual

of the

bending brace, struc-

and dust cover— 2000-02

CHRYSLER CORPORATION

8-20 5.

NEON

Thoroughly, clean the gasket 'mating

surfaces.

To install: 6.

7.

New

•

Oil

pan gasket

oil

pan and torque the screws

105 inch

lbs.

bending brace

•

Lateral

•

Structural collar

•

Oil filter

•

adapter and torque the

60

bolts to

ft.

the engine with clean

Fill

9.

Start the engine,

Oil

Nm)

(80

lbs.

Oil filter

8.

if

to

Nm)

(12

Transaxle lower dust cover

•

repair

line.

connect the following:

Install or

•

pump-

to the oil

Apply silicone sealer

to-engine block parting

check

oil

for leaks

and

necessary.

Pump

REMOVAL & INSTALLATION PUMP Boor

Oil 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Drain the engine

3.

Remove •

oil.

or disconnect the following:

Negative battery cable

•

Crankshaft damper

•

Timing

belt

•

Timing

belt tensioner,

on 2000-02

models • •

Oil

Use calipers

pan

Exploded view

Oil

pickup tube

•

Oil

pump

•

Front crankshaft seal

•

to

measure the outer

rotor

thickness

C-4685-C2

Insert Tool

•

Oil

pump

cover

4.

pump assembly

Crankshaft sprocket, using Tool

6795 and

•

of the oil

Oil

Wash

cover screws and

lift

the

off

pump

rotors

parts in a solvent; then,

all

inspect carefully for

damage

or wear, as fol-

lows: a.

Inspect the mating surface of the

pump should be smooth. Replace pump cover, scratched or grooved.

oil

the

Use a feeler gauge and straightedge

if

b.

pump

check the

cover surface.

If

a 0.003

to

warpage

for

and the inner rotor thickness

in. e.

feeler

Slide the outer rotor into the

gauge can be inserted

between the cover and the straightedge,

Measure the thickness and diame-

the rotor

surement the outer rotor.

If

(79.95mm)

and the housing. is

0.015

in.

If

the

(0.39mm)

in.

(7.64mm)

replace the housing only is

if

fin-

face of the bolt holes.

(0.102mm)

the diameter

is

3.148

if

d.

housing, between the

a feeler

or

gauge

more can be

of

0.004

in.

inserted

between the rotors and the straightedge, replace the

the outer rotor

h.

pump

Inspect the

assembly. oil

pressure

relief

valve

plunger for scoring and free operation

within specification.

in

in. f.

or less, replace the outer

the inner rotor

(7.64mm)

If

or more,

pump

Install the inner rotor into the

housing,

If

its

the clearance between

bore. Small

with

rotor. If

pump

mea-

the outer rotor

thickness measures 0.301 or less, or

pump

housing, press to one side with your

gers and measure the clearance between

the cover should be replaced.

ter of

pump cover

Lay a straightedge across the

(0.076mm)

c.

oil

measures 0.301

the inner and outer rotors

is

0.008

in.

i.

marks may be removed

400 grit wet or dry sandpaper. The relief valve spring has a free

in.

(0.203mm) or less, replace the inner rotor. g.

or more, replace both rotors.

Place a straightedge across the

length of about 2.39

should

test

in.

(60.7mm) and

between 18-19

lbs.

(8.1-8.6

Q Oi o C

CHRYSLER CORPORATION NEON

the metal case of the crankshaft

Crankshaft Sprocket Installer Tool

6792

FEELER

GAUGE

I

seal.

•

Oil

pump

•

Oil

pan

•

Timing

•

pickup tube

Angle the tool through the dust

lip

against the metal case of the seal. belt tensioner,

on 2000-02

Pry out the seal.

models OUTER ROTOR

7922EG30

and

•

Timing

•

Crankshaft damper

DO NOT

•

Accessory drive belts

crankshaft seal surface. Contact of

•

Negative battery cable

belt

front cover

the engine with clean

8.

Fill

9.

Start the

the prytool contact the

the tool blade against the crankshaft oil.

engine and check

then, recheck the fluid level

Measure the outer

let

edge (chamfer)

is

permitted.

for leaks:

and add as nec-

To install:

rotor clearance in the

essary.

housing 3.

Rear Main Seal

the crankshaft edge (chamfer) has any burrs or scratches on the, clean it up with 400 grit sand paper to preIf

REMOVAL & INSTALLATION

damage during new seal.

vent seal 1

.

of the

Before servicing the vehicle, refer to

installation

the precautions in the beginning of this sec-

»No

tion. 2. 7922EG31

Apply a small amount the

of

gasket maker to

pump body cover mounting

surface

Remove

or disconnect the following:

•

Transaxle

•

Flexplate/flywheel

•

Rear main seal. Insert a seal

remover between the dust

when compressed

kg)

to

1

.60

the

pump

is

oil

pressure

for oil

Place Crankcase Seal Pilot Tool

6926-1 on the lip

tool with a

and

4

crankshaft: this

SEAL

pressure loss.

install:

5.

Assemble the pump, using new

parts

as required, as follows: a.

with the

Install the inner rotor

chamfer facing the cast iron

oil

pump

cover. b. oil

Apply Mopar gasket maker

to the

pump. c.

Install the oil ring into the oil

pump

body discharge passage. 6.

by

Prime the

oil

pump

filling the rotor cavity 7.

Install or

•

Oil

The

pump,

align the rotor flats with

may

Torque the

flats.

bolts to 21

ft.

front crankshaft seal

out of the

oil

connect the following:

the crankshaft

pump

before installation

with engine

pump

lbs.

(28 Nm).

MUST

to align or

CRANKSHAFT

be

SEAL DUST

damage

result.

•

New

front crankshaft seal,

Seal Driver Tool •

using

6780

When

prying the seal out. be sure to use the prytool at the proper angle

Crankshaft sprocket, using a

For Maintenance Interval recommendations, see Section

1

a pilot

Position the seal over the Pilot Tool:

for other rea-

To

is

magnetic base.

ENGINE BLOCK

REAR CRANKSHAFT

within specifications, inspect for

worn engine bearings or sons

low and the

is

necessary when

falls

it

if

outside of specifications. If

is

in.

(40.6mm). Replace the spring,

j.

lubrication

installing the seal.

of this

manual

LIP

CHRYSLER CORPORATION

8-22

NEON Gap

of

side

rail

lower^^.

No

1

ring

gap

ft m

F Front of engine

y

No. 2 ring gap and spacer expander gap

Gap rail

2.0L (VIN C and Y) engines Chrysler engine connecting rod and cap

— ensure

Place a proper size pilot tool with a mag-

installation

netic base on the crankshaft

and rod prior

be sure the words THIS SIDE

OUT

to

on the

matchmark

to

of

upper side

— piston

ring

end-gap spacing

the cap

disassembly

Identification

mark

“1

R"

can be read.

seal

^The

pilot tool

should stay on the

crankshaft during installation of the seal. Be sure the seal lip faces the

crankcase during installation. 7922AG56

WARNING

K

2.0L (VIN C)

The arrow If

the seal

flush, this

is

driven

in

or weight

positioning.

marking (L or H) must

the block past

may cause an

face the timing telt side of the engine

leak.

oil

Common

Drive the seal into the block, using

5.

Engine— piston

tion

Chrysler piston ring identifica-

mark locations

Crankshaft Seal Tool 6926-2 and Handle C-

4171,

until the tool

bottoms out against the

block. Install

6.

Lock

&

the flexplate/flywheel. Apply

Seal Adhesive to the bolt treads.

Torgue the bolts

in

70

a star pattern, to

ft.

(95 Nm).

lbs.

Install the transaxle.

7.

Piston and Ring

2.0L (VIN Y) Engine

— piston positioning.

The small arrows on the crown

of the pis-

tons must point toward the front of the

POSITIONING

engine

FUEL SYSTEM Fuel System Service Precautions Safety

is

an important factor

when

ser-

•

Always

relieve the fuel

system pres-

Ensure that

component

tainer.

(injector, fuel rail,

pressure reg-

ulator, etc.), fitting or fuel line

maintenance and repairs

Exercise extreme caution whenever relieving

may

a safe

manner

result in serious personal injury.

tenance and testing

Main-

of the vehicle’s tuel

sys-

tem components can be accomplished safely

and

effectively

by adhering to the

•

To avoid the possibility of

fuel

system pressure,

skin, face

and eyes

to avoid

fol-

trate the skin or

any part

of the

be

may pene-

body

that

it

and per-

•

to

• Do come

not allow fuel spray or fuel vapors into contact with a spark or

Always place a shop towel or cloth

sonal injury, always disconnect the negative

around the

battery cable unless the repair or test proce-

loosening to absorb any excess fuel due to

dure requires that battery voltage be

spillage.

applied.

quickly removed from engine surfaces.

fitting or

Ensure

that

connection prior to

all

fuel spillage is

open

flame. •

Always use a back-up wrench when

loosening and tightening

contacts. fire

extinguisher near the work area.

fire

exposing

to fuel spray. Please

Always keep a dry chemical (Class B)

•

connection.

advised that fuel under pressure

lowing rules and guidelines:

soaked cloths or towels

are deposited into a suitable waste con-

vicing the fuel system. Failure to conduct in

all fuel

sure prior to disconnecting any fuel system

fuel line

tion fittings. This will prevent

and torsion

stress •

pipe

to fuel line piping.

Always replace worn

Do

rings. is

connec-

unnecessary

fuel fitting

0-

not substitute fuel hose where fuel

installed.

Q OQ o L.O

CHRYSLER CORPORATION NEON Fuel System Pressure

Fuel

Fuel Filter A combination

RELIEVING

assembly

tor

is

The

fuel filter/pressure regula-

used, which

is

voir, level

REMOVAL & INSTALLATION

the fuel system. Service vehicles

NEVER smoke while

the precautions in the beginning of this sec-

come

to

a dry chemical fire

an open container due to

in

fire or

1998-99 Models

risk of 1

explosion.

Remove

or disconnect the follow-

Before servicing the vehicle, refer to

1.

•

Negative battery cable

•

Fuel

•

Protective cap from the fuel

filler

cap rail’s

into

an

fuel

pressure

will

bleed

off

Disconnect the quick-connect supply

line

nipple. 5.

Depress the locking spring tab

located on the side of the fuel filter/regulator,

tainer.

sure the upper and lower O-rings are kit

C-4799-B

then rotate 90 degrees and pull out Be

on the

6.

The vehicle

is

now

filter

safe for servic-

ing.

system,

finished working on the fuel

install the fuel filler

clean engine

cap

TEST

in

align the 2

oil.

filter

O-rings with

Insert the filter into the

the fuel

pump module,

•

hold-down tabs with the

tor

filter

clockwise

until the

to

bleed

the container

off

through the hose into

spring tab

pump mod-

Fuel

it

to

electrical lock

unlock

pump module

it

electrical

down on

con-

the

connector retainer and pulling the

in the locating slot

connector

Attach the fuel line to the filter/regula-

5.

Support the

off of the

module

fuel tank with a

transmis-

sion jack

Connect the negative battery cable

•

The Depress the spring pull the fuel filter

pump module

nector by pushing

Relieve the fuel system, allowing the

pressure

Fuel

by sliding

assembly. 9.

Fuel lines from the fuel

nect retainers

then

•

rotate the

or disconnect the following:

Negative battery cable

ule by depressing the quick-con-

While applying downward pressure,

catches 8.

Remove •

flange. 7.

FUEL

4

•

Lightly coat the

opening

When

still

assembly.

To install:

contains hose C-4799-1.

Drain the fuel tank.

The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

from the filter/regulator

through the hose into the gasoline con-

**Fuel pressure gauge

Properly relieve the fuel system pres-

** WARNING

Disconnect the negative battery cable.

4 fuel

other end of the hose to the fuel pressure

The

3.

sure. 3.

approved gasoline container. Connect the

test port.

Properly relieve the fuel system pres-

2.

C-4799-1)

2.

sure.

tion.

Place the open end of a fuel pressure

release hose (tool

5.

Before servicing the vehicle, refer to

tion.

the precautions in the beginning of this sec-

pressure port

4.

.

the precautions in the beginning of this sec-

ing:

3.

pump

REMOVAL & INSTALLATION

contact with a spark or

in

tion. 2.

the fuel

not allow fuel spray or fuel vapors

open flame. Keep

Before servicing the vehicle, refer to

If

pump module.

Do

extinguisher nearby. Never store fuel .

inlet strainer, fuel

requires service, replace the entire fuel

[i]

in

servicing the vehicle!

fuel reser-

sensor, inlet strainer and fuel

only serviceable items.

well ventilated areas and avoid igni-

pump

with the

is integral

pressure regulator and level sensor are the

Relieve the fuel system pressure before servicing any components of

1

pump

pressure regulator. The

CAUTION

tion sources.

fuel

module, which also contains the

located on

pump module.

the top of the fuel

Pump

tab, then rotate

fuel

module assembly contains

pump, pressure

and

assembly out

For Tune-up, Capacities and Firing orders, see Section

Fuel tank strap bolts; then, lower

strainer and level sensor

1

of this

manual

the

regulator, reservoir, inlet

CHRYSLER CORPORATION

8-24

NEON •

Negative battery cable

•

Vapor

line

•

from the Evaporative

EVAP

canister

con-

electrical

nector

Emissions (EVAP) canister tube •

pump module

Fuel

8.

•

Fuel line, to the fuel

•

EVAP

•

pump module

canister

Vapor

line to the

EVAP

canister

tube

7922EG37

To loosen the fuel

pump module

The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. •

locknut,

pump mod-

nect retainers with your

repair

•

module

•

Fuel

Fuel

locknut using a

pump module

electrical

pump and

down on

con-

the 2.

Release the

3.

Remove

connector retainer and pulling the

and spanner wrench

connector

discard the O-ring

seal

Fuel

oft of

the

tube and

filler

from the

install:

module filler

fuel tank’s filler

Support the

vent tube

hose

fuel tank with a

transmis-

sion jack. •

Take care

avoid wiping

to

dirt or

debris into the fuel tank opening.

module •

the fuel

pump mounting

Fuel

locknut using a 4.

Fuel

and spanner wrench

pump and

7.

of the tank clean.

connect the following:

New

in

O-ring seal

To

^Be

the tank open-

h

pump

sure the alignment tab on the of the fuel in

wiping

•

Fuel injector(s) and discard the 0-

Fuel

pump module

locknut. Using

torque the locknut to 41

ft.

lbs.

Wipe

7.

•

with the fuel injectors

Install or

connect the following:

new O-rings

Fuel injector(s) using

lbs.

flange

connect the following: in

O-ring seal

Fuel

rail

with the fuel injectors and

torque the bolts to

of the tank clean.

New

Fuel injector retainers

5.

repair

170-230

inch

(20-25 Nm)

•

Fuel injector electrical connectors

•

Fuel line(s) to fuel

•

Negative battery cable

Start the vehicle, if

rail

check

for leaks

and

necessary.

the tank open-

ing •

Fuel tank strap bolts and torque

them

pump mounting

Install or

•

Nm). •

the fuel

and surrounding area

(55

rail

rail

install:

dirt or

the notch on the fuel

the ratchet and spanner wrench,

to

45

ft.

lbs. (61

Nm)

Negative battery cable

2000-02 Models Before servicing the vehicle, refer to

Fuel

pump

'•Be sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank. •

the precautions in the beginning of this sec-

Fuel

pump module

the ratchet

tion.

locknut. Using

and spanner wrench,

torque the locknut to 41 Properly relieve the fuel system pres-

ft.

lbs.

(55

Nm). 3 - FUEL INJECTOR

sure.

4.

to avoid

Such contaminants may clog or damage the new fuel pump.

pump module

6.

•

3.

Fuel injector retainers

•

WARNING

Take care

tank.

2.

Fuel

•

debris into the fuel tank opening.

flange sits

.

•

•

Fuel

underside

1

Fuel injector electrical connectors

^Lubricate the O-rings with clean engine oil.

install:

ing •

Fuel line(s) from fuel

•

discard the O-ring

flange

Install or

•

Negative battery cable

•

•

seal

and surrounding area

system pressure.

rings

To

pump module

ratchet •

Wipe

Fuel tank strap bolts; then, lower

fuel

or disconnect the following:

•

the tank slightly for access to the

Such contaminants may clog or damage the new fuel pump. 6.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

nector by pushing

•

To

and

for leaks

tion.

pump module

ratchet

check

necessary.

REMOVAL & INSTALLATION 1.

Fuel

if

Fuel Injector

thumb and

forefinger

the tank slightly for access to the

•

Negative battery cable

Start the vehicle,

ule by depressing the quick-con-

5.

use a ratchet and spanner wrench

Fuel line from the fuel

•

Drain the fuel tank.

Remove

or disconnect the following:

•

Fuel tank

•

Fuel

filler

f

tube and

filler

to the fuel tank's filler

9306EG01

vent tube

hose

Exploded view

of the fuel rail

assembly

CHRYSLER CORPORATION NEON

8-25

DRIVE TRAIN 4. •

Transaxle Assembly

REMOVAL & INSTALLATION

Intake manifold support bracket

•

Upper

starter bolt

•

Upper

bell

Install

housing bolt

an engine bridge fixture and

support the engine securely.

Manual Transaxle 1998-99

MODELS

When

installing the halfshafts,

retaining clips

MUST

reuse the old clips.

If

be used.

new NEVER

old clips are

•

Front wheels

used, the inner CV-joints

•

Halfshafts

gage.

may

disen-

Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section. 2.

Drain the transaxle

3.

Remove • •

fluid.

or disconnect the following:

Battery cables

Power Distribution Center (PDC), pull

it

move

up and out it

of

its

bracket and

aside

•

Battery heat shield

•

Battery and tray

equipped

•

Cruise control,

•

Vehicle Speed Sensor (VSS) wire

if

Pull the clutch cable

backward,

to discon-

nect the clutch cable from the bell hous•

Back-up lamp switch wiring from

ing— 1998-99 manual

transaxle

the transaxle

WARNING

Removing bolts

the lower starter mounting

— 1998-99 manual transaxle

Pry with equal amounts of force on both sides of the shifter cable isolator

bushing to avoid damaging the

cable isolator bushing. •

Both gearshift cable ends from the transaxle shift levers, using 2 pry tools

•

Clutch housing vent cap, exposing the clutch cable

end and clutch

release lever •

Clutch cable from the

•

Shift cable (linkage)

•

Accelerator cable shield,

bell

housing

mounting

Remove 1

the clutch cable from the lever

998—99 manual transaxle

bracket

Unfasten the 2 bolts, then remove the bracket (strut) from the engine and

if

equipped

Use 2 prytools

to

transaxle

— 1998-99 manual

transaxle

disconnect the gearshift

cable ends from the shift levers—1998-99

Exploded view

manual transaxle

bracket

of the

linkage mounting

— 1998-99 manual transaxle

Exploded view

of the left

mount through-bolt

For complete service labor times, order the Chilton Labor Guide

manual transaxle

— 1998-99 models

CHRYSLER CORPORATION

8-26 •

NEON

Power hop damper and bracket mounting

•

Lower

•

Transaxle-to-rear lateral bending

starter

bolt

Support the transaxle with a

5.

When

from the engine and transaxle

strut

installing the halfshafts,

MUST

retaining clips

reuse the old clips.

jack.

be used.

If

old clips are

•

Front motor

mount through-bolt

used, the inner cv joints

•

Front motor

mount

gage.

bolts from the

new NEVER

may

disen-

engine and transaxle •

•

Lower dust shield Rotate the crankshaft clockwise

6.

Halfshafts

Front wheels

•

in

12.

order to access the driveplate-to-modular fill

clutch bolts.

Fill

and support. tion

4 driveplate-to-modular

Install the

Upper

bell

•

Upper

starter bolt

•

Intake manifold support bracket

torque the bolts to 70

Push

modular clutch assembly

the

housing

into the transaxle bell

Remove

•

Frame

transaxle

rail-to-left

mount from

Left transaxle

transaxle, then

the

push the mount up

Transaxle

•

Modular clutch assembly from the

•

VSSwire

transaxle input shaft

•

Cruise control,

connect the following:

Install or

•

Modular clutch assembly

to the

transaxle input shaft •

Transaxle and torque the transaxle-

to-engine bolts to 70

Nm) and bolts to 1 1

ft.

lbs.

40

lbs.

ft.

(54

•

mount

Left transaxle

15. jack.

•

lbs.

Frame

(54

rail-to-left transaxle

(108

40

mount

Nm)

in

•

4 driveplate-to-modular clutch bolts

•

Lower dust shield and torque the bolts to

•

to the

108 inch

lbs.

mount

Front engine

(12

lbs.

•

80

lbs.

ft.

Battery

•

Battery heat shield

•

PDC

Nm) and

Battery cables

Be sure the

vehicle’s

back-up

• •

lbs. (61

Adjust the crossover cable

in

order

transaxle

Lower

1

a.

Remove

b.

Loosen the adjusting screw on the

the floor shift console.

Pin the transaxle crossover cable

the

3-4

neutral position using a 14

the

on the top

of the

con-

test the vehicle to

be sure the

operating properly.

Before servicing the vehicle, refer to

.

tion. 2.

Drain the transaxle

3.

Remove

fluid.

or disconnect the follow-

ing: •

Battery

•

Air cleaner/throttle

body assem-

•

Crankcase vent hose

•

Throttle Position Idle Air

Sensor (TPS)

Control (IAC) con-

nectors •

Throttle

bady

air

duct from the

intake manifold

45

ADJUSTMENT

SCREW

t

•

'/i

7922EG47

bolt

crossover cable at the shifter

ft.

Proportional Purge Solenoid

ft.

Power hop damper and bracket and

Nm)

is

and

torque the damper bolts to 40

(54

lip

(PSS)

Loosen the adjustment screw on the

lbs.

all

the precautions in the beginning of this sec-

at the shifter.

c.

Nm) mounting

into

2000-02 MODELS

CROSSOVER

starter

from the

drill bit

fol-

SHIFTER

40

to

the

Reinstall the center shift console.

Road

lights

CABLE

ft.

Remove

Seat the boot

mount through-bolt

and torque the through-bolt

center during screw

bly

Nm)

Front motor

off

sole.

•

to

mechanism

f.

Nm)

mount-to-engine bolt

(54

lbs. (8

Blouse the boot out around the console.

bolts to the

(108

70 inch

gears.

engine mount-to-transaxle

bolt to

front

to

tightening.

engine and transaxle and torque the front

loaded and

check by shifting the transaxle

equipped

Battery tray

crossover cable

ft.

14

nm). Be careful to avoid moving the 16. shift

ensure proper shifter adjustment as

Nm)

drill bit

at least

neutral position. Torque the

in its

lows:

to the

through-bolt and torque to 80 lbs.

to

case

shifter is spring

adjustment screw

and speedometer are functioning properly.

Nm)

transaxle and torque the bolt to ft.

if

•

•

the boss

transaxle case and perform a functional

•

14.

(95

the lateral bending strut

Support the transaxle with a

.

housing

transaxle

To install:

The

e.

•

10.

beil

Back-up lamp switch wiring

•

into the transaxle

d.

transaxle shift levers

to provide clearance

in

(12mm).

mounting

Both gearshift cable ends to the

•

the

in

if

Clutch housing vent cap

•

Align the hole

self-centering. Allow the shifter to rest

Clutch cable to the

•

in. drill bit.

goes

bracket

mount

the 3-4 neutral posi-

crossover lever with the hole

in.

Shift cable (linkage)

or disconnect the following:

in

— 1998-99 manual transaxle

on the transaxle case. Be sure the

equipped

for easier

through-bolt •

Lbs. (95

ft.

Accelerator cable shield,

•

transaxle removal.

•

and

nm)

the clutch.

9.

housing bolt

•

clutch bolts, to separate the driveplate from

8.

the engine bridge fixture

crossover lever

the driveplate and pressure plate before removing any bolts. 7.

Insert a 'A in. diameter drill bit to pin the

Remove

13.

^•For installation purposes, matchmark

the transaxle to the bottom of the

plug hole.

transaxle

— manual

Accelerator cable

equipped

•

Cruise control cable,

•

Battery tray from the bracket

•

Ground cable from the bracket

if

battery tray

CHRYSLER CORPORATION

8-27

NEON Back-up Bell

light

switch connector

•

Driveplate-to-clutch

Clutch cable from the fork and

under the engine’s

transaxle

engine.

Shift cable-to-bracket clips

through-bolt.

Shift selector

and crossover

cables from the levers and

Remove

bolts to

pan and support the

the transaxle’s upper

mount

Left engine-to-transaxle lateral

To

bending brace

housing dust cover

•

If

•

installing a

to

the jack and

Driveplate-to-clutch

and torque

new

or replacement

transaxle, transfer the upper

lateral

Remove

9.

install:

6.

upper mount aligns with the mount

80

ft.

lbs.

mount

bending brace

new

Starter

mount-to-transaxle bolts to 50

Starter lbs.

•

to the

transaxle; then, torque the upper ft.

wooden

block.

Transaxle

•

(95 Nm).

mount bracket through-bolt

transaxle

Structural collar

lbs.

ft.

(108 Nm).

an assistant to support the

Right engine-to-transaxle

until the

Transaxle-to-engine bolts, using

•

Halfshafts

70

Raise the engine/transaxle assembly

8.

bracket hole. Torque the upper mount-to-

to provide clearance.

aside

Bell

oil

Torque the transaxle-to-engine

bolts

wood

Lower the engine/transaxle assembly

5.

move

module

Place a jack and block of

4

housing cap

to

65

ft.

module lbs.

(88

and torque the bolts

(54

bolts

Nm) to

40

Starter electrical connectors

and

torque the positive cable bolt to 89

lbs.

inch lbs. (10

(68

Nm)

Nm). Install or

7.

connect the following

•

Transaxle

•

Transaxle-to-engine bolts, using an assistant to support the transaxle.

1

- AIR

CLEANER ASSY THROTTLE BODY DUCT

2 -

View

of the air

throttle

1

-

SHIFT CABLES

2 -

CUPS

3

BRACKET

-

View

cleaner assembly and

body duct— 2000-02 models

ol

A

the shift

1

-

LATERAL BEKO- *«G BRACE

?

-

STRUCTURAL COLLAR OUST COVER

cables— 2000-02 manual

3 -

transaxle

View

of the left lateral

structural

1

-

2 3 -

CLUTCH CABLE TRANSAXLE BELLHOUSING CAP

1

CONNECTOR 2-SFNSOR 1

3 4

-

-

2 -

O-RlNG

3

SPEEDO PINION

bending brace and

collar— 2000-02 models

TRANSAXLE ENGINE LATERAL BENDING BRACE

S908EQ30

View

of the clutch

View

cable and bell housing

cap— 2000-02 manual

of the

Vehicle Speed Sensor (VSS)

2000—02 manual transaxle

transaxle

Please

visit

our web

site at

ft.

Nm)

View

of the right lateral

2000-02 models

www.chiltonsonlme.com

bending brace

CHRYSLER CORPORATION

8-28

NEON Automatic Transaxle

1998-99

MODELS

Before servicing the vehicle, refer to

1.

the precautions

in

the beginning of this sec-

tion.

The transaxle and torque converter must be removed as an assembly; otherwise the

pump bushing may be damaged. The driveplate

torque converter driveplate, or

oil

will

seal

not support a load; therefore, none of

the weight of the transaxle should be

allowed to rest on the plate during removal. -

1

2 3 -

MOUNT BRACKET

Remove

2.

BOLT 1

MOUNT

-

2 -

or disconnect the following:

MOUNT TRANSAXLE

•

Battery cables

•

Power Distribution Center (PDC),

9306EG33

9306EG35

View

of the

upper mount through-bolt

2000—02 models

•

Left

View

engine-to-transaxle

60

ft.

•

lateral

lbs. (81

Nm)

Install the structural collar

10.

and

torque the bolts as follows:

pan

1

Step

a.

bolts:

b.

—

transaxle bolts:

40

bolts:

1 1

Install or

.

•

80

lbs.

ft.

3— Structural

Step

c.

lbs. (3

2— Structural

pan

ft.

lbs.

to

60

ft.

lbs. (81

VSS

•

Shift selector

electrical

Battery tray

housing cap

Back-up

•

Ground cable

light

•

Vehicle Speed Sensor (VSS) wiring

to the battery tray

•

transaxle

Cruise control cable,

collar-to-oil

•

Air cleaner

Throttle

if

body

air

ft.

WARNING

equipped

assembly and torque the

nuts and bolts to 10

lbs.

(14

Nm)

duct to the intake

manifold

Pry up on both sides of the shift cable isolator bushing, evenly, to

avoid damaging the cable isolator

bushing.

•

TPS and IAC connectors

•

Crankcase vent hose

to the throttle

•

body connector

and crossover cables

Shift cable-to-bracket clips

Neutral safety switch and torque

converter control wiring, from the

•

Nm)

if

bracket

(108 Nm).

•

equipped

Cruise control,

switch connector

Battery tray to the bracket

lateral

and

•

Accelerator cable

to the levers •

•

•

housing dust cover

Bell

•

Battery

transaxle

•

Halfshafts

•

Battery heat shield

•

connect the following:

of its bracket

aside

•

Nm).

Right engine-to-transaxle

up and out it

•

Bell

(54 Nm).

it

Clutch cable to the fork and

collar-to-

bending brace and torque the bolts

•

pull

move

•

Structural collar-to-oil

30 inch

Step

— 2000-02 man-

ual transaxle

bending brace and torque the bolts to

upper mount

of the

•

PSS

•

Battery

to the throttle

body

•

Fill

13.

Road

Gearshift cable bracket bolt from the transaxle

the transaxle to the proper level.

12.

Gearshift cable end from the

transaxle shift lever

test the vehicle

and inspect

•

Throttle pressure control cable from

•

Throttle pressure control cable

•

Transaxle’s dipstick tube

•

Transaxle’s

for

leaks.

the lever

bracket bolts from the transaxle

them •

oil

cooler lines plug

to prevent

contamination

Throttle pressure control cable support bracket bolts

1

~

MODULAR CLUTCH ASSEMBLY

2 - CLIP

3 4 -

TRANSAXLE CLUTCH MODULE BOLT

(4)

9306EG34

Disconnect the gearshift cable end from the transaxle shift lever

Exploded view

of the transaxle

and related components

— 2000-02 manual transaxle

matic transaxle

— 1998-99 auto-

:*

CHRYSLER CORPORATION

3.

housing bolts

•

Upper

bell

•

Upper

starter bolt

an engine bridge

Install

fixture

Front wheels

•

Halfshafts

new DO NOT

must be used.

reuse the old clips. Failure to use new clips could cause the inner CVjoints to

mount

•

VSS

Left

mount-to-transaxle bolts and

•

Cruise control,

•

Battery tray

torque to 40

mount through-bolt was removed

Battery Battery heat shield

from the transaxle, be sure to align the

.

PDC

pump

•

Battery cables

inner gear pilot flats with the torque

Nm) and

The exhaust flex joint must be disconnected from the exhaust manifold anytime the engine is lowered. If the engine is lowered with the flex pipe

ft.

108 inch

strut,

Front engine bracket through-bolt

•

Front engine bracket bolts

Lower

•

Lower dust shield screws

•

Front engine bracket through-bolt

will

•

Transaxle-to-rear lateral bending

the weight of the transaxle should be

^Matchmark

Exhaust pipe

•

Exhaust

new

the converter to the flex-

10.

Remove or disconnect the • Left mount through-bolt

Proportional Purge Solenoid (PSS)

new must be used. DO NOT

installing the halfshatts,

the engine bridge fixture

•

Upper

bell

•

Throttle pressure control cable sup-

•

Transaxle

to

transaxle

work the transaxle and the

C-clamp

housing. This

will

of the crankshaft.

to the

edge

lbs

•

•

cooler lines. Torque

(12

•

Nm) and

cooler line

fitting to

21 •

Transaxle

oil

cooler lines and plug

Shift cable

and bracket from Ihe

Kickdown cable and bracket from the transaxle

Transaxle

bracket bolts to the transaxle

Halfshafts

Throttle pressure control cable to

•

Structural collar

the lever

•

•

transaxle •

Gearshift cable

end

•

oil

pan

Left engine-to-transaxle lateral

bending brace

Gearshift cable bracket bolt to the

to the transaxle

housing duct cover

•

Bell

•

Starter

•

4

Adjust the gearshift and throttle

connect the following:

Neutral safely/back-up light switch

transaxle

(28 Nm).

Torque converter-to-driveplate bolts

Using a jack and a block

of

wood,

support the engine/transaxle assembly

cables.

Rear engine bolt to the transaxle

Torque converter clutch solenoid

the lines to prevent contamination

shift lever

Install or

•

Battery tray from the bracket

•

Support the transaxle with a

9.

•

if

assembly

•

Nm)

transaxle jack.

Air cleaner

Throttle pressure control cable

transaxle and torque the ft.

oil

equipped

Cruise control cable,

•

•

•

Install the

Transaxle kickdown cable

Transaxle's dipstick tube

removal

transaxle-to-cylinder block bolt: 70

lbs.

duct from the

•

•

of the

hold the torque con-

install:

8.

ft.

air

connector

the oil cooler line-to-radiator fitting lbs.

body

connector

Rear engine bolt from the transaxle

108 inch

Throttle

Accelerator cable

port bracket bolts oil

Control (IAC) connectors

•

housing bolts

Transaxle's

Sensor (TPS) and

Idle Air

•

•

•

end

Throttle Position

intake manifold

Front wheels

starter bolt

•

off

Crankcase vent hose

•

cause the inner CV-

Upper

body assembly

•

•

mount

verter in place during transaxle

(95

•

mount-to-transaxle bolts

Attach a small

To

Battery Air cleaner/throttle

•

15.

fluid.

or disconnect the following:

•

Left

the

Remove •

Left

hub from

Drain the transaxle

3.

Halfshafts

•

Carefully

2.

fold bolts

Remove

14

following:

engine block dowels. Disengage the con-

bell

mani-

•

7.

not support a load; therefore, none of

and support.

Support the transaxle with a

torque converter assembly rearward

verter

manifold

flex joint-to-exhaust

clips could

•

transaxle jack. 6.

to the

seal

allowed to rest on the plate during removal.

engine and transaxle

•

oil

joints to disengage.

bolts

plate for alignment during installation. 5.

torque converter driveplate,

starter bolt

reuse the old clips. Failure to use

Rotate the engine clockwise and

4.

remove the converter

pump bushing may be damaged. The driveplate

or

When

starter bolt

The transaxle and torque converter must be removed as an assembly; otherwise the

Front engine bracket bolts

retaining clips

•

Nm)

* WARNING

from the engine and transaxle

•

tion.

Lower

•

Transaxle-to-rear lateral bending

(12

lights

Before servicing the vehicle, refer to

.

•

Exhaust pipe from the manifold

•

1

housing cover bolts

lbs.

back-up

the precautions in the beginning of this sec-

Lower dust shield screws and bell

vehicle’s

•

fold bolts •

Be sure the

2000-2002 MODELS

connect the following:

strut to the

mani-

Fill

17.

to the converter bolts. Install or

the transaxle to the proper level.

16.

and speedometer are working properly.

(68 Nm).

lbs.

will occur.

flex joint-to-exhaust

flex-

(95

lbs.

ft.

Rotate the engine clockwise to get

12.

to

Exhaust

70

the flexplate-to-torque converter

50

bolts:

Torque the

flats.

plate-to-crankshaft bolts to

torque the

•

equipped

•

•

damage

if

•

Left If

13.

attached,

Nm)

wiring

the torque converter

•

access

disengage.

(54

lbs.

ft.

converter impeller hub

installing the halfshafts,

retaining clips

Left

•

11.

WARNING

When

•

and

support the engine. •

8-29

NEON

Neutral safety switch

and torque con-

verter control wiring to the transaxle

Timing belt service

is

covered

in

Section

3

of this

5.

Remove

through-bolt.

manual

the transaxle upper

mount

CHRYSLER CORPORATION

8-30

1

NEON

- SHIFT LEVER

2 - SHIFT

CABLE 9306EG36

View

of the

gear

shift

cable— 2000-02

automatic transaxle

- CLIP BOLT

1

2 -

3

_ TRANSAXLE

4 -

(3)

Exploded view

of the

transaxle and related

CONVERTER BOLT

(4)

components—2000-02 automatic

1 1

Remove

.

12.

and wooden block.

the jack

Install or

transaxle

connect the following:

Torque converter-to-driveplate bolts

•

and torque the bolts (88 •

Starter lbs.

- LEVER

1

2 3 -

BRACKET KICKDOWN CABLE

to

65

and torque the bolts

to

40

ft.

Nm)

(54

Starter electrical connectors

•

lbs.

ft.

Nm)

and

torque the positive cable bolt to 90 9306EG37

Nm)

inch lbs. (10

View

of the

kickdown cable— 2000-02

•

automatic transaxle

•

Bell

housing dust cover

Left

eng ne-to-transaxle bending i

brace and torque the bolts to 60 lbs. (81

13.

ft.

Nm)

the structural collar and

Install

torque the bolts as follows: 9306EG40

View

of the

upper

mount— 2000-02

auto-

matic transaxle

1— Structural

Step

a.

pan

bolts:

b.

30 inch

2— Structural

Step

10.

transaxle bolts: 80 •

-

1

2 4 -

bolts:

14.

Install or

•

Torque converter from the front

•

Halfshafts

pump

•

Speed control

To install:

•

Right engine-to-transaxle

If

installing a

new

new

mount

to

to the

transaxle; then, torque the upper

mount-

Vehicle Speed Sensor (VSS)

2000—02 automatic transaxle

9.

•

upper mount through-bolt may be accessed through the left side wheel house. 6.

for clearance. 7.

Remove

or disconnect the following:

ft.

lbs.

ft.

lbs.

to

•

mount bracket through-bolt

•

(108 Nm).

lbs.

it

equipped lateral

lbs. (81

21

ft.

oil

lbs.

Nm)

cooler lines and

oil

cooler line-to-radia-

108 inch oil

(28

lbs.

(12

cooler line

Nm)

fitting

Nm)

Torque converter clutch solenoid light

switch connectors

upper mount aligns with the mount

ft.

cable,

and neutral safely/back-up

bracket hole. Torque the upper mount-to-

80

ft.

and trans^xle

Raise the engine/transaxle assembly

to

lbs.

tor fitting to

•

(95 Nm).

60

Transaxle

torque the

(68 Nm).

and tighten the

support the transaxle. Torque the transaxle-

to-engine bolts to 70

until the

Lower the engine/transaxle assembly

50

transaxle

transaxle-to-engine bolts, using an assistant to

•The

Install

ft.

connect the following:

bending brace and torque the bolts

or replacement

transaxle, transfer the upper

to-transaxle bolts to of the

(54 Nm).

pan

Transaxle

9306EG38

View

collar-to-oil

assistant to support the transaxle

8.

SENSOR

40

(108 Nm).

lbs.

ft.

3— Structural

Step

Nm). collar-to-

•

CONNECTOR SPEEDO PINION

3 - O-RING

c.

Transaxle-to-engine bolts, using an

collar-to-oil

lbs. (3

Transaxle dipstick tube Gearshift cable bracket bolt to the transaxle

CHRYSLER CORPORATION

8-31

NEON •

plant have modular clutch assemblies.

lever

Battery tray

•

Battery

If

the 11th digit of the VIN code

is

“D”,

cracks, deep grooves or ridges. Replace

the VIN

parts as required.

“T”, the vehicle was produced Toluca assembly plant.

•

Transaxle kickdown cable

•

Cruise control cable,

•

Air cleaner

1998-99 Models

(14

lbs.

ft.

Nm)

TOLUCA BUILT VEHICLES 1

Crankcase vent hose

tion.

to the throttle

body

the transaxle and check for leaks.

15.

Fill

16.

Be sure the vehicle’s back-up

lights

and speedometer are working properly.

Remove

3.

Matchmark

if

0.008

the position of the clutch

hub

mechanism

is

maintains tension on the cable. This tension

and not discolored from exces-

sive heat.

Each

at a time, in a

Wipe the

f.

damage

keeps the clutch release bearing continu-

ment

When and

ing pull it

No manual

if

from the dash panel.

Damage

to

remov-

2.

(11kg) of 1.

mine

If

if

Using a surface All

plate, test the

sections around the

with the surface plate within 0.015

The cover should be a snug

i.

the flywheel dowels.

Inspect for

oil

leakage through the

engine rear main bearing transaxle input shaft seal.

should be fixed

oil seal If

bly

and

there

at this

is

in.

(0.381mm).

If

on

fit

the clutch assem-

does not meet these requirements,

it

should be replaced

leak-

To install:

time

pull the clutch

••The heavy side

draw the

ol the

flywheel

is

indicated by a white paint mark, near the outside diameter.

effort the

2-2.0

in.

the cable

the

h.

cover for flatness.

to

faces.

it

free

the clutch cable housing toward

25

To minimize the effects

lbs.

mechanism

tion procedure:

indi-

a

function

is

Loosely assembly the flywheel

the crankshaft.

does not adjust, deter-

mechanism

of flywheel

unbalance, perform the following installa-

cable housing should

(30-50mm). This

cates proper adjuster 3.

(0.0-0.1mm) below the should also be

attaching bolt holes should be in contact

taut.

Push

It

necessary.

cable

age,

the dash panel. With less than

move

if

••Handle the components carefully

b

release lever end of the cable to

in.

9. outer diameter.

from discoloration, burned areas, cracks,

occur.

With slight pressure,

0 000-0.0039

grooves or ridges

the flywheel,

avoid contaminating the friction sur-

To check the function of the adjuster

cable

assembly

remove

mechanism, use the following procedure: 1.

the clutch pressure plate.

do not

to the

flat-to-

slightly concave, with the inner diameter

Inspect the clutch assembly as fol-

adjust-

installing the clutch cable,

on the clutch cable housing

may

Remove

should be

plate friction area

lows:

servicing this vehicle or

self-adjuster

pressure plate for flatness. The pressure

clutch chatter.

the clutch cover

spirits.

Using a straightedge, check the

dirt

and disc from the flywheel

a.

obtainable.

is

the clutch disc facing

may cause

Remove Remove

8.

ously loaded against the fingers of the clutch cover assembly.

g.

tight.

friction surface of the

pressure plate with mineral

transferred from your hands onto the clutch disc

arched springs

of the

between the facings should be

crisscross

with oily or dirty hands. Oil or

7.

fit

dry. clean

1-2 turns

6.

snug

portions of the disc assembly should be

to prevent the clutch disc

located with the

clutch cable assembly. The preload spring

of the rivet heads.

Loosen the clutch cover attaching

••DO NOT touch

adjuster

(0.20mm)

and damaging the facings

falling

gradually, avoiding cover

This

oil

without signs of excessive wear. Metallic

a clutch alignment tool through

Install

1998-99 Models

for clutch disc wear.

in.

transaxle input shaft should be a

4

pattern. This releases the spring pressure

compensate

or

during installation.

bolts,

tem has a unique self-adjusting mechanism

show grease

The splines on the disc hub and

5.

The manual transaxle clutch release sys-

the facings

soakage, or wear to within less than

the transaxle assembly.

cover and flywheel for proper alignment

from

ADJUSTMENT

The clutch disc should be handled

e.

without touching the facings. Replace the disc

2.

the clutch disc

Clutch

is

warped, replace the flywheel.

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

to the throttle

the surface

If

severely scored, heat checked, cracked or

TPS and IAC connectors body

then wipe the surface

with mineral spirits.

equipped

if

assembly and torque the

nuts and bolts to 10

to

Clean the flywheel face with

d.

medium sandpaper,

Accelerator cable

PSS

friction faces of the flywheel

excessive discoloration, burned areas,

at the if

The

c.

and pressure plate should not have

is

at the

•

•

was produced

Belvidere assembly plant;

code

•

at the

the vehicle

and bracket

•

•

Belvidere assembly

cles

shift lever

Transaxle kickdown cable to the

•

made

Gearshift cable end to the transaxle

If

available, use

new

to

fly-

wheel attaching bolts which have sealant

properly seated

on the threads.

on the bracket.

If

new

able, apply Loctite

REMOVAL & INSTALLATION

bolts are not avail-

sealant to the threads

of the original bolts. This sealant is

required to prevent engine

'Vehicles made at the Toluca, Mexico assembly plant have conventional clutch and flywheel assembles. Vehi-

Exploded view

components

of the

conventional clutch

— 1998-99 vehicles

b.

built in

until the

Toluca

Heater Core replacement

covered

in

Section

2

of this

leakage.

white paint (heavy side)

12 o'clock position.

is

oil

Rotate the flywheel and crankshaft

manual

is at

the

CHRYSLER CORPORATION

8-32 c.

NEON transaxle input shaft seal.

Tighten the flywheel attaching

bolts, in a crisscross pattern, to lbs.

(95 Nm).

10.

Mount

70

ft.

being careful to properly align the

tool,

should be fixed

it

To assembly on the

the clutch

flywheel with the disc centered on the align-

ment

noted,

If

any leakage

lbs.

•

install:

^Always use new

bolts

marked

for

the

new

REMOVAL & INSTALLATION •

Modular clutch assembly onto the Before servicing the vehicle, refer to

input shaft

is installed,

•

align the orange cover balance spot as close

Apply pressure

Center the

tip of

to the

alignment

tool.

the tool into the crankshaft

and the sliding cone

into the clutch fingers.

Tighten the clutch attaching bolts sufficiently

the precautions

Transaxle

Use a crisscross

pattern, until

all

bolts

•

to hold. the disc in position.

ft.

lbs.

•

Transaxle lower support brackets

•

Starter

•

Negative battery cable

until all bolts

Use a crisscross pattern

ft.

lbs.

•The

Remove

13.

Install the transaxle.

2000-02 Models

the clutch alignment tool. 1

precautions

in

• • • •

Modular clutch-to-driveplate

Rear and front transaxle brackets

Modular clutch-driveplate bolts and

•

Modular clutch assembly from the

Install or

•

Transaxle •

come

Modular clutch assembly from the •

•

Front caliper-to-steering knuckle

•

Caliper from the steering knuckle

Support the caliper out

6.

connect the following:

strut.

Modular clutch assembly onto the

it

DO NOT

allow the caliper to hang by

•

Rotor from the hub

•

Outer

tie

rod end-to-steering

knuckle nut by holding the

ft.

end stud with a ”/&

Nm)

New modular

way by

the brake hose.

Transaxle assembly and torque the

(95

of the

with a piece of wire from the

transaxle input shaft

lbs.

•

Front wheel

suspending

transaxle-to-engine bolts to 70

out as an assembly.

or disconnect the following:

•

bolts

install:

3.

Remove

5.

Transaxle assembly

vehicles equipped with

the front wheel speed sensor.

bolts

•

To

On 2000-02

4.

Anti-lock Brake System (ABS), disconnect

transaxle input shaft

'•The transaxle and modular clutch will

•

motor assembly

discard the bolts •

or disconnect the following:

Negative battery cable

nut.

and discard the bolts

or disconnect the following:

Negative battery cable Starter

the beginning of this section.

•

the beginning of this section.

Remove

2.

in

Remove

2.

Before servicing the vehicle, refer to the

.

hub

Before servicing the vehicle, refer to the

.

precautions

BELVIDERE BUILT VEHICLES 1

hub and driveshaft are

front

splined together and retained by the

(28 Nm).

12.

brakes applied, loosen, but do not remove the stub axle-to-hub and bearing retaining nut.

assembly

are seated. Tighten the bolts to a final

torque of 21

locknut and spring

With the vehicle on the ground and

3.

To avoid distorting the clutch cover,

time.

remove the

vehicles,

it),

stub axle.

(75 Nm).

Clutch inspection cover

tighten the bolts gradually, a few turns at a

11.

cotter pin (discard

washer, from the end of the outer CV-joint

are seated. Tighten the bolts to a final

torque of 55

On 1998-99

2.

tighten the bolts gradually a few turns at a time.

the beginning of this sec-

in

tion.

To avoid distorting the driveplate,

5.

as possible to the orange flywheel balance spot.

Negative battery cable

connect the following:

Install or

4.

proper installation.

clutch or flywheel

ft.

Halfshafts

1. If

65

veplate.

before removal. The flywheel side of the is

to

Nm)

(88

when mounting

the modular clutch assembly to the dri-

dowels and the alignment marks made

clutch disc

and torque the bolts

bolts

is

at this time.

clutch-to-driveplate

in.

tie

rod

socket

while loosening the nut

transaxle input shaft.

^Handle

the

components

carefully to

avoid contaminating the friction surface. 3.

Inspect for

oil

leakage through the

engine rear main bearing

ENGINE

UPPER

oil

seal

and

CRANKSHAFT

1

-

2 7922EG51

MODULAR CLUTCH ASSEMBLY CUP

3

- TRANSAXLE

4 -

CLUTCH MODULE BOLT

(4)

The transaxle and modular clutch are

removed as an assembly— 1998-99 vehi-

Exploded view

cles

cles

of the

manual transaxle, clutch module and related components— 2000-02 vehi-

CHRYSLER CORPORATION

8-33

NEON dinner

tripod joint removal

easier

is

which

Remove

the inner tripod joints from

punch

gear.

punch sharply with a hammer

the ball joint stud. 18.

to

dislodge

and washer

—

position the

halfshaft service

left

punch

in

Tie rod

end stud from the steering

hammer

joint

knuckle •

a

Ball joint stud-to-steering

knuckle

7.

to

punch sharply with

from the side

left

Remove

inner tripod

gear.

Be careful when separating the ball joint stud from the steering knuckle,

it

joint

inter-

ing

damaged.

into the steer-

rod end-to-steering tie

rod end.

of the tie rod

end

socket, tighten the

in

Nm).

lbs. (61

ft.

the rotor back onto the

Install

hub

and bearing assembly. 21

Position the caliper on the steering

.

oil seal.

knuckle. Slide the top of the caliper under

the tripod joint, do not

the transaxle-to-tripod joint

lip of

rod end nut to 45

tie

20.

let

the spline or snapring drag across the seal-

so the ball joint seal does not get

'Vx

crow's foot and

and

straight out of the

transaxle side gear and transaxle

When removing

end

tie

knuckle nut onto the stud of the

the inner tripod joint from the

transaxle by pulling

(95 Nm).

lbs.

ft.

While holding the stud

connecting shaft of the driveshaft assembly

nut and bolt

70

stationary, tighten the nut. Then, using a

Hold the inner tripod

1 1

to

Insert the tie rod

ing knuckle. Start the

the groove of the

dislodge the

steering knuckle-to-

stud bolt and nut. Tighten the nut

If

side inner tripod joint,

inner tripod joint. Hit the •

and bolt

NEW

a

Install

ball joint

19.

removing the

of the cotter pin, locknut

Slide the driveshaft back into the

17.

front hub. Install the steering knuckle into

joint. Hit the

the right inner joint from the side gear.

has no

before installing

it

into the steering knuckle.

right side inner tripod joint, position the

punch against the inner tripod

that the outer CV-joint,

into the steering knuckle,

to

removing the

If

fits

debris or moisture on

dislodge the inner tripod joint retaining ring

from the transaxle side

Exploded view

Be sure

16.

hammer.

the transaxle side gears using a

debris and moisture out of

all

the steering knuckle.

punch with a

joint 10. while hitting the

Clean

15.

by applying outward pressure on the

the top abutment on the steering knuckle,

then

bottom

install the

of the caliper against

oil

the bottom abutment of the steering

seal.

knuckle •

from the steering

Ball joint stud

knuckle by prying

down on

** WARNING

1998-00

vehicles, perform the

following steps:

Remove

a.

the

hub and bearing-to-

Install a puller

The driveshaft, when installed, acts as a bolt which secures the front hub and bearing assembly. If the vehicle is to

be supported or

wheels with

stub axle retaining nut b.

on the hub and

moved on

its

install a

and nut to 135 ft. lbs. (183 Nm). This will ensure that the hub bearing cannot loosen.

Install

c.

on the stud.

flat-bladed prytool to keep the turning.

Using the

Install a

hub from

puller, force the outer

To

24

Clean

seal sealing surface

on the tripod

all

lbs. (31

Nm).

vehicles equipped with

front

wheel speed sensor.

foreign matter from the

oil

and tighten the

the threads nut.

With the vehicle's brakes applied to

prevent the axle shaft from turning, tighten

hub nut to 150 ft. lbs (203 Nm) for 1998-99 models or 180 ft. lbs (244 Nm) lor 2000-02 models the

On 1998-99

26.

Thoroughly clean the spline and

ft.

hub nut and washer onto

install:

12.

stub axle from the hub and bearing.

ABS, connect the

25

bolt

a wheel lug nut on wheel stud

caliper-to-knuckle bolts

On 2000-02

23.

Install

through the front hub. Tighten the

to protect the threads

23

of the stub axle

hold

in place.

to

threads of the outer CV-joint stub axle.

removed, proper-sized bolt and nut a driveshaft

bearing assembly, using the lug nuts to it

Install the

and tighten

lower control arm

For

22.

the

vehicles, install the

new

spring washer, locknut and

cotter pin

joint.

into the outer CV-joint stub axle

Lightly lubricate the

Be careful when separating the inner CV-joint during this operation. let

Do

mission

must be sup-

13.

away from

knuckle assembly

the outer CV-joint of the

driveshaft assembly. Support the outer of the driveshaft 9.

pod

Insert a prybar

joint

end

fluid.

100 and interconnecting

between the inner

tri-

and the transaxle case. Pry against

the inner tripod joint until the joint retaining

snapring side gear.

is

disengaged from the transaxle

Install the front

or

ft.

far

Nm) for 1998-99 models Nm) for 2000-02 models.

(128

fluid level,

low-

ering the vehicle as necessary.

as possible by hand.

Carefully align the tripod joint with

CV-Joints

the transaxle side gears. Then, grasp the driveshaft interconnecting shaft

until fully seated.

and push

Be sure the snapring

by hand.

If

the snapring

is fully

OVERHAUL

is

engaged with the side gear by trying remove the tripod joint from the transaxle

fully

to

seated with

Tri-Pot (Inner) Joint 1

the side gear, the tripod joint will not be

is

covered

.

Remove •

or disassemble the following:

Halfshaft

and place

jawed vise

removable by hand.

Brake service

(135

lbs.

tire

nuts and tighten to

Check the transaxle

28.

14.

wheel and

Install the lug

lbs.

ft.

95

shaft,

transaxle side

the tripod joint into the transaxle side gear

assembly.

27

assembly

Holding the driveshaft assembly by

the tripod joint

gear as Pull the steering

out and

seal sealing surface

install the tripod joint into the

ported. 8.

oil

joint with fresh, clean trans-

not

the driveshaft hang by the inner

CV-joint, the driveshaft

on the tripod

in Section

4 of this manual

it

in a soft-

8-34

CHRYSLER CORPORATION NEON

3 4 -

GROOVE INTERCONNECTING SHAFT 9306EG04

Positioning the boot on the

shaft— Tri-pot

and Rzeppa joints 1

- STUB AXLE

4 -

OUTER C/V JOINT OUTER C/V JOINT BOOT TUNED RUBBER DAMPER WEIGHT

5 -

INTERCONNECTING SHAFT

6 -

OUTER

7 -

STUB AXLE

2 3 -

C/V JOINT

8 - OUTER C/V JOINT 9 - RIGHT DRIVESHAFT 10 - INNER TRIPOD JOINT

BOOT

TRIPOD JOINT INNER TRIPOD JOINT 13 - INNER TRIPOD JOINT BOOT 11

- INNER

12 -

BOOT

14 -

INTERCONNECTING SHAFT LEFT DRIVESHAFT 9306EG02

View

of the halfshaft

assemblies—Typical

3 4 -

SEALING BOOT CLAMP INNER TRIPOD JOINT 9306EG05

Adjusting the Tri-pot boot length

—

Hytrel

plastic boot

•

Tri-pot joint boot

boot '

down

clamps and the

the shaft

WARNING

When removing

the spider joint, hold

the rollers in place on the trunions to

keep the rollers and needle bearings in

place. •

Spider/shaft assembly from the

tri-

pot housing •

Snapring from the shaft

•

Spider assembly

**lf necessary, tap the spider

from the shaft with a brass

When removing do not 1

-

HOUSING ASM. RETAINER & SPACER SPIDER. TRIPOTD JOINT

2 - RING. 3 -

11

- CLAMP, SEAL RETAINING

•

'

4 - RING. RETAINING 5 - RETAINER. BALL &

12 - SHAFT.

AXLE (RH SHOWN. LH SIMILAR)

ROLLER

15 - RING.

RACE RETAINING

16 - BALL,

CHROME ALLOY

8 - CLAMP, SEAL RETAINING

18 -

17 - RACE. C/V JOINT INNER

CAGE. C/V JOINT 19 - RACE, C/V JOINT

9 - BUSHING, TRILOBAL TRIPOD 10 - SEAL. DRIVE AXLE INBOARD

If

Boot by sliding

it

oft

the shaft

any parts show excessive wear,

replace the halfshaft assembly; the

OUTER

component 9306EG03

of the halfshaft

the spider assembly,

the outer bearings.

13 - SEAL. DRIVE AXLE OUTBOARD 14 - CLAMP, SEAL RETAINING

6 - BALL. TRIPOD JOINT 7 - ROLLER, NEEDLE

Exploded view

hit

assembly

drift.

assembly

—

Typical

able.

parts are not service-

CHRYSLER CORPORATION

8-35

NEON

h-

©

Position the boot onto the tri-pot

b.

housing retaining groove and retaining

install

the

clamp evenly on the boot.

Using the Crimper Tool C-4975-A,

c.

place the tool over the clamp bridge, tighten the tool nut until the jaws are

completely closed (face-to-face). 8.

installing a

If

low profile latching type

Clamp

boot clamp, position Snap-On - 115 MILLIMETERS

1

2 - SILICONE SEALING

Locking Tool YA3050 prongs

INNER TP POO JOINT HOUSING 2 - TOP BANK OF ClAMP MUST BE RETAJNEE BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT ClAMP 3 - SEALING BOOT 1

BOOT

3 - CLAMP 4 - INNER TRIPOD JOINT

-

I

9306EGG6

Secured the low

rubber boot

cone rubber Tri-pot boot

profile boot

clamp band

clamp— Sili-

the lower

is

latched behind the 2 tabs

Rzeppa (Outer) Joint new small boot clamp and

Install a

2.

slide

it

on the

1

shaft.

bead on the inside the boot seal

is in

Remove

.

•

the

4

new

installing a

If

grease

in

boot, distribute

•

Vfe

V2

•

inside

Install or

joint

Rzeppa hitting

the boot.

•

Rzeppa

the boot

the service package inside

the tri-pot housing and the other

1 - SEALING BOOT 2 - SPECIAL TOOL C-4975

and place

Halfshaft

in

it

a soft-

jawed vise

shaft groove.

of the

or disassemble the follow-

ing:

Position the boot so that the raised

3.

joint it

to drive

connect the following

boot clamps and slide

down

the shaft

housing, by sharply

with a soft-faced

hammer

off the shaft

it

Spider assembly, face the cham-

•

Circlip from the shaft

fered side toward the shaft

•

Boot by sliding

it

off

the shaft

CLAMP BRIDGE

** WARNING

93060G13

Tightening the high profile boot Tri-pot joint (Hytrel plastic) boot

Rzeppa

joint

clamp— If

and

necessary, tap the spider assembly

onto the shaft using a brass

boots

be

drift;

careful not to hit the outer bearings. Snapring making sure

•

seated

in the

it

is fully

groove

Spider/shaft assembly into the

•

tri-

pot housing

New

•

inner boot

clamp and posi1

tion

it

evenly on the sealing

-

NTE*CC*#4ECT**J SHAT*

2 -

CROSS

9 -

OJTO OV JO»»T

ASSEUOiY

boot 6.

Using a trim

107mm

length to 1

-

stick, adjust the

(hytrel plastic) or

boot Aligning the cross splines with the shaft

115mm

splines— Rzeppa

CLAMP

2 - SPECIAL 3 - SEALING

joint

(silicone rubber). TOOL YA3050 BOOT

7. 9306EG07

Tightening the low profile boot

clamp—

installing a high profile boot

If

clamp, perform the following procedure:

Silicone rubber Tri-pot boot

Using the Crimper Tool C-4975-

a.

A, place the tool over the

clamp

To assemble:

bridge, tighten the tool nut until the

** WARNING

face).

jaws are completely closed (face-to-

The Tri-pot sealing boots are made

of

** WARNING

2 different types of material; silicon

rubber (high temperature) which

is

and pliable or hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot

soft

made

on

clamp band.

Install the halfshaft.

9.

5.

3 -

clamp

holes and squeeze the tool until the upper

3306EG06

Adjusting the Tri-pot boot length— Silicone

in the

The seal must not be dimpled, stretched or out of shape.

If

sary, equalize the seal pressure

shape

it

1

-

SOFT FACED HAMMER

2 - STUB AXJJE 9 - OUTER OV JOINT 4 - NUT

neces-

and

by hand. Driving the Rzeppa joint onto the shaft

of the correct material.

For complete Engine Mechanics I specifications, see Section

1

of this

manual

CHRYSLER CORPORATION

8-36

NEON •

Rzeppa

joint, align the shaft

and tap

2.

•

ing

Vfe of

Newsmall boot clamp and

and the other Install the

5.

slide

it

position

onto the shaft

Vfe

the grease

Rzeppa

the ser-

in

hous-

joint

and

by hand.

Position the boot onto the Rzeppa

housing retaining groove and

install the

clamp evenly on the boot.

retaining 8.

inside the boot.

new small boot clamp and

Using the Crimper Tool C-4975-A,

place the tool over the clamp bridge, tighten the tool nut until the jaws are completely

Using the Crimper Tool C-4975-A,

6.

it

locks on the

evenly on the sealing boot

it

sary, equalize the seal pressure

shape 7.

Distribute

4.

assemble the following:

Install or

it

circlip

vice package inside the

To assemble:

splines

onto the shaft with a soft-

hammer so

faced

any parts show excessive wear,

If

replace the halfshaft assembly; the component parts are not serviceable.

it

closed (face-to-face). 9.

•

Boot and slide

•

Circlip,

it

place the tool over the clamp bridge, tighten

onto the shaft

!'

3.

if

removed

Position the boot so that the raised

bead on the inside the boot seal

is in

closed (face-to-face).

The seal must not be dimpled,

the

stretched or out of shape.

shaft groove. •

joint

If

neces-

sary, equalize the seal pressure

Halfshaft

.

WARNING

the tool nut until the jaws are completely

hub nut onto the Rzeppa

threaded shaft so

it

is

flush

shape

The seal must not be dimpled, stretched or out of shape.

If

it

and

by hand.

neces-

with the end

Install the halfshaft.

STEERING AND SUSPENSION Air

connecting and isolating the negative bat-

Bag

**

CAUTION

tery cable.

Allow the

tor at least

2 minutes

removing any

air

air

to

ever the

crossmember

discharge before

vehicle,

it

bag system components.

Rack and Pinion Steering Gear

air

Failure to follow safety and disabling

NET BUILD

front

suspension

alignment settings are determined as the

front

is

designed by the location

suspension components

the body. This

in

it

when handling

the

is

the inflator

module

is

front

to

underbody

method

Several precautions must be observed

still

in

the

of the vehicle

front

suspension toe

be adjusted by the outer

carried out

in

relation to

when

building

of

meter gauge holes located of the vehicle.

With

this

designing and building a vehicle,

no longer possible

1998-99 Models

of the

to adjust a vehicle’s

suspension alignment settings

to the

Before servicing the vehicle, refer to

1.

the precautions

in

the beginning of this sec-

tion.

From

2.

inside the vehicle, disconnect

the steering gear coupler from the steering

column

shaft coupler.

Remove

3.

•

or disconnect the following:

Both front wheels

to avoid STEERING GEAR

•

Never carry the

inflator

module by

the

wires or connector on the underside of the

module. •

When

carrying a live inflator module,

hold securely with both hands, and ensure that the •

bag and trim cover are pointed away.

Place the inflator module on a bench

or other surface with the bag and trim cover facing up. •

With the

inflator

module on the bench,

never place anything on or close to the

module which may be thrown of

in

the event

an accidental deployment.

DISARMING Proper Supplemental Restraint Ssystem (SRS) disarming can be obtained by dis-

tie

REMOVAL & INSTALLATION

accidental deployment and possible per-

sonal injury:

same was

it

alignment settings. This means that the

crossmember

PRECAUTIONS

be replaced

body

when-

removed from a

These vehicles are designed and assembled using

the vehicle, by precisely locating the front

repairs.

settings can

is

rod ends.

vehicle

procedures could result in accidental air bag deployment, possible personal injury and unnecessary system

MUST

location on the

removed from. The

Some

vehicles are equipped with an bag system. The system MUST BE disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors.

required specifications. As a result,

bag system capaci-

CHRYSLER CORPORATION

8-37

NEON Power steering

• STEERING COLUMN SHAFT COUPLER

FRONT SUSPENSION CROSSMEMBER

fluid

pressure and

hoses from the power steer-

return

ing gear COUPLER PINCH BOLT NUT FRAME RAIL

Before removing the crossmember from the vehicle, the location of the crossmember MUST be scribed or marked on the vehicle. This must be done so the crossmember can be

LOWER STEERING COLUMN COUPLER

/ BOLT

reinstalled in 7922EG57

7922EG54

vehicle— 1998-99 vehicles

ing

exact location.

its

If

done, the proper NET

BUILD alignment specifications

Location of the front crossmember mount-

Disconnect the steering gear coupler from inside the

this is not

not be obtained and

bolts— 1998-99 vehicles

dling and/or tire

may

wear problems.

Matchmark the crossmember

4.

will

lead to han-

to the

chassis.

Place a transmission jack under the

5.

center of the crossmember. The jack will be

used

to lower, support

and raise the cross-

member when removing the steering gear. 6 Remove both front crossmember-toframe DAMPENER

LOWER CONTROL ARM

FRONT SUSPENSION CROSSMEMBER

rails bolts

Then, loosen both rear

crossmember/lower control arm

body

to the

Lower the crossmember while loos-

bolts.

ening the rear bolts.

Some

vehicles are equipped with a bobble

damper

vice

steering

must be removed from the

that

crossmember during steering gear

Lower the crossmember

gear— 1998-99

for

access

Using the transmission

7.

to the

crossmember enough

the

vehicles

removed from the crossmem-

ing gear to be

ser-

— 1998-99 vehicles

STEERING GEAR BOLTS

MOUNTING

ber.

When

not

lei

jack, lower

to allow the steer-

lowering the crossmember, do

the

crossmember hang from

the

lower control arms. The weight should be

supported by the jack

Remove

8

—STEERING GEAR

FRONT SUSdNSION - CROSSMEMBER

or disconnect the following:

•

4 steering gear-to-crossmember bolts

•

Steering gear

"»lf a

new

steering gear

being

is

necessary parts

installed, transfer any

trom the old steering gear

to the

new

steering gear. View

of the steering

gear mounting

To install:

bolts— 1998-99 vehicles Because

of the

the vehicle,

method used

9

Install the steering

crossmember and torque for aligning

rod end stud with an

matchmark the crossmember

"fa

in.

socket

lbs.

while loosening the nut with a wrench.

gear on the

50

the bolts to

It.

(68 Nm).

10.

Using the transmission

jack, raise

installed position prior to steering gear

removal

— 1998-99 vehicles

•

Tie rod

the crossmember/steering gear

ends from the steering

against the chassis frame

knuckles, using a Side Puller Tool •

MB-991

Engine/transaxle bobble damper •

from the front suspension cross-

member,

if

equipped •

^The

bobble strut does not have removed from the transaxle. •

Outer

tie

to

be

is

removed by holding the

Power steering

fluid

the 2

bolts; then,

the 2 front crossmember-to-frame

pressure

rail

volts.

Tighten the 4 bolts until the crossmember

Power steering pressure/return

aligned with the mounting points. Torque

hose routing bracket from the

the bolls to

front

••When

'•The bracket does not have to be removed trom the power steering prestie

crossmember-to-chassis

switch connector

crossmember

rod end-to-steering

knuckle nut

'•The nut

rear

113.

assembly

rails. Start

it

MUST

the

illustrations,

see Section

1

of this

Nm)

crossmember

is

installed,

align with the removal match-

front

tings.

For Accessory Drive Belt

lbs. (2

marks; the purpose

BUILD

sure and return hoses.

20 inch

is

manual

is

maintain NET

suspension alignment set-

CHRYSLER CORPORATION

8-38

NEON

Tap the crossmember into position,

11.

with a rubber mallet, the

until

is

it

aligned with

matchmarks. Once positioned, torque

both rear crossmember/lower control arm

120

bolts to

120

ft.

Power steering

•

(163 Nm).

lbs.

connect the following:

Install or

12.

(163 Nm); then, both

lbs.

ft.

front bolts to

fluid

pressure/return hoses into the steering gear ports and torque the line-to-steering gear tube nuts to

23

ft.

lbs. (31

Nm)

Power steering

•

fluid

pressure/return hose routing bracket and screw on the cross-

member and

torque the bracket-to-

attaching bolt to 17

Nm)

(23

lbs.

ft.

Wiring harness connector onto the

•

power steering

gear’s fluid pressure

switch and securely latch the wiring

FWD

harness connector’s locking tab Tie rod end, into the steering

•

knuckle. While holding the

1

- OUTER TIE

2

- JAM NUT

rod

tie

STEERING GEAR FRONT SUSPENSION CROSSMEMBER

3 4 -

ROD

stud, torque the tie rod end-to-

9306EG42

steering knuckle nut, using a crow’s foot

40

wrench and

ft.

lbs.

W

View

32

in.

power steering gear and crossmember

socket, to

(55 Nm).

Engine/transaxle bobble

•

of the

— 2000-02 vehicle

•Locking the steering wheel keeps the strut,

ing the locking tab

if

equipped, onto the crossmember bracket

clockspring

in

alignment position.

•

Working inside the passenger com-

3.

•

Both front wheels and torque the

•

lug nuts, in a crisscross pattern, to

100

ft.

lbs.

(135

column cou-

ing

column

(28

pling retainer pin, pinch bolt nut/bolt and

shaft coupler,

under the

Remove

4.

•

or disconnect the following:

ft.

•

Outer

'•Remove

•

tie

the proper type of fluid.

NEVER sub-

automatic transmission fluid

the tie rod nut by holding

hose

equipped

tie

•

fluid return

clip

not equipped with a

hose

C-clamps,

if

power steering

fluid cooler

rod ends from the steering •

Power steering

fluid

pressure hose

from the steering gear's routing clips

Tie rod heat shield

Power steering

fluid

pressure

switch wiring connector by releas-

power steering pump

FULL-COLD

proper type and amount of

Outer

Power steering

from the routing

MB991113 •

for the specified fluid.

the

if

rods-to-steering knuckle

knuckle using Remover Tool

and bleeding the power steering system, always use refilling

Refill

fluid cooler

nuts

the stud securely.

reservoir to the

Power steering

with a power steering fluid cooler

Nm)

retaining bolt retention pin

stitute

hose

not

Both front wheels

from the steering gear,

Upper-to-lower steering coupler

When

if

fluid cooler

• •

fluid return

separate the couplings.

dash, and torque the bolt to 21 lbs.

Power steering

from the steering gear,

•

13.

pressure hose

fluid

equipped with a power steering

Nm)

Steering gear coupler to the steer-

•

partment, remove the steering

Power steering

from the steering gear

fluid

level with the

fluid.

Bleed the

system.

2000-02 Models 1.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Place the steering wheel

in

the

straight-ahead position. Lock the steering

wheel holder.

in place,

using a steering wheel

View

of the

sure switch

power steering gear

—2000-02 vehicle

fluid pres-

View

of the

power steering gear hoses and

routing clips

— 2000-02 vehicle

CHRYSLER CORPORATION

8-39

NEON

** WARNING Do

not completely

remove the rear

bolts for they are designed to disen-

gage from the body threads and

will

arm rear

stay within the lower control isolator bushing.

••The threaded tapping plates allow the lower control

arm

to stay in

place

on the crossmember. 4 -

POWER STEERING Aliow the tank

to

lower

until the fuel

2.

3.

Remove

the fuel

any gasoline spillage.

to catch

•

Negative battery cable

•

Fuel

Fuel tank straps. Support with a

•

Wrap shop towels around

fuel

Squeeze

fuel filter

Locking tabs on the

•

Strainer and O-ring Inlet filter

fuel

jack prior to loosening the straps.

pump 7.

Carefully lower the tank.

8.

Clean the top

from the assembly

any loose

To

install:

4.

Install or

•

New

•

Locking tabs on the

0-ring and strainer •

fuel

pump

module

supply

(to filter)

the return tube (to fuel

tube and

pump module)

5,.

repair

pump Module

•

Fuel

•

Negative battery cable

Start the vehicle, if

K

check

for leaks

and

necessary.

are permanently attached to the fuel

The ends of the fuel supply and return tubes have different size quickdisconnect fittings. The large quick-dis-

1.

filter.

connect

fitting

Fuel

Pump

REMOVAL & INSTALLATION

attaches to the large

nipple (supply side) on the fuel

pump The in-tank

module. The smaller quick-disconnect fitting

Fuel

pump

wrench

tool.

locknut using Spanner

6856

filter

To install: fuel

pump mod-

ule

lines

^•The

Fuel lines from the fuel

Inlet filter

hose connector

releasing tabs and detach the fuel

Fuel

remove

or disconnect the following:

connect the following: •

•

of the tank to

dirt.

Remove

9.

pump module.

from the

pump module

•

•

Fuel line quick-disconnect fittings

•

filler

or disconnect the following:

hose

CAUTION

•

or disconnect the following:

Fuel tank inlet and from the

•

crossmember.

hoses

Remove

6.

tank neck touches the rear suspension

-

Properly relieve the fuel system pres-

sure.

attaches the small nipple (return

side) on the fuel

the fuel

fuel

pump and

pump module

CAUTION

The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.

pump

•

Fuel

•

Fuel tank 0-ring and discard

it

contains

pressure regulator which

adjusts fuel system pressure to approxi-

pump module.

mately 49 psi (337.8 kPa). Voltage to the

pump is supplied through the fuel pump relay. The fuel pump is serviced as part of the fuel pump module. The fuel pump module

fuel

is

installed in the top of the fuel tank

contains the electric fuel pump, fuel reservoir, inlet strainer fuel unit, fuel

supply and return

and the pressure strainer, fuel

regulator.

and

pump

gauge sending line

The

connections inlet

pressure regulator and

level

sensor are the only serviceable items. 7922FG43

Fuel

filter

mounting location

pump requires pump module.

fuel

If

the

service, replace the fuel

Before servicing the vehicle, refer to

Removing

the fuel

pump module

using special tool 6856

lock ring

CHRYSLER CORP CIRRUS

•

SEBRING CONVERTIBLE

To install:

Remove

4.

Thoroughly clean

10.

STRATUS

•

all

Wipe

parts

the

Install or

.

Fuel supply line quick quick-con-

•

nect fitting from the fuel

connect the following:

•

New

O-ring onto the fuel tank

•

Fuel

pump module

in

discard the gasket

the tank

Fuel injector electrical connec-

sure the alignment tab on the

pump module

underside of the

tors

flange •

sits in

rail

Upper intake manifold plenum and

•

•

•Be

or disconnect the follow-

ing:

seal area of the tank clean. 1 1

9-41

BREEZE

•

Fuel

the corresponding notch in the

rail

from the intake mani-

fold fuel tank.

Locking ring and torque

•

ft.

lbs.

to

it

•Cover

40-45

to

(54-61 Nm), using Spanner

keep

Wrench Tool 6856

•

the intake manifold openings dirt

from entering the system.

Fuel injector clip

6.

•

Fuel tank assembly

•

Negative battery cable

12.

Refill

of the fuel

surize the system.

Check

rail

and discard the O-rings

injector— 2. OL. 2.4L and

the fuel tank.

Turn the ignition switch

13.

View

Fuel injector(s) from the fuel

•

9306FG08

To

install:

5.

Install or

engines

ON

to

pres-

the fuel system for

•

Fuel injector electrical connectors

•

connect the following:

Fuel injector to the fuel

new O-rings

leaks.

rail

using

lubricated with engine

Fuel supply line quick quick-con-

•

oil

nect fitting to the fuel

Fuel Injector

rail

Negative battery cable

•

•

Fuel injector clip

•

Fuel

rail

and torque the bolts

Use a Diagnostic Readout Box (ORB)

REMOVAL & INSTALLATION

ft.

scan tool Automatic Shutdown (ASD)

system

Check

2.0L and 2.4L Engines

test to

Before servicing the vehicle, refer to

.

•Be

1

from the

left

.

Fuel injector electrical connec-

ground cable

is

equipped with

•

left

bolts to 13

shock tower.

an insulator grommet which should be placed on the stud to prevent the negative battery

•The

ground cable

grounding. Relieve the fuel system pressure

Fuel supply line quick quick-connect fitting from the fuel

Negative battery cable

Fuel injector electrical connectors

•

Fuel

connectors

Use a Diagnostic Readout Box (DRB)

system 3.

Check

Relieve the fuel system pressure

test to pressurize the fuel

fuel

system

for leaks

using the recommended procedure.

3.0L Engine 1

from the intake manifold

rail

electrical

rail

•

•Cover

Sensor

•

grounding.

recommended procedure. Remove or disconnect the following:

•

•

Nm)

scan tool Automatic Shutdown (ASD)

using the 4.

lbs (18

Throttle cables

equipped with

from accidentally

ft.

•

6 tive battery cable

3.

is

an insulator grommet which should be placed on the stud to prevent the nega-

cable from accidentally

rail

Upper intake manifold plenum using a new gasket and torque the

Disconnect the negative battery cable

from the

Fuel supply line quick quick-connect fitting to the fuel

the precautions in the beginning of this sec-

2.

•The

•

Before servicing the vehicle, refer to

tion.

shock tower.

fuel rail

tors

the precautions in the beginning of this sec-

Disconnect the negative battery cable

8

sure the spacers are located

under the

for leaks.

2.5L and 2.7L Engines

tion, 2.

to

Nm)

fuel

pressurize the fuel system

• 1

(12

lbs.

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

the fuel injector holes in the

2.

intake manifold.

Properly relieve the fuel system pres-

sure. • •

Fuelinjectorclip

Fuel injector(s) from the fuel

rail

and

discard the O-rings

Install or

•

connect the following:

Fuel injector to the fuel

new O-rings

rail

using

lubricated with engine 1

- FUEL RAIL BOLTS

oil 930BFGO7

•

Fuelinjectorclip

•

Fuel

and torque the screws

rail

14-19

ft.

Drain the cooling system

4

Remove

or disconnect the follow-

ing:

To install: 5.

3.

lbs.

(19.5-25.5

Nm)

View

of the fuel rail

to

assembly

—

•

Negative battery cable

•

Intake manifold

•

Fuel injector electrical connector

•

Fuel supply and return hoses

•

Vacuum hose

•

Fuel pressure regulator

•

Fuel

•

Insulators

2. 51-

engine

For Wheel Alignment specifications, see Section

1

of this

plenum

manual

rail

with the injectors

CHRYSLER CORP.

9-42 •

CIRRUS

Fuel injectors

•

SEBRING CONVERTIBLE

and discard the

•

Fi-

•

STRATUS

Fuel

•

and torque the bolts

rail

5.

•

To install: Fuel injector with a

lbs. (9

Nm)

new O-ring

lubricated with clean engine •

13

oil

Insulators

•

Fuel pressure regulator and

torque the bolts to 80 inch

connect the following:

Install or

•

to

Nm)

inch lbs. (12

rings

BREEZE

6.

Fuel injector electrical connector

plenum

•

Intake manifold

•

Negative battery cable

Fill

the cooling system to the proper

level.

•

Vacuum hose

•

Fuel return and supply hoses

7.

Start the vehicle,

repair

if

check

for leaks

and

necessary.

DRIVE TRAIN Tra nsaxle

port bracket bolt

Assembly •

REMOVAL & INSTALLATION Manual 2.0L, 2.4L (VIN X)

Upper

bell

housing-to-throttle body

support bracket stud nut

AND 2.5L

body support bracket

•

Throttle

•

Left transaxle

•

Upper

•

Vehicle Speed Sensor (VSS)

•

ENGINES

bell

Back-up

mount upper

bolts

housing bolts

light electrical

connector

from the transaxle Install

3.

an engine support fixture tool

and support the engine. If

the vehicle

its

going to be rolled on

is

wheels while the transaxle

of the vehicle,

is

•

out

•

obtain 2 outer CV-

joints to install in the hubs.

vehicle

is

If

Remove

4.

•

the

•

•

be usable. Before servicing the vehicle, refer to

Remove •

to

side bolts,

from the

left

mount

Engine-to-lower crossbar bolts

mount

Front steel engine

•

3 front aluminum engine mount

•

Starter

•

Rear transaxle mount bracket

•

Transaxle-to-rear lateral bending

bracket

bracket bolts

or disconnect the following:

Negative battery cable from the

left

Lower bracket

•

the beginning of this sec-

tion. 2.

advance

Lower splash shield/battery cover

transaxle

bearings, the bearings will no longer

in

the driveplate clutch bolts

Halfshafts

from the

rolled without the proper

the precautions

Remove

rotate the engine clockwise to

the next bolt

torque applied to the front wheel

1.

or disconnect the following:

Front wheels

left

shock tower.

strut

8.

from engine/transaxle assem-

bly

’•The ground cable

is

equipped with •

an insulator grommet which should be placed on the stud to prevent the nega-

Transaxle bell housing cover

Using a transaxle

5.

jack,

support the

transaxle.

tive battery cable

Rotate the engine clockwise to gain

6.

access

and intake hoses

Air cleaner

•

Clutch housing vent cap

•

Clutch cable from the bell housing

to the driveplate clutch bolts.

•

Driveplate clutch bolts

•

Lower engine-to-transaxle bolts

• 7.

the lower engine-to-transaxle

mounting bolts

from accidentally

grounding. •

Removing

or reinstall the front

Transaxle

To prepare the vehicle for

support the engine with a suitable support

motor mount

to the

engine. Then, reinstall the ball joints to the steering knuckle and install the retaining

rolling,

bolt. Install the

obtained outer CV-joints to

the hubs, install the washers and tighten the

Using equal force, pry up on both sides of the shifter cable isolator

axle nuts to

vehicle

bushings to avoid damaging the

To

Install or

•

•

•

(244 Nm). The

connect the following:

Transaxle and torque the transaxle-

Selector lever and crossover cables

to-engine bolts to 70

Nm)

Shift cable

mounting bracket from

• •

body

(95

Upper

•

body

starter-to-throttle

body sup-

•

appropriate support fixture

(95

to

70

ft.

lbs.

Nm)

Transaxle

bell

housing cover and

torque bolts to 9

Secure the engine assembly with an

lbs.

Lower engine-to-transaxle bolts and torque the bolts

Accelerator cable bracket from the

ft.

Driveplate clutch bolts

Accelerator cables from the throttle

throttle •

lbs.

be safely rolled.

from the transaxle

the transaxle •

ft.

install:

cable isolator bushing. •

180

may now

ft.

lbs.

(12

Nm)

Transaxle-to-rear lateral bending

Q.ylO

CHRYSLER CORP. CIRRUS assem-

strut to the engine/transaxle

bly

and torque the

(54

Nm)

40

bolt to

ft.

•

lbs.

torque the bolts to 40

•

(54

lbs.

ft.

Nm)

lbs. (9

mounting bracket

•

Driveshaft connection

•

Clutch release bearing engagement

housing

•

Clutch housing vent cap

bracket bolts and torque the bolts

•

Air cleaner

•

Negative battery cable

Front steel •engine

•

and torque the

mount bracket

bolt to

45

lbs. (61

ft.

Nm) Engine-to-lower crossbar bolts

•

Lower bracket bolts

to the left

mount and torque 40 ft. lbs. (54 Nm)

transaxle bolts to

to the

left

side

Front wheels fixture tool.

connect the following:

Install or

•

Back-up

•

VSS

•

Upper

Check the transaxle Be sure the reverse

when

in

•

ft.

•

Stabilizer link

and torque the nut

33

Nm)

•

proper oper-

to

40

Transaxle

ON

Upper

3.

Remove

Tranasxle

ENGINES

Rear

•

to

or disconnect the following:

(45

Nm)

•

13

(18

lbs.

ft.

Starter

Nm)

motor and

electrical

connec-

Air cleaner

Front exhaust pipe, 3 0L only

(95

•

Shift

bolts

•

Back-up

switch connection

•

Front exhaust pipe, 3.0L engine

lbs

•

Vehicle Speed Sensor (VSS) con-

•

Air cleaner

nector

•

Battery

assembly

and selection cable connec-

•

VSS

•

Back

•

Shift

ft.

•

Starter

Fill

Clutch release cylinder connector Transaxle assembly upper coupling

Nm)

6

•

Centermember

•

Rear

Accelerator cable bracket to the

•

Transaxle

•

Stabilizer link

•

Wheel Speed Sensor (WSS),

mount bracket and stopper

the vehicle

its

Brake hose clamp

Lower arm

is

going

to

be rolled on

wheels while the transaxle

joints to install to the hubs.

vehicle •

and

for leaks

of the vehicle, obtain 2 outer

end

Tie rod

•

check

necessary.

** WARNING If

•

if

if

equipped •

tray

the transaxle fluid to the proper

Automatic

stopper

roll

assembly

and

Start the vehicle,

repair

port bracket bolt

body

up light switch connector and selection cable connec-

level.

bolts

body sup-

connector

—

tions light

•

throttle

Nm)

(81

•

•

starter-to-throttle

lbs

tors

body

Upper

ft.

stopper and torque the nut lbs.

ft.

Nm)

•

bell housing-to-throttle

(43

33

(57

Clutch release cylinder and torque to

fluid.

support bracket stud nut and torque lbs.

lbs.

ft.

mount stopper and

Centermember

•

5.

roll

to

mount bracket and torque

Battery and tray

body support bracket

ft.

(45

the nut to 42

•

Nm)

Throttle

lbs.

•

lbs.

mount upper

equipped

if

torque the nut to 60

3.0L

to

WSS. ft.

80

Nm)

(28

•

tions

Left transaxle

the nut to 32 •

AND

Drain the transaxle

housing bolts and

and torque the bolts

•

for

lights turn

end and torque the nut

lbs.

ft.

to

•

Before servicing the vehicle, refer to

Nm)

(54

fasteners

•

2.

sensor

torque the bolts to 70

•

all

reverse.

2.4L (VI N G)

connector

light electrical

bell

21

tion.

Remove engine support

10.

to be sure that

3.0L engine

bolt,

Nm)

(108

lbs.

Tie rod

•

and connections made.

ation.

1

ft.

and intake hoses

pan

oil

Lower arm and torque the nut

•

the transaxle.

Refill

13.

bell

the precautions in the beginning of this sec-

Halfshafts

• 9.

the

Lower splash shield/battery cover

•

Check

.

are tightened 12.

•

•

1 1

Nm)

(26

lbs.

Selector lever and crossover cables

3 front aluminum engine mount

Nm)

ft.

to

to the transaxle

•

(54

transaxle bolt to 19

to the

—

the cover

Upper

Clutch cable to the

lbs.

engine bolt to 80 inch

•

•

ft.

to

Nm) and

transaxle

Starter

40

3

BREEZE

•

——

cover

body

•

to

STRATUS

•

Accelerator cables to the throttle

Shift cable

•

Rear transaxle mount bracket and

•

SEBRING CONVERTIBLE

•

Clutch release bearing engagement,

is

If

is

out

CVthe

rolled without the proper

torque applied to the front wheel

3.0L engine

bearings, the bearings will no longer •

Driveshaft connection

•

Upper

oil

pan

be usable. bolt,

3 0L engine

housing cover

•

Bell

•

Transaxle assembly lower coupling

1

bolts •

.

tion

Transaxle assembly

2.

Drain the transaxle.

3.

Disconnect the negative battery cable

To install: 4.

Install or

•

connect the following:

(48 to

connect the ground cable

from the

Nm)

at the

lbs. (71

ft.

•The

lbs.

2.4L engine and to 52

shock tower.

Bell

ground cable

placed on the stud

Nm) 3.0L engine

tive battery cable

housing cover and torque the

grounding.

For Maintenance Interval recommendations, see Section

is

equipped with

an insulator grommet which should be

ft

starter •

left

Transaxle assembly. Torque the

lower coupling bolts to 36

Be sure

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

1

of this

manual

to

prevent the nega-

from accidentally

MM

CHRYSLER CORP.

9 -*#**

CIRRUS

•

SEBRING CONVERTIBLE

•

STRATUS

Matchmark

BREEZE

•

•

Starter

location. Rotate the crankshaft clockwise to

•

New engine

align the converter bolts.

•

Upper transaxle mount remaining

7.

Install or

8.

the converter-to-flexplate

connect the following:

bolts to the •

•

Crankshaft Position (CKP) sensor, •

Lower splash shields

•

Transaxle electrical connectors

•

Front wheels

Right side steering gear and K-

•

fold

equipped

frame bolts •

Sway

bar

mounts

•

chain, secure the transaxle and support Install or

connect the following:

•

housing-to-engine bolts

•

Bell

•

Transaxle, by

moving

the K-frame

1 1

To prepare the vehicle

.

for rolling,

support the engine with a suitable support or reinstall the front motor

mount

to the

steering knuckle and install the retaining bolt. Install the

obtained outer CV-joints to

the hubs, install the washers and tighten the axle nuts to

vehicle

To

cable and clamp

ft.

Transaxle cooler lines

connect the following:

Air cleaner duct

•

Transmission Control Module

Dipstick tube from the transaxle

Transaxle cooler lines

Air cleaner duct

Negative battery cable

cables. the transaxle.

16.

Refill

1 7.

Check the transaxle

ation.

Be sure the back-up

proper oper-

for

lights

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

ft.

2.

(95

lbs.

3.

Drain the transaxle.

Remove

or disconnect the following:

•

Air cleaner

Right side steering gear and K-

•

Transaxle dipstick tube

frame bolts

•

•

Transaxle electrical connectors

CKP

mounts

sensor,

equipped

if

•

Negative battery cable

assembly

Transaxle cooler lines flush with the fittings

•

•

Align the converter-to-flexplate

13.

and

tion.

housing-to-engine bolts and

bar

connector

Adjust the gearshift and throttle

•

•

from the transaxle

•

electrical

•

Solenoid pack electrical connector

•

TCM

Mm) Sway

(TCM) •

•

•

1

moving the K-frame

or disconnect the following:

•

Solenoid pack

SEBRING, STRATUS SEDAN ONLY

Transaxle, by

Bell

Dipstick tube to the transaxle

•

safely rolled.

torque the bolts to 70

Shift lever cable

14

speedometer are working properly.

rearward •

•

(244 Nm). The

lbs.

ft.

may now be Install or

•

•

180

install:

12.

Remove

to

Nm)

•

15.

engine. Then, reinstall the ball joints to the

4.

and torque the nut

(19

bolt

rearward

shift

bolts, to

side

left

lever

Location of the transaxie solenoid assem10.

both sides

Shift lever cable to the transaxle

lbs.

it.

to

Upper transaxle mount top the

Using a transmission jack and a safety

9.

Removing the

exhaust mani-

to the

Converter-to-flexplate bolts

•

8-way connector and retaining

side

left

Exhaust pipe

•

if

bly

oil filter

matchmark. Rotate the crankshaft clockwise

Solenoid/pressure switch assembly

Transmission range sensor connector

lever

Using an engine support

5.

to align the converter bolts.

14.

Install or

support the engine assembly.

Remove

6.

•

•

or disconnect the following:

•

Front wheels

Lower splash shields from both •

Exhaust pipe from the exhaust

Upper transaxle mount remaining bolts from the

•

Engine

108 inch

Both

(61 •

•

left

Shift cable

lateral

lbs.

(12

bending

Nm) 45

ft.

lbs.

from the manual valve

and bracket

•

Crankshaft Position (CKP) sensor

•

Throttle

•

Oxygen Sensor (0 2 S) harness

strut brackets to

body support bracket

retainer •

Nm)

Rear mount bracket

—

to

transaxle case bolts

Radiator’s lower

crossmember and

torque the bolts to 45

side

lever

ft.

and torque the bolts

and torque the bolts

manifold •

55

Nm)

Flexplate cover to

sides •

(74

lbs.

• •

•

nectors

Torque converter and torque the

side

left

Input and output speed sensor con-

connect the following:

converter-to-flexplate bolts to

Upper transaxle mount top bolts from the

•

fixture tool,

ft.

lbs. (61

•

Upper

•

Halfshafts

Rear mount and bracket

starter bolt

Nm)

•

•

Rear mount bracket

•

Front

•

Centermember

•

Starter

•

Torque converter dust shield and

oil filter

Starter

•

Front engine

•

Rear mount bracket through-bolt

•

Centermember

mount bracket

bolts to •

Rear mount bracket

•

Radiator lower

•

Flexplate cover

lateral

lbs. (61

Nm)

bending

mount bracket and mount assembly

Rear mount bracket through-bolt

properly support the

and torque the through-bolt

engine/transaxle assembly

ft.

crossmember •

Both

ft.

and torque the

bolts

•

•

45

bolts

lbs. (61

•

mount bracket and

torque the bolts to 24

Nm)

45

Nm)

Front engine

strut brackets

to

ft.

lbs.

Left

— —

mount bracket

bolts

slightly

(33 •

to

transaxle

and lower the assembly

Transaxle assembly

Q.vIE

CHRYSLER CORP. CIRRUS To install:

70

Nm)

(95

lbs.

ft.

into position

and torque the

through bolt

to

55

(70

lbs.

ft.

assembly sup-

the engine/transaxle

Push the clutch cable housing toward

1. 2—2.0 in.

25

(30-50mm). This

•The

lbs. (11

the cable

move

placed on the stud

indicates tive battery

•

Starter

on the bracket.

•

Rear and front transaxle support

•

Starter

•

Front

REMOVAL & INSTALLATION

•

and lower

if

the

mechanism

is

properly seated

brackets

bolt

Clutch inspection cover

•

mount and bracket Rear mount and bracket

•

Halfshafts

•

Upper

•

0 2 S harness

•

Throttle

•

CKP

•

Gearshift cable to

•

Output and input sensor connectors

leakage through the engine rear crankshaft

•

Transmission range sensor connec-

oil

tor

leakage

Solenoid/pressure switch connec-

this time.

•The

removed

starter bolt

retainer

1

body support bracket

sensor

transaxle assembly must be

manual valve

in

Oil

Modular clutch-to-flywheel bolts

•

Transaxle assembly with the clutch as an assembly

Clutch assembly from the transaxle

•

input shaft

the beginning of this sec-

To install:

tion.

Clean

3.

lever

seal

all

is

noted,

it

shaft seal.

Transaxle dipstick tube

•

Air cleaner

•

Negative battery cable

If

should be corrected

It

is

at

pre-lubricated and

sealed and should not be washed

kit

oil

Examine the throwout or clutch

4.

in solvent.

The bearing should turn smoothly when

A

held in the hand with a light thrust load.

assembly

the transaxle fluid to the proper

light

drag caused by the lubricant

mal.

If

fill

is

nor-

the bearing is noisy, rough or dry,

replace the complete bearing assembly. In Start the vehicle, if

check

for leaks

most cases where a clutch

and

viced, the

necessary.

ENGINE

BOLT

DRIVE PLATE BOLT

TRANSAXLE

The manual transaxle clutch release system has a unique self-adjusting mechanism

compensate

for clutch disc wear.

mechanism

is

clutch cable assembly.

This

located with the

The preload spring

maintains tension on the cable, This tension

keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. is

When and

No manual

adjust-

servicing this vehicle or

if

installing the clutch cable,

on the clutch cable housing

from the dash panel

self-adjuster

may

TRANSAXLE CASE UPPER COVER

necessary.

Damage

to

remov-

DRIVE PLATE

do not

CLUTCH ASSEMBLY

remove

to the cable

occur.

To check the function of the adjuster

being ser-

TO DRIVE PLATE DRIVE PLATE BO LT BACKING TO CLUTCH PLATE

FREE-PLAY

adjuster

is

complete clutch assembly and

CRANKSHAFT

UPPER

COVER

2.0L, 2.4L (VIN X) and 2.5L Engines

it

parts well. Inspect for

and transaxle input

release bearing.

cooler lines using the service

•

Fill

•

assembly.

Before servicing the vehicle, refer to

the precautions

connector

electrical

to service the clutch

ADJUSTMENT

ing

prevent the nega-

mine

Clutch

pull

to

cable from accidentally

grounding.

level.

ment

equipped with

Torque converter dust shield

splice

to

is

does not adjust, deter-

tor

6.

ground cable

an insulator grommet which should be

proper adjuster mechanism function. It

left

shock tower

the dash panel. With less than

3.

or disconnect the following:

Negative battery cable from the

•

port

•

repair

Remove

2.

3 HU

BREEZE

•

•

•

5.

STRATUS

taut.

kg) of effort, the cable housing should

Nm)

Torque converter bolts and remove

•

cable 2.

Upper mount. Raise the assembly

•

pull the clutch

•

release lever end of the cable to draw the

connect the following:

Transaxle and torque the bolts to

•

SEBRING CONVERTIBLE

With slight pressure,

1.

Install or

4.

•

Exploded view

ot the clutch

assembly

mechanism, use the following procedure:

For Tune-up, Capacities and Firing orders, see Section

1

of this

manual

CHRYSLER CORP.

9-46

CIRRUS

•

SEBRING CONVERTIBLE

•

STRATUS

BREEZE

•

release bearing are usually replaced together.

Check the condition

5.

of the stud pivot

spring clips on the back side of the clutch fork.

If

the clips are broken or distorted,

replace the clutch fork. The pivot ball pocket in

the fork

installed

Teflon® coated and should be

is

WITHOUT

grease which

any lubricant such as

break

will

down

the Teflon®

coating. Be sure the ball stud and fork

pocket are clean of contamination and

When assembling

dirt.

the fork to the bearing,

must go over

the small pegs on the bearing the fork arms.

Check

6.

or grooves.

machine

the flywheel for cracks, glazing

any

If

of

these conditions exist,

(reface) or replace the flywheel to

prevent clutch chatter and premature clutch wear.

manual transaxle

i-^The

with a reverse brake.

It

synchronizer, but only

When

not moving.

depressed

if

equipped

is

functions as a the vehicle

the clutch pedal

and held

to the floor

is is 4.

for 3

seconds, and the transaxle shifts to reverse, no gear clash should be present.

If

there

is,

When

be checked.

removed

the input shaft should the transaxle

is

check the

for clutch service,

input clutch shaft, clutch disc splines

and release bearing

for dry rust.

1

- ISOLATORS

2 -

WATTS LINK (LOWER) BELL CRANK

5 -

JOUNCE BUMPER

6 -

3 - SHOCK ABSORBER 4 - WATTS LINK (UPPER)

7 - AXLE 8 - COIL

SPRING 9346JG12

3.

Exploded view

of the clutch

assembly-3. OL engine

If

washer and clutch tube

present, clean rust off and apply a light

•

Insulator,

coat of high temperature bearing

•

Union, union bolt and gasket

and torque the fastener

•

Valve and spring, 3.0L engine

(15

grease on the input shaft splines only

•

Clutch release cylinder

where the clutch disc

•

Clutch cover and disc

the clutch disc slides freely along the

•

Release fork shaft, 3.0L engine

input shaft splines.

•

Left

•

Release fork

•

Clutch release bearing

grease

7.

Install or

•

Apply

to the input shaft splines.

slides. Verify that

connect the following:

Modular clutch assembly onto the

•

transaxle input shaft •

Transaxle assembly

•

New

•

clutch-to-driveplate (flywheel)

bolts. Tighten the bolts, in a criss-

•

ft.

lbs.

(75

at

Fluid line bracket

14

ft.

lbs.

lbs.

and torque the (19

Nm)

Negative battery cable

Check and top

Release fork boot and fulcrum, 2.4L

Release fork boot and maintenance

To

off

the fluid level,

if

Halfshafts

•

Transaxle lower support brackets

•

Starter

•

Negative battery cable

check

2.0L, 2.4L (VIN X) 2.5L and 2.7L

connect the following:

Release fork boot and maintenance cover, 3.0L engine

•

REMOVAL & INSTALLATION

install:

a time

Nm)

test the vehicle to

ft.

cover, 3.0L engine

Clutch inspection cover

Road

to 11

necessary.

•

Engines

"Hf the vehicle

Release fork boot and fulcrum and torque the fulcrum to 26

8.

•

washer and clutch tube

Nm)

bolt to

support spring, 3.0L engine

Install or

55

•

Insulator,

engine

cross pattern, a few turns to

•

ft.

lbs.

(35

Nm) for •

Clutch release bearing

•

Release fork

is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install to the hubs.

proper clutch operation.

2.4L (VIN G) and 3.0L Engine

•

Left

support spring and release fork

shaft,

3.0L engine

the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no If

1

.

Before servicing the vehicle, refer to

•

the precautions in the beginning of this section. 2.

Remove

or disconnect the following:

•

Negative battery cable

•

Clutch fluid line bracket

Clutch disc and cover and torque the bolts to 14

ft.

lbs.

(19

Nm)

•

Clutch release cylinder

•

Valve and spring, 3.0L engine

•

longer be usable.

Union, bolt and gasket and torque the bolt to 17

ft.

lbs.

(23

Nm)

1

.

Before servicing the vehicle, refer to the

precautions

in

the beginning of this section.

CHRYSLER CORP. CIRRUS

•

SEBRING CONVERTIBLE

STRATUS

•

•

Q./17 w HI

BREEZE

2.

Remove

2.4L (VIN G) and 3.0L Engine

or disconnect the follow-

ing:

Before servicing the vehicle, refer to

1

• •

Negative battery cable the precautions in the beginning of this sec-

Cotter pin, nut lock and spring

tion.

washer •

Halfshaft nut, loosen

it

Remove

2

while the

is

on the

or disconnect the following:

Negative battery cable

•

vehicle

floor with the •

Front wheel

•

Vehicle Speed Sensor (VSS) cable

brakes applied •

Wheel

•

Brake caliper assembly and support

if

Brake hose clip and cotter pin

•

Driveshaft nut

on a wire

it

•

Brake rotor

and washer

•

Halfshaft nut

•

Tie rod end from the steering

may damage

Inserting the prybar too far

the transaxle seal

•

Lower arm

•

Tie rod end

•

Stabilizer link

•

Driveshaft and circlip

knuckle using joint separation Tool

MB991113 To install: 3.

To

Inspect the halfshaft boot for

Check

or deterioration.

Use

of

improper methods

separation can result

in

of joint

damage

4.

bracket,

•

Sway

•

bar link from the

damper

fork, •

•

Damper

•

Steering knuckle from the lower control

fork

assembly

it

Halfshaft into the

hub by pulling

Washer. Make sure the chamfered

Halfshaft nut

it

from the

•

hub

Control

arm

to the steering knuckle

and torque the nuts

^After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from

lbs. •

Damper

fork

Nm) and

WARNING

•

damages

on the shaft. Doing so

the inboard joint.

43-52

ft

and torque the lower

Do not

•

•

•

ft.

to

17-25

install a

ft.

new

Sway

Brake hose clip

•

VSS

•

Front wheel

•

Negative battery cable

76

lbs

bar link to the

damper

link nut to

ft

if

equipped

Inner Tri-pot Joint

lbs

Nm)

Remove

or disassemble the follow-

•

ft.

Halfshaft

Large and small boot retaining

lbs.

•

Wheel

•

Negative battery cable

down

the shaft

away

housing.

•When

separating the spider joint

from the

tri-pot joint

housing, hold the

vent the rollers and needle bearings

from falling away. 3.

Carefully slide the shaft/spider

assembly from the

the transaxle.

Test drive the vehicle

tri-pot

rollers in place on the trunions to pre-

cotter pin

Refill

Slide the boot

from the

Brake rotor and caliper assembly

New

7.

Negative battery cable

•

clamps

securely tightening the axle

•

6.

•

•

wheel bearings.

to

cable,

fork

29

nut, be sure there is no load on the

NOT

Nm)

OVERHAUL

Lockwasher and axle nut and

• Before

careful

to a

CV-Joints

2.

knuckle— be

it

(226

the driveshaft

•

cot-

(200-260 Nm)

the threads or splines on the joint

lbs.

(88

lbs.

torque the nut to 145-188

remove the outer CV-joint from

ft.

ing:

(39

damage

Driveshaft nut and torque

maximum of 167 New cotter pin to

pin

and torque the

the steering

•

1

ter

Carefully

end

ball joint

Tie rod end, to the steering knuckle

(24-33 Nm) and

insert the prybar too far or the oil

7922FG53

cotter pin to the tie rod

Nm)

and torque the nut pull

to

the upper pinch bolt to

(103

lbs.

ft.

Do not

Lower arm

to

Nm)

(28

New

to

(59-71 Nm)

through-bolt/nut to 65

the transaxle.

end and torque the nut

lbs.

ft.

•

arm

Halfshaft by pressing

Nm)

(44

nut

and tighten temporar-

ily

•

and torque the nut

lbs.

ft.

•

edge faces outward •

Stabilizer link

Tie rod

4

assembly outward

connect the following:

33 21

seated

the knuckle

necessary

if

•

is fully

System (ABS) •

of

Halfshaft into the transaxle until

connection

Driveshaft

connect the following:

Install or

equipped with an Anti-lock Brake

if

Install or

•

Replace the circlips on the ends

ball joint

install:

•

the halfshaft(s). 5.

Speed sensor cable routing

3

and

splines for wear. to

the joint, leading to possible failure. •

damage

the ball joints

equipped

•

Remove and check

tri-pot

housing.

the spider assembly-to-shaft

for

snapring; then, slide the spider assembly

proper operation. the shaft

For complete service labor times, order the Chilton Labor Guide

off

CHRYSLER CORP.

9-48

CIRRUS

•

SEBRING CONVERTIBLE

•

STRATUS

•

- STUB AXLE - OUTER C/V JOINT 3 - OUTER C/V JOINT BOOT

BREEZE

1

8 -

2

9 -

4 -

CA/ JOINT

RIGHT DRIVESHAFT 10 - INNER TRIPOD JOINT BOOT 11 - INNER TRIPOD JOINT 12 - INNER TRIPOD JOINT 13 - INNER TRIPOD JOINT BOOT

TUNED RUBBER DAMPER WEIGHT

- INTERCONNECTING SHAFT 6 - OUTER C/V JOINT BOOT 5

7 -

OUTER

STUB AXLE

14 -

INTERCONNECTING SHAFT LEFT DRIVESHAFT 9306EG02

9.

View

of the halfshaft

assemblies— Typical

of excessive wear.

If

necessary, replace the

necessary, tap the spider assembly

If

off

the shaft using a brass

careful not to hit

be the outer bearings. drift;

^••Component parts are not serviceable and must be replaced as an assembly.

Slide the boot off the shaft.

6.

Throughly inspect

all

&

parts for signs

Slide the inner tri-pot boot clamp

is

visible

shaft just far

shaft.

spider assembly onto the

enough so

that the

WARNING

Tri-pot sealing boots are

made

WARNING

of

2 different types of material; silicon

If

rubber (high temperature) which

onto the shaft using a brass

is

and pliable or Hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot

made

snapring

can be installed.

soft

1

on the

Install the

I:

The

shaft; then, position the

boot so that only the thinnest (sight) groove

8.

To assemble; 5.

7.

and boot onto the

halfshaft.

necessary, tap the spider assembly drift;

be

careful not to hit the outer bearings. Install the

snapring onto the shaft;

of the correct material.

- SNAP RING

2 - SEALING

BOOT

©

3 -

SPIDER ASSEMBLY 4 - SNAP RING PLIERS 1

5 - INTERCONNECTING SHAFT

2 9306BG1

3

BOOT - RAISED BEAD IN THIS AREA OF SEALING BOOT - GROOVE - SEALING

4 -

View

of the halfshaf? inner tri-pot joint

snapring

1

and

- SEALING

BOOT

2 - SPECIAL TOOL C-4975 3 - CLAMP BRIDGE

INTERCONNECTING SHAFT

9306BG13

9306EG04

View

of the halfshaft

boot and shaft

Securing the halfshaft boot clamp

Q_>IQ

CHRYSLER CORP. CIRRUS

•

SEBRING CONVERTIBLE

housing retaining groove and retaining

14

If

•

STRATUS

•

3

BREEZE

install the

clamp evenly on the boot. using a crimp type boot clamp,

perform the following procedure:

Using the Crimper Tool C-4975-A

a.

place the tool over the clamp bridge, tighten the tool nut until the jaws are

completely closed (face-to-face).

Using the Crimper Tool C-4975-A,

b.

place the tool over the clamp bridge, 1

-

CLAMP

TOOL YA3050 - SEALING BOOT

2 - SPECIAL 3

1

-

2 3 4 -

tighten the tool nut until the jaws are

SOFT FACED HAJ4MER STUB AXLE

OUTER NUT

15.

9306EG07

Tightening the low profile boot

If

9306EG10

using a latching type boot clamp,

Driving the Rzeppa joint onto the shaft

perform the following procedure:

clamp—

Position Snap-On Clamp Locking YA3050 prongs in the clamp holes.

a.

Silicone rubber Tri-pot boot

Tool b.

Squeeze the

clamp band

tool until the

upper

Boot and slide

•

Circlip,

•

4.

Install

•

Rzeppa

in

it

•

Rzeppa hitting

joint

to drive profile boot

clamp— Sili-

cone rubber Tri-pot boot

off

•

Circlip from the shaft

Boot by sliding

it

off

Distribute

5.

hammer

in

that the

snapring

is fully

Install or

6.

New

•

the shaft

WARNING

seated If

of the

If

installing a

grease

in

new

boot, distribute

Vfe

the service package inside

the tri-pot housing

and the other

Vfc

11.

12.

7

any parts show excessive wear,

it

shaft

onto the shaft

hammer so

it

of the grease in the

VS>

inside the boot.

connect the following:

small boot clamp and position

evenly on the sealing boot

Using the Crimper Tool C-4975-A,

the tool nut until the laws are completely

replace the halfshaft assembly; the

component

closed (face-to-face).

parts are not serviceable.

inside

the boot.

** WARNING To assemble:

Carefully, slide the spider

and shaft

flush

place the tool over the clamp bridge, tighten

the groove. 10.

Rzeppa

is

service package inside the Rzeppa joint

it

make sure

it

and align the

housing and the other

the shaft

•

the

locks on the circlip

housing by sharply

with a soft-faced it

joint

with a soft-faced

the shaft

9306EG08

Secured the low

Rzeppa

•

a soft-

boot clamps and slide

down

it

hub nut onto

threaded shaft so

splines and tap

joint

the boot

-

the

with the end

jawed vise

2.

INNER TRIPOD JOINT HOUSING 2 - TOP BANK OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP 3 - SEALING BOOT

joint

and place

is in

or assemble the following:

Halfshaft

or disassemble the following:

Halfshaft

onto the shaft

shaft groove.

Rzeppa (Outer) Joint Remove

it

removed

Position the boot so that the raised

•

1

if

bead on the inside the boot seal

Install the halfshaft into the vehicle.

16.

•

3.

latched behind the 2 tabs

is

on the lower clamp band.

1

GV JONT

completely closed (face-to-face).

assembly

Install or

into the tri-pot housing.

•

Position the inner boot clamp evenly

New

The seal must not be dimpled,

assemble the following

small boot clamp and slide

it

stretched or out of shape.

on 13. the sealing boot.

shape

** WARNING

8.

If

it

neces-

Position the boot onto the Rzeppa

retaining

neces-

9.

and equalize the seal pressure and shape it by hand.

sary, use a trim stick to seat

and

by hand.

housing retaining groove and

The seal must not be dimpled, stretched or out ot shape.

If

sary. equalize the seal pressure

onto the shaft

install the

clamp evenly on the boot.

Using the Crimper Tool C-4975-A,

place the tool over the clamp bridge tighten the tool nut until the jaws are completely

closed (face-to-face). ft>

bead

No.

1

compression stroke

for the

Remove

or disconnect the follow-

•

Water

pump

•

Intake

vacuum

•

ing:

drive pulley

•

(2-3mm) to the

12.

Install the

Accessory drive belts

•

A/C compressor

•

Alternator

•

13

Tighten the camshaft journal cap

For

Tire,

body

and

Wheel and Ball Joint

right intake

manifolds

specifications,

see Section

Step 1:62-106 inch

b.

Step

14.

1

sequence as follows:

a.

Surge tank and supports Lett

in

their original positions.

Exhaust Gas Recirculation (EGR)

Throttle

camshaft journal caps

lines

bolts in •

inch

side cylinder head intake camshaft jour-

tube •

1

and sealant

nal thrust cap. of the

cylinder.

4.

of silicone gasket

head similar left

(TDC)

camshafts with the timing

Apply a 0.08-0. 1

1 1

ixsumi

ter

install the

marks facing up

Balt

left

camshafts Match the

i?N*(6 2

16-21 Nett

Camshaft installation— 3. 4L (VIN N) engine— Right head shown,

lifters in their

camshaft and chain timing marks as shown,

oi

aiapa

RH

Install the

10.

Carnahan journal Thrust Cap (Pan or eo«6) (2 Raj

.

.

hydraulic

Description Carnahan KHiahaeei

6250

7

Waaner (20

Req'd)

6

6

Install the

original positions

Part

of this

Install

2:

a

12-15

ft

lbs.

lbs

new camshaft

manual

(7-12 Nm).

(16-21 Nm). seal with a

-i

9

FORD MOTOR CO

Q O

1 I

I

TAURUS

•

SABLE Remove

3.

the upper intake manifold

and valve covers. Rotate the crankshaft so that the

4.

camshaft lobe

directed

is

away from

the

valve tappet to be measured. Insert a feeler

5.

camshaft lobe

gauge under

the

90 degree angle

at a

to the

camshaft. Clearance for the intake valves

should be 0.006-0.010 inch (0.15-0.25mm). Clearance

exhaust valves should be

for the

0.010-0.014 inch (0.25^).35mm). 6.

pet

If

adjustment

is

required, install Tap-

Compressor T89P-6500-A under

camshaft next

to the lobe

the

and depress the

valve tappet.

Tappet Holder T96P-6500-AH

Install

7.

and remove the compressor

i-* Camshaft journal cap

Cam

bolt tightening

spacer to

Install or

•

and

Left

connect the following: right

(VIN N) engine

Front cover

is

checked with

micrometer. 10.

Install the

Accessory

•

Oil

.

Before servicing the vehicle, refer to

spacer

2.

Disconnect the negative battery cable.

CKP

CMP

installing the tappet

CAM LOBE IN

Repeat the procedure

sensor

for

each valve

requiring adjustment.

POSITION

Install the

13.

sensor

valve covers and the upper

intake manifold.

Crankshaft pulley

•

Power steering pump

•

Left

and

right valve

•

IMRC

Engine control sensor wiring har-

cable and bracket

and

right intake

Surge tank and supports Throttle

To measure the valve clearance, slide the

body

feeler

EGR

Intake

vacuum

•

Water

pump

•

Alternator

•

A/C compressor

•

Accessory drive

•

Engine assembly

the engine

and check

for leaks

Starter Motor

• •

Run

manifolds

•

•

Connect the negative battery cable.

15.

and proper engine operation.

•

Left

14.

covers

ness and brackets

16.

compressor, then

belt idler pulleys

•

•

properly seated.

remove the tappet compressor. 12.

•

is

Release the tappet holder by

tion.

pan

•

replacement adjusting

spacer with the numbers down. Be sure the

the precautions at the beginning of this sec-

pulse ring

•

of the adjusting

spacer or by measuring with a

of the

*The valve clearance the engine COLD.

11.

CKP

the valve adjusting spacer off

spacer by the numbers on the bottom face

3.4L (VIN N) engine

1

•

toward

air

camshaft chain ten-

Timing chain

•

lift

Determine the size

9.

sioners •

tool.

compressed

of the valve tappet.

Seal Replacer T89-6256-A. 15.

jet of

the hole in the face of the valve adjusting

sequence— 3. 4L

T89P-6256-B and Cam

Seal Expander

Direct a

8.

tube

the lines

gauge between the base

cam and

the

REMOVAL & INSTALLATION

circle of

tappet— 3. 4L (VIN N)

1

.

Before servicing the vehicle, refer to

the precautions at the beginning of this sec-

engine

drive pulley

tion. 2.

Remove

or disconnect the follow-

ing:

belts into the vehicle.

Run the engine and check

for leaks

and proper operation.

•

Negative battery cable

•

Splash shield

•

Starter electrical connectors

•

Starter

To install:

Valve Lash

3.

Install or

•

ADJUSTMENT

connect the following:

and tighten the bolts

16-21,ft. lbs. •

to

(21-29 Nm)

Starter electrical connectors

and

tighten the battery cable nut to

3.0L (VIN U and S) Engines The lash adjusters (valve tappets), are hydraulic and are not adjustable.

Starter

80-123

inch lbs. (9-14

Correct positioning of the tappet compres-

•

Splash shield

— 3.4L (VIN N) engine

•

Negative battery cable

sor and holder tools

Nm)

FORD MOTOR CO. TAURUS

SABLE

•

2.

Drain the engine

3.

Remove •

12-19

oil.

or disconnect the following:

Negative battery cable tube

•

Oil dipstick

•

Low

•

Starter

•

Heated Oxygen (HO 2 S) sensor con-

oil level

sensor,

if

equipped

motor and brace

nectors

9346KG24

Remove

Oil

pan— 3.0L

(VIN U) engine

the front splash shield for access 5.

To install: 4

pan with new gaskets.

Install the oil

Step

10

Step

2:

Loosen

all

bolts.

Step

3:

Tighten

all

bolts to

4

Install the oil

to

ft.

to

10

ft.

connect the following:

•

Engine rear plate

• • •

Starter

•

Low

•

Oil dipstick

•

Negative battery cable

5.

:

Step

2:

108 inch Step

Tighten the 4 corner bolts

lbs.

lbs.

3:

(12 Nm).

Tighten the remaining bolts (12 Nm).

Retighten

all

bolts to

Install or

Dual converter Y-pipe

•

Dual converter Y-pipe

HO 2 S

sensor connectors

•

HO 2 S

motor and brace

•

Starter

•

Low

•

Oil dipstick

•

Negative battery cable

oil level

Fill

7.

Start the

sensor,

if

equipped

tube

the crankcase.

engine and check

for leaks.

sensor connectors

motor and brace

oil level

sensor,

if

equipped

tube

the crankcase.

6.

Fill

7.

Start the

engine and check

3.0L (VIN S) Engine .

Before servicing the vehicle, refer to the

the beginning of this section

at

precautions

at

the beginning of this section.

(VIN S) and 3.4L (VIN Oil

N) engines

Pen Removal Sequence

Pan

REMOVAL & INSTALLATION

3.0L (VIN U) Engine Item 1

1998-99 ENGINES

2

Description Upper Cylinder Block

Lower Cylinder Block 0010)

(Pert

of .

Before servicing the vehicle, refer to the

precautions

at the

beginning of this section.

2.

Drain the engine

3.

Remove

oil.

or disconnect the following:

•

Negative battery cable

•

Oil dipstick

•

Low

•

Starter

•

Heated Oxygen (HO 2 S) sensor con-

Pen

3

Otl

4

Stud Bott (5 Req d)

Req

5

Bolt (10

6

Oil

7

Engine Front Cover

d)

Pen Gasket

tube

oil level

sensor,

if

equipped

motor and brace FRONT Of ENGINE

nectors •

Dual converter Y-pipe

•

Engine rear plate

•

Oil

pan

Oil

for leaks.

Before servicing the vehicle, refer to the 1

1

108

connect the following:

Engine rear plate

precautions

Oil

1

•

9346KG26

motor— 3. OL

pan with new gaskets.

inch lbs. (12 Nm).

2000-01 ENGINES

Starter

Step

108 inch

c.

(14 Nm).

6

1

pan

Tighten the bolts as follows:

b.

b.

Install or

Oil

a.

bolts to

c.

lbs.

— 3.0L (VIN U) engine

all

Engine rear plate

•

install:

(14 Nm).

lbs.

Starter motor

Tighten

1:

Dual converter Y-pipe

•

To

Tighten the bolts as follows: a.

•

pan

bolt

removal sequence

—

3 OL (VIN S) engine

For Wheel Alignment specifications, see Section

1

of this

manual

19 on £“£U

ford motor co. TAURUS

I

SABLE

•

6.

connect the following:

Install or

•

Dual converter Y-pipe

•

Negative battery cable the crankcase.

7.

Fill

8.

Start the

engine and check

for leaks

and proper operation.

Oil

Pump

SEALER WSE-M4G323-A1

REMOVAL & INSTALLATION 3.0L (VIN U) Engine NOTE: APPLY 8 (0.31

mm

INCH)

DIAMETER BEAD OF

1

.

Before servicing the vehicle, refer to the

SILICONE GASKET

ANO SEALANT

precautions at the beginning of this section.

F6AZ-19562-AA

GO

OR EQUIVALENT MEETING FORD

2.

Drain the engine

SPECIFICATION

3.

Remove

WSE-M4G323-A6 AT TWO PLACES

AS SHOWN VIEW A SIMILAR

TIGHTEN BOLTS/STUDS

TWO PLACES

I 1

Oil

pan

sequence— 3. OL

bolt tightening

•

Negative battery cable

•

Oil dipstick

•

Low

•

Starter

motor and brace

•

Fleated

Oxygen Sensor (HO 2 S) con-

IN

SEQUENCE SHOWN

(VIN S) engine

oil.

or disconnect the following:

tube sensor,

oil level

if

equipped

nectors 2. 3.

Drain the engine

Remove

oil.

or disconnect the following:

Dual converter Y-pipe

•

Engine rear plate

•

Negative battery cable

•

Oil

pan

•

Dual converter Y-pipe

•

Oil

pump

•

Transaxle support bracket

•

Oil

4.

the

pan by following the bolt

removal sequence shown

To install: 4.

•

•

Oil

15-22

ft.

lbs.

sequence

in

install:

5.

Insert the intermediate shaft into the

pump •

to

71-106

until the

Install or

Oil

inch lbs. (8-12

snapring seats.

connect the following:

pump and

30-40

(20-30 Nm).

Transaxle support bracket. Tighten the nuts to

pump.

oil

To

6.

new gasket and

pan. Use a

tighten the bolts

•

oil

connect the following:

Install or

Separate (he intermediate shaft from

ft.

lbs.

tighten the bolt to

(40-55 Nm)

pan

•

Oil

•

Engine rear plate

•

Dual converter Y-pipe

(20-30 Nm).

•

HO 2 S

•

Dual converter Y-pipe

•

Starter

•

Negative battery cable

•

Low

•

Oil dipstick

•

Negative battery cable

Nm) and

the bolts to

15-22

lbs.

ft.

Oil

the crankcase.

5.

Fill

6.

Start the

pan

bolt tightening

(VIN N) engine

engine and check

for leaks

sequence

—

3.4L

sensor connectors

motor and brace

oil level

and proper operation.

sensor,

if

equipped

tube

APPLY SILICONE

3.4L (VIN N) Engine 1

.

Before servicing the vehicle, refer to the

precautions

at the

beginning of this section.

2.

Drain the engine

3.

Remove •

oil.

or disconnect the following:

Negative battery cable

•

Dual converter Y-pipe

•

Oil

pan

To

install:

4.

Apply a 0.16 inch (4mm) bead

cone sealer on the entire

oil

of sili-

pan sealing

surface. 5.

bolts

Install the oil

and studs

in

pan. Tighten the

sequence

(20-30 Nm). Tighten the case bolts

to

25-34

ft.

to

oil

15-22

pan

ft.

lbs. 7922KG40

oil

lbs.

pan-to-transaxle

(34-46 Nm).

Apply silicone sealant

to the entire sealing surface of the oil

pan— 3.4L

(VIN N) engine

FORD MOTOR CO. TAURUS

Exploded view

of the oil

•

SABLE

lO.OI £ L. I

pump mounting—

3.0L (VIN U) engine

the crankcase.

7.

Fill

8.

Start the

engine and check

for leaks

and proper operation.

3.0L (VIN S) Engine 1

Before servicing the vehicle, refer to the

.

precautions

at the

beginning

of this section

Remove the engine from the vehicle and mount on an engine stand. 3. Remove or disconnect the following: 2.

it

I '

•

Upper intake manifold

•

Valve covers

•

Accessory drive

•

Power steering pump

REMOVE BOLTS IN SEQUENCE SHOWN

OIL

Description

Item

1

Cylinder Block

2

Oil Pan Baffle

3

Nut (5 Req'd)

4

Nut

5

Oil Pump Screen Cover and Tube

6

Oil Pump Inlet Tube Gasket

7

Oil Pump

A

Tighten to 14-25 Nm (11-18 Lb-Ft)

B

Tighten to 8-14 Nm (71-123 Lb-In)

belt

CRANKSHAFT (2

Req'd)

PUMP

BOLT 4 RFQ’O

FRONT OF

CYLINDER BLOCK

ENGINE

9300KG15

Oil

pump

(VIN S) similar

bolt

30CKG16

removal sequence— 3. OL

engine— 3. 4L

(VIN N) engine

is

Exploded view

ot the oil

(VIN S) engine

is

pump

pickup tube and screen

mounting— 3. 4L

similar

For Maintenance Interval recommendations, see Section

1

of this

manual

(VIN N)

engine— 3. OL

I

10 99 L~CC I

FORD MOTOR CO. TAURUS

SABLE

•

3.4L (VIN N) Engine 1

Rear Main Seal

Before servicing the vehicle, refer to

.

the precautions at the beginning of this sec-

REMOVAL & INSTALLATION

tion.

Remove

2.

and mount

the engine from the vehicle

Remove

3.

or disconnect the follow-

1

7922KG43

Oil

pump

bolt tightening

engine—3. 4L

(VIN S)

sequence

—3.0L

(VIN N) engine

•

Accessory drive

•

A/C compressor

•

Alternator

•

Water

pump

•

Intake

vacuum

Exhaust Gas Recirculation (EGR) tube

•

Surge tank and supports

•

Left

A/C compressor and bracket crankshaft accessory drive pul-

ley shaft

has left-hand threads. Rotate

the pulley shaft clockwise to remove.

•

Oil

pump

Front cover

Timing chains

•

Crankshaft timing gears

•

Oil

install:

•

Camshaft Position (CMP) sensor

•

Crankshaft Position (CKP) sensor

•

Oil

pan

•

Oil

pump

•

Accessory

•

Front cover

Front cover Oil

pump

71-106

71-106

Nm), and the nut

•

'The

8.

Check

9.

Start the

•

Oil

to

15-22

ft.

Water

pump

•

Alternator

•

Power steering pump Accessory drive belt

Engine

6.

Start the

fill

as needed. for leaks.

9346KG27

Timing chain

•

CKP

Jet Plug

engine and check

Remover 310-005— 3. OL (VIN U)

engine

pulse ring

•

Front cover

•

Accessory

•

Oil

pump

belt idler pulleys

screen and tube. Tighten

71-123

ft.

lbs.

inch lbs. to

(14-25 Nm).

pan

•

Oil

•

CKP

•

CMP

•

Crankshaft pulley

•

Power steering pump

•

Left

sensor sensor

and

right valve

9346KG28

Rear Seal Replacer 303-323— 3. OL (VIN

covers

•

Surge tank and supports

•

Throttle

•

EGR

•

Intake

vacuum

•

Water

pump

U) engine

body

3.0L (VIN S) and 3.4L (VIN N) Engines

tube lines

drive pulley

•

Alternator

•

A/C compressor

•

Accessory drive belts

•

the vehicle.

and proper operation.

and

inch lbs.

.

Before servicing the vehicle, refer to

the precautions at the beginning of this sec-

2.

Engine

for leaks

6.

Fill

Attach an engine support fixture to

the engine lifting eyes.

into the vehicle 3.

5.

the crankcase.

Fill

fluid levels

engine and check

tion.

intake manifold in

all

tighten the bolts in

80-115

1

•

(73-87 Nm).

lbs.

mounting

A/C compressor and bracket

to

Crankshaft timing sprocket

11-18

•

Upper

lbs.

transaxle and the negative

connect the fotlowing:

pump and

•

inch lbs. (8-12

•

5.

Oil

(8-14 Nm) and the bracket nuts

bracket bolts are torque-to-yield bolts

•

ft.

oil seal.

pump

the tube nuts to

and must be replaced when removed.

Valve covers

main

and tighten the

battery cable.

pulse ring

Install or

Crankshaft pulley

•

54-64

Install the

7.

Crankshaft timing sprocket

inch lbs.

pan

air conditioning

•

bolts to

belt idler pulleys

•

•

(20-30 Nm). Oil

Install the flexplate

6.

CKP

screen and tube. Tighten

the bolts to

•

screen and tube

on Rear Seal

rear of the engine. Tighten the bolts

Timing chain

tighten the bolts in

Timing chains

•

on the

alternately to seat the rear

•

Crankshaft timing gears

•

seal

oil

(9-13 Nm)

(8-12 Nm)

•

Jet

Replacer 303-323. Position the tool and seal

•

connect the following:

to

Use the

Plug Remover to remove the rear main seal.

covers

Position the rear

•

pump and

of Jet Plug

into the seal.

5.

sequence

sequence

•

Remover 310-005

To

4.

pump

Install or

and the cylinder block.

Power steering pump

To install: 4.

lip

Screw the threaded end

To install:

•

Oil

and punch a hole

seal metal surface

Crankshaft pulley

screen and tube

Oil

main

between the seal 4.

right valve

a sharp awl

•

pan

•

the negative battery cable,

•

Crankshaft pulley

•

•

body

and

Use

3.

into the rear

lines

Throttle

pump

Water

•

•

drive pulley

•

is

Remove

2.

transaxle and flexplate.

Alternator

•

'The

tion.

belts

•

similar

•

Before servicing the vehicle, refer to

.

the precautions at the beginning of this sec-

ing:

(71*106 LB-IN)

3.0L (VIN U) Engine

on an engine stand.

it

Remove

or disconnect the following:

the crankcase.

Start the

engine and check

•

Negative battery cable

•

Transaxle

•

Flexplate

for leaks

and proper operation.

19.00

FORD MOTOR CO. TAURUS 4.

Use Seal Remover T95P-6701 -EH

and a slide

hammer

to

remove the

Seal Replacer

•

crankshaft seal.

6.

Install

•

or connect the following:

Rear main seal flush with the cylinder block surface. Use Rear Main

CRANKSHAFT REAR

Timing Chain, Sprockets and Front Cover and Seal

Flexplate and tighten the bolts to

54-64

To install: 5.

T82L-6701-A and

Adapter Bolts T91 P-6701 -A.

rear

SABLE

•

ft.

lbs.

(73-87 Nm)

REMOVAL & INSTALLATION

•

Transaxle

•

Negative battery cable

Run

the engine

and check

for leaks.

3.0L (VIN U) Engine 1

REAR CRANKSHAFT

Before servicing the vehicle, refer to

.

the precautions at the beginning of this section.

Drain the engine

2.

oil

and the cooling

system.

Remove

3. •

or disconnect the following:

Negative battery cable

•

Accessory drive

belt

•

Accessory drive

belt tensioner

and

idler pulley

pump

•

Water

•

Crankshaft pulley

•

Crankshaft Position (CKP) sensor

•

Coolant hoses

pulley

•

Dual converter Y-pipe

•

Oil

•

Front crankshaft seal

•

4

pan

Front cover Rotate the crankshaft until the No.

piston

1

Top Dead Center (TDC) and the

is at

timing sprocket marks are aligned.

Remove

5.

the timing chain

and

sprockets

To /

install:

•The

camshaft

passage

Rear Crankshalt Seal Remover T95P-6701 -EH — 3.0L (VIN S) and 3 4L (VIN N) engines

in

it

has

bolt

for

a drilled oil

timing chain lubrica-

tion. Prior to installation, clean the

passage and be sure

it

Never

clear.

is

replace the camshaft bolt with a stan-

dard bolt. 6

Install the

timing chain and sprock-

ets with the timing

marks aligned Tighten

the camshaft sprocket bolt to

46

ft.

(63

lbs.

Nm).

Use

7.

front cover

a

new gasket and

Apply sealant

3 Tighten bolts 1-10

and

bolts

11-15

Install or

8.

to

19

84 inch

ft

1

,

2 and

lbs (25

lbs

Nm)

(10 Nm).

connect the following

•

Front crankshaft seal

•

Oil

•

Dual converter Y-pipe

pan

•

Coolant hoses

•

CKP

•

Crankshaft pulley and tighten the

sensor

damper

bolt to

107

ft.

lbs.

(145

Nm)

T91 P-6701 -A •

Water

pump

bolts to 16

Rear Seal Replacer T82L-6701-A and Adapters T91P-6701-A— 3.0L (VIN S) and 3.41 (VIN N) •

engines

1

of this

pulley

ft.

manual

and tighten the

lbs. (21

Accessory drive idler pulley

For Tune-up, Capacities and Firing orders, see Section

to

install the

to bolts

Nm)

belt tensioner

and

10

0/1 FORD MOTOR CO. TAURUS

I

•

SABLE

Accessory drive

9. •

•

TIMING MARKS MUST BE IN POSITION SHOWN WITH NO. 1 PISTON AT TDC FIRING

CAMSHAFT SPROCKET

Fill

the cooling system.

10.

Fill

the crankcase.

1 1

Start the

.

Before servicing the vehicle, refer to

the precautions at the beginning of this section. 7922KG47

Remove

2.

and mount Timing chain alignment marks

— 3.0L (VIN U) engine

Application

Slz*

LB-FT

N-m

M8 x

1

25x43

5

F /CTO

BLOCK

20 30

15 22

M8x

1

25x43

5

F/CTO BLOCK

20-30

15 22

W/P A F/C TO BLOCK W/P & F/C TO BLOCK

20-30

15 22

20 30

15 22

M6x

3A 4A

M8x

1

1

25x73

25x 104

3

6A

M8

x

1

25

73

F/CTO BLOCK

20 30

15 22

6A

M8x

1

25x73

20 30

15 22

7A

M8x

1

25

20 30

15-22

20 30

15 22

20 30

15-22

x

16

M6

x

1

x

28 5

12B

M6

x

1

x

28 5

W/P & F/CTO BLOCK W/P A F/C TO BLOCK W/P A F/C TO BLOCK W/P A F/C TO BLOCK F/CTO BLOCK W/P TO F/C W/P TO F/C

t3B

M6 x

1

x

28 5

MB

M6

x

1

x

28 5

15B

M6

x

1

x

28 5

x

73

8A

M8

x

1

25

x

9A

M8x

t

25

x 104 3

10A

M8

x

1

or disconnect the following:

F**t*n*r

No.

2A

the engine from the vehicle

on an engine stand.

Torque Specifications

Fa*t*n*r»

1

it

Remove

3.

Faatanar And Hot*

25

1

104 3

x

52

20-30

15 22

8 12

71 106

(lb-in)

8 12

71-106

(lb in)

W/P TOF/C

8-12

71 106 (lb

W 'PTC F/C W PTOF/C

8 12

7M06 (lb

in)

8 12

71 106 (lb

.n)

-

in)

f

W /P — Water Pump F/C

— Engine Front Cover 7922KG4B

Timing chain

front cover bolt location

and identification

— 3.0L (VIN U) engine

for leaks

3.0L (VIN S) Engine 1.

CHAIN

engine and check

and proper operation.

CRANKSHAFT SPROCKET

TIMING

belt

Negative battery cable

TAURUS pump

Oil

Crankshaft Position (CKP) sensor

camshaft thrust caps must be removed before loosening the remain-

camshaft journal cap bolts

connector

ing

Camshaft Position (CMP) sensor

ensure that the thrust caps are not

connector

damaged.

•

Front cover

•

CKP

sensor pulse

ring.

Note the

Camshaft journal caps. Loosen the

•

keyway alignment

for installation.

bolts in

Access the power steering pump bolts through the holes

in

the

pulley— 3. OL (VIN

is

passes

used on several

keyway

ferent engines. Note the

ment

S) engine

Crankshaft Position Sensor

(CKP) pulse ring

•

in

Valve covers

•

Accessory drive

•

Power steering pump

•

Rotate the crankshaft so that the key-

is at

No.

1

Alternator

Dead Center (TDC)

pump

Water

•

A/C compressor and bracket

Verify that the alignment arrows

crankshaft

1

on

and

has left-hand threads. Rotate

the pulley shaft clockwise to remove. Crankshaft pulley

•

Crankshaft damper

•

Oil

keyway

at the 11

o'clock position. This will position the

left

not, rotate the

If

complete revolution and

cylinder head camshafts to their neutral position.

way

Verify that the alignment arrows

on

Rotate the crankshaft so that the key-

6.

the camshafts are aligned. is at

the 3 o’clock position. This posi-

Remove

tions the right cylinder head camshafts to

Remove

7.

•

the

left

cylinder head timing

chain tensioner retaining bolts and the tim-

the neutral position. •

Rotate the crankshaft 2 revolutions

recheck.

crankshaft accessory drive pul-

ley shaft

Right timing chain and crankshaft

locate the crankshaft

9.

—The

order for installation.

for 8. 10.

the camshafts are aligned.

•

be

sprocket

cylinder.

5.

to

the 11 o’clock position to locate

the crankshaft at Top belt

several

Right timing chain tensioner arm

•

way

in

camshaft

Rocker arms. Keep the rocker arms

•

align-

for installation.

4

Upper intake manifold

sequence and to allow the

raised from the cylinder head evenly.

dif-

•

•

to

Camshaft thrust caps

•

—The

CO. SABLE

—The

screen and tube

•

•

•

•

OE tJ

O 1It

FORD MOTOR

ing chain tensioner. or disconnect the following

Right timing chain tensioner

pan

—The

camshaft thrust caps must be

removed before loosening

the remain-

using a thin prytool. release and hold the liming chain tensioner ratchet/pawl mech-

anism— 3

1

2

3

Exploded view engine

—

left

RH Eahauet Camshaft RH Intake Camshaft RH Timing Chain Crankshaft

6

Timing

Cham

7

Bon

Req

0

Timing

Sprocket

0

Timing Chain Guide

4

RH

6

Boll (2

Timing Chain

Req

10

d)

A

of the right cylinder

side similar

(2

01 (VIN S) engine

Teneaon#/

d)

Cham

Tenetoner Aim

RH Cylinder Heed Tighten to 20 30 N-m Lb-Ft)

(

IS 22

head timing chain and related components— 3. OL (VIN S)

Retain the piston with a paperclip

—

For complete service labor times, order the Chilton Labor Guide

3

1

5mm

OL (VIN S) engine

wire or

n nc

4

FORD MOTOR CO.

I£'"£0

TAURUS

•

SABLE •

THRUST CAPS

•

Right timing chain tensioner arm Right timing chain tensioner and

15-22

tighten the retaining bolts to lbs.

ft.

(20-30 Nm)

'•-The crankshaft

keyway must be

In

the 11 o’clock position to install the

left

cylinder head rocker arms.

••The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions. Install the left cylinder

14.

Camshaft journal

bolt

tightening sequence — 3.0L (VIN

arms

S) engine

••Do not

head rocker

positions.

in their original

camshaft journal

install the

thrust caps until the other journal caps

have been installed and tightened. Tighten the

15.

caps

in

passes

to

Install the left

16.

camshaft journal

left

shown and in several 71-106 inch lbs. (8-12 Nm).

the order

camshaft journal thrust

caps and tighten the bolts lbs.

Remove

17. left

to

71-106

inch

(8-12 Nm). the retaining wire from the

timing chain tensioner.

••The crankshaft keyway must be

in

the 3 o’clock position to install the right cylinder

Rotate the crankshaft so that the key-

18.

way

head rocker arms.

is in

the 3 o’clock position.

••The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original

13.

positions. Be sure the timing marks are as shown

after the chain

Install the right

19.

has been installed— 3. OL (VIN S) engine

arms

camshaft journal cap bolts

ing

that the thrust caps are not

Remove

11.

to

ensure

damaged.

ratchet/pawl

mechanism through

access hole

in

or disconnect the follow-

Slowly compress the tensioner.

d.

Lock the piston with a 1.5mm wire

e.

Camshaft journal caps. Loosen the

•

bolts in

passes

sequence and to allow the

in

to

for the right

chain tensioner.

be

still

is

at the 11 o’clock position. Install or

connect the following:

evenly. •

Left

Rocker arms. Keep the rocker arms in

Left

timing chain tensioner arm

•

Left

timing chain and crankshaft

timing chain and crankshaft

camshaft journal

and tighten the bolts

71-106

to

inch lbs. (8-12 Nm). 22.

Remove

the retaining wire from the

sprocket. Align the colored links

••The Crankshaft Position Sensor (CKP) pulse ring is used on several different engines. The keyway position for the 3.0L (VIN S) engine will be marked

•

Left

timing chain tensioner arm

•

Left

timing chain tensioner and

install:

tighten the retaining bolts to

Prepare the timing chain tensioners

ft.

for installation as follows: •

Place the

left

chain tensioner

in

lbs.

15-22

Right timing chain and crankshaft sprocket. Align the colored links

Using a small prytool, release and

hold the timing chain tensioner

30,

30RFF

or wjth an

ORANGE

stripe.

(20-30 Nm)

a

vise. b.

Install the right

with the index marks on the

camshaft and crankshaft sprockets.

a.

shown and in several 71-106 inch lbs. (8-12 Nm).

the order to

order for installation.

•

12.

21.

Tighten the right camshaft journal

right timing chain tensioner.

sprocket

To

in

thrust caps

raised from the cylinder head

•

caps

passes

••Be sure that the crankshaft keyway

several

camshaft

not install the camshaft journal

thrust caps until the other journal caps

20.

Repeat

cylinder head rocker

positions.

have been installed and tightened.

or paperclip.

Camshaft thrust caps

•

•Do

the

the timing chain tensioner.

c.

ing:

in their original

with the index marks on the

camshaft and crankshaft sprockets.

23.

Install the

CKP

sensor pulse

Align the keyway with the proper 24.

Replace the crankshaft seal

front cover with a

engine

oil to

new

the seal

ring.

slot. in

the

one. Apply clean

lip.

FORD MOTOR CO. 1 TAURUS

O 07

\C C!

SABLE

•

25. Apply silicone sealer to the 6 critical

shown

areas

View A,

in

block to prevent

new

Place

26.

to the cylinder

seepage.

oil

front cover gaskets onto the

dowel pins on the cylinder block and heads. 27.

Place the front cover into position.

28.

Install the

6

front cover retaining

and stud bolts where the silicone

bolts

was

sealer

applied.

Tighten the bolts and stud bolts until

29.

the front cover contacts the cylinder block

and heads, then turn the bolts and stud bolts an additional 14 turn.

30.

and stud

Tighten

31.

ing bolts

VIEW A

remaining front cover

Install the

retaining bolts

all

bolts.

of the front cover retain-

and stud bolts

15-22

ft.

•The

air

in

sequence

to

(20-30 Nm).

lbs.

conditioning mounting

bracket bolts are torque-to-yield bolts

and must be replaced. 32.

Install or

CMP

•

connect the following:

sensor connector

CKP sensor connector pump screen and tube

• •

Oil

•

pan

Oil

33.

Install the

crankshaft

damper and

tighten the bolt as follows: To prevent

oil

ft.

FRONT OF ENGINE

• LOCATION

\

fc

w

OF STUDS

FOUR PLACES TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN FINGER-TIGHT

Step

a.

leakage, apply sealant to the places indicated— 3. OL (VIN S) engine

ft

1

:

Tighten the bolt to

b.

Step

2:

Loosen the

c.

Step

3:

Tighten the bolt to

lbs.

d

78-99

(105-135 Nm)

lbs.

bolt

one

full

turn.

35-39

(47-53 Nm). Step 4 Tighten the bolt

85-95

degrees

34

Install or

•

connect the following

Crankshaft pulley and tighten coun-

70-77

terclockwise to

lbs

ft.

(95-105 Nm) •

pump

Water

•

Alternator

•

35.

A/C compressor and bracket

•

Power steering pump and

tighten

the bolts to 18

Nm)

ft

•

Accessory drive

•

Valve covers

lbs (25 belt

•

Upper intake manifold

•

Engine assembly into the vehicle

Run

the engine

and check

for leaks

and proper operation.

3.4L (VIN N) Engine 1.

Before servicing the vehicle, refer to

the precautions at the beginning of this sec-

* STUD LOCATIONS

tion. 2.

Front cover bolt torque

sequence— 3. OL

3.

Please

visit

Remove

and mount

(VIN S) engine

our web

site at

www.chiltonsonline.com

it

the engine from the vehicle

on an engine stand.

Remove

or disconnect the following:

12-28

FORD MOTOR CO. TAURUS

•

SABLE •

Accessory drive belts

•

A/C compressor

•

Alternator

•

Intake

•

Exhaust Gas Recirculation (EGR)

vacuum

lines

tube

body

•

Throttle

•

Surge tank and supports

•

Left

•

Engine control sensor wiring har-

and

manifolds

right intake

ness and brackets Use the special

tool or a slide

remove the crankshaft

hammer

front oil seal

Left

•

Power steering pump

•

Crankshaft pulley

•

Front crankshaft seal

•

Crankshaft Position (CKP) sensor

to

—3.4L

and

•

Timing chain tensioner— 3. 4L (VIN N)

covers

right valve

engine

(VIN N) engine

Oil

•

Accessory

•

Front cover

CKP

•

(TDC)

No.

1

belt idler pulleys

pulse ring

Set the crankshaft at Top Dead Cen-

4. ter

pan

•

of the

compression stroke

for the

cylinder.

Remove

5.

or disconnect the following:

•

Timing chain tensioner

•

Tensioner arm

•

Timing chain

Do not

more

rotate the crankshaft

than 45 degrees counterclockwise or

more than 90 degrees clockwise from

TDC

the previously set No. 1 cylinder 7922KG53

Timing chain alignment marks

position with the timing chain

removed, or valve

—3.4L (VIN N) engine

to piston contact

could occur.

To 6.

install:

Using a small prybar, release the tim-

ing chain tensioner ratchet/pawl

through the access hole

in

mechanism

the timing chain

tensioner. Insert a small wire into the top of

the piston and unseat the

oil

check

Com-

ball.

press the timing chain tensioner by hand. 7.

With the tensioner compressed,

install a

0.060 inch (1.5mm)

into the small hole

drill bit

above the

engaging the lock groove

in

or wire

ratchet,

the rack of the

timing chain tensioner. 8.

Match the sprocket and chain timing

marks, and

install the

timing chain with the

crankshaft, camshaft and balance shaft

marks aligned. 9.

Install the

arm and

* APPLY 3 mm

(0.118 INCH)

tensioner pivot bolt to

BEAD OF SEALANT MEETING FORD SPECIFICATIONS

ft.

lbs.

(34-53

14-20 ft. lbs. (18-27 Nm). Remove the locking wire from

bolts to 10. 9306KG03

heads—3.4L

25-39

Nm). Tighten the Timing chain tensioner

(WSE-M4G323-A6) PRIOR TO INSTALLATION Apply sealant to the cylinder block and

timing chain tensioner

tensioner. Tighten the timing chain

the

timing chain tensioner. 11.

Apply silicone sealer

(VIN N) engine cal areas of the cylinder

to the

13

criti-

block as shown.

FORD MOTOR CO. -IO TAURUS

•

SABLE

£

OQ

Piston and Ring POSITIONING

TOP COMPRESSION RING

BOTTOM COMPRESSION RING

CONTROL RiNGS AND EXPANDER OIL

CENTER

LINE

OF P STON

PARALLEL TO WRIST PIN BORE

UPPER COMPRESSION RING GAP LOCATION

*922A3 , S

FRONT OF ENGINE Ring end-gap positioning— 3. 4L (VIN N) engine

CONTROL SEGMENT RING GAP OIL

LOCATION

7922KG26

Install the

new

crankshaft front

oil

seal

using a suitable seal driver or the special

tool— 3.4L (VIN N) engine

EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION

OIL

CONTROL SEGMENT

RING GAP LOCATION

?9Z2«16

Install or

12.

connect the following

•

CKP

•

Front cover and tighten the bolts to

•

Accessory

•

Oil

•

CKP

•

Front crankshaft seal

13.

ft.

lbs.

—

3

0L (VIN S and

U) engines

pulse ring

14-20

Ring end-gap spacing

(18-28 Nm)

belt idler pulleys

PISTON

NOTCH ON PISTON DOME AND BUTTON ON CONNECTING ROO 8200 IDENTIFICATION MARKS MUST BE ON SAME SIDE

pan sensor

Install

the crankshaft pulley and

tighten the bolt as follows:

Step

a. ft.

lbs. b.

1:

Tighten the bolt to

78-99

(105-135 Nm). Step

2:

Loosen the

Step

3:

Tighten the bolt to

bolt

one

full

turn. c. ft.

lbs. d.

35-39

(47-53 Nm). Step

4:

Tighten the bolt

85-95

VIEWED FROM FRONT OF ENGINE

degrees. 14.

Install or

•

connect the following

Power steering pump and

•

Left

•

Engine control sensor wiring har-

right valve

Piston and connecting rod positioning

Piston and connecting rod positioning

3.0L (VIN S and U) engines

3 4 L (VIN N) engine

covers

ness and brackets Left

•

Surge tank and supports

•

Throttle

•

EGR

right intake

manifolds

body

tube

vacuum

•

Intake

•

Alternator

•

A/C compressor

•

Accessory drive belts

•

15.

and

•

lines

Engine assembly

Run

the engine

into the vehicle.

and check

for leaks

Piston ring positioning— 3. 4L (VIN N) engine

and proper operation.

Timing belt service

is

covered

in Section

3

of this

manual

19 QH L“OU

FORD MOTOR CO TAURUS

S

SABLE

•

FUEL SYSTEM Fuel System Service Precautions

Pressure Gauge T80L-9974-A or equivalent, to the valve

Safety

most important

the

is

when

factor

performing not only fuel system maintenance but any type of maintenance. Failure to con-

duct maintenance and repairs

may

ner

death.

a safe

in

man-

result in serious personal injury or

Maintenance and testing

vehicle’s fuel

of the

system components can be effectively

ing to the following rules

and guidelines.

•

To avoid the possibility of

fuel

FUEL LINE DISCONNECT TOOL

through the

T90T-9550-B T90T-9550-C

On

flex-fuel engines,

Pressure Gauge T80L-9974-A or equivalent

and Fuel Pressure Test

Kit

134-R0035

or

equivalent, to the Schrader valve. Drain the

through the drain tube

into a suitable

7.

After the fuel

relieved,

and per-

and

system pressure

remove the

install the

fuel

7922KG55

Push connect

is

cap on the Schrader valve.

8.

Install the fuel

battery cable unless the repair or test proce-

9.

Connect the negative battery cable

dure requires that battery voltage be applied.

install:

sure prior to disconnecting any fuel system

component

Install the fuel filter

tank

fill

cap.

tighten the

system repairs are completed.

after

Fuel Filter

and eyes

advised that

connection.

trate the skin or

any

body

part of the

loosening

that

Connect the negative battery cable.

absorb any excess

it

occur)

is

all

engine and check

fuel

due

1

.

Pump

Before servicing the vehicle, refer to

the precautions at the beginning of this sec-

REMOVAL & INSTALLATION

2.

Disconnect the negative battery cable.

3.

Relieve the fuel system pressure.

4.

Disconnect the

5.

Loosen the

Before servicing the vehicle, refer to

the precautions at the beginning of this sec-

fuel lines.

tion.

to

filter

retaining

clamp and 2.

remove the

fuel spillage

fuel

Relieve the fuel system pressure.

filter.

quickly removed from

engine surfaces. Ensure that

soaked

fuel

all

cloths or towels are deposited into a suit-

able waste container.

Always keep a dry chemical (Class B)

•

extinguisher near the work area.

fire

Do

•

come

not allow fuel spray or fuel vapors to

into contact with a

spark or open flame.

Always use a back-up wrench when

•

loosening and tightening

fuel line

tion fittings. This will prevent

stress

and torsion

connec-

unnecessary

to fuel line piping.

Always

follow the proper torque specifications.

Always replace worn

•

rings with new. or equivalent,

Do

fuel fitting Fi-

not substitute fuel hose

where

fuel

pipe

is

installed.

Fuel System Pressure RELIEVING

1

.

Pump Locking Retainer

1

Fuel Ring

2

Fuel Tank Pressure/ Vacuum Transducer

Before servicing the vehicle, refer to

the precautions at the beginning of this section. 2. 3.

Disconnect the negative battery cable.

Remove

the fuel tank

fill

cap

to relieve

the pressure in the fuel tank. 4.

Remove

the cap from the Schrader

3

Locking Tab

4

Fuel Tank

5

O-Ring Seal

6

Connector

7

Fuel

On

gasoline engines, attach Fuel

f

Pump Module

valve located on the fuel supply manifold. 5.

for fuel

and proper operation.

it

connection prior to

Ensure that

spillage.

(should

to

fit-

heard.

Start the

1.

fitting or

to the filter

tion.

Always place a shop towel or cloth

around the

is

9.

Fuel

Please be

contacts. •

on

REMOVAL & INSTALLATION

exposing

to avoid

to fuel spray.

under pressure may pene-

fuel

retaining clamp. fuel lines

8.

Exercise extreme caution whenever relieving

system pressure,

filter

Push the

pressure reg-

(injector, fuel rail,

ulator, etc.), fitting or fuel line

skin, face

with the flow

tings until an audible click

leaks

fuel

tool

arrow facing the proper direction and

system pres-

relieve the fuel

and removal

6.

7.

Always

fitting

To

pressure gauge

sonal injury, always disconnect the negative

•

OR

connect Fuel

container.

by adher-

fire

6.

fuel

accomplished safely and

and drain the

drain tube into a suitable container.

7922KG58

Exploded view

of the fuel

pump module mounting

19_01 t U

FORD MOTOR CO. TAURUS 3.

Drain the fuel tank.

To

install:

4.

Remove

4.

Install

or disconnect the following:

•

Negative battery cable

•

Fuel lines •

con-

electrical

Fuel tank

•

Fuel

5.

the fuel

Install

ensure the

are not

damaged.

pump module

(Jse a

carefully

float

new O-ring

rod

seal.

pump module and the fuel tank retainer and push the fuel pump module into the fuel tank retainer. When the fuel pump module is properly engaged, a 6.

Align the fuel

definite click will

ing tabs 7.

Fuel supply manifold

of the fuel

—3.0L (VIN U)

engine 5. •

Fuel supply manifold and tighten

89 inch

lbs.

(10

Nm)

vacuum

Fuel pressure regulator

•

Fuel injector electrical connectors

bolts to •

pump.

•

Upper intake manifold

•

Fuel lines

•

Air cleaner outlet tube

•

Negative battery cable

Start the

engine and check

for leaks.

Fuel supply manifold with the injectors attached

be heard engaging 2 lock-

on the outside

Install or

Use new O-ring

line

and hoses and

filter

I

•

pump module

To install:

to

I

or connect the following:

Fuel injectors.

the bolts

nector •

SABLE

seals.

pump module

Fuel

•

•

•

89 inch

and tighten the

lbs.

(10

Fuel pressure regulator

3.4L (VIN N) Engine

Nm) 1

vacuum

.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

connect the following:

line

tion.

pump module

•

Fuel

•

Fuel tank

•

Fuel

pump module

locking ring

Fuel injector electrical connectors

•

Upper intake manifold

•

con-

electrical

•

2.

Relieve fuel system pressure.

3.

Remove

or disconnect the follow-

Fuel lines ing:

• • 8.

nector

•

Air cleaner outlet tube

Fuel lines

•

Negative battery cable

Negative battery cable

Add

a

minimum

of

5.

10 gallons

Start the

for leaks.

3.0L (VIN S) Engine

engine and check

Negative battery cable Air cleaner outlet tube

•

Fuel lines

•

Throttle

•

Surge tank

of

clean fuel to the tank. 9.

engine and check

Start the

•

•

for leaks

Fuel injector electrical connectors

tion.

•

Fuel pressure regulator

3.

3.0L (VIN U) Engine

Relieve fuel system pressure.

Remove

or disconnect the following

•

Negative battery cable

•

Air cleaner outlet tube

•

Fuel lines

•

Fuel supply manifold with the

•

Injectors from the supply

Upper intake manitold

To

install:

Fuel injector electrical connectors

4

Install or

tion.

•

Fuel pressure regulator

2. 3.

Relieve fuel system pressure.

Remove

Negative battery cable

•

Air cleaner outlet tube

•

Fuel lines

•

Upper intake manifold

•

Fuel injector electrical connectors

•

Fuel pressure regulator

•

•

•

connect the following:

Fuel injectors Use

new O-ring

seals.

•

Fuel supply manifold

•

Injectors from the lower intake

injectors attached

manifold

bolts to

•

Fuel supply manifold with the

11-16

ft.

and tighten the lbs

•

Fuel pressure regulator

vacuum

•

Fuel injector electrical connectors Left

Fuel supply manifold with the

•

Surge tank

injectors attached

•

Throttle

Injectors from the supply manifold

•

Fuel lines

•

Air cleaner outlet tube

•

Negative battery cable

install: Install or

connect the following:

Fuel injectors. Use

new 0-ring

vacuum

line

•

4

(15-23

Nm)

line

To

•

vacuum

line

or disconnect the following:

•

mani-

fold

•

Before servicing the vehicle, refer to

vacuum

injectors attached

•

.

right intake

line

the precautions in the beginning of this sec-

1

manifolds

Left

•

.

2.

REMOVAL & INSTALLATION

and

•

the precautions in the beginning of this sec-

1

Fuel Injector

Before servicing the vehicle, refer to

body

Retaining bolts (1) and Fuel supply Manifold

(2)—3.0L

5.

(VIN S) engine

Start the

seals.

Heater Core replacement

is

covered

In Section

and

2 of this manual

right intake

manifolds

body

engine and check

for leaks.

0 QO L“OL TAURUS*

FORD MOTOR CO.

•4

SABLE

*

I

DRIVE TRAIN •

Transaxle

Steering rack and pinion gear and

84-113

tighten the nuts to

•

Before servicing the vehicle, refer to

•

ft.

lbs.

(29

Dual converter Y-pipe

•

•

HO 2 S

•

Axle halfshafts and tighten the hub

lifting

Remove

3.

•

and

•

tray

Lower

170-202

assembly

•

Air cleaner

•

Transaxle electrical connectors

•

ft.

35-46

Shift cable

•

Front wheels

•

Transaxle cooler lines

•

Front wheels

•

Shift cable

Stabilizer bar links

•

Transaxle electrical connectors

•

Lower

•

Air cleaner

•

Axle halfshafts

•

Battery and tray

•

Heated Oxygen Sensor (HO 2 S) con-

Starter

•

Steering rack and pinion gear. Support the gear with safety wire.

•

Powertrain support insulators

•

Subframe

•

Torque converter nuts

mission

Start the engine.

Check

For 1999-01

Install the transaxle.

•

Stabilizer bar links

all

(40-60 Nm).

subframe. Use 2 pieces of

ment holes behind the to align the

front

in

the align-

subframe

subframe

to the body.

Tighten the subframe mounting “ bolts to

57-76

ft.

lbs.

•

connect the following:

Tighten the bracket bolts to 65

(88

bolts to

Nm) and 90

ft.

lbs.

away from

Drive the CV-joint

with a brass

in

tie

drift

clamps and

the joint. off

the halfshaft

and a hammer.

the CV-joint with fresh grease and

on

to the halfshaft.

Use new clamps and

install the

CV-

joint boot.

rod ends

if

a vise.

the CV-joint boot

equipped with

air

the subframe

(122 Nm).

•

Wheel speed sensors

•

Steering knuckle from the halfshaft

•

Halfshafts

To install:

3.

Powertrain support insulators.

lbs.

Remove

7.

ball joints

Height sensors,

'•Use new

(77-103 Nm).

Install or

9.

3.

suspension

% inch outside diameter pipe mounts

•

(27-46 Nm).

Install the

the beginning of this section.

Place the halfshaft

Fill

Tighten the torque converter nuts to lbs.

in

2.

slide the joint

30-44

lbs.

Before servicing the vehicle, refer to the

Replace the snapring.

Outer

8.

.

6.

or disconnect the following:

•

ft.

Outer CV-Joint

install:

other engines, tighten the flange bolts to

(33-46 Nm). For

The inner CV-

5.

Lower

lbs.

ft.

(68-92

boot can be serviced by removing the

To

Remove

lbs.

serviced with the

tion.

•

ft.

joint

slide the boot

Before servicing the vehicle, refer to

Front wheels

25-33

is

the precautions at the beginning of this sec-

2.

ft.

outer CV-joint.

•

20-34

and

REMOVAL & INSTALLATION

3.0L (VIN S) engines, tighten the flange

7.

for leaks

4.

To install:

bolts to

The inner CV-joint

'•Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

1.

50-68

axle shaft as an assembly.

Halfshaft

the transaxle flange bolts

(47-63 Nm)

and tighten the

CV-Joint

1

and remove the transaxle.

6.

assembly

jack.

Remove

5.

lbs.

ft.

Front wheels

precautions

Support the transaxle with a trans-

4.

35-46

ball joints

Inner Tripod Joint

proper operation.

•

(77-103 Nm)

rod ends and tighten the

tie

Lower

and tighten the

lbs.

ft.

REMOVAL & REPLACEMENT

•

Dual converter Y-pipe

Outer

57-75

(47-63 Nm)

Transaxle cooler lines

nectors

•

and tighten the

lbs.

ft.

•

•

air

(68-92 Nm)

lbs.

•

ball joints

Stabilizer bar links

fasteners to

lbs.

and tighten the

ft.

Stabilizer bar links

nuts to

10.

51-67

equipped with

if

Nm)

ball joints

nuts to

Height sensors,

nuts to •

(230-275 Nm)

or disconnect the following:

Battery

sensor connectors

retainer nuts to

eyes.

Wheel speed sensors

nuts to

tion.

Attach a powertrain support to the

•

to

Nm)

the precautions at the beginning of this sec-

2.

•

suspension

and tighten the fasteners

Starter

21

engine

•

lbs.

(113-133 Nm)

REMOVAL & INSTALLATION 1.

ft.

ft.

nuts, bolts

Install or

and

circlips.

connect the following:

•

Halfshafts

•

Steering knuckle to the halfshaft

•

Hub retainer nut and tighten to 170-202 ft. lbs. (230-275 Nm)

1

2.

CV-Joint boot

CV-Joint 9306HG07

Removing the outer CV-joint

TAURUS*

19 QQ £ OO

FORD MOTOR CO. SABLE

*

2.

STEERING AND SUSPENSION Check the functioning

RUN air

Some

vehicles are equipped with an

bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and senair

bag

of the air

system by turning the ignition key

to the

position and visually monitoring the

bag indicator lamp

cluster.

in

the instrument

The indicator lamp should

illumi-

nate for approximately 6 seconds, then turn

OFF

If

lamp does not

the indicator

nate, stays

ON, or flashes

at

has been detected by the

fault

illumi-

any time, a air

bag diag-

nostic monitor.

sors. Failure to follow the safety pre-

cautions and the disarming

procedure could result

in

accidental

bag deployment, possible injury and unnecessary system repairs.

Power Rack and Pinion Steering Gear

air

PRECAUTIONS

REMOVAL & INSTALLATION 1

.

Before servicing the vehicle, refer to

the precautions at the beginning of this sec-

Several precautions

when handling

must be observed

the inflator

accidental deployment

module

to

avoid

and possible per-

tion. 2.

Remove

or disconnect the follow-

ing:

sonal injury.

Support the rear

subframe with 2

of the

jackstands while removing the steer-

tall

ing gear

•

Negative battery cable

•

Intermediate steering shaft

wires or connector on the underside of the

•

Front wheels

•

module.

•

Dual converter V-pipe

•

Left stabilizer link

•

Outer

Never carry the

•

When

inflator

module by

the

Heat shield

tie

rod ends and tighten the

carrying a live inflator module,

•

Outer

hold securely with both hands, and ensure

•

Left stabilizer link

•

Heat shield

•

Dual converter Y-pipe

•

Power steering hose bracket

•

Front wheels

Auxiliary actuator connector,

•

Intermediate steering shaft

•

Negative battery cable

•

that the

bag and trim cover are pointed

away.

Place the inflator module on a bench

•

or other surface with the

•

bag and trim cover •

With the

module on the bench,

inflator

never place anything on or close to the

module which may be thrown 1.

in

•

the event of

•

Rear subframe bolts and lower the

operation

the steering gear to the

Steering gear through the

3.

•

Steering gear. Use fittings.

mounting nuts for the air

bag

before con-

•

tinuing. 6.

connect the following

hydraulic

cable.

to drain

•

ARMING •

After service is

seals on the

Tighten the

85-100

ft.

lbs.

tion. 2.

Remove

completed, connect •

Brake service

or disconnect the follow-

ing:

•

Negative battery cable

Rear subframe bolts and tighten

•

Front wheels

to

57-76

ft.

lbs.

(77-103

•

Nm)

repair.

the battery cables, negative cable last.

to

new

Before servicing the vehicle, refer to

the precautions at the beginning of this sec-

(115-135 Nm). them

Proceed with the

wheel

1

Install or

Disconnect the positive battery

minute

left

To install:

cable.

1

Strut

Front

Disconnect the negative battery

at least

and proper

opening

a straight-ahead position.

Wait

for leaks

REMOVAL & INSTALLATION

•

5.

left

hoses

Position the vehicle with the front

back-up power supply

and bleed the power steering sys-

access the power steering

tion.

4.

Nm)

Steering gear mounting nuts, then

Power steering hoses

3.

(48

necessary

•

in

lbs.

Check the alignment and adjust as

5.

subframe about 4

the precautions in the beginning of this sec-

wheels

Fill

ft.

Check the system

connector

move

Before servicing the vehicle, refer to

4.

tem.

to

2.

if

inches

DISARMING

.

nuts to 35

Power steering pressure switch

rear of the

an accidental deployment.

1

rod ends

equipped

facing up. •

tie

Height sensor and wiring,

equipped with

air

if

suspension

Power steering pressure switch

•

connector

•

Disc brake caliper and rotor

Auxiliaryactuatorconnector.it

•

Wheel speed sensor and wiring

equipped

•

Outer

Power steering hose bracket

•

Stabilizer link

is

covered

in

Section 4 of this manual

Brake hose bracket

tie

rod end

O OA

A

FORD MOTOR CO. TAURUS

SABLE

•

•

Steering knuckle pinch bolt

•

Strut

To

assembly

install: Install or

3.

•

connect the following:

Strut assembly. Tighten the

22-29

nuts to

lbs.

ft.

upper

(30-40

Nm), and the knuckle pinch bolt to

73-97

(98-132

lbs.

ft.

Nm). •

•

Stabilizer link

and tighten the nut

55-75

(75-101 Nm)

Outer

tie

nut to 35 • •

lbs.

ft.

to

rod end and tighten the ft.

lbs.

(48

Nm)

Wheel speed sensor and wiring Disc brake caliper and rotor and tighten the caliper anchor bracket bolts to

65-87

(88-118

lbs.

ft.

Nm) • •

Brake hose bracket Height sensor and wiring,

equipped with

air

•

Front wheels

•

Negative battery cable

Road

4.

if

suspension

test the vehicle

and check

for

proper operation.

Item

Description Front Coil Spring

i

Rear 1

Item

Shock Absorber

2

Front

3

Tie

4

Wheel Hub

Rod End

Description

Wheel Knuckle

5

Front

6

Front Suspension Lower

7

Front Stabilizer Bar

8

StabilLer Bar Link

Arm

Before servicing the vehicle, refer to

.

7922KG61

the precautions at the beginning of this secFront suspension

tion.

Remove

2.

component

identification

or disconnect the follow-

ing: •

Rear package tray trim panel

•

Rear wheels

•

Brake load sensor

•

Brake hose

•

Stabilizer bar bracket

•

Tension strut

•

Spindle pinch bolt

•

Strut

and

link

assembly

To install:

•Use new 3.

mounting nuts and

Install or

•

Strut assembly. bolt

bolts.

connect the following:

and tighten

Use a new pinch to

50-67

lbs.

ft.

(68-92 Nm). Tighten the 3 upper mounting nuts to 19-25 ft. lbs. (25-34 Nm). •

Tension strut and tighten the nut to

35-46 •

ft.

lbs.

(68-92 Nm)

and 60-81 inch

Stabilizer bar link

tighten

the nut to

lbs.

(7-9

Stabilizer bar bracket

the bolts to

25 -33

ft.

and tighten lbs.

(34-46

Nm) • •

1

2

Nm) •

Item

Brake hose Brake load sensor

•

Rear wheels

•

Rear package tray trim panel

Description Rear Stabilizer Bar

Item 10

Rear Spring

3

Shock Absorber

4

Nut

5

Washer

6

Lower Suspension Arm

Description Rear Suspension

Tie

Bushing

(4

Req’d)

(2

Req’d)

Rod

11

Washer

12

Rear Suspension Tension Strut and Bushing (2 Req'd)

13

Rear Suspension Lower Arm (Front) f

(Rear) 7

Rear Wheel Spindle

8

Nut (4 Req'd)

9

Washer

(2 Req'd)

A

Tighten to 68-92 Lb-Ft)

B

Tighten to 46 7-63.3 ap>gMM———b—ega—

FORD MOTOR CO.

—

m—

r

6.

•

Torque converter cover

•

Cruise control cable,

•

Torque converter

•

Accelerator cable

Transaxle fluid cooler lines

•

Air cleaner

Axle halfshafts

•

MAF

•

Intermediate shaft bracket

•

Battery, tray

•

Starter

•

Crankshaft pulley Right engine

•

Transaxle flange bolts. Support the transaxle

To

To install:

sensor connector

Engine front mount

•

Crankshaft Position (CKP) sensor

•

Engine

Fill

9.

Start the

1

engine and check

in

Drain the cooling system.

CKP

4.

Loosen the

•

Engine front mount. Tighten the

bolts to

35

(80

the

35

ft.

and the small bolts

lbs.

(48

16

Remove

5.

Battery, tray

•

Mass

and cables

(120 Nm).

motor

35

lbs.

ft.

(48 Nm).

•

Axle halfshafts

•

Transaxle fluid cooler lines

•

Torque converter. Tighten the nuts to

27

lbs.

ft.

(37 Nm).

•

Torque converter cover

•

Exhaust front pipe

•

Lower

•

A/C compressor,

ball joints.

bolts to

37

ft.

lbs.

•

Power steering pressure pipe

lbs.

(48 Nm).

pipe

assembly and tubes

if

equipped

belt

Power steering pressure switch connector Drive belt cover

•

Transaxle fluid cooler lines

Ignition coil connectors

•

Shift select cable

Heated Oxygen (HO 2 S) sensor con-

•

Coolant expansion tank Radiator hoses

if

equipped

and bracket

nectors

•

Fuel injector harness connectors

•

Coolant bypass hoses

•

Powertrain Control Module

•

Fuel line

(PCM)

vacuum

connectors

•

Intake manifold

•

Radiator cooling fan

•

•

Evaporative Emissions (EVAP) can-

•

EGR vacuum line DPFE system sensor vacuum

line

•

Power brake booster vacuum

line

vacuum

lines

•

Power brake booster vacuum

•

EVAP

•

Delta Pressure Feedback Electronic

•

Radiator cooling fan

(DPFE) system sensor vacuum

(50 Nm).

equipped

ft.

•

ister

Tighten the pinch

if

flex

•

Intermediate shaft bracket. Tighten the bolts to

35

Exhaust

•

•

lbs.

ft.

bolts to •

(PCV) valve and hose

•

88

•

line

canister

vacuum

PCM

•

Fuel injector harness connectors

vacuum

•

HO 2 S

•

Ignition coil connectors

connectors

Drive belt cover Alternator and bracket

•

Intake manifold

•

Power steering high pressure pipe

•

Fuel line

•

Cruise control cable,

•

Power steering pump and reservoir

•

Coolant bypass hoses

•

Accelerator cable

•

Accessory drive

•

Radiator hoses

•

Air cleaner

•

Coolant expansion tank

•

Coolant expansion tank

•

PCV

valve and hose

•

Radiator hoses

•

Shift select cable

•

MAF

sensor connector

•

Coolant bypass hoses

•

Transaxle fluid cooler lines

•

Battery, tray

•

Fuel line

•

Drive belt cover

•

Power steering pressure switch

line

•

Accessory drive

line

•

A/C compressor,

line

vacuum

line

and bracket

1 1

•

Intake manifold

•

•

EGR vacuum line DPFE system sensor vacuum Power brake booster vacuum EVAP canister vacuum lines

•

Power steering pump

•

Radiator cooling fan

•

Power steering pressure pipe

•

PCM

connectors

•

Exhaust

•

HO 2 S

sensor connectors

•

Right engine

•

Fuel injection wiring harness con-

•

Lower

nector

•

Axle halfshafts and intermediate shaft

• •

•

line

connector

flex

belt if

equipped

assembly and tubes

and cables

Tighten the strut center nuts to 35

.

ft.

the cooling system.

12.

Fill

13.

Start the

engine and check

for leaks.

Water Pump

pipe

REMOVAL & INSTALLATION

mount

ball joints

6.

Support the powertrain from below

switch connector

7.

Remove

mounts.

if

equipped

Power steering pump pressure Ignition coil connectors

sensor connectors

(48 Nm).

lbs.

SOHC 1

•

lines

•

line

•

vacuum

line

Exhaust Gas Recirculation (EGR)

•

belt

Nm) lbs.

(50 Nm).

Accessory drive

Cruise control cable,

Starter

ft.

Right engine mount. Tighten the

•

Accelerator cable

to

98

Tighten the pinch

Positive Crankcase Ventilation

•

(48 Nm).

lbs.

lbs.

Power steering pump

•

ft.

ft.

A/C compressor,

Air cleaner

35

37

•

•

Crankshaft pulley. Tighten the bolt

ball joints.

nector

Flow (MAF) sensor con-

Right engine mount. Tighten the bolts to

Lower

•

Air

•

(22 Nm).

•

or disconnect the following:

•

Nm)

ft.

•

front strut center nuts 5

lbs.

to

to

Axle halfshafts and intermediate

bolts to

turns.

(48 Nm).

lbs.

ft.

Nm) and

Transaxle flange bolts. Tighten the large bolts to

•

•

•

•

lbs.

(48

lbs.

ft.

shaft

2.

Relieve the fuel system pressure.

ft.

Rear engine mount. Tighten the

(133 Nm).

the beginning of this sec-

3.

nuts to 59

the

(48 Nm).

lbs.

and the center nut

Engine sensor

ft.

Nm) and

(80

lbs.

ft.

outer nuts to 35

•

•

•

for leaks.

tion.

connect the following:

Install or

35

bolts to

Before servicing the vehicle, refer to

.

Front engine mount. Tighten the nuts to 59

the cooling system.

8.

the precautions

install:

•

•

ft.

connect the following:

Install or

10.

DOHC ENGINE

•

•

Lower the vehicle over the powertrain.

9.

and cables

(48 Nm).

lbs.

mount

Raise the vehicle away from the pow-

8.

ertrain.

Tighten the strut center nuts to 35

7.

•

equipped

housing and tubes

•

•

motor

if

the front

and

rear

engine

.

Engine

Before servicing the vehicle, refer to the

precautions

in

the beginning of this section.

FORD MOTOR CO.

15-5

FOCUS 2.

Drain the cooling system.

3.

Drain the cooling system.

3.

Remove

4.

Relieve the fuel system pressure.

or disconnect the following:

•

Negative battery cable

•

Accessory drive

•

Front cover

•

Timing

belt.

Timing

•

Water

Refer to the Timing

Engine

•

air

cleaner intake tube

Tag and disconnect the vacuum

6.

hoses from the following components:

belt tensioner

pump

Exhaust Gas Recirculation (EGR)

•

?306SG02

valve

connect the following:

Install or

•

—

Positive Crankcase Ventilation

Cylinder head torque sequence

(PCV) valve

SOHC

2.0L

•

Water pump. Tighten the bolts (25 Nm).

•

Throttle

•

Timing

belt tensioner

•

Fuel pressure regulator

•

Upper

•

Timing

belt

•

Intake manifold

•

Heater hose

•

Accessory drive

•

Cylinder head bolts. Loosen the

•

Negative battery cable

18

lbs.

ft.

to

belt

Remove

7. •

the cooling system.

5.

Fill

6.

Start the

engine and check

or disconnect the following:

and

if

Engine

To install:

Speed control cable bracket 2

fuel

hose

Cylinder head and gasket

•

bolt,

if

equipped •

radiator

bolts in sequence.

equipped, the speed

control cable

for leaks.

engine

body

Accelerator cable, throttle control lever

•

DOHC 1

Refer to the Timing

belt.

Belt unit repair section.

To install: 4.

or disconnect the following:

Timing

•

Belt unit repair section. •

Remove

5.

belt

charging wiring electrical

•Use new

cylinder head bolts for

assembly.

Before servicing the vehicle, refer to

.

connections

the precautions in the beginning of this sec•

Install

8.

Crankshaft Position (CKP) sensor

the cylinder head and tighten

the bolts in sequence as follows

tion.

and Heated Oxygen (HO 2 S) sensor

Drain the cooling system.

2.

electrical

Remove

3.

or disconnect the following:

•

Negative battery cable

•

Accessory drive

pump

•

Water

•

Front cover

•

Timing

belt.

connections

Timing

•

Water

Step

1:

37

b

Step

2:

Loosen

c.

Step

3:

37

install:

4.

Install or

13

ft.

d

Step

4:

Plus 90 degrees

Step

6:

Plus 90 degrees

bracket and hose aside Alternator lower bolt, loosen only

•

Alternator upper bolt

Refer to the Timing

Install or

9.

•

•

and pivot the

Engine

oil

connect the following:

Timing

belt tensioner

•

Timing

belt

Front cover

•

Water

pump

•

dipstick tube bracket

Valve cover

•

Exhaust manifold heat shield

•

Air conditioning

•

Catalytic converter

•

Right-hand splash shield

•

Engine

Fill

6.

Start the

Engine

oil

10. •

dipstick tube from the

engine and check

ft.

and lbs.

•

Air conditioning

•

Engine accessory drive bracket

•

Valve cover

compressor

oil

compressor

dipstick tube

Heater and upper radiator hoses

•

Timing

•

Power steering pressure hose

•

CKP

belt

the cooling system.

5.

Right-hand splash shield bolts and

cylinder block

Negative battery cable

15-18

to

•

Accessory drive

lbs

(20-25 Nm)

Exhaust Gas Recirculation (EGR)

pulley

•

ft.

Air conditioning line bracket

lighten the bolt to

the shield

•

30-40

(40-55 Nm)

•

• •

connect the following:

Accessory drive bracket. Tighten

tube

(18 Nm).

•

lbs (50

the fasteners to

alternator forward •

ft

V4 turn

Nm)

e

belt tensioner

lbs.

Nm)

bolts

bracket bolts, then position the pulley

Water pump. Tighten the bolts

(50

Power steering pressure hose

• •

all

•

bolt

To

lbs.

Fuel supply line

belt

pump

ft

•

Belt unit repair section. •

a

belt

and

alternator

sensor and 2 main

fuel

charg-

ing electrical connections •

Engine

•

EGR

for leaks.

Cylinder Head

REMOVAL & INSTALLATION

oil

dipstick tube bolt

valve tube

•

Fuel supply line

•

Catalytic converter

•

Heat shield

•

Speed control cable

bracket,

if

equipped

SOHC

Engine

•

Throttle control lever accelerator

cable and 1.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

2.

9J06SG0I

Disconnect the negative battery

following components:

—SOHC

Please

equipped, the speed

Connect the vacuum hoses

tion.

cable.

if

control cable

Cylinder head loosening sequence

•

engine

•

visit

our web

site at

www.chiltonsonline.com

EGR PCV

valve valve

to the

FORD MOTOR CO.

15-6

FOCUS

Exploded view

EGR

valve

EGR

valve gasket

3.

Accelerator cable bracket Throttle

body gasket

16.

Throttle Position (TP) sensor

17.

6.

Idle Air Control (IAC) valve

18.

7.

IAC valve gasket

8.

Throttle

9.

Fuel injection supply manifold

body

19.

20.

21.

10.

Fuel injector

22.

11.

IMRC

23.

12.

Oil filler

actuator

of the cylinder

cap

head, exhaust manifold and intake manifold mounting

body

Throttle

Fuel pressure regulator

•

Intake manifold

•

Air cleaner outlet tube

•

•

12.

Start the

engine and check

•

for leaks.

Engine

the precautions

in

•

Thermostat housing Cylinder head bolts. Mark each bolt

Crankshaft Position (CKP) sensor

with a

and Pleated Oxygen (HO 2 S) sensor

the

connections

Power steering pump and bracket

•

Alternator

punch and loosen them

install:

'The

cylinder head bolts

may be

reused twice. Replace bolts that have

•

Engine

•

Splash shield

•

Air conditioning

•

Spark plug wires

•

Valve cover

•

Upper

•

Heater hose

a.

Step

1:

15

ft.

lbs.

(20

•

Camshafts

b.

Step

2:

30

ft.

lbs.

(40

•

Ignition coil

c.

Step

3:

Plus 90 degrees

the beginning of this sec-

oil

in

sequence shown.

Cylinder head and the gasket

•

To

Fuel line

•

Before servicing the vehicle, refer to

.

•

main engine connector

electrical

the cooling system.

— 2.0L SOHC engine

Fuel charging electrical connectors at the

Negative battery cable Fill

DOHC

14.

15.

4.

•

•

13.

5.

•

11.

1

1.

2.

dipstick tube

compressor

two punch marks. Lubricate the cylinder bolts

8.

engine

when

oil.

tion.

Disconnect the negative battery

2.

cable.

Drain the cooling system.

3. 4.

Relieve the fuel system pressure.

5.

Remove

or disconnect the following:

•

Air cleaner

•

Timing

assembly

belt.

radiator

Install the

9.

hose

the bolts in

cylinder head and tighten

sequence as follows:

Nm) Nm)

outlet tube

Refer to the Timing

Belt unit repair section.

Tag and disconnect the vacuum

6.

hoses from the following components: •

Positive Crankcase Ventilation

•

Throttle

•

Fuel pressure sensor

(PCV) valve

•

Intake manifold

Remove

7 •

body

or disconnect the following:

Speed control and accelerator

Cylinder head bolt loosening sequence

Cylinder head torque

cables from the control lever

DOHC

DOHC

engine

engine

sequence— 2. OL

FORD MOTOR CO.

15-7

FOCUS • 3. •

Rocker arm bolts

To install:

Rocker arms and seats

connect the following:

Seats and rocker arms

•

Rocker arm ft.

S346SG01

Install or

8. •

in their orig-

bolts.

17-22

Tighten to

•

Valve cover

•

Negative battery cable

•

Engine

•

EGR

DOHC

Engine

dipstick tube

oil

manifold tube. Tighten

15-20 •

sequence— DOHC

Valve cover torque

new gasket. 15-22 ft. lbs.

(20-30 Nm).

(23-30 Nm).

lbs.

connect the following:

Intake manifold with a

Tighten the nuts to

positions

inal

the intake manifold

oil

mounting studs.

Install or

•

Clean and

7.

To install:

lbs.

ft.

it

to

(20-28 Nm).

IAC valve and TP sensor

electrical

connections

Engine

The Install or

10.

DOHC

•

engine

is

not equipped with

rocker arms. The camshafts act directly on

connect the following:

Speed control cable bracket

lbs.

•

and the camshafts

•

Ignition coil

•

Heater and upper radiator hoses

•

Valve cover

•

Sparkplugs Spark plug wires Air conditioning

compressor

SOHC

Splash shield

•

Engine

• •

oil

Alternator reservoir

•

Fuel line

•

CKP

dipstick tube

and the power steering

and bracket

sensor,

HCbsensor and 2 main

charging electrical connections

fuel

Accelerator cable and

•

1

if

Connect the vacuum hoses

Connect the vacuum hoses

.

PCV

•

Throttle

•

Fuel pressure sensor

•

Intake manifold

Drain the cooling system Relieve the fuel system pressure

10.

Fill

4.

Remove

1 1

Start the

• •

•

14.

Start the

.

DOHC 1

Exhaust gas Recirculation (EGR)

body

Fuel pressure regulator

•

•

Drain the cooling system

4

or disconnect the following

and

Speed

if

•

Air cleaner outlet tube

•

Throttle Position (TP) sensor con-

nector

by the crankshaft pulley •

Control (IAC) valve and

oil

Main engine control sensor wiring

•

Connectors from the mounting bracket Intake manifold

•

Positive Crankcase Ventilation

dipstick tube bracket

tion.

Remove •

'•Keep

or disconnect the following:

•

Engine

oil

tube located below

dipstick tube from the

•

Drive belt

•

Alternator

•

Fuel line

•

Intake manifold

block

Negative battery cable Valve cover all

EGR manifold the EGR valve

valve train components

•

Intake manifold lower nuts

•

Intake manifold upper nuts

in •

To 5.

install: Install or

•

Intake manifold

order for assembly.

connect the following:

Intake manifold. Tighten the fasteners to 13

Timing belt service

is

covered

lines

(PCV) hose

intake manifold •

vacuum

•

bolt that attaches the tube to the

Before servicing the vehicle, refer to

Heater hoses

•

connections

Engine

Bolt that secures the pipe located

if

Throttle Position (TP) sensor elec-

•

or disconnect the following:

Negative battery cable

•

control cable bracket bolt,

Idle Air

Remove •

equipped, the speed

equipped

trical

Before servicing the vehicle, refer to

Relieve the fuel system pressure.

control cable

•

•

Engine

3.

Accelerator cable, throttle control lever

for leaks.

REMOVAL & INSTALLATION

2.

for

2

Intake manifold

Remove

6.

the precautions in the beginning of this sec-

engine and check

tion.

Positive Crankcase Ventilation

•

Rocker Arms/Shafts

.

the cooling system.

the precautions in the beginning of this sec-

(PCV) valve

•

1

Negative battery cable

coolant leaks.

valve •

SOHC Engine

body

Air cleaner outlet tube

connect the following:

engine and check

to the

hoses from the following components

the cooling system.

Fill

Negative battery cable

Tag and disconnect the vacuum

•

Negative battery cable

13.

•

or disconnect the following

belt

Air cleaner outlet tube

Fuel pressure regulator

3.

Throttle

•

•

2.

•

Timing

Throttle

Intake manifold

body

•

valve

•

Air cleaner outlet tube

valve

Install or

12.

valve

PCV

•

following components: •

EGR

•

•

5.

to the

•

the precautions in the beginning of this sec-

the speed control cable to the con-

1 1

Engine

tion.

equipped,

trol lever

equipped, the speed

following components:

Before servicing the vehicle, refer to

.

if

control cable 9.

•

(8-10 Nm).

Throttle control lever, accelerator

cable and

Intake Manifold

REMOVAL & INSTALLATION

•

if

the valves.

Thermostat housing

•

bolt,

equipped. Tighten to 71-88 inch

in Section

3 of this manual

ft.

lbs.

(18 Nm).

FORD MOTOR CO.

15-8

FOCUS Remove

2.

Fuel line

•

Alternator

•

Negative battery cable

•

Drive belt

•

Fan motor

•

PCV hose

•

Fan shroud

•

Intake manifold

•

Connectors

•

Main engine control sensor wiring

•

Catalytic converter

•

Heater hoses

•

Engine

•

in

vacuum

the

•

lines

trical

Bolt that secures the pipe located by

71-97

bolt to

TP sensor

•

Air cleaner outlet tube

•

Negative battery cable

Fill

7.

Start the

2.

•

(18 Nm).

lbs.

6700-CH,

inch lbs. (8-11 Nm).

seal.

dipstick tube bracket.

oil

Catalytic converter

•

H02sensor

•

Fan shroud and the fan motor

electrical

connection

Rocker arms and valve tappets

•

Camshaft thrust

Cup

Exhaust Gas Recirculation (EGR)

engine and check

Camshaft from the

•

for leaks.

To

Front Crankshaft Seal

1

Power steering pressure hose

cylinder with clean

Before servicing the vehicle, refer to

.

the precautions

bracket

Install or

in

the beginning of this sec-

•

Catalytic converter

•

Exhaust manifold

•

Exhaust manifold. Tighten the nuts to

•

15-18

ft.

lbs.

(20-24 Nm).

Catalytic converter. Tighten the nuts to

26-34

ft.

lbs.

crankthe

seal.

Alternator

•

Power steering pressure hose

To

install:

to

4.

Use

and

Exhaust manifold heat shield. Tighten the nuts to

45-62

HO 2 S

•

Drive belt

sensor

•

Rocker arms

•

Ignition coil bracket

Install the

Apply a

oil to

b.

new

crankshaft sprocket and the

connection

DOHC

engine and check

Camshaft and Valve

Lifters

REMOVAL & INSTALLATION

SOHC

fol-

Use

lip

thin film of

5W-30 motor

of the seal.

seal replacer

T81P-6292-A,

camshaft front

Before servicing the vehicle, refer to

Install the inner

engine front

Install the

timing belt tensioner.

Tighten the tensioner bolt to

(20-30

15-22

ft.

Nth).

tion.

Install the

camshaft sprocket and

the timing belt

Before servicing the vehicle, refer to

the precautions

in

to

seal.

cover.

e.

Engine

Engine

the precautions in the beginning of this section.

coil

for leaks.

1 1

and

camshaft front seal as

inch lbs.

Negative battery cable

Start the

plug and the tappets

cylinder head front face.

belt.

lbs. 4.

bolts.

inch

’•The seal depth should be 0.002-0.04 in. (0.05-1. Omm) below flush with the

d.

•

and the

T81P-6700-A

seal.

c.

electrical

the

install the

Install the

timing

T92C-6700-

(5-7 Nm). •

rear of the

(8-13 Nm).

New cup

7.

front oil seal.

seal replacer tool

install the

5.

•

tool

CH, remove the crankshaft

EGR tube. Tighten the fasteners 45-62 inch lbs. (5-7 Nm).

oil.

lows:

Using seal remover

bracket

the

71-115

•

a.

(34-48 Nm).

•

to damage the when removing

Be careful not shaft surface

3.

•

WARNING

connect the following:

plate

Tighten the bolts to lbs.

install:

in

connect the following:

Camshaft thrust

the timing belt and crank-

shaft sprocket.

:

bore

cylinder head •

Remove

2.

cam

5W-30 motor

Camshaft through the

•

tion.

Alternator

Install or

rear of the cylin-

install:

6.

tube

3.

and the

plug from the rear of the cylin-

’•-Liberally coat the

•

To

plate bolts

plate

der head and discard

REMOVAL & INSTALLATION

Exhaust manifold heat shield

•

and bracket

Ignition coil

•

connection

•

•

or disconnect the follow-

der head

Oxygen (HO 2 S) sensor elec-

Pleated trical

front

•

Drive belt

•

T92C-

remove the camshaft

to

•

Negative battery cable

Start the

4.

seal removal tool

Remove

5.

wiring

or disconnect the following:

the inner engine front

ing:

(8-11 Nm).

•

•

Use

e.

Tighten the retainers to 71-101

Engine

the beginning of this section.

Remove

d.

cover.

Exhaust manifold heat shield.

•

Tighten the bolt to 71-101 inch

Negative battery cable

•

ft.

and remove the tensioner.

bolt

Exhaust manifold. Tighten the fas-

Before servicing the vehicle, refer to the

Remove

T74P-6256-B, and remove the

Unfasten the timing belt tensioner

c.

connect, the following:

teners to 13

lbs.

in

Use cam sprocket holding/remov-

camshaft sprocket.

REMOVAL & INSTALLATION

.

the timing belt.

Exhaust manifold

•

precautions

Align the timing marks and remove

a.

dipstick tube bracket

•

•

Engine

the camshaft front seal as

b.

Install or

for leaks.

Remove

ing tool

Exhaust Manifold

SOHC

4.

Exhaust manifold heat shield

3.

engine and check

the air cleaner and valve

•

the cooling system.

6.

Remove

follows:

To install:

connection

electrical

elec-

connection

oil

3.

cover.

bolt

inch lbs. (8-11 Nm).

•

connection

electrical

Disconnect the negative battery

2.

cable.

Oxygen (HO 2 S) sensor

Pleated

mounting bracket

the crankshaft pulley. Tighten the

1

or disconnect the following:

•

the beginning of this sec-

8.

Install

the valve cover and the air

cleaner assembly. 9.

Connect the negative battery cable.

FORD MOTOR CO.

15-9

FOCUS

uoougi;

Exploded view

of the cylinder

head— SOHC

engine

DOHC

Engine Before servicing the vehicle, refer to

1

the precautions in the beginning of this section.

Remove

2 •

or disconnect the following

Timing

belt

Refer to the Timing

Belt unit repair section.

Remove and Removing

the camshaft front

seal— SOHC

engine

•

Valve cover and camshaft sprockets

•

Oil control

solenoid flange

discard the cup plug located

at the rear ol the cylinder

head

•Mark

— SOHC

a

engine

the camshaft journal caps with

number •

to identity their location.

Camshaft journal caps. Loosen the bolts in

sequence and

in several

passes •

Camshafts

•

Oil control

sensor and bushing

To install: ing

3. Install the oil control solenoid bushand flange on the exhaust camshaft.

4

Coat the surface of the front

camshaft journal cap with gasket maker

E2AZ-19562-B Use seal Replacer T81P-6292-A,

Remove

the camshaft thrust plate retain-

ing bolts (A)

engine

and the plate

(B)

— SOHC

5. to install

the camshaft front seal 0 002—0.04

in.

(0.05-1. Omm) below Hush with the cylinder head front

Heater Core replacement

face— 2.0L SOHC engine

is

covered

in Section

Place the camshafts in position and

lubricate the bearing surfaces with engine

assembly 6.

D9AZ-19579-D new camshaft front oil

lubricant

Install

2 of this manual

seals.

M0T0RC °'

15-10

FOCUS 8.

7.

Apply a thin coat

of silicone gasket

and sealant F6AZ-19562-AA

to the sealing

9.

Install the

caps and tighten the

Inspect the

bolts in several 2-turn passes in the

surface of the of the front camshaft journal

sequence

bearing cap.

(13-17 Nm).

illustrated to

—Camshaft Bearing Cap

10-12

ft.

flange 10. 0-rings for

lbs.

oil

control solenoid

damage

Install the oil

Spark Plug

19

Engine Lifting Eye Bolt

Camshaft Intake

20

Engine Lifting Eye

4

Camshaft Exhaust

21

Camshaft Sprocket

5

Plug

22

Exhaust Camshaft Sprocket

6

Adjusting Shim

Bolt

2

Camshaft Bearing Cap

3

—Valve

—Exhaust

Bolt

Clearance

23

7

Valve Tappets

24

Blanking Plug

8

Valve Spring Retainer Key

25

Bolt

Camshaft Sprocket Intake

Blanking Plug O-Ring

—

Intake

Camshaft

Valve Spring Retainers

26

10

Valve Spring (Color Coding: Exhaust - Blue, Intake - Red)

27

Camshaft Front Seal

28

O-Ring

11

Valve Stem Seal

29

Camshaft Front Seal

12

Camshaft Position Sensor

30

Oil Feed Ring

13

CMP Sensor Bolt

31

Oil Feed Flange Bolts

14

Intake Valves

32

Oil Feed Flange

15

Exhaust Valves

33

Guide Sleeve

16

Cylinder Head

17

Cylinder Head Bolts

9

wear and

control solenoid flange

18

1

or

replace, as necessary.

f

—Front Camshaft

Bearing Cap

34

Fifth

Camshaft Bearing Cap 9300MG06

Exploded view

o!

t!

inder

head and camshaft mounting

— DOHC engine

FORD MOTOR CO. 1

-

FOCUS

9.5-10.5

Nm

(84-92

bolts in this

1 1

i

—DOHC engine

sequence

Nm)

to

84-92

inch lbs.

the sequence.

in

Rotate the camshafts a

.

check

II

control solenoid flange

oil

and tighten the bolts (9.5—10.5

C.1

o

lb 'n)

r

Tighten the

I

full

turn

and

for binding.

12.

Install or

connect the following:

•

Camshaft sprockets and timing

•

Valve cover

belt

Valve Lash

ADJUSTMENT

SOHC

Engine

The lash adjusters are hydraulic and are ^C2IIG66

not adjustable.

Camshaft journal cap loosening sequence— DOHC engine

DOHC 1

.

Engine

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

0—

is

2.

Remove

3

Rotate the crankshaft so that the valve

closed and measure the clearance

between the

rffelWri

the valve cover

base

circle

lifter

shim and the camshaft

Intake valve clearance should be

0 004-0 007 inches Exhaust valve

clear-

ance should be 0.010-0.013 inches 4

Measure each valve and note the

clearance.

5

If

adjustment

the camshafts

is

necessary, remove

and replace the shims To

obtain the correct shim size, measure the

V

vj

ifs r\

13-17

Nm

(10-12

fe

Ib/ft) 33QEHG04

Camshaft journal cap torque sequence— DOHC engine

Brake service

Checking valve clearance— 2. OL engine

is

covered

in Section

4 of this manual

HC

"

S

FORD MOTOR CO.

O L

i 8

FOCUS

current shim, add the

sequence and

measured clearance,

18

tor intake valves

and subtract 0.006 inches

or 0.012 inches for exhaust valves.

connect the following:

Install or

6.

•

Camshafts

•

Valve cover

lbs.

ft.

in

several passes to

(24 Nm).

sensor connector

•

Oil lever

•

Catalytic converter

•

Negative battery cable the crankcase to the correct level.

5.

Fill

6.

Start the

engine and check

for leaks.

Starter Motor 3

)

REMOVAL & INSTALLATION Oil

SOHC 1

.

Before servicing the vehicle, refer to the

7

pan torque sequence— SOHC engine

2.

Drain the engine

3.

Remove

the beginning of this section.

in

Remove

or disconnect the following:

oil.

•

Negative battery cable

•

Catalytic converter

Negative battery cable

•

Intake manifold bracket

•

Intermediate shaft bracket

•

Two

•

Coolant pipe bolt

•

S

•

Oil

top starter motor bolts

terminal wire and the

B terminal

nut and cable from the solenoid

To

install:

Lower

4.

Apply silicone sealant

•

Starter

starter

motor

bolt

and

5.

•

S

mounting

terminal wire,

and

bolt to

nut.

B

18-20

terminal cable

Tighten the nut to

80-120

inch lbs. (9-13.5 Nm). •

Top

•

Air cleaner outlet tube

•

Negative battery cable

starter

bolts to

DOHC

motor

18-20

ft.

ft.

lbs.

pump

Intermediate shaft bracket

•

Intake manifold bracket

•

Catalytic converter

•

Negative battery cable

7.

Start the

Before servicing the vehicle, refer to the in

the beginning of this section.

Remove

or disconnect the following:

Crankshaft Position (CKP) sensor

•

Oil

•

Oil

Lubricate the crankshaft front

Oil

•

Oil

pump. Tighten ft.

pump

for leaks.

•

CKP

•

Oil

•

Timing

Fill

6.

Start the

DOHC

Engine

oil.

or disconnect the following:

1

.

Before servicing the vehicle, refer to

tion.

•

Oil

pan

To install:

'-Apply a bead

•

Starter.

•

Starter electrical connectors

•

Air cleaner

•

Negative battery cable

Tighten the bolts to 26

sealer to the

oil

of silicone

in

the beginning of this sec-

2.

Drain the engine

3.

Remove

gasket

pan flange.

Negative battery cable

•

Timing

belt.

4.

Install or

•

Oil

connect the following:

pan. Tighten the bolts

in

•

Oil

pan

•

Oil

•

Oil

pump pump

pickup tube

To install:

Pan

connect the following:

Install or

•

Oil

pump. Tighten

inch lbs.,(11

REMOVAL & INSTALLATION

•

Oil

pump

SOHC Engine Before servicing the vehicle, refer to the in

the beginning of this section. Oil

pan torque sequence— DOHC engine

the bolts to

97

Nm)

pickup tube. Tighten the

fasteners to

precautions

Refer to the Timing

Belt unit repair section.

4.

1

oil.

or disconnect the following:

•

ft.

(35 Nm).

belt

engine and check for leaks.

Catalytic converter

connect the following:

inch lbs.

the crankcase to the correct level.

5.

•

Install or

71-97

sensor

Air cleaner

connectors

pickup tube. Tighten the

pan

•

Starter electrical

the bolts to

(8-11 Nm).

the precautions

Starter

seal

(13-16 Nm).

lbs.

retaining bolts to

Negative battery cable

•

oil

oil.

connect the following:

Install or

•

•

pickup tube

with clean engine

10-12

Before servicing the vehicle, refer to

Remove

pump pump

Negative battery cable

lbs.

Oil

•

install:

Engine

Drain the engine

belt

pan

•

To install: 3.

3.

Oil

•

tion. 2.

•

3.

and brackets

engine and check

or disconnect the following:

Timing

To

4.

the precautions in the beginning of this sec-

precautions

lip

Remove •

the crankcase to the correct level.

(25-27 Nm).

DOHC

in

(25 Nm).

Coolant pipe bolt

Fill

1.

18

•

6.

Engine

to

•

bolts. Tighten the lbs.

2.

to the oil

Tighten the bolts

sequence

(25-27 Nm)

lbs.

Oil pan.

Before servicing the vehicle, refer to

tion.

connect the following:

Install or

•

motor assembly and tighten

Starter

.

rear seal retainer joints.

connect the following:

Install or

Engine

the precautions in the beginning of this sec-

pan

•

ft.

2.

REMOVAL & INSTALLATION

1

and brackets

Air cleaner outlet tube

the lower

.

Pump

SOHC

•

•

1

Oil

or disconnect the following:

•

To install: 3.

v

Engine

precautions 2.

!

9306SG05

88 inch

lbs.

(10 Nm).

pan

•

Oil

•

Timing

•

Negative battery cable

belt

the crankcase to the correct level.

5.

Fill

6.

Start the

engine and check

for leaks.

FORD MOTOR CO. -IE FOCUS

19 10

TOP COMPRESSION

Rear Main Seal

RING

BOTTOM COMPRESSION

REMOVAL & INSTALLATION

RING 1

CONTROL RINGS AND EXPANDER

OIL

Before servicing the vehicle, refer to

.

the precautions in the beginning of this section.

Remove

2.

or disconnect the following:

•

Negative battery cable

•

Transaxler-

•

Clutch,

•

Flexplate/flywheel

•

Oil seal

if

CENTER

LINE OF PISTON PARALLEL TO WRIST PIN BORE

UPPER COMPRESSION RING GAP LOCATION

equipped

To install: •

)F

connect the following:

Install or

3.

Oil seal. Seat the seal flush with the

CONTROL SEGMENT RING GAP

OIL

rear of the crankshaft oil seal retainer. •

82

lbs.

ft.

(112 Nm).

equipped

•

Clutch,

•

Transaxle

•

Negative battery cable

Start the

4.

LOCATION

Flexplate/flywheel. Tighten the bolts to

if

ENGINE

engine and check

for leaks.

OIL

EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION

Piston and Ring

CONTROL SEGMENT

RING GAP LOCATION

’322N29

POSITIONING

Ford 2.0L (VIN 3 and P) engines ing.

—

piston ring positioning, end-gap spacing and piston position-

The small directional arrow must lace the

front of the

engine

FUEL SYSTEM Fuel System Service Precautions

trate the skin or

any part of the body

that

it

Fuel System Pressure

contacts.

Safety

the

is

most important

performing not only

nance but any type to

fuel

of

factor

manner may

injury or death.

in

a

result in serious personal of

components can

be accomplished safely and effectively by

adhering

to the following rules

•

(should

fire

Do come •

to

flame.

Always

relieve the fuel

system pres-

component

(injector, fuel rail,

ulator, etc.), fitting or fuel line

pressure reg-

connection

Exercise extreme caution whenever relieving

system pressure,

skin, face

and eyes

advised that

fuel

to

avoid exposing

to fuel spray.

Please be

under pressure may pene-

all fuel

soaked

•

into contact with a spark or

until

fuel line

stress

and torsion

Do

or equivalent,

unnecessary

fuse from the

engine and allow

it

to idle

stalls.

Crank the engine that the fuel

for

5 seconds

to

pressure has been

relieved. 5.

Disconnect the negative battery cable.

6.

When

repairs are completed, connect

the negative battery cable fuel

pump

and replace the

fuse.

fuel fitting

Fuel Filter

0-

not substitute fuel hose

where

fuel

pipe

installed

is

Before servicing the vehicle,

REMOVAL & INSTALLATION

make sure

to refer to the precautions in the of this section

pump

box

to fuel line piping.

Always replace worn

rings with new.

connec-

the fuel

Start the it

ensure

Always use a backup wrench when

tion fittings. This will prevent

•

open

the beginning of this section.

battery junction

4

not allow fuel spray or fuel vapors

in

Remove

2

3.

loosening and tightening

sure prior to disconnecting any fuel system

fuel

quickly removed from

extinguisher near the work area

battery cable unless the repair or test proce-

•

is

Always keep a dry chemical (Class B)

•

sonal injury, always disconnect the negative

applied.

occur)

Before servicing the vehicle, refer to the

.

precautions

able waste container.

and per-

dure requires that battery voltage be

it

1

that all fuel spillage

cloths or towels are deposited into a suit-

fire

To avoid the possibility of

Ensure

engine surfaces. Ensure that

and guide-

lines.

RELIEVING

or connection prior to

fitting

loosening to absorb any excess fuel due to spillage.

Maintenance and testing

the vehicle’s fuel system

Always place a shop towel or cloth

•

around the

maintenance. Failure

conduct maintenance and repairs

safe

when

system mainte-

beginning

as well.

For complete Engine Mechanical specifications, see Section

1

.

Before servicing the vehicle, refer to the

precautions

1

in

the beginning of this section.

of this manual

-|K 1/1 FORD MOTOR CO.

D"1 4

I

FOCUS

2.

Relieve the fuel system pressure.

3.

Remove •

•

Evaporative Emissions (EVAP)

•

Rollover valve line

•

Fuel tank retainer strap. Support

line

Fuel

filter

lines

Fuel

filter

and bracket assembly

•

Fuel

filter

•

•

5.

Fuel

filter

•

Fuel

filter

•

Fuel

EVAP vapor

lines line

engine and check

Start the

pump module

Fuel tank pressure sensor connec-

Fuel tank

•

Fuel

install: Install or

Fuel

Pump

connect the following:

pump module. ft.

Tighten the

lbs.

(80 Nm).

Fuel tank

•

Fuel tank pressure sensor connec-

Fuel

.

Before servicing the vehicle, refer to

the precautions

in

•

pump module

2.

18

harness con-

3.

Remove

or disconnect the following:

•

Exhaust center muffler

•

Heat shield

•

•

Fuel

tiller

Fuel line and retaining clip

•

Pressure regulator vacuum hose

•

Accelerator cable

•

Fuel injector electrical connectors

•

Fuel supply manifold with the

Rollover valve line

•

EVAP vapor

Install or

•

Fuel supply line

•

Fuel

filler

•

injectors attached. Tighten the bolts

5.

and vent hoses

Heat shield

•

Exhaust center muffler

Fuel supply line Start the

new O-ring

Fuel supply manifold with the

to

line

•

and vent hoses

connect the following:

Fuel injectors using

seals

6. 5.

Injectors from the supply manifold

install:

4.

(25 Nm).

lbs.

ft.

•

Relieve the fuel system pressure.

•

Fuel tank retainer strap. Tighten the bolt to

or disconnect the following:

Negative battery cable

•

the beginning of this sec-

tion.

Remove •

•

nector 1

the beginning of this section.

in

Relieve fuel system pressure.

To

tor •

Before servicing the vehicle, refer to the

injectors attached

•

REMOVAL & INSTALLATION

2.

pump module

4.

•

.

3.

•

To

for leaks.

1

precautions

locknut to 59

Fuel

harness con-

tor

and bracket assembly

•

filter

Fuel

nector

connect the following:

•

REMOVAL & INSTALLATION

the fuel tank.

•

•

Install or

Fuel Injector

line

vapor

To install: 4.

Evaporative Emissions (EVAP)

vapor

or disconnect the following:

engine and check

for leaks.

88 inch

(10 Nm).

lbs.

•

Fuel injector electrical connectors

•

Accelerator cable

•

Pressure regulator vacuum hose

•

Fuel line and retaining clip

•

Negative battery cable

•

Air intake pipe

•

Air cleaner

DRIVE TRAIN Transaxle Assembly

REMOVAL & INSTALLATION

•

Rear engine mount and bracket

•

Starter

•

Transaxle flange bolts. Support the

•

MAF

transaxle.

•

Battery and tray

Transaxle

Tighten the strut center nuts to 35

•

Manual

To install:

.

precautions

in

Transaxle. Tighten the flange bolts ft.

lbs.

(48 Nm). 1

Before servicing the vehicle, refer to

the precautions

Loosen the

front strut center nuts 5

the beginning of this sec-

in

Rear engine mount bracket. tion.

Tighten the fastener to 59

ft.

lbs.

turns. 4.

.

motor

Starter

eyes. •

3.

35

Attach a support fixture to the engine •

lifting

Automatic

the beginning of this section. to

2.

ft.

connect the following:

Before servicing the vehicle, refer to the •

assembly

sensor connector

(48 Nm).

lbs.

Install or 1

motor

2.

Attach a support fixture to the engine

(80 Nm).

Remove

or disconnect the following:

lifting

• •

Battery and tray

•

Mass

3.

outer nuts to 35

Flow (MAF) sensor con-

Air

Rear engine mount. Tighten the ft.

(48

lbs.

Nm)

and the center nut

to

98

ft.

lbs. 4.

Air cleaner

•

Air intake pipe

•

Clutch slave cylinder fluid line

•

Shift cables

•

Exhaust

•

Engine front mount

VSS

or disconnect the following:

•

Battery

•

Mass

sensor connector

•

Reverse

•

Drive belt cover

light

and

Air

tray

Flow (MAF) sensor con-

switch connector nector •

• flex

Remove

(133 Nm).

assembly

•

front strut center nuts 5

turns.

nector •

eyes.

Loosen the

Axle halfshafts and intermediate

Positive Crankcase Ventilation

(PCV) hose

pipe shaft •

•

Lower

•

Axle halfshafts and intermediate

Lower

ball joints.

bolts to •

37

ft.

lbs.

Turbine^Shaft Speed (TSS) sensor

(50 Nm).

connector •

Drive belt cover

•

Reverse

•

Vehicle Speed (VSS) sensor con-

light

bolts to

35

Exhaust

flex pipe

ft.

lbs.

Transmission range sensor connec-

(48 Nm). tor

•

switch connector • •

nector

Air intake pipe

•

Right engine mount. Tighten the

shaft •

and resonator

•

Tighten the pinch

ball joints

•

Transaxle harness connector

•

Starter

•

Shift cable

Shift cables

motor

Clutch slave cylinder fluid line

and bracket

NCH wC

FORD MOTOR CO. i FOCUS

•

Front wheels

•

Exhaust front pipe

•

Right engine support

•

Outer

•

Lower

•

Axle halfshafts and intermediate

reservoir until the level reaches the

Clutch

4.

REMOVAL & INSTALLATION

1

Before servicing the vehicle, refer to

.

Transaxl^

•

ml brake

Remove

Torque converter

•

Transaxle

Negative battery cable

•

Transaxle

•

dipstick tube

oil

•

**The transaxle flange bolts vary

in

length. Note their locations for installa-

•

To

install:

5.

Install or

to

35

lbs.

ft.

or connect the following air

Tighten the fastener to 59

ft.

in

V2 turns to

21

ft.

lbs.

1 1

(29

Transaxle

•

Negative battery cable

outer nuts to 35

and

Check the brake

fill

with

DOT

Install or

13. •

lbs.

ft.

to

Nm)

(48

98

ft.

1

(133 Nm).

Torque converter. Tighten the nuts

oil

lbs.

•

Transaxle

•

OSS

Remove

2.

dipstick tube

•

Air cleaner

Air intake pipe

MAF

•

Air cleaner

•

Outer to

•

35

ball joints.

37

•

Mass

Air

-The

is used engine and the MTX75 manual transmission is used with the DOHC engine.

Flow (MAF) sensor con-

•

3.

Air intake pipe

Remove

IB5

with the

fluid

from the brake

fluid

manual transmission

SOHC

ft.

lbs.

Tighten the pinch

(50 Nm).

lbs.

(48 Nm).

Right engine support. Tighten the bolts to

•

35

ft.

lbs.

(48 Nm).

Exhaust front pipe. Tighten the fasteners to

35

ft.

lbs.

(48 Nm).

•

Front wheels

•

Shift cable

•

Starter

•

Transaxle harness connector

•

Transmission range sensor connec-

and bracket

motor

tor •

TSS sensor connector

•

Air intake pipe

•

PCV hose

and resonator

•

MAF

•

Battery and tray

sensor connector

Tighten the strut center nuts to 35

6.

ft.

Left halfshaft lbs.

assembly

Left

rod ends. Tighten the nuts

tie ft.

sensor connector

REMOVAL & INSTALLATION

shaft

bolts to

as necessary.

assembly

nector

cooler lines

oil

or disconnect the following

•

(37 Nm).

sensor connector

Lower

fluid,

connect the following:

•

Axle halfshafts and intermediate

•

fluid reservoir level

4 brake

tion.

Transaxle

•

proper opera-

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

lbs.

•

tt.

for

Halfshaft

and the center nut

27

no more

BLEEDING

lbs.

Rear engine mount. Tighten the

to

Check the clutch

.

12.

•

until

tion.

(80 Nm). •

full

bubbles are seen.

Rear engine mount bracket.

•

the pedal at

Repeat the procedure

10.

Clutch disc and pressure plate

Hydraulic Clutch System

(48 Nm).

the tool.

Close the bleeder before releasing

9.

Transaxle. Tighten the flange bolts

•

system.

travel.

Nm).

connect the following:

pump 80

the clutch pedal.

evenly

Transaxle

Nm) and remove

4-5 times and hold

pedal

steps.

Tighten the pressure plate bolts

Transaxle flange bolts. Support the transaxle.

•

V2 turn

the bleed nipple and

fluid into the clutch control

Have an assistant depress the clutch

8.

Clutch disc

Install

3.

(10

lbs.

To install:

tion. •

in

4 brake fluid.

Tighten the bleed nipple to 88 inch

7.

Pressure plate. Loosen the bolts evenly

Rear engine mount and bracket

•

or disconnect the following:

•

cooler lines

oil

•

Open

6.

tion. 2.

connector

DOT

bleed nipple.

shaft

Output Shaft Speed (OSS) sensor

the reservoir of Special Tool

with

Attach the tool to the slave cylinder

5.

ball joints

the precautions in the beginning of this sec•

Fill

416-D002

rod ends

tie

MIN

mark.

removal— IB5 manual

transaxle

(48 Nm).

For Accessory Drive Belt

illustrations,

see Section

1

of this

manual

HC

-fC FORD MOTOR

lU'IO

CO.

FOCUS To

install:

"•Use a new retaining 6.

Install or

•

clip for

assembly.

connect the following:

Axle halfshaft and intermediate shaft assembly. Tighten the nuts to

18 •

•

ball joint.

bolt to

37

Hub

7.

ft.

Tighten the pinch

(50 Nm).

lbs.

retainer nut. Tighten the nut to

232 •

(25 Nm).

lbs.

ft.

Lower

lbs.

ft.

(316 Nm).

Front wheel

Check the transaxle

fluid

and add, as

necessary. 8.

Tighten the strut center nuts to 35

ft.

(48 Nm).

lbs.

CV-Joints

OVERHAUL ’•The hub nut may be reused 4 times.

Mark the nut

Install or

7.

removal and only use hub nuts with 3 or fewer marks for assembly. i

at

•

•

•

the precautions

in

ball joint.

bolt to

37

Hub 232

Before servicing the vehicle, refer to the beginning of this sec-

connect the following:

Lower

ft.

lbs.

1

(50 Nm).

retainer nut. Tighten the nut to lbs.

ft.

.

2.

3.

Loosen the

Remove • • •

4.

strut center nut

5 turns.

Front wheel fluid

3.

and add, as

or disconnect the following:

retainer nut.

Lower

Mark

the nut.

Separate the inner CV-joint from the

transaxle as follows: •

If

remover

308-256 If

Right

MTX75 manual

transaxle or with an automatic transaxle, use Halfshaft

1

.

6.

Install

the circlip

slide

Remover

2.

Loosen the

3.

Remove

into the

circlip for

to seat.

assembly.

Draw

the stub shaft

wheel hub with Halfshaft

205-379.

Installer

strut center nut

4.

•

Front wheel

•

Hub

•

Lower

•

Intermediate shaft retaining clip

in

a vise.

Tripod joint boot clamps

•

Tripod joint boot

•

Tripod joint housing

•

Snapring

•

Tripod joint

install:

Install or

connect the following:

Tripod joint

•

Snapring

•

Tripod joint housing.

the joint

•

Tripod joint boot

•

Tripod joint boot clamps

Install

the halfshaft.

the nut.

ball joint

Press the stub shaft out of the wheel

Outer CV-Joint The outer CV-joint

is

serviced with the

halfshaft as an assembly.

Remove

Fill

housing with grease.

5.

hub. 5.

it

or disconnect the following:

•

5 turns.

or disconnect the follow-

Mark

Remove

•

the beginning of this sec-

retainer nut.

the axle halfshaft from the

assembly.

ing:

hammer

the halfshaft inner joint so that

is felt

in

the beginning of this section.

"•Use new snaprings and boot clamps for

Before servicing the vehicle, refer to

the precautions

To install:

"•Replace the

To

tion.

equipped with the

205-241 and a

"•The hub nut may be reused 4 times. Mark the nut at removal and only use hub nuts with 3 or fewer marks for assembly.

4.

eguipped with the IB5 manual

transaxle, use Halfshaft

•

ft.

ball joint

Press the stub shaft out of the wheel

hub. 5.

Tighten the strut center nuts to 35

(48 Nm).

lbs.

Front wheel

Hub

necessary. 9.

in

Remove

vehicle and place

tion. 2.

Before servicing the vehicle, refer to the

precautions

(316 Nm).

Check the transaxle

8.

Inner Tripod Joint

Tighten the pinch

the right axle halfshaft and

the intermediate shaft as an assembly.

The outer CV-joint

boot can be serviced by removing the inner tripod joint.

lw 17/

FORD MOTOR CO. -|C FOCUS

I

STEERING AND SUSPENSION bag indicator lamp

The

in

the instrument cluster

lamp should illuminate

indicator

approximately 6 seconds, then turn

•

for

OFF

7.

if

the indicator lamp does not illuminate, stays

These vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety pre-

• •

on, or flashes at any time, a fault has been

detected by the

tie

35

rod ends. Tighten the nuts

(48

lbs.

ft.

Power Rack & Pinion Steering Gear

Nm)

Front wheels Steering shaft pinch bolt. Tighten the bolt to 21

bag diagnostic monitor.

air

Outer to

ft.

lbs.

(28 Nm).

•

Lower instrument panel cover

•

Negative battery cable

Check the wheel alignment and adjust as necessary.

Strut

REMOVAL & INSTALLATION

cautions and the disarming

procedure could result in accidental bag deployment, possible injury and unnecessary system repairs. air

1

.

1

tion. 2.

PRECAUTIONS

REMOVAL & INSTALLATION

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

LOCK

ignition to the 3.

Several precautions must be observed

Remove •

.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

Center the steering wheel and turn the

tion.

position

2.

or disconnect the following

Remove

or disconnect the following:

Negative battery cable

•

Front wheel

•

Lower instrument panel cover

•

Brake hose bracket

accidental deployment and possible per-

•

Steering shaft pinch bolt

•

Stabilizer bar link

sonal injury.

•

Front wheels

•

Wheel speed sensor,

•

Outer

•

Brake caliper and rotor

wires or connector on the underside of the

•

Stabilizer bar links

•

Outer

module

•

Power steering

•

Lower

•

Steering knuckle pinch bolt. Sepa-

when handling

the inflator

Never carry the

•

When

module

to

avoid

module by

inflator

the

tie

rod ends

fluid cooler

hose

mount

carrying a live inflator module,

•

Right engine

hold securely with both hands, and ensure

•

Steering gear heat shield

•

Power steering hose support clamp

•

that the

bag and trim cover are pointed away

Place the inflator module on a bench

•

or other surface with the

bag and trim cover

•

Power steering hoses

•

6 subframe

facing up inflator

module on

the bench,

never place anything on or close to the

module

may be thrown

that

in

the event of

an accidental deployment Before servicing the vehicle, also be sure to refer to the precautions in the of this section

•

Steering gear pinion extension

•

Steering gear

install:

4

Install or

beginning

•

•

.

the precautions in the beginning of this section. 2.

• 5.

Position the vehicle with the front in

3.

Disconnect the negative battery cable

Nm).

4.

Disconnect the positive battery cable

6.

5.

Wait

at least 1

backup power supply

minute

bag

for the air

to drain before contin-

Proceed with the

7.

Once

repair.

repairs are completed, connect

the battery cables, negative cable

Check

position and visually monitoring the air

For

Tire,

ft

lbs.

upper

(25 Nm).

bolt to

66

Lower

ball joint

Tighten the pinch

37

(50 Nm).

ft

ft

lbs.

lbs.

rod end. Tighten the nut to

Outer

tie

35

lbs (48

ft

(90 Nm).

Nm).

Brake caliper and rotor

(35 Nm).

•

Wheel speed sensor,

Floor seal

•

Stabilizer bar link. Tighten the nut

ft.

lbs.

Subframe Alignment Pins 502-

raise the

subframe

the other bolts to

to

into position.

85

(200

lbs.

ft

ft

37

ft

lbs (50

if

equipped

Nm).

•

Brake hose bracket

•

Front wheel

Check the wheel alignment and adjust

4

(115

lbs

connect the following

•

Power steering hoses

•

Power steering hose support

Shock Absorber REMOVAL & INSTALLATION

•

Steering gear heat shield

•

Right engine bolt to

ignition key to the

18

as necessary

last.

the functioning of the air bag

system by turning the

RUN

•

to

Steering knuckle. Tighten the pinch

bolt to

Nm)

clamp

6.

connect the following

Strut assembly. Tighten the

•

Install or

uing.

8.

(80

Tighten the 4 rear bolts to 147

Nm) and

a straight-ahead position.

•

connect the following

lbs

strut.

mount nuts

assembly

mount nuts

Steering gear pinion extension

Install

002 and

wheels

ft.

knuckle from the

strut

Install or

•

Tighten the pinch bolt to 26

Before servicing the vehicle, refer to

Strut

Steering gear. Tighten the bolts to

59

as well

•

•

Floor seal

DISARMING

1

3.

•

To

Upper

rod end

To install:

frame.

With the

•

•

equipped

ball joint

rate the

Support the sub-

bolts.

tie

if

37

ft.

mount Tighten lbs.

the

3 Door Model

(50 Nm).

•

Power steering

•

Stabilizer bar links. Tighten the

nuts to 37

ft.

fluid cooler

lbs.

hose

1

.

Before servicing the vehicle, refer to the

precautions

in

the beginning of this section.

(50 Nm).

Wheel and Ball Joint specifications, see Section

1

of this manual

“ 1 OO E

i

FORD MOTOR CO. FOCUS

I

1

Remove

2.

or disconnect the following:

Luggage compartment

•

interior trim

panel

Upper shock absorber mounting

•

nut •

Lower shock absorber mounting

•

Shock absorber

bolt

To install:

^Tighten the shock absorber mounting fasteners with the suspension at curb height and the vehicle weight sup-

ported by the wheels. connect the following:

Install or

3.

Shock absorber. Guide the rod

•

into

the locating hole.

Lower shock absorber mounting

•

Tighten the bolt to 85

bolt.

ft.

lbs.

(115 Nm).

Upper shock absorber mounting

•

nut.

Tighten the nut to 13

lbs.

ft.

(18 Nm).

Luggage compartment

•

interior trim

panel

Wagon 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this secFront strut assembly exploded view

tion.

2.

Remove

the upper and lower

mounting bolts and remove the shock absorber.

To install:

^Tighten the shock absorber mounting fasteners with the suspension at curb height and the vehicle weight sup-

ported by the wheels. 3.

Install the

tighten the

shock absorber and

mounting bolts

to

85

lbs.

ft.

(115 Nm).

Coil spring

REMOVAL & INSTALLATION

Front 1.

Before servicing the vehicle, refer to

the precautions at the beginning of this section. 2.

Remove

3.

Compress the

suitable spring

the strut from the vehicle.

comes away from 4.

Remove

coil

spring using a

compressor

until the

spring

the seat.

the large center nut

and

slowly release the spring compressor.

To

install:

5.

Compress

the strut.

the spring

and

install

it

on Coil spring

compressor and adapters

E 1Q 3

FORD MOTOR CO. H FOCUS Install the

6.

the nut to 7.

35

Install

ft.

upper lbs.

strut

mount. Tighten

(48 Nm).

the strut assembly in the

vehicle.

Front bolt

cannot be adjusted.

Control arm

excessive, check the wheel

To

install:

•Use new washers

Rear

3. 1

.

Before servicing the vehicle, refer to the

precautions

in the

sprincpcompressor 204-167

b.

the coil spring

2:

Step

it.

(120

lbs.

d.

the coil spring and

Step

Front

•The

hub nut may be reused 4 times. nut at removal and only use hub nuts with 3 or fewer marks for assembly.

Mark the

ft.

plus 90 degrees

Check that 125-169 ft.

3

bolt No. lbs.

Ball Joint

the precautions in the beginning of this sec-

REMOVAL & INSTALLATION

•

5.

ball joint is

replaced with the

tion.

Install or •

Before servicing the vehicle, refer to

1.

is

(170-230

Nm) 4.

The lower

ft.

4:

tightened to

Lower

Tighten nut No. 2 to 88

to

1

Tighten bolt No. 3 to 88

3:

remove the

compressor.

ft.

Nm)

To install: Install

connect the following

Lower

ball joint.

bolt to

37

ft.

lbs.

Tighten the pinch

2.

Loosen the

3.

Remove

(50 Nm).

Front wheel

Check

the wheel alignment

and adjust

as necessary.

lower control arm as an assembly.

CONTROL ARM BUSHING REPLACEMENT The lower control arm bushings are

Front wheel

•

Wheel speed sensor,

•

Hub

•

Brake caliper and rotor

•

Outer

•

Lower

4

replaced with the lower control arm as an

strut center nut

5 turns.

or disconnect the following:

•

•

Lower Control Arm REMOVAL & INSTALLATION

is

plus 60 degrees

Nm)

and remove c.

5.

correct,

REMOVAL & REPLACEMENT

74

Tighten nut No.

1:

Nm)

Step

(120

lbs.

Compress

is

required.

assembly.

Step

(100

with Adapters 204-215. 4.

ball bearing

beginning of this section.

Raise and support the vehicle. Install

the torque

If

is

retainer nut

replacement of the wheel bearing

the control arm. Tighten the

Install

lbs. 3.

and

hub

fasteners in sequence as follows: a.

2.

nuts, bolts

for

proper torque.

for

I

wheel bearing play

•

•

If

I

if

equipped

Mark the

retainer nut.

nut.

rod end

tie

ball joint

Steering knuckle pinch bolt

Press the stub shaft out of the wheel

hub.

assembly.

5.

Press the hub out of the wheel bear-

6.

Remove

7.

Press the bearing out of the hub

ing. 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

Wheel Bearings

tion. 2.

Remove • • •

or disconnect the following:

To install:

ADJUSTMENT

8

Front wheel

Lower

ball joint

Rear bracket bolts

The bearings on the

the snapring

front

and

Press the bearing into the hub.

9

Install the

snapring.

rear

wheels are a one piece cartridge design and

10

Press the hub into the wheel bearing

1 1

Draw

hub with 12

the stub shaft into the wheel

Install or

•

bolt to

66

Lower

ball joint

bolt to •

•

37

Outer

tie

35

lbs.

ft

ft

ft

lbs (90

Nm).

Tighten the pinch

lbs (50

Nm).

rod end. Tighten the nut to

(48 Nm).

Brake caliper and rotor

Hub

•

232

retainer nut ft.

lbs.

(316

Tighten the nut to

Nm)

•

Wheel speed sensor,

•

Front wheel

if

equipped

Tighten the strut center nuts to 35

lbs (48 14.

connect the following

Steering knuckle Tighten the pinch

•

13.

205-379

Halfshaft installer

ft.

Nm).

Check the wheel alignment and

adjust as necessary.

Rear 1.

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

For Wheel Alignment specifications, see Section

1

of this manual

15-20 2.

Remove

FORD MOTOR CO. FOCUS

or disconnect the following:

•

Rear wheel

•

Dust cap

•

Hub

•

Brake drum

•

Wheel speed sensor tone

•

Snapring

Remove install:

the wheel bearing with a press.

^Use a new wheel speed sensor tone ring for assembly.

nut

equipped

3.

To

•

Snapring

•

Wheel speed sensor tone

• •

ring,

if

4.

brake 5.

Press the wheel bearing into the

drum hub. Install or

connect the following:

ring,

equipped Brake drum

Hub 173

nut. ft.

Tighten the hub nut to

lbs.

•

Dust cap

•

Rear wheel

(235 Nm).

if

FORD MOTOR CO. 2000-01 Lincoln

16-19 16-2

DRIVE TRAIN..' ENGINE REPAIR FUEL SYSTEM

16-18 16-2

PRECAUTIONS

Removal & Fuel

16-20

A 16-20

Disarming

16-20

Precautions

16-20 16-2

Alternator Installation

16-2

Removal

16-2

C Camshaft And Valve

Fuel System Pressure

Lifters

Installation

Installation

16-19

Installation

16-21

Removal &

Installation

Removal &

16-3

Installation

16-8

Exhaust Manifolds Installation

&

Installation

16-7

Intake Manifold

Removal &

Installation

16-18 16-18

16-11

Installation

Rocker Arms/Shafts Installation

16-11

16-7 16-7

S 16-10

Motor

Removal &

Installation

16-10 16-20

Strut

Removal

&

Installation

16-20

T

16-7

Front Cover and Seal

Removal &

Installation

Transmission Assembly

Removal &

Installation

i

Lower

16-21

Ball Joint

Removal &

Installation

Lower Control Arm Control

16-21 16-21

16-21

Replacement Installation

Upper

16-21

&

Installation

Upper Control Arm

Removal & Oil

Pump Removal &

16-10 16-11

16-17 16-17

16-21

16-9 16-9

Adjustment

W Water

Pump

16-5

16-20

Installation

Wheel Bearings

&

16-5 16-21 16-21

Adjustment

Removal

Power Rack and Pinion Steering Gear

16-21

Installation

Valve Lash

Removal &

r

Positioning

16-21 16-21

Replacement

Removal &

16-11 Installation

16-19

V 16-10

Installation

16-19

Arm Bushing

O Pan

16-12

16-21

Ball Joint

Removal Control

Arm Bushing

Removal &

16-12

U

L

Piston and Ring

16-18

Fuel Filter

Fuel Injector

16-3

16-8

F

16-19

16-3

Timing

Adjustment

Oil

16-3

Removal &

16-19

16-5

Engine Assembly

Rear Main Seal

Starter

16-20

16-20

Timing Chain, Sprockets,

16-5

E

Removal &

Installation

Bleeding

16-20

Overhaul Cylinder Head

Removal

Removal &

16-20

CV-Joint

Installation

R

Removal &

16-20

Hydraulic Clutch System

16-21

Coil Spring

Removal &

16-18

Halfshaft

16-19

Removal &

16-18

16-19

Adjustments

16-18

H

16-8 16-8

16-18

Fuel System Service

Ignition

Clutch

Removal &

Installation

Precautions

Bag

16-18 16-18

Relieving

SUSPENSION

Removal &

Installation

Pump

Removal &

STEERING AND

Air

LS

Replacement

16-21

FORO MOTOR CO.

16-2

LINCOLN LS

PRECAUTIONS of the following precautions,

all

which deal with personal of

prevention

safety,

component damage, and important points

when

consideration

to take into

servicing a

motor vehicle:

tor or

cooling system

hot; serious

when

the engine

is

burns can occur from the steam

Observe

tions

all

applicable safety precau-

when working around

fuel.

Whenever

servicing the fuel system, always work well-ventilated area. or vapors to

come

Do

in

a

not allow fuel spray

oil

may cause

a

should always buy the correct type

can-

fluid for

You should make every to

(a hot

mini-

effort to

used engine

oil.

worn when Wash your hands and any

fire

your vehicle.

If

of brake

the brake fluid

becomes contaminated, completely system with new

Any brake

flush the

Never reuse any

fluid.

removed

Protective gloves should be

brake

changing

from the system should be discarded. Also,

oil.

exposure

sible after

Soap and

to

used engine

oil.

hand cleaner

water, or waterless

new

All

now equipped

Supplemental

Inflatable Restraint (SIR) sys-

come in condamage

fluid to

will

it

the paint.

Never operate the engine without the

•

vehicles are

fluid that is

do not allow any brake

should be used. •

fluid.

tact with a painted surface;

proper amount and type of engine

so WILL result

Supplemental Restraint System (SRS) or

drop

example). Keep a dry chemical

Timing

•

belt

maintenance

Many models

important.

doing

oil;

severe engine damage.

in

extremely

is

an

utilize

interfer-

extinguisher near the work area. Always

tem. The system must be disabled before

ence-type, non-freewheeling engine.

keep

performing service on or around system

timing belt breaks, the valves

fuel in a container specifically

and

essential to the safe

proper operation of the brake system. You

of skin disorders, including

mize your exposure

is

prolonged con-

with an air bag system, often referred to as a

contact with a spark,

in

open flame, or excessive heat light, for

used engine

tact with

number

that

other exposed skin areas as soon as pos-

and hot coolant. •

The EPA warns

•

Clean, high quality brake fluid from a

•

sealed container

medical assistance.

cer.

Never open, service or drain the radia-

•

IMMEDIATELY seek

brake fluid internally,

Before servicing any vehicle, please be

sure to read

in

If

the

the cylinder

components, steering column, instrument

head may

panel components, wiring and sensors.

tially

possibility of fire or explosion. Refer to the

Failure to follow safety and disabling proce-

expensive) engine damage. Refer to the

additional fuel system precautions later

dures could result

designed

for fuel storage; also,

always

properly seal fuel containers to avoid the

in

this section.

Fuel injection systems often remain

«

pressurized, even after the engine has been

in

accidental air bag

unnecessary system

ment

Always wear safety goggles when

•

working with, or around, the

be relieved before disconnecting any fuel

tem.

do so may

and/or personal

injury.

•

Brake

fluid often

contains polyglycol

ing a

and wash your hands thoroughly

handling brake

after

brake fluid

fluid.

If

with clean, running water for 15 minutes.

eye

irritation persists, or

if

bag sys-

face,

non-deployed

air

When

plac-

always face the bag and trim cover

reduce the motion of the module

if

it

will

If

you have taken

tional air

bag system precautions

later in

interval charts in the front of

for the

recommended

replace-

and

interval for the timing belt,

to the

inspection.

Disconnecting the negative battery

•

cable on

some

vehicles

may

interfere with

the functions of the on-board

tem^) and may

require the

computer sys-

computer

to

undergo a relearning process once the negative battery cable

When

•

is

accidentally deployed. Refer to the addi-

causing poten-

timing belt section for belt replacement and

air

bag on a work sur-

upward, away from the surface. This

you do get

your eyes, flush your eyes

in

air

carrying a non-deployed

pointed away from your body.

ethers and polyglycols. Avoid contact with the eyes

When

bag, be sure the bag and trim cover are

result in fire

manual

this

turned OFF. The fuel system pressure must

lines. Failure to

maintenance

deployment, possible personal injury and repairs.

strike the pistons,

serious (also time-consuming and

is

servicing

reconnected.

drum

brakes, only dis-

assemble and assemble one side

at a

time,

leaving the remaining side intact for refer-

ence.

this section.

ENGINE REPAIR '•Disconnecting the negative battery cable on

some

vehicles

may

interfere

with the functions of the on board

puter system. The computer

com-

may

•

Lower splash shield

•

Alternator

•

Alternator harness connectors

•

Alternator

INSTALLATION

mounting bolts

3.0L Engine

undergo a relearning process once the negative battery cable

is

reconnected.

Install or

3.9L Engine 1

.

connect the following:

•

Alternator

•

Alternator harness connectors. Tighten

Before servicing the vehicle, refer to

Alternator

the battery cable terminal nut to

70 inch

lbs.

the precautions in the beginning of this sec(8

Nm).

tion.

REMOVAL

• 2.

Remove

Alternator

or disconnect the followbolts to

35

ft.

mounting

lbs.

bolts. Tighten the

(48 Nm).

ing:

3.0L Engine 1

.

•

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

Remove •

•

or disconnect the following:

Negative battery cable

Accessory drive

belt

•

Lower splash shield

•

Accessory drive

•

Negative battery cable

Negative battery cable

•

Air intake tube

•

Accessory drive

belt

belt

•

Lower splash shield

•

Alternator mounting bolts

•

Alternator harness connectors

•

Alternator

3.9L Engine 1

.

tors,

bolts

Install the alternator

then in

harness connec-

install the alternator.

sequence as follows:

Tighten the

FORD MOTOR CO.

16-3

LINCOLN LS •

Front brake calipers

•

Lower

•

Upper

ball joints

•

Lower

strut

•

Starter

stabilizer bar links

mount

bolts

motor wiring harness con-

nectors •

Power Steering Pressure (PSP) switch connector

•

Steering shaft pinch bolt

•

Torque converter,

front

if

equipped

Support the engine, transmission,

7.

and center crossmembers and the

cooling system with a powertrain

lift

and

transmission support bracket.

Support the rear

8.

of the vehicle with

10. safety stands.

Remove

9.

or disconnect the following:

•

Transmission crossmember bolts

•

Subframe bolts

•

Crossmember

•

Powertrain assembly

2.

bolts

9306TGI

Alternator torque sequence

— 3.9L engine

Attach a hoist to the engine.

Remove

1 1

Step

a.

(48

lbs.

(20

lbs.

(48

lbs.

2:

Nm)

Step

c.

35

ft

Tighten bolt No. 2 to 15

ft

ft

Tighten bolt No.

1

to

Nm)

Step

b.

1:

3:

plus 90 degrees

Tighten bolt No. 3 to 35

Nm)

Install or

connect the following:

•

Air cleaner

• •

housing and outlet tube

Wire harness retainers

Engine appearance cover

•

Starter

Upper

radiator shield

•

Heated Oxygen (HO 2 S) sensor

•

Upper

radiator support brackets

•

A/C pressure switch connector

•

Motor mount nuts

•

Power steering

•

Accessory drive

•

Fuel line

•

Power steering pump

•

Vapor Management Valve (VMV)

•

Hydraulic cooling fan

cover

•

Upper

Lower splash shield

•

Accessory drive

•

Air intake tube

•

VMV

vacuum hose

•

Negative battery cable

•

Cowl

leaf

belt

Timing

ADJUSTMENT

•

screens

•

Chassis vacuum lines

Cross vehicle support bar

•

Fresh

•

Intake manifold rear

intake housing

12 of the

•

torless Ignition

timing the

is

equipped with a Distribu-

System

(DIS).

not adjustable.

is

It

is

Accelerator cable and cruise control

cable

The ignition

To

•

Cable bracket

•

Ground

controlled by

PCM. •

strap

Lift

•

3.0L Engine 1

Before servicing the vehicle, refer to

.

tion.

Drain the cooling system.

2.

Relieve the fuel system pressure.

3.

Main transmission wiring harness

•

Transmission from the engine

install:

14.

Install or

•

the flange bolts to 35

•

charging harness connectors

2

•

A/C

•

Hydraulic cooling fan reservoir

•

Left, right

•

A/C compressor manifold and tube

•

assembly

•

line

mounting bracket

•

Coolant hoses

•

Exhaust front pipe and heat shields

•

Driveshaft

refrigerant.

•

Shift cable

oil.

•

Front wheels

or disconnect the following:

•

lbs.

(48

•

Nm)

lbs (63

Oil cooler

hoses

Transmission

and bracket

Front wheel speed sensor connec-

oil

cooler lines,

if

equipped

Upper radiator hose Hydraulic cooling fan pump. Tighten the bolts to 18

•

ft.

lbs.

(25 Nm).

Power steering pump. Tighten bolts to 18

Drain the engine

Negative battery cable

ft.

Powertrain on the subframe

ft.

•

and center splash shields

Recover the A/C

Remove

connect the following:

Transmission to the engine. Tighten

Tighten the motor mount nuts to 46

5.

•

hoses

Transmission flange bolts

Nm)

4.

6.

or disconnect the following

•

•

the precautions in the beginning of this sec-

if

and transmission out

Oil cooler

Main engine wiring harness con-

fuel

the engine

Remove

connector

REMOVAL & INSTALLATION

cooler lines,

•

nector

Engine Assembly

oil

subframe

13.

main vacuum

hose This vehicle

pump

hose

radiator

Transmission

belt

equipped

•

air

motor

bracket

reservoir

•

Ignition

or disconnect the following:

•

ft

lbs.

•

Accessory drive

•

HO 2 S

belt

sensor bracket. Tighten the

nut to 89 inch lbs. (10 Nm).

tors

For complete service labor times, order the Chilton Labor Guide

the

(25 Nm).

FORD MOTOR CO.

16-4 •

Starter motor. Tighten the bolts to

18 •

•

LINCOLN LS

(25 Nm).

lbs.

ft.

Negative battery cable the crankcase to the correct level.

Powertrain assembly. Tighten the

16.

Fill

the cooling system.

crossmember

17.

Recharge the A/C system.

18.

Start the

76

bolts to

ft.

lbs.

Steering shaft pinch bolt. Tighten

if

switch connector

Alternator harness connectors

Lower transmission flange bolts

•

Torque converter

•

Inner air deflector

•

Engine block heater,

equipped

if

Support the engine, transmission,

Before servicing the vehicle, refer to

.

front

the precautions in the beginning of this sec-

and center crossmembers and the

cooling system with a powertrain

motor wiring harness con-

Starter

motor harness connectors

Starter

•

7. 1

PSP

for leaks.

3.9L Engine

(25 Nm).

lbs.

ft.

•

engine and check

Steering shaft bolt and coupling

and ground cable

equipped.

Torque converter,

•

the bolts to 18

• •

Fill

•

•

Air cleaner

•

15.

Wire harness retainers

(103 Nm).

•

housing and outlet tube

•

and

lift

tion.

nectors •

Lower

mount

strut

129

the bolts to •

Upper to

66

ft.

lbs.

Drain the cooling system. Relieve the fuel system pressure.

(175 Nm).

Recover the A/C

refrigerant.

5.

Drain the engine

oil.

Lower

stabilizer bar links. Tighten

the nuts to 41

ft.

(55 Nm).

lbs.

•

Front brake calipers

•

Front wheel speed sensor connec-

Remove

Front wheels

•

Shift cable

Negative battery cable

•

Air cleaner inlet tube

•

Upper Upper

•

A/C pressure switch connector

•

Driveshaft

•

•

Exhaust front pipe and heat shields

•

Coolant hoses

•

A/C compressor manifold and tube

•

Front

•

Center crossmember bolts

Power steering

Powertrain assembly

•

A/C compressor manifold and tube

•

Power steering pump

•

Hydraulic cooling fan return hose

•

Lower radiator hose

Power steering reservoir Vapor Management Valve (VMV) •

Upper radiator hoses

•

Knock Sensor (KS) connector

lbs. (21

•

Main vacuum supply hose Cowl vent screens

and center splash shields

Left, right

•

Hydraulic cooling fan reservoir

•

A/C

2 fuel charging harness connectors

•

Main transmission wiring harness

Cross vehicle support bar

•

Degas

•

Accelerator cable

bottle

Cruise control cable

Ground Fresh

air filter

and housing

Powertrain harness connectors

Ground

10.

Attach a hoist to the engine.

11.

Remove

the motor

mount nuts and

the powertrain out of the subframe.

Remove

12.

tower

or disconnect the follow-

ing:

•

Fresh

•

Main engine wiring harness con-

(10 Nm).

Hydraulic cooling fan pressure line

at

Main engine wiring harness con89 inch

and

and bracket

lift

•

line

strap

right strut

•

hose

• •

inch lbs. (10 Nm).

Power steering pressure bracket

•

connector. Tighten the bolt to 89

lbs.

Transmission cooler lines and

•

•

nector. Tighten the bolt to

Heater hose

•

bracket

mounting bracket

line

•

•

•

•

canister

•

Nm).

•

vacuum hose and

purge hose

ft.

hose

return

return line clip

cover

assembly. Tighten the bolt to 15

bolts

assembly

•

VMV

crossmember

•

radiator support brackets

•

•

or disconnect the following:

Transmission crossmember bolts

radiator shield

•

and bracket

rear of the vehicle with

•

or disconnect the following:

•

tors •

Remove

9.

(90 Nm). 6.

•

Support the

8.

safety stands.

4.

Tighten the nuts

ball joints.

ft.

2.

3.

bolts. Tighten lbs.

transmission support bracket.

air filter

panel •

strap. Tighten the bolt to

Wiring harness retainers

•

Upper transmission flange bolts

•

Transmission from the engine

nector

89 inch •

lbs.

(10 Nm).

•

Cable bracket. Tighten the bolts

Main transmission wiring harness

To

to

connector

89 inch

lbs.

(10 Nm). •

•

Heater hoses

install:

13. at

Install or

•

valve. Note the locations for

cable Intake manifold rear

main vacuum •

Hydraulic cooling fan reservoir

•

Water control valve harness con-

hose Fresh

•

Cross vehicle support

air intake

to the engine. Tighten

housing

the nuts to

the bolts to 15 •

ft.

lbs.

Tighten

(20 Nm).

• •

Front wheels

•

Inner splash shields

• •

Cowl

leaf

•

VMV VMV

vacuum hose

89 inch

lbs.

•

•

Power steering reservoir

•

•

Brake calipers

•

Lower

A/C pressure switch connector Upper radiator support brackets. Tighten the bolts to 89 inch

• •

Engine appearance cover

30

ft.

lbs.

(40

Hydraulic cooling fan pressure

line

Power steering pressure

line

and

bracket ,

Upper

ball joints

•

Lower

strut

•

Left, right

mount

•

Transmission cooler lines and

•

Heater hose

•

Knock sensor connector

bolts

bracket

and center splash shields

•

A/C suction and discharge

•

Shift cable

lines

lbs.

and bracket

•

Power steering

•

Rack and pinion harness connectors

Upper radiator shield

to

stabilizer bar links

•

(10 Nm).

mount nuts

and bracket •

*

Fuel line

•

•

and harness clips

cover

•

(10 Nm).

Nm).

Wheel speed sensor connectors

screens

lbs.

Powertrain to the subframe. Tighten the

Chassis vacuum lines

ft.

Wiring harness retainers. Tighten

nector bar.

35

(48 Nm). •

•

Transmission

the upper flange bolts to

assembly. •

connect the following:

the water control

Accelerator cable and cruise control

line

frame

rail

•

Upper

radiator

hoses

•

Lower

radiator

hose

•

Hydraulic cooling fan return hose

clip

FORD MOTOR CO.

1I

LINCOLN LS •

Power steering pump

•

Cowl vent screens

•

A/C compressor manifold and tube

•

Main vacuum supply hose

assembly. Tighten the bolt to 15

•

VMV vacuum

lbs. (21

•

return

hose

ft.

Powertrain assembly. Tighten the front to

and center crossmember bolts

76

ft.

Nm) and

(103

lbs.

30 •

(40 Nm).

lbs.

Engine block

heater,

equipped

if

Power steering reservoir

Upper radiator support brackets

•

Upper

•

•

ft.

(38 Nm).

lbs.

Lower transmission flange Tighten the bolts to 35

ft.

bolts.

(47

lbs.

Nm). • •

return line clip

A/C pressure switch connector

•

28

Power steering

•

Inner air deflector

to

cover

•

Torque converter. Tighten the nuts

Drain the cooling system.

3.

Remove

Air cleaner inlet tube

4.

Negative battery cable Fill

the crankcase to the correct level-

15.

Fill

the cooling system.

motor harness connectors

lbs.

ft.

bolt to

Nm) and

(35

22

16.

Recharge the A/C system. engine and check

for leaks.

1

•

Shift cable

•

Left, right

Lower

66

•

bolts. Tighten

129

lbs.

Lower

lbs.

•

Before servicing the vehicle, refer to the

(175

Drain the cooling system

Negative battery cable

•

Air cleaner outlet tube

•

6.

Start the

•

Wheel speed sensor connectors

Upper radiator hose Heater supply hose

Lower radiator hose Water crossover assembly Water

•

Water control valve harness con-

inlet

4

Hydraulic cooling fan reservoir

Accessory drive

water control

belt

and

Relieve the fuel system pressure

Drain the engine

5.

Remove

•

Upper and lower intake manifolds Valve covers

Accessory drive

•

Fresh

air filter

Ground

at

and housing

strap

•

Cruise control cable

•

Accelerator cable

• •

Degas

bottle

hose bar.

ft.

Water

Water crossover assembly

•

Lower radiator hose

lbs.

(20 Nm).

6.

Please

visit

inlet

hose

pump hose

•

Water

•

Heater supply hose

•

Upper

radiator

Motor mount nuts

•

Subframe bolts

•

Oil

•

Front cover

•

Timing chains

•

Camshafts

Engine vent hose

•

Air cleaner outlet tube

our web

engine and check

site at

Exhaust manifolds

•

Ground

•

Positive Crankcase Ventilation

strap

•

Ignition noise suppressor

•

Coolant outlet tube

Engine

oil

Install the

dipstick tube

subframe bolts and

remove the engine support

the cooling system.

Start the

•

• 8.

Negative battery cable

Fill

pan

(PCV) tube

hose

•

or disconnect the follow-

•

idler pul-

•

Tighten 5.

the bolts to 15

(10 Nm).

and

•

•

Cross vehicle support

lbs.

Remove

ing:

•

belt

a support fixture to the engine

eyes.

to

(25 Nm).

89 inch

Accessory drive belts Install

ley

right strut tower •

lbs.

Negative battery cable

•

7

connect the following:

teners to

panel

Powertrain harness connectors

lifting

oil.

or disconnect the following:

•

•

Water pump. Tighten the bolts ft.

Head

4

6

Bracket assembly Tighten the fas-

Main engine wiring harness con-

air filter

for leaks.

Drain the cooling system.

idler pul-

•

Main transmission wiring harness

Fresh

engine and check

Before servicing the vehicle, refer to

•

pump

Water

18

nector •

belt

3.

Bracket assembly

Install or

•

connector •

plus

2.

hose

To install:

valve •

Nm)

3 OL Engine

pump hose

Water

•

•

Front wheels

at the

(10

tion.

•

•

Inner splash shields

Heater hoses

lbs.

REMOVAL & INSTALLATION

1

Engine vent hose

•

•

Brake calipers

nector •

pulley. Tighten the

89 inch

the cooling system.

Fill

ley

•

pump

Accessory drive

5.

and harness clips •

to

plus 90

the precautions in the beginning of this sec-

•

•

(55 Nm).

or disconnect the following

•

•

Nm)

Tighten the nuts

lbs.

the beginning of this section

Remove

stabilizer bar links. Tighten ft.

in

3.

(90 Nm).

the nuts to 41 •

ft.

Water

Cylinder

2.

lines

mount

ball joints. ft.

clip

and center splash shields

strut

Upper to

•

rail

and bracket

the bolts to •

frame

A/C suction and discharge

•

Nm)

45 degrees.

REMOVAL & INSTALLATION

precautions line

Water pump. Tighten the bolts

degrees. •

3.0L Engine

tors

Power steering

connect the following:

Install or •

Water Pump

Rack and pinion harness connec-

•

belt

pulley

the shaft

(30 Nm).

lbs.

ft.

pump Water pump

bolts to

Steering shaft bolt and coupling.

26

•

Water

71 inch lbs. (8

Tighten the coupling pinch bolt to

•

•

To install:

and ground cable •

Accessory drive

Alternator harness connectors Starter

or disconnect the following:

•

•

Start the

the beginning of this sec-

2.

radiator shield

14

17.

in

tion.

VMV

•

Before servicing the vehicle, refer to

.

the precautions

•

•

1

hose and canister

•

•

the

transmission crossmember bolts to ft.

3.9L Engine

purge hose

Nm).

C C U J

for leaks.

www.chiltonsonline.com

9.

Remove

fixture.

the cylinder heads.

Front cover

•

•

Oil

pan

•

Intake manifold

•

Subframe

bolts. Tighten the bolts to

•

Valve covers

76

(103 Nm).

—3.0L

engine

To

in

sequence as follows:

Front cover

Timing chains

belts

• •

Camshafts

•

Valve covers

•

Water outlet pipe

•

Upper and lower intake manifolds

•

•

Negative battery cable

ft.

lbs.

Fill

the crankcase to the correct level.

14.

Fill

the cooling system.

15.

Start the

engine and check

Cylinder head temperature sensor

connector

13.

Step

1:

22

b.

Step

2:

Plus 90 degrees

c.

Step

3:

Loosen

lbs.

ft.

(30

bolts

all

1.

Nm)

a.

for leaks.

5.

•

Exhaust front pipes

•

Exhaust Gas Recirculation (EGR) tube Bolts and stud bolts at the rear of

•

Cylinder heads. Loosen the bolts

•

the precautions in the beginning of this sec-

To install: Install the

Step

4:

22

Step

5:

Plus 90 degrees

f.

Step

6:

Plus 90 degrees

Install the

lbs.

ft.

(30

cylinder heads. Tighten the

tion.

one

full

Nm)

d.

bolts in 2.

Drain the cooling system.

3.

Relieve the fuel system pressure.

sequence as follows:

4.

Remove

or disconnect the following:

b.

•

Step

1:

M10

bolts to

15

ft.

lbs.

(20

Step

2:

M10

bolts to

26

ft.

lbs.

(35

Nm)

Negative battery cable

Nm)

engine support fixture and

remove the subframe

bolts. 1

Install or

12.

in

reverse of the tightening sequence.

Before servicing the vehicle, refer to

a.

e.

.

Accessory drive

(63 Nm).

46

cylinder heads. Tighten

turn

1 1

• •

Accessory drive belts

3.9L Engine

Install the

the bolts

nuts. Tighten the nuts

the cylinder heads

install:

10.

lbs.

•

to

Cylinder head torque sequence

ft.

Motor mount

•

9306TG01

Engine appearance cover

•

10

Nm

(89

lb-in) |

connect the following:

•

Engine

•

Coolant outlet tube

•

Ignition noise

•

PCVtube

•

Ground

•

Exhaust manifolds

oil

dipstick tube

suppressor

strap

•

Camshafts

•

Timing chains

9346TG03

Right cylinder head torque

sequence-

s' engine

Left valve cover torque

sequence

Engine

1

Left valve cover torque

sequence

—3.9L

10

Nm

(89 ItHn)

|

—3.0L

Engine

9346TG02 9346TG04

Right valve cover torque sequence

Engine

— 3.0L

Left cylinder

engine

head torque sequence— 3. 9L

Right valve cover torque sequence

Engine

—3.9L

FORD MOTOR CO.

16-7

LINCOLN LS Step

c.

M10

3:

bolts to

33

ft.

lbs.

(45

Nm) d.

Step

4:

M10

e.

Step

5:

M10

Step

6:

M8

bolts to 15

Step

7:

M8

bolts plus

Positive Crankcase Ventilation

(20

•

Exhaust Gas Recirculation (EGR)

90 degrees

•

vacuum line EGR tube

•

Cowl vent screen

90 degrees

bolts plus

ft.

lbs.

ister

Nm) g.

6.

Install or

•

connect the following:

Cross vehicle support bar

ft.

lbs.

(50 Nm).

•

Exhaust front pipes

•

•

EGR

Fuel pressure sensor shield

•

Upper intake manifold vacuum

Water outlet pipe

Camshafts

•

Timing chains

•

Front cover

•

Accessory drive belts

•

Valve covers

5.

•

Upper

EVR

•

Upper intake manifold vacuum hose

•

Fuel pressure sensor shield

Intake Manifold Tuning Valve

•

EGR

(IMTV) connector

•

Chassis vacuum supply hose

Vacuum

Regulator (EVR)

vacuum

•

pressure transducer

Cross vehicle support bar Tighten the bolts to 15

line

EGR tube EGR vacuum line EVAP canister purge hose

brackets

•

•

Upper intake manifold

•

Fuel line and bracket Fuel pressure sensor

•

PCV hose

•

Negative battery cable

•

Fuel injector harness connectors

•

Throttle

the cooling system.

•

PCV

•

Cable bracket

•

Lower intake manifold assembly

To

Rocker Arms/Shafts

in this

connect the following

Lower intake manifold assembly. Tighten the bolts

in

sequence

to

89

body coolant bypass hose

•

Cruise control cable

•

Accelerator cable

•

IAC valve connector

•

TP sensor connector

•

Air cleaner outlet tube

inch lbs. (10 Nm).

•

Engine appearance cover

•

PCV

•

Negative battery cable

•

Fuel injector harness connectors

section are

equipped with rocker arms/shafts. The

line

tube

Install or

REMOVAL & INSTALLATION The vehicles covered

•

vacuum

install:

•

(20 Nm).

Cowl vent screen

•

for leaks.

lbs.

•

•

engine and check

ft.

Upper intake manifold support

Intake manifold

Start the

89

vacuum

hose

Exhaust

lbs.

IMTV connector

Engine appearance cover

8.

89 inch

valve connector and

•

Fill

to

intake manifold support

•

7.

not

•

pressure transducer

valve connector and •

sequence

line

•

•

•

•

•

Cylinder head temperature sensor

connector

(10 Nm).

inch lbs. (10 Nm).

Chassis vacuum supply hose

37

lbs.

Upper intake manifold. Tighten the

brackets. Tighten the bolts to

•

tube

89 inch

line

(10 Nm). •

•

EGR

•

bolts in

Bolts and stud bolts at the rear of

bolts to

Fuel line and bracket. Tighten the

purge hose

the cylinder heads. Tighten the

•

Fuel pressure sensor

•

bolt to

Evaporative Emissions (EVAP) can-

vacuum

•

(PCV) hose •

degrees

f.

Throttle

•

90

bolts plus

body coolant bypass hose

•

tube

camshaft directly actuates the valves.

6

Fill

7.

Start the

the cooling system.

engine and check

for leaks

3.9L Engine

Intake Manifold 1

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

REMOVAL & INSTALLATION

tion.

3.0L Engine 1.

the precautions in the beginning of this sec-

Lower intake manifold torque sequence—

tion.

3.0L engine

Drain the cooling system.

3.

Relieve the fuel system pressure.

4.

Remove

or disconnect the following:

•

Negative battery cable

•

Engine appearance cover

•

Air cleaner outlet tube

•

Throttle Position (TP) sensor con-

Idle Air Control (IAC) valve

Accelerator cable

•

Cruise control cable

•

Cable bracket

Remove

or disconnect the following:

•

Negative battery cable

•

Air cleaner outlet tube

•

Cowl vent screen

•

Cross vehicle support bar

•

Accelerator cable

•

Cruise control cable

•

Intake manitold

•

Exhaust Gas Recirculation (EGR)

vacuum hoses

valve

Camshaft Position (CMP) sensor connector

con•

nector •

Relieve the fuel system pressure.

•

nector •

Drain the cooling system

4

Before servicing the vehicle, refer to

2.

2.

3.

Evaporative Emissions (EVAP) canister

Upper intake manifold torque sequence

—

3.0L engine

Timing belt service

is

•

vacuum •

covered

in

Section

3

of this

purge valve

manual

line

Fuel pressure sensor connector and

Fuel line

line

FORD MOTOR CO.

8

1

LINCOLN LS vacuum hoses

•

Knock Sensor (KS) connector

•

Intake manifold

•

Cylinder head temperature sensor

•

Cruise control cable 5.

connector

•

Accelerator cable

•

Sensor connector bracket

•

Cross vehicle support

•

Wiring harness and hose bracket

•

Left

•

Idle Air

•

Throttle Position (TP) sensor

bank

fuel injector

the bolts to 15

connectors

Control (IAC) valve con-

nector

con-

ft.

lbs.

•

Cowl vent screen

•

Air cleaner outlet tube

•

Negative battery cable

bar.

Tighten

(20 Nm).

•

Secondary

•

Exhaust front pipes

air

tubes

•

Lower splash shields

•

Heat shields

•

Negative battery cable

engine and check

Start the

for leaks.

3.9L Engine

the cooling system.

6.

Fill

7.

Start the

1

nector

•

engine and check

.

Before servicing the vehicle, refer to

for leaks.

the precautions

in

the beginning of this sec-

Positive Crankcase Ventilation tion.

(PCV) tube 5.

•

Throttle

Exhaust Manifolds

2.

body coolant hoses

Remove •

•

Right bank fuel injector connectors

•

Delta Pressure Feedback Electronic

REMOVAL & INSTALLATION

•

Power steering pump reservoir

•

Oil dipstick

•

Exhaust front pipes

(DPFE) system sensor •

Intake manifold.

Loosen the

bolts

3.0L Engine

• in

reverse of the tightening 1

sequence.

2.

Install or

connect the following:

Intake manifold. Tighten the bolts in

•

sequence

to

18

ft.

lbs.

(25 Nm).

DPFE system sensor

•

Right bank fuel injector connectors

•

Throttle

•

PCV

body coolant hoses

TP sensor connector

•

IAC valve connector Left

bank

fuel injector

Wiring harness and hose bracket

Sensor connector bracket

Pleat shields

•

Lower splash shields

•

Exhaust front pipes

•

•

Secondary

•

Exhaust front pipes

•

Exhaust Gas Recirculation (EGR)

•

Oil dipstick

tube

•

Power steering pump reservoir

•

Negative battery cable

Install

KS sensor connector Fuel line

Step

1:

b.

Step

2:

•

bolts to 18

tubes

sequence as follows: 15

ft.

lbs.

(20

15

ft.

lbs.

(20

Nm) Nm)

EGR

ft.

lbs.

(25 Nm).

tube

tube

engine and check

Start the

for leaks.

Camshaft and Valve

Lifters

REMOVAL & INSTALLATION

connect the following:

Exhaust Gas Recirculation (EGR) tube

Fuel pressure sensor connector

vacuum

Install or

•

Exhaust manifolds. Tighten the

the exhaust manifolds. Tighten

connector

•

connect the following:

Install or

•

4.

a.

Cylinder head temperature sensor

•

air

3.

Exhaust manifolds

the fasteners in

4.

Exhaust manifolds

install:

Negative battery cable

connectors

•

•

To

•

•

3.

Exhaust Gas Recirculation (EGR)

•

To install:

•

•

or disconnect the following:

tube

tube

the beginning of this section.

in

Remove

tube

•

•

Before servicing the vehicle, refer to the

precautions

To install: •

.

or disconnect the following:

Negative battery cable

3.0L Engine

and 1

line

.

Before servicing the vehicle, refer to

•

EVAP

canister purge valve line

the precautions

•

CMP

sensor connector

3. tion.

•

EGR

2.

valve

Remove

Right exhaust manifold torque sequence

the beginning of this sec-

or disconnect the following:

•

Negative battery cable

•

Valve covers

•

Front cover

•

Timing chains

|:

3.0L engine

in

WARNING

The camshaft journal thrust caps must be removed before loosening the remaining camshaft journal cap bolts to ensure that the camshaft journal thrust caps are not damaged.

^Keep

all

valvetrain

components

in

order for assembly.

9306TG06

Intake manifold torque

engine

sequence

—3.9L

Left

exhaust manifold torque sequence

3.0L engine

To

•

Camshaft journal thrust caps

•

Remaining camshaft journal caps

•

Camshafts

•

Valve tappets and shims

install: Install or

connect the following:

FORD MOTOR CO.

-1C

IU Q 3

LINCOLN LS

6.

3306TC13

6 Camshaft

5.

lift

fools

Remove

—3.0L engine

303-659

the center camshaft bearing

journal caps.

Remove

7

pressed

9306TGH

air

the valve

shims with com-

and replace as required

to

achieve the correct adjustment.

Camshaft journal cap torque sequence—

Camshaft journal bearing cap torque

3.0L engine

sequence

8

—3.9L engine

Valve clearance should be

0.007-0 009

4.

valves or •

Valve tappets and shims

in their

original locations •

Camshafts

•

Camshaft journal caps

journal caps in

sequence

in their orig-

last.

to

Tighten the bolts

89 inch

lbs.

(10

Nm). Timing chains

•

Front cover

•

Valve covers

•

Negative battery cable

Start the

2.

Plus 90 degrees

lbs. (6

•

Timing chains

•

Front cover

1 1

Valve covers

•

Negative battery cable

engine and check

or disconnect the following:

1

the precautions in the beginning of this sec

lbs (10

Nm)

•

Valve covers

•

Ignition coils

•

Engine appearance covers

•

Negative battery cable

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

Remove

2.

or disconnect the following

•

•

Front cover

•

Engine appearance covers

•

Timing chains

•

Ignition coils

Negative battery cable

2.

Remove

or disconnect the following:

•

Negative battery cable

•

Engine appearance covers

•

Ignition coils

Valve covers

•

components

connect the following

Rear bearing journal cap and the

tion.

Valve covers

in 3.

Measure the valve clearance while

order for assembly. the camshaft lobe

is

pointed away from the

Camshaft journal bearing caps

valve shim. Rotate the crankshaft as neces-

•

Camshafts

sary for each valve to be measured.

•

Valve tappets and shims

• Keep

•

the service tools.

Install or

3.9L Engine

•

valvetrain

center bearing journal

bearing journal caps in sequence to

Before servicing the vehicle, refer to

Negative battery cable

all

Remove .

for leaks

for leaks

the beginning of this section

for intake

33—0 38mm)

thrust journal cap Tighten the

engine and check

3.0L Engine

Remove

Install the

•

ADJUSTMENT

1

(0

caps.

10

•

23mm)

in.

exhaust valves. 9.

connect the following:

•

•Keep

for

Valve Lash

Before servicing the vehicle, refer to the in

53 inch

3:

89 inch

3.9L Engine 1.

2:

Step

Start the

•

precautions

Step

Install or

inal positions. Install the thrust

Nm)

b. c.

(0.18-0

in.

0013—0015

To install:

all

valvetrain

components

in

order for assembly. 3.

4.

caps

Install or

connect the following:

•

Valve tappets and shims

•

Camshafts

Install the in their

bolts in a.

4.

camshaft journal bearing

original positions. Tighten the

sequence as follows: Step

1:

Finger tight

Remove

the camshaft thrust cap

and

the rear camshaft bearing journal cap from the camshaft that requires 5.

Install

shim adjustment

Service Tool set 303-659

in

place of the bearing journal caps, with the taller tool in

place of the rear bearing cap

Heater Core replacement

is

covered

in

Section

—3.91

Valve adjustment tool base plate

engine

2 of this manual

FORD MOTOR CO.

16-10

LINCOLN LS 3.

To

install:

connect the following:

Install or

•

Starter motor. Tighten the bolts to

•

Starter

•

Negative battery cable

18

Oil

ft.

lbs.

(25 Nm).

motor wiring connectors

Pan

REMOVAL & INSTALLATION 3.0L Engine Valve adjustment tool attachment

—3.9L engine

1

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

Drain the engine

3.

Install a

lifting

4.

• 3.

the shims with

compressed

air

—3.9L engine

Remove

Negative battery cable

•

Air cleaner outlet tube

•

Accessory drive

•

Alternator

belt

•

Center and right splash shields

•

A/C compressor

•

Electronic Thermactor Air (ETA) if

equipped

•

Rack and pinion steering gear

•

Lower control arm through

Valve covers

is

pointed away from the

valve shim. Rotate the crankshaft as neces-

sary for each valve to be measured. 4.

Valve clearance should be

0.007-0.009

in.

(0.18-0.23mm)

valves or 0.009-0.011 for

in.

for intake

(0.23-0.28mm)

exhaust valves. 5.

If

adjustment

is

necessary, compress

the valves with the special tools and

shim with compressed

the

each valve 6.

to

air.

remove

Repeat

for

be adjusted.

connect the following:

Install or •

Valve covers

•

Ignition coils

•

Engine appearance covers

•

Negative battery cable

Starter Motor

REMOVAL & INSTALLATION 1

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

Remove

or disconnect the following:

•

Negative battery cable

•

Starter

motor wiring connectors

•

Starter

motor

9306TG14

Oil

pan torque sequence— 3. OL engine

engine

or disconnect the following:

•

Measure the valve clearance while the

camshaft lobe

to the

eyes.

bracket,

Remove

oil.

support fixture

bolts

FORD MOTOR CO. 1 LINCOLN LS

•

Transmission cooler

•

Engine mount nuts

•

Left

and

subframe

right

down

the subframe

line bracket

Wiring harness bracket

•

Oil

pan

To

install:

5.

Install or

install:

4

Install the oil

pan. Tighten the bolts in

sequence as follows:

for clearance.

•

•

Pry

bolts.

To

a.

Step

1:

44 inch

b.

Step

2:

108 inch

Nm) (12 Nm)

lbs. (5 lbs.

the crankcase to the correct level.

5.

Fill

6.

Start the

engine and check

for leaks.

connect the following:

Oil pan.

Tighten the pan bolts

sequence

to

18

ft.

(25

lbs.

the transmission bolts to

in

Oil

ft.

lbs.

•

and

REMOVAL & INSTALLATION

subframe

right

(103

lbs.

Nm).

.

Engine mount nuts. Tighten the ft.

lbs.

2.

(63 Nm).

•

Transmission cooler

•

Lower control arm through

line bracket

Tighten the bolts to 129

ft.

bolts. lbs.

(175 Nm).

Rack and pinion steering

gear.

Tighten the nuts to 76

lbs.

ft.

(103

Nm). • •

bracket,

if

equipped

A/C compressor

•

Center and right splash shields

•

Alternator

•

Accessory drive

•

Air cleaner outlet tube

•

6.

ETA

belt

Negative battery cable

Fill

3.

engine and check

.

at

the beginning of this section or disconnect the following:

Upper intake manifold the crankcase.

Before servicing the vehicle, refer to the

•

Crankshaft pulley

•

Front cover

•

Primary timing chains

•

Oil

•

Oil

Accessory drive

•

Power steering pump

•

New

•

Alternator

•

Oil

•

Water

•

A/C compressor and bracket

•

Primary timing chains

•

Crankshaft pulley

•

Front cover

•

Oil

pan

•

Crankshaft pulley

•

Oil

pump

belt

To

install:

3.

Install or

pump

pump. Tighten the

Nm)

bolts to

53

plus 90 degrees

screen and tube

•

Front cover

•

Timing chains

•

Crankshaft timing gears

•

Oil

Rear Main Seal REMOVAL & INSTALLATION

pump

Install or

Oil

3.0L Engine

connect the following:

pump. Tighten the

bolts to

89 1

.

Before servicing the vehicle, refer to the

•

Timing chains Front cover

•

Oil

oil.

pan,

pump

•

•

the beginning of this section.

Oil

Attach an engine support fixture to

the engine lifting eyes

Remove

or disconnect the following:

screen and tube. Tighten

the bolts to •

tion.

at

Crankshaft timing gears

•

the precautions in the beginning of this sec-

oil

connect the following:

gasket

inch lbs. (6

3.

the

bolts

Valve covers

inch lbs. (10 Nm).

Before servicing the vehicle, refer to

Remove

pump mounting pump

•

3.9L Engine

3.

beginning of this section.

or disconnect the following:

•

•

Drain the engine

in the

Remove

precautions

2.

engine and check for leaks.

Upper intake manifold

2.

.

•

belt

•

for

leaks.

1

Valve covers

Start the

2.

Remove

•

Start the

•

To install:

the crankcase to the correct

level. 7.

Power steering pump Accessory drive

5.

Before servicing the vehicle, refer to the

precautions

nuts to 46

•

•

•

Fill

1

3.0L Engine

bolts. ft.

1

•

Alternator

4.

Wiring harness bracket Left

Water

•

precautions

Tighten the bolts to 76

pump

•

3.9L Engine

(47 Nm). •

1I

Pump

Nm) and

35

C U

89 inch

lbs.

(10

Nm)

•

Negative battery cable

•

Transmission

•

Clutch,

•

Flywheel

•

Rear crankshaft seal

pan if

equipped

Crankshaft pulley

A/C compressor and bracket

To install: 4

connect the following:

Install or

•

Rear main seal flush with the cylinder block surface

•

Flywheel. Tighten the bolts to 59 lbs (80

5.

equipped

•

Clutch,

•

Transmission

•

Negative battery cable

Start the

ft.

Nm). if

engine and check

for leaks.

3.9L Engine 1

Oil

pan torque sequence

.

Before servicing the vehicle, refer to

the precautions at the beginning ol this sec-

— 3.9L engine

tion.

Brake service

is

covered

in

Section 4 of this manual

FORD MOTOR CO.

16-12

LINCOLN LS

Attach an engine support fixture to

2.

the engine lifting eyes.

Remove

3.

or disconnect the following:

•

Negative battery cable

•

Transmission

•

Flywheel

•

Rear crankshaft seal

To install: connect the following:

Install or

4.

Rear main seal flush with the cylin-

•

der block surface •

Flywheel

Tighten the flywheel bolts

5.

in

a cross-

ing pattern as follows:

Nm) Nm)

a.

Step

1:

11

ft.

lbs.

(15

b.

Step

2:

81

ft.

lbs.

(110

connect the following:

Install or

6.

•

Transmission

•

Negative battery cable

engine and check

Start the

7.

for leaks. 9.

Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION

Sprocket

g

4

RH

5

Bolt (2 Req'd)

Timing Chain

10

Timing Chain Guide

rh Cylinder Head

A Tighten

to

20-30 N-m (15-22

Lb-Ft)

3.QL Engine 1

7922KG49

Before servicing the vehicle, refer to

.

the precautions at the beginning of this sec-

Exploded view left

ol the right cylinder

head timing chain and related components— 3. OL engine-

side similar

tion. •

Right timing chain tensioner

intake manifold

•

Right timing chain tensioner arm

•

Right timing chain and crankshaft

•

Upper

•

Valve covers

•

Accessory drive

•

Power steering pump

•

Alternator

•

Water

•

A/C compressor and bracket

•

Crankshaft pulley

•

Oil

pan

•

Oil

pump

•

Crankshaft Position (CKP) sensor

pump

screen and tube

Camshaft Position (CMP) sensor

they are assembled

^The

Front cover

positions.

in their

original

they are assembled

sensor pulse ring

Camshaft thrust caps

Dead Center (TDC)

Camshaft journal caps. Loosen the in

sequence and

in

Verify that the alignment arrows

to allow the

camshaft

to

•

be

or disconnect the following:

Camshaft thrust caps

If

crankshaft

1

complete revolution and

recheck.

Rotate the crankshaft so that the keythe 3 o'clock position. This posi-

tions the right cylinder head camshafts to

the neutral position.

Remove

Camshaft journal caps. Loosen the

evenly.

bolts in

Right bank camshafts

passes

sequence and

in

several

not, rotate the 7.

is at

•

on •

6.

original

cylinder.

the camshafts are aligned.

way

Remove

10.

several

in their

for

raised from the cylinder head

5.

cylin-

positions.

the 11 o’clock position to locate

passes 4.

camshaft journal caps and

der heads are numbered to ensure that

Rotate the crankshaft so that the keybolts

1

ensure that the thrust caps are not

connector

is at

arm

and crankshaft

The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts

damaged.

the crankshaft at Top

No.

Left timing chain

WARNING

to

•

way

Left timing chain tensioner

•

sprocket

damaged.

•

head timing chain ten-

•

"•The camshaft journal caps and cylinder heads are numbered to ensure that

CKP

• 3.

or disconnect the following:

Left cylinder

sioner

WARNING

The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts to ensure that the thrust caps are not

connector

•

•

sprocket

belt

I'

•

Remove

or disconnect the following:

Remove

2.

at the

o’clock position. This will position the

cylinder head camshafts to their neutral

Verify that the alignment arrows

To 1 1

position. 8.

•

1

left

to

be

Left

bank camshafts

install:

Prepare the timing chain tensioners

.

for installation as follows:

on

a.

or disconnect the following:

the camshafts are aligned.

camshaft

raised fifim the cylinder head evenly.

Rotate the crankshaft 2 revolutions

and locate the crankshaft keyway

to allow the

vise.

Place the

left

chain tensioner

in

a

FORD MOTOR CO. i I LINCOLN LS

Using a small prytool, release and

b.

ratchet/pawl

mechanism through

access hole

in

d.

Lock the piston with a

•

Repeat

•Be

for the right

chain tensioner.

sure that the crankshaft keyway

still at

Right timing chain and crankshaft

camshaft and crankshaft sprockets. •

wire

or paperclip. e.

9 O

with the index marks on the

the timing chain tensioner.

Slowly compress the tensioner.

.5mm

I

sprocket. Align the colored links

the

c.

1

H

Camshaft thrust caps

•

•

hold the timing chain tensioner

C O

Right timing chain tensioner arm

Right timing chain tensioner.

Tighten the retaining bolts to

15-22

lbs.

ft.

(20-30 Nm).

is

Remove

16

the 11 o’clock position.

the retaining wire from the

right timing chain tensioner.

12.

Install or

Using a thin prytool, release and hold the

bank camshafts

Camshaft journal caps

front cover with a

•

Camshaft thrust caps

engine

•

Left timing chain

sprocket. Align the colored links

•

Left

timing chain tensioner arm

•

Left

timing chain tensioner. Tighten

the retaining bolts to

15-22

ft.

Remove

1.5mm

wire or

paperclip— 3. OL engine

the retaining wire from the

the 3 o'clock position.

is in

15.

Retain the piston with a

21

lbs.

Rotate the crankshaft so that the key-

14.

Install or

connect the following:

•

Right bank camshafts

•

Camshaft journal caps

Place

in

the

one. Apply clean

lip.

View A.

new

the dowel pins

to the

6

critical

to the cylinder block.

front cover gaskets onto

on the cylinder block and

Place the front cover into position.

.

22. bolts

Install the

23.

6 front cover retaining

and stud bolts where the silicone

sealer

timing chain tensioner.

way

the seal

ring.

in

heads.

(20-30 Nm). 13.

shown

areas 20.

camshaft and crankshaft sprockets.

oil to

new

Apply silicone sealer

19.

with the index marks on the

sensor pulse

Replace the crankshaft seal

•

and crankshaft

CKP

Install

18.

Left

engine

left

the

17.

•

timing chain tensioner ratchet/pawl mech-

anism— 3. OL

connect the following:

was

applied.

Tighten the bolts and stud bolts until

the front cover contacts the cylinder block

and heads an, then turn the bolts and stud bolts an additional V* turn.

24.

Install the

retaining bolts

remaining front cover

and stud

Timing mark alignment— 3. OL engine

For complete Engine Mechanical specifications, see Section

1

of this

manual

bolts.

I

0“ -f I

A FORD MOTOR s

t LINCOLN

CO.

LS Tighten

25.

15-22

ft.

26.

cover retain-

of the front

all

and stud bolts

ing bolts

sequence

in

connect the following:

Install or

•

CMP

•

CKP sensor connector Oil pump screen and tube

• •

Oil

27.

to

(20-30 Nm).

lbs.

sensor connector

pan

Install

damper and

the crankshaft

tighten the bolt as follows:

Step 1:78-99

a.

ft.

(105-135

lbs.

Nm). b.

Step

2:

Loosen one

c.

Step

3:

35-39

d.

Step

4:

Plus an

28.

VIEW A

ft.

full turn.

(47-53 Nm).

lbs.

85-95 degrees.

connect the following:

Install or

•

A/C compressor and bracket

•

Water

•

Alternator

pump

•

Power steering pump

•

Accessory drive

•

Valve covers

•

29.

belt

Upper intake manifold engine and check

Start the

for leaks.

3.9L Engine Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section.

Apply sealant to the places indicated— 3. OL engine 2.

Drain the cooling system.

3.

Remove • •

FRONT OF ENGINE

* LOCATION

\

fc

OF STUDS

or disconnect the following:

Negative battery cable

Engine appearance cover and brackets

FOUR PLACES TIGHTEN BOLTS/STUDS

•

IN w SEQUENCE SHOWN FINGER-TIGHT

Valve covers

•

Engine cooling fan assembly

•

Accessory drive

•

Water

•

Alternator

pump

•

Lower

•

Heater hose

belt

pulley

hose and pipe

radiator

•

Idler pulleys

•

Crankshaft pulley

•

Front crankshaft seal

•

Power steering

•

Power steering pump and bracket

•

Hydraulic cooling fan reservoir

•

Hydraulic cooling fan

reservoir hose

hose and bracket

pump and

bracket •

Front cover wiring harness clips

•

Front cover. Loosen the bolts

in

sequence. • • 4.

*

STUD LOCATIONS

After

Torque converter access panel Cranksfiaft Position

Top Dead Center (ATDC). The crank-

shaft

keyway

tion.

Check

sequence— 3. OL engine

1

full

turn.

be

will

that the

facing upwards. Front cover torque

(CKP) sensor

Rotate the crankshaft to 45 degrees

If

in

the 6 o'clock posi-

camshaft lobes are

not, rotate the crankshaft

—

9306TG19

—3.9L

Timing chain tensioner preparation engine

To install: 1 1

Prepare the primary and secondary

.

timing chain tensioners for installation as follows:

Step

a.

1

:

Use a

thin wire to unseat

the check valve

Step 2: Compress the tensioner

b.

piston fully into the bore by hand

Step

c.

12.

3:

Install or

•

10.

Remove

the wire

connect the following:

Secondary timing chain tensioners. Tighten the bolts to 97 inch lbs. (11 Nm).

•

Intake

and exhaust camshaft

sprockets and secondary timing 330STG16

Front cover loosening 9.

sequence

chain assemblies

— 3.9L engine

•

Left

bank timing chain and crank-

shaft timing sprocket 5.

645

Install

in

Install

6.

530

Crankshaft Holding Tool 303-

place of the

CKP

sensor.

left

bank camshafts and

bank camshafts.

Remove

sprockets forward on the bolts or disconnect the follow-

ing:

tensioner and blanking plate

Tensioner arm

•

Timing chain guide

•

or disconnect the follow-

•

•

Tensioner arm

•

Timing chain guide

Left

Left

13

bank timing chain and crank-

Intake

Intake

tie

97 inch

lbs (11

strap to take

Nm).

up the slack

timing chain.

Secondary timing chain tensioners

9306TG17

Tool—3.9L engine

a

exhaust camshaft

sprockets and secondary timing

Crankshaft Holding

Nm).

and exhaust camshaft

chain assemblies •

lbs. (11

bank primary timing chain tensioner and blanking plate. Tighten

Use Timing Chain Tensioning Tool 303-532 to apply tension to the left bank

and exhaust camshaft

Right bank timing chain and crank-

the locking tool from the

Nm).

14

sprocket bolts •

lbs. (11

Left

Install

in the

shaft timing sprocket •

•

97 inch

Tensioner arm Tighten the bolts to

the bolts to

shaft timing sprocket

Remove

Timing chain guide. Tighten the bolts to

97 inch

Right bank primary timing chain

•

•

bank primary timing chain tensioner and blanking plate

• •

on the

•

camshaft sprocket bolts and slide the

Remove

it

ing:

Loosen the exhaust and intake

8

install

bank camshafts.

Camshaft Locking Tool 303-

to the right 7.

right

Use a Camshaft Locking Tool

—3 9L engine

For Accessory Drive Belt illustrations see Section ,

tie

strap to

remove slack from

primary timing chain— 3. 9L engine

1

of this manual

the

0“ iR O

-ip S

i

FORD MOTOR CO. LINCOLN LS ••Tighten the exhaust camshaft bolt first.

Tighten the

15.

left

bank camshaft

sprocket bolts as follows: a.

Step 1:15

b.

Step

Remove

16.

ft.

lbs.

(20

Nm)

Plus 90 degrees

2:

the locking tool from the

bank camshafts and

install

it

on the

left

right

bank camshafts. 17.

Install or

connect the following:

Right bank timing chain and crank-

•

shaft timing sprocket. Ensure that

the crankshaft sprocket

installed

is

as shown. •

Timing chain guide. Tighten the

•

Tensioner arm. Tighten the bolts to

97 inch

bolts to

lbs. (11

Nm).

9306TG21

Timing Chain Tensioning Tool

97 inch

—3.9L engine

Nm).

lbs. (11

Right bank primary timing chain

•

tensioner and blanking plate.

Tighten the bolts to 97 inch

lbs. (11

Nm). Install a tie strap to

18. in

take up the slack

the timing chain.

Use Timing Chain Tensioning Tool

19.

303-532

to

apply tension to the right bank

exhaust camshaft.

^Tighten the exhaust camshaft

bolt

first.

Tighten the right bank camshaft

20.

sprocket bolts as follows:

Crankshaft sprocket alignment— 3. 9L engine

Nm)

a.

Step

1:

15

b.

Step

2:

Plus 90 degrees

Remove

21.

ft.

lbs.

(20

the camshaft locking

tool.

Apply silicone sealant

22.

to the areas

indicated and install the front cover.

Tighten the front cover bolts

23.

in

sequence as follows: a.

Step

1:

44 inch

lbs. (5

b.

Step

2:

89 inch

lbs.

24.

Nm) Nm)

(10

Remove

the crankshaft locking

Install or

connect the following:

tool.

25. •

CKP

•

Torque converter access panel

•

Front cover wiring harness clips

•

sensor

Hydraulic cooling fan

pump and

bracket. Tighten the bolts to lbs.

•

18

ft.

(25 Nm).

Hydraulic cooling fan reservoir

hose and bracket •

Power steering pump and Tighterrthe bolts to 18

ft.

bracket. lbs.

Nm).

|

3

mm (0.1 2 in) 9306TG23

Apply silicone

sp;»The rear brake calipers must be

Differential front retaining nuts.

Take frequent bearing preload torque

9.

or disconnect the following:

•

•

OFF

tion before raising the vehicle.

connect the following:

Install or

.

rectly. 8.

posi-

1 1

while tightening the flange nut to

luggage com-

partment, must be turned to the

pinion flange nut

Rotate the pinion flange occasion-

7.

the precautions in the beginning of this sec-

2.

or connect the following:

Install

6.

on the left-hand side

Never loosen the pinion nut to reduce bearing preload. II it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut.

To install:

REMOVAL & INSTALLATION

1.

the pinion flange and

seal.

12.

higher

the differential with gear lubri-

Fill

cant and check for leaks.

than the specification for used bearings,

Turn the

13.

then tighten the pinion flange nut to the

ON

suspension switch

air

to the

position.

original reading as recorded.

preload.

STEERING AND SUSPENSION Air

that the

Bag

bag and trim cover are pointed

flashes or remains

away.

**

•

CAUTION

a fault in the air

vehicles are equipped with an bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and senair

is

Power Rack and Pinion Steering

and trim cover

Gear

facing up. •

continuously, there

Place the inflator module on a bench

or other surface with the bag

Some

lit

bag system.

With the

inflator

module on

the bench,

never place anything on or close to the

module

that

may be thrown

in the

REMOVAL & INSTALLATION

event of

an accidental deployment 1.

DISARMING

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

sors. Failure to follow the safety pretion.

cautions and the disarming

procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

1.

the precautions

in

the beginning of this sec-

Disconnect both battery cables from

the battery, negative cable

PRECAUTIONS

3.

Wait

1

when handling

the inflator

module

to

avoid

accidental deployment and possible per-

sonal injury. •

Never carry the

module by

the

wires or connector on the underside of the

module. •

When

carrying a live inflator module,

is

the time

required for the back-up power supply

After service

is

in

Remove •

Outer

•

Engine

•

tie

rod ends

oil filter

Power steering

fluid

pressure and

air

OFF

If

•

Steering shaft pinch bolt

•

Steering gear retaining nuts

•

Steering gear

last.

RUN

bag indicator should

To install:

light

4

continuously for approximately 6 seconds, then turn

position

or disconnect the following:

Front wheels

its

completed, reconnect

Turn the ignition switch to the

The

OFF

return lines

the battery cables, negative cable 5.

suspension switch, located on

•

stored energy.

position.

hold securely with both hands, and ensure

3.

first.

the air bag diagnostic monitor to deplete

4.

inflator

air

before raising the vehicle.

minute before proceeding with

the service procedure. This

Several precautions must be observed

The

the left-hand side of the luggage compart-

ment, must be turned to the

tion. 2.

2.

Before servicing the vehicle, refer to

For complete Engine Mechanical specifications, see Section

Install or •

the indicator fails to light,

1

connect the following:

Steering gear. Tighten the retaining

of this

manual

10 10" 14

FORD MOTOR CO. MARK

I

VIII 7.

nuts to

100-143

lbs.

ft.

(135-195

•

Turn the

ON

Nm).

air

suspension switch

to the

30-42

(41-57

lbs.

ft.

Power steering

pressure and

fluid

REMOVAL & INSTALLATION

•

Engine Outer

retaining nuts to

40-53

ft.

power steering

5.

Fill

6.

Check the engine air

posi-

or disconnect the follow-

Rear wheel

•

Air spring solenoid valve harness

Before servicing the vehicle, refer to

Air spring solenoid valve

Depress the 4 plastic locking fingers

5. .

Air spring solenoid valve air line

•

bottom

at the

oil level.

suspension switch

•

•

fluid reservoir. 1

Turn the

OFF

connector

must be supported by the suspension during this procedure.

the precautions 7.

Remove

The weight of the vehicle

lbs.

Front wheels the

Deflate the air springs.

4.

Rear

rod ends. Tighten the

(53-72 Nm). •

3.

oil filter

tie

luggage com-

ing:

return lines

•

of the

tion before raising the vehicle.

Shock Absorber

Nm). •

suspension switch, located

air

partment, must be turned to the

Steering shaft pinch bolt. Tighten the bolt to

The

2.

on the left-hand side

position.

of the air spring piston

and

the beginning of this sec-

in

detach the

to the

spring from the lower control

air

tion.

ON

arm.

position.

The

2. 8.

air

suspension switch, located on

Depress the metal locking tab

6.

Align the vehicle. the left-hand side of the luggage compart-

ment, must be turned

OFF

to the

top of the

air

position

gage the

air

at

the

spring and rotate to disen-

spring cap from the body

before raising the vehicle. bracket.

Remove

3.

or disconnect the follow-ing:

Remove

7.

Rear compartment trim panels

•

To

the air spring.

install:

Upper shock absorber retaining

•

spring solenoid

Install the air

8.

nuts valve. •

Lower shock absorber

•

Shock absorber

bolt Install the air

9.

spring cap to the body

bracket and rotate to lock

in

place.

To install:

Do

not attempt to service the suspen-

sion without

first

Insert the

10.

connect the following:

Install or

4.

deflating the air

•

Shock absorber

•

Upper shock absorber retaining

the lower control arm. 1 1

springs.

nuts. Tighten the nuts to

•-Servicing the air suspension requires

lbs.

a scan tool with bi-directional capabili-

Install or

.

Air spring solenoid valve air line

•

Air spring solenoid valve harness

ft.

connector bolt.

Tighten

the bolt to

83-113

ft.

lbs.

Turn the

12. 1

.

(113-153 Nm).

Before servicing the vehicle, refer to

5.

tion.

The

suspension switch, located on

air

ON

ON

air

suspension switch

to the

position.

Rear compartment trim panels

•

the precautions in the beginning of this sec-

2.

Rear wheel

•

ties to deflate the air springs.

connect the following:

•

(23-31 Nm).

Lower shock absorber

•

17-23

4 plastic locking fingers to

Turn the

air

suspension switch

to the

Upper

position.

Ball Joint

the left-hand side of the luggage compart-

ment, must be turned to the

OFF

position

REMOVAL & INSTALLATION

Air Spring

before raising the vehicle. 3. 4.

5.

REMOVAL & INSTALLATION

Deflate the air springs.

Remove

or disconnect the following:

•

Front wheel

•

Suspension height sensor

•

Air spring solenoid valve

•

Front strut cover cup

•

Upper

•

Lower

Remove

strut

mount nuts

strut

mount

Front

The

Lower front air spring

front strut as

is

.

::

•

Strut

and spring assembly. Tighten

mount nuts to 17-23 (23-32 Nm) and the lower

the upper lbs.

mounting

bolt to

126-169

(170-230 Nm). •

Do

connect the following:

Front strut cover cup

ft.

ft.

lbs.

CAUTION

sion without

first

in

the beginning of this sec-

tion.

not attempt to service the suspendeflating the air

2.

Remove

the vehicle 3.

springs.

arm from

the lower control

and place

it

Press the lower

in

a vise.

ball joint

out of the

control arm. '

—Servicing the air suspension requires a scan tool with bi-directional capabilities to deflate the air springs.

To

install:

4.

Press lower

arm so

that

it

ball joint into the control

is fully

seated to the control

arm.

•

Air spring solenoid valve

•

Suspension height sensor

the precautions

Front wheel

tion.

•

Before servicing the vehicle, refer to

the precautions

To install: Install or

Ball Joint

REMOVAL & INSTALLATION 1

assem-

bly from the vehicle.

6.

serviced with the

ball joint is

serviced with the

an assembly.

Rear

bolt

the strut and spring

The upper

upper control arm as an assembly.

1

Before servicing the vehicle, refer to in

the beginning of this sec-

5.

Install the control

vehicle. 6.

Align the vehicle.

arm

to the

FORD MOTOR CO. H MARK •Servicing the

Upper Control Arm

air

suspension requires

OHIJC

IO

VIII

Lower Control Arm

a scan tool with bi-directional capabilities to deflate the air springs.

REMOVAL & INSTALLATION

1

.

REMOVAL & INSTALLATION

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

Front

Front tion. 2.

The

suspension switch, located on

air

the left-hand side of the luggage compart-

Do not attempt sion without

to service the

first

suspen-

deflating the air

'•Servicing the air suspension requires

Deflate the air springs.

4

Remove

suspension switch, located on

air

springs.

•Servicing the

OFF

•

Upper control arm pivot bolts

ties to deflate the air springs.

•

Upper control arm

the precautions in the beginning of this sec-

suspension

bolts with the

tion.

at curb height.

2.

5.

or connect the following

Install

•

Upper control arm pivot

bolts.

50-68

Front wheel

•

Air

bolt to

suspension height sensor

•

Upper

•

Upper control arm bushing

117-142

ft.

lbs.

3.

Deflate the air springs.

4.

Remove

(158-193

ball joint

Check

the wheel alignment

Front wheel

•

Lower

•

Lower arm

•

Strut

and adjust

bolts

as necessary. •

To

Upper control arm

CONTROL ARM BUSHING REPLACEMENT

'•Use new control arm bushing joint and ball joint pinch bolts for assembly.

To

at curb height.

Upper control arm Upper control arm bushing bolts. Tighten the bolts to

6.

ON

56-88

ft

Tighten the pinch

bolt to

50-68

lbs.

(68-92 Nm)

suspension height sensor

Air

Front wheel

Turn the

air

install:

5.

Remove

the control

3.

•

Remove

the control

arm bushings

suspension switch

to the

•

install:

4.

Press the bushings into the control

arm. Install the control

arm

•

to the

Pivot bolt

Tighten the bolt to

82-114

lbs

Check

the wheel alignment

Strut

and spring assembly lower

118-162

Lower arm

•

Rear •

The control arm bushings are

deflating the air

lbs.

ft.

(160-220

ser-

6.

viced with the control arm as an assem-

ON

bly.

Tighten the nut

lbs.

(120-160

ball joint.

83-113

ft.

Tighten the nut

lbs.

(113-153

Front wheel

Turn the

Check

as necessary.

illustrations,

see Section

1

air

suspension switch

to the

position.

7.

springs.

For Accessory Drive Belt

strut. ft

Nm).

CAUTION

first

89-118

Lower to

sion without

(110-155

Nm).

and adjust

as necessary.

not attempt to service the suspen-

ft

bolt.

to

vehicle. 6.

connect the following:

Lower control arm

Nm).

Rear

Do

bolts with the

curb height.

Nm).

To

5.

position.

**

at

Install or

•

arm from the

with a hydraulic press.

ball joint.

•

Lower control arm

suspension

vehicle.

joint

(75-120 Nm).

•

Before servicing the vehicle, refer to

tion.

Upper

ft.

.

2.

•

lbs.

Pivot bolt

•

the precautions in the beginning of this sec-

connect the following:

•

•

•

•Tighten the bushing 1

Install or

strut

and spring assembly lower

Front

'•Tighten the bushing bolts with the

5.

ball joint

bolt

install:

suspension

or disconnect the follow-

•

Rear wheel

joint 6.

position

ing:

Nm). •

OFF

ft.

(68-92 Nm) and the outer

lbs. •

suspension switch, located on

before raising the vehicle.

Tighten the inner bolt to or disconnect the follow-ing

air

ment, must be turned to the

Upper control arm

Deflate the air springs.

Remove

The

the left-hand side of the luggage compart-

position

before raising the vehicle.

4.

Before servicing the vehicle, refer to

install:

•

3.

suspension requires

a

the left-hand side of the luggage compart-

ment, must be turned to the

air

scan tool with bi-directional capabili-

Rear wheel

1.

To

suspen-

deflating the air

or disconnect the follow-

•Tighten the bushing

tion.

to service the

first

•

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

The

Do not attempt

ing:

ties to deflate the air springs.

2.

position

sion without

3.

scan tool with bi-directional capabili-

1.

OFF

before raising the vehicle.

springs.

a

ment, must be turned to the

of this manual

the wheel alignment

and adjust

40 0“ iC I

I

FORD MOTOR CO

U

MARK

VII!

Rear

CAUTION Do not attempt sion without

to service the

first

suspen-

deflating the air

Brake caliper and rotor

Tighten the mounting bolts to 87

•

Rear wheel

lbs.

Turn the

6.

ON

•

air

suspension switch

Front wheel

•

to the

ft.

(119 Nm).

position.

Check

7.

the wheel alignment

and adjust

Rear

as necessary.

springs.

CAUTION

L

CONTROL ARM BUSHING REPLACEMENT ^Servicing the

Do not attempt

suspension requires

air

sion without

a scan tool with bi-directional capabili-

Front

ties to deflate the air springs. 1

Before servicing the vehicle, refer to

.

the precautions

in

the beginning of this sec-

.

suspen-

deflating the air

springs. Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

^Servicing the air suspension requires a scan tool with bi-directional capabili-

tion.

tion. 2.

1

to service the

first

The

suspension switch, located on

air

the left-hand side of the luggage compart-

OFF

ment, must be turned to the

position

3.

Deflate the air springs.

4.

Remove

or disconnect the following:

Rear wheel

•

Brake caliper and rotor

•

Rear wheel knuckle and hub

•

Air spring

Parking brake cable

•

Sway

•

Lower shock absorber

•

Control arm inboard pivot bolts

•

Lower control arm

the control

arm bushings

ties to deflate the air springs.

3.

bolt

Before servicing the vehicle, refer to

1.

Remove

the precautions in the beginning of this section.

To

install:

4.

Press the bushings into the control

The

2.

suspension switch, located of the

luggage com-

partment, must be turned to the

arm

5.

Install the control

6.

Check the wheel alignment and adjust

to the vehicle.

3.

Deflate the air springs.

4.

Remove

arm as an assembly.

posi-

Rear wheel

•

Axle hub nut

•

Brake caliper and support

•

Upper control arm pivot

•

Lower control arm pivot bolts

bolt

Rear wheel knuckle and hub

• 5.

Press the hub out of the wheel bearing.

6.

Remove

7.

Press the bearing out of the knuckle.

axle hub nut for assembly.

ADJUSTMENT

or disconnect the following:

•

Wheel Bearings

To

at curb height.

OFF

tion before raising the vehicle.

The control arm bushings are serviced with the control

'•Tighten the bushing bolts with the

air

on the left-hand side

Rear

bar link

To install:

suspension

arm from the

as necessary.

•

new

the control

arm.

•

a

Remove

with a hydraulic press.

before raising the vehicle.

••Use

2.

vehicle.

the wheel bearing snapring.

install:

The wheel bearings are not adjustable. 5.

Install or

connect the following:

They are serviced by replacement

•

Lower control arm

•

Control arm inboard pivot bolts.

lbs.

bolt to

83-113

ft.

bolt.

Tighten

lbs.

new

axle hub nut for assembly.

suspension

.

in

the beginning of this section.

Remove

or disconnect the follow-

to

in

the bore.

the snapring.

Press the hub into the bearing.

10. 1 1

bottoms out Install

9.

Before servicing the vehicle, refer to the

precautions

it

Install or

.

•

ing:

Sway bar link. Tighten the nuts 96-120 inch lbs. (10-14 Nm).

Press the bearing into the knuckle

8.

until

connect the following:

Rear wheel knuckle and hub. Tighten the lower bolts to 94-131

•

Front wheel

•

Disc brake caliper and rotor

ft.

lbs.

(128-178 Nm) and the

117-142

•

Parking brake cable

•

Grease cap

upper bolt

•

Air spring

•

Spindle retainer nut

(158-193 Nm).

Rear wheel knuckle and hub.

•

Hub and

•

Tighten the lower bolts to 94-131

(128-178 Nm) and the upper bolt to 117-142 ft. lbs.

ft.

lbs.

To 3.

Install or

•

188-254

Nm).

ft.

•

connect the following:

•

Hub and

lbs.

(255-345

ft.

lbs.

•

bearing assembly. Tighten

188-254

ON

(255-345).

•

Grease cap

•

Disc brake caliper and

12.

ft.

lbs.

188-254

ft.

lbs.

(255-345 Nm).

Brake caliper and rotor Rear wheel Turn the

air

suspension switch

position.

13. rotor.

to

Axle hub nut. Tighten the hub nut to

the spindle retainer nut to

Axle hub nut. Tighten the hub nut to

bearing assembly

install:

(158-193 Nm). •

bolts with the

at curb height.

Front

2.

(113-153 Nm). •

REMOVAL & INSTALLATION

1

Lower shock absorber the bolt to

a

166-203

(225-275 Nm) and the rear 141-191 ft. lbs. (191-259

Nm). •

••Use

•Tighten the bushing

Tighten the front bolt to ft.

only.

Check th^wheel alignment and

adjust as necessary.

to the

FORD MOTOR

CO.

1998-01

Ford-Crown

Victoria

•

Lincoln-Town Car

19-17 19-2 19-15 19-2

DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM

PRECAUTIONS STEERING AND

•

Mercury-Grand Marquis

19-17

Fuel Injector

Removal & Fuel

Installation

Pump

Removal &

19-19

Installation

19-16 19-15

19-15

Relieving

Air

19-19

Disarming

Removal &

Installation

19-21

19-2

Adjustment

Lower

Removal &

Installation

Lower Control Arm Control

Removal &

Lifters

Installation

&

Installation

Removal &

Installation

19-4

Removal &

19-2

Installation

&

19-2 19-7

Exhaust Manifold Installation

Removal &

Installation

Removal &

19-12

Installation

19-16

Installation

Removal &

19-19 Installation

Positioning

Removal &

19-19 19-15

Power Steering Gear Installation

Front Cover and Seal

Removal & Removal &

Installation

Installation

Upper

Installation

Upper Control Arm Control

Installation

Removal &

19-17

19-22

19-23 19-23

Installation

19-23

V 19-10

Valve Lash

19-10

Adjustment

W Water

Pump

Removal &

19-3 Installation

Wheel Bearings Removal &

19-12

19-17

Arm Bushing

Adjustment

19-12

19-12

19-22

Ball Joint

19-19 19-19

19-12

U

19-15

R Removal &

19-10

T

P Pinion Seal

19-20

19-10

Motor

19-10 19-12

Rear Main Seal

19-16

Starter

Installation

Replacement

Pump

19-7

F Fuel Filter

Oil

Installation

Piston and Ring

E

Engine Assembly

19-23

19-10

19-20 19-4

Cylinder Head

19-23

Pan

Removal &

19-8

Removal &

Removal &

0 Oil

19-8

19-23

Installation

19-18

19-20

Coil Spring

Removal &

19-20

Shock Absorber

19-23

Arm Bushing

Replacement

19-18

C Camshaft and Valve

Installation

19-6

S

Transmission Assembly

19-23

Ball Joint

Removal &

19-2

Removal Axle Shaft, Bearing and Seal

Removal

Installation

19-6

L

19-2

Installation

Removal

Removal &

19-2

Alternator

19-6

Intake Manifold

19-21

Air Spring

19-6 Installation

Timing Chain, Sprockets,

I

19-19

Precautions

&

19-15

Precautions

19-19

Bag

Removal

Removal &

Fuel System Service

A

Rocker Arms

19-16

Fuel System Pressure

SUSPENSION

19-17

19-3

19-23 19-23

Installation

19-24

FORD MOTOR CO.

192

CROWN

•

VICTORIA

TOWN CAR

•

GRAND MARQUIS

PRECAUTIONS of the following precautions,

all

which deal with personal of

component damage, and important points

when

to take into consideration

servicing a

motor vehicle:

tor or

cooling system

hot; serious

when

the engine

is

burns can occur from the steam

Observe

tions

all

applicable safety precau-

when working around

fuel.

Whenever

servicing the fuel system, always work

Do

well-ventilated area. or

vapors

to

light, for

come

in

in a

You should make every

should always buy the correct type

can-

fluid for

oil.

worn when Wash your hands and any

example). Keep a dry chemical

becomes contaminated, completely system with new

flush the

Never reuse any

fluid.

Any brake

removed

brake

from the system should be discarded. Also,

oil.

used engine

sible after

exposure

Soap and

water, or waterless

to

oil.

hand cleaner

new

All

now equipped

Supplemental

Inflatable Restraint (SIR) sys-

fluid to

painted surface;

come in condamage

will

it

the paint.

Never operate the engine without the

•

vehicles are

fluid that is

do not allow any brake tact with a

should be used. •

fluid.

proper amount and type of engine so

WILL

Timing

•

belt

maintenance

Many models

important.

extremely

is

utilize

an

interfer-

tem. The system must be disabled before

ence-type, non-freewheeling engine.

keep

performing service on or around system

timing belt breaks, the valves

designed

container specifically

for fuel storage; also,

always

properly seal fuel containers to avoid the

components, steering column, instrument

head may

panel components, wiring and sensors.

tially

possibility of fire or explosion. Refer to the

Failure to follow safety

additional fuel system precautions later

dures could result

in

this section.

Fuel injection systems often remain

•

in

and disabling proce-

accidental air bag

ment

•

Always wear safety goggles when

turned OFF. The fuel system pressure must

working with, or around, the

be relieved before disconnecting any

tem.

lines. Failure to

do so may

and/or personal

injury.

•

fuel

wash your hands thoroughly

handling brake

brake fluid

in

fluid.

If

eye

if

face,

plac-

work sur-

always face the bag and trim cover

reduce the motion

your eyes, flush your eyes

irritation persists, or

When

upward, away from the surface. This

you do get

with clean, running water for 15 minutes.

bag sys-

ing a non-deployed air bag on a

ethers and polyglycols. Avoid contact with

after

air

carrying a non-deployed air

pointed away from your body.

Brake fluid often contains polyglycol

the eyes and

When

bag, be sure the bag and trim cover are

result in fire

module

of the

if

will

it

is

accidentally deployed. Refer to the addiIf

you have taken

manual

this

tional air

bag system precautions

later in

If

the

the cylinder

causing poten-

serious (also time-consuming and

maintenance

unnecessary system repairs.

pressurized, even after the engine has been

strike the pistons,

in

expensive) engine damage. Refer

deployment, possible personal injury and

doing

oil;

engine damage.

result in severe

extinguisher near the work area. Always fuel in a

brake

of

the brake fluid

If

Protective gloves should be

Supplemental Restraint System (SRS) or

fire

your vehicle.

changing

with an air bag system, often referred to as a

contact with a spark,

and

essential to the safe

is

proper operation of the brake system. You

a

mini-

effort to

mize your exposure to used engine

not allow fuel spray

or excessive heat (a hot drop

open flame,

may cause

oil

of skin disorders, including

other exposed skin areas as soon as pos-

and hot coolant. •

number

prolonged con-

that

used engine

tact with

cer.

Never open, service or drain the radia-

•

The EPA warns

•

Clean, high quality brake fluid from a

•

sealed container

medical assistance.

prevention

safety,

IMMEDIATELY seek

brake fluid internally,

Before servicing any vehicle, please be

sure to read

to the

interval charts in the front of

recommended

for the

interval for the timing belt,

replace-

and

to the

timing belt section for belt replacement and inspection. •

Disconnecting the negative battery

cable on

some

vehicles

may

interfere with

the functions of the on-board

tem^) and may

require the

computer sys-

computer

to

undergo a relearning process once the negative battery cable •

When

is

servicing

reconnected.

drum

brakes, only dis-

assemble and assemble one side

at a time,

leaving the remaining side intact for refer-

ence.

this section.

ENGINE REPAIR Alternator

•

Accessory drive

•

Alternator

ADJUSTMENT

belt

The 4.6L engine

REMOVAL

INSTALLATION tributorless Ignition

is

equipped with a Dis-

System

(DIS).

No

adjustments are necessary. 1

.

Before servicing the vehicle, refer to

the precautions

in

tion. 2.

Install or

the beginning of this sec-

•

to

Remove

or disconnect the following:

15-22 •

connect the following:

Alternator. Tighten the ft.

lbs.

mounting

bolts

Engine Assembly

(20-30 Nm).

Alternator bracket. Tighten the bolts to

REMOVAL & INSTALLATION

•

Negative battery cable

•

Engine cover

•

Accessory drive

•

Pushpins and wiring harness

•

Pushpins and wiring harness

•

Mounting bolts

•

Engine cover

the precautions ir^the beginning of this sec-

•

Alternator bracket

•

Negative battery cable

tion.

71-106

inch lbs. (8-12 Nm). belt

1.

Before servicing the vehicle, refer to

FORD MOTOR CO. CROWN

VICTORIA

•

2.

Drain Ihe engine cooling system.

engine support insulator to the

3.

Recover the refrigerant from the

front

air

conditioning system.

5.

Drain the engine

6.

Remove

10.

Connect engine

Hood

ing brackets

•

Engine cooling

•

Windshield wiper governor and

from the transmission. Do not

support bracket

converter

fan,

shroud and

1 1

to the

the torque

•

Engine/transmission harness con-

engine compartment and position on a

nector from the retaining bracket

workstand.

Accelerator and cruise control

ment.

cables •

•

at

Electrical

the throttle

12.

body

connector and vacuum

Carefully

lift

Remove

To

install:

13.

Engine

the engine out of the

hose from the evaporative emission

engine using a floor crane installed to the lifting

Positive battery cable from the

from the workstand into the

the flywheel

and align the paint marks on

•

Both heater hoses

the flywheel

and torque converter. Be sure

•

Alternator harness from the front

the studs on the torque converter align with

fender apron and the power distri-

the holes in the flywheel. 15.

hoses from the

air

conditioning compressor •

Body ground

•

Fully

16.

strap from the dash •

3 bolts and

transmission knee

•

4 bolts retaining the power steering

pump

to the cylinder block

•

and

•

Engine

Hood

equipment and brack-

•

verter nuts.

Rotate the crankshaft until each of the 4

the crankcase to the correct level.

18

Fill

the cooling system

6 engine-to-transmission retaining

19

Start the

and tighten

to

30-44

ft.

lbs

lbs.

(20-30 Nm)

22-25

ft.

Check

Starter

and proper

fluid lev-

21

Evacuate and recharge the

.

air

condi-

Road

22.

and check the

test the vehicle for

proper opera-

to the

Water Pump cylin-

ft.

lbs.

REMOVAL & INSTALLATION

(20-30

Engine-to-transmission brace and

bolts

Support the transmission with a floor

1

motor

through-bolts

and

and stud

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

1

to

stud. Tighten the

18-31

ft.

2.

Drain the cooling system.

3.

Remove

lbs.

(25-43 Nm).

• •

Bolt retaining the right-hand front

for leaks

tion.

Power steering pump on the

the 3 bolts

wood.

to reach

els.

engine and transmission

lbs.

Transmission housing cover

Engine support insulator (mount)

jack and a block of

it

tioning system.

4 torque converter retaining nuts to

engine and allow

normal operating temperature

Nm). • •

bolts

1

20

Front engine support insulator

Tighten to 15-22

or disconnect the following:

6 transmission-to-engine retaining

Battery

port bracket

der block and the 4 retaining nuts.

accessible and remove the nuts

and shroud

cleaner outlet tube

Fill

cylinder block •

air

7

(20-30 Nm)

Transmission housing cover from the

Remove

engine mount insulator sup-

and tighten

cylinder block to access the torque con-

•

Radiator, cooling fan

ets

ft.

position aside

9.

Fuel supply and return lines

lifting

through-bolts and tighten to 15-22

motor

•

•

support bracket

(40-60 Nm)

stud retaining the

1

power brake booster

Windshield wiper governor and

•

Engine

bolts

to the

Engine/transmission harness con-

•

connect the following

hung from

•

emission

Accelerator and cruise control

the •

front

Starter

•

to the trans-

engine sup-

front

manifolds and support with wire

Retaining nut from the transmission

connector and vacuum

to the evaporative

cables at the throttle body •

•

braces

8.

•

•

crossmember

box and harness

canister purge valve

Bolt retaining the right-hand front

the

Electrical

hose

engine support insulator to the

•

is

power

distribution

Exhaust system from the exhaust

engine

7.

Positive battery cable to the

•

nector to the retaining bracket on

engage the engine

Install or

line bracket •

throttle

Start the converter pilot into

mission and lower onto

•

panel •

Vacuum supply hose to the body adapter vacuum port

port insulators.

Power steering control valve harness connector

•

Both heater hoses

•

engine

compartment.

bution box

bution box

•

Lower the engine

14.

Alternator harness at the front

•

equipment and remove the engine

Vacuum supply hose from the throttle body adapter vacuum port

Air conditioning

•

brackets. Support the

lifting

strap to the dash panel

fender apron and the power distri-

•

•

Air conditioning lines to the air

the engine lifting equip-

canister purge valve

power distribution box and harness

Ground

•

conditioning compressor

Engine

cleaner outlet tube

•

out of the transmission.

fall

•

air

Power steering valve harness connector

carefully separate the engine let

(27-41 Nm). Be sure

crossmember. Adjust as necessary.

lift-

•

and

lbs.

ft.

the exhaust system clears the No. 3

Raise the engine slightly using a

.

floor crane

t

equipment

lifting

Exhaust system to the exhaust

20-30

head and to

Battery

(20-30

manifolds. Tighten the 4 nuts to

the rear of the right-hand cylinder head.

•

lbs.

ft.

Nm).

bracket to the

•

•

nuts

lifting

15-22

Tighten to

•

engine

Install

19-3

GRAND MARQUIS

engine mount insulator sup-

front of the left-hand cylinder

oil.

or disconnect the following:

radiator

•

port bracket

Relieve the fuel system pressure.

4

TOWN CAR

Transmission

line bracket to the

brace stud and

1

or disconnect the following:

Negative battery cable

•

Cooling fan and shroud

•

Accessory drive

retaining nut.

For complete service labor times, order the Chilton Labor Guide

belt

r

FORD MOTOR CO.

4

•10

"*f

I

CROWN

•

VICTORIA a—^Mt w

mmauaa

~i

r«

TOWN CAR

GRAND MARQUIS

«

t

air

suspension switch, located on the

hand side

must be turned

OFF

to the

tor

Drain the engine cooling system.

4.

Properly relieve the fuel system

Be sure

manifold

Exhaust pipes from the exhaust

•

manifolds. Lower the exhaust pipes

or disconnect the following:

and hang with wire from the cross-

•

Negative battery cable

•

Cooling fan and shroud assembly

•

Engine

•

Windshield wiper governor (mod-

harness

ule)

hand cylinder head

pump mount-

water

to tighten the

air

member. •

cleaner outlet tube

Bolts retaining the starter wiring

ing bolts to the specification

4 water pump pulley-to-water pump

•

bolts •

Ignition wires

Ignition wire brackets

Water

pump

4.

Clean the sealing surfaces of the

pressure

block.

•

Accelerator cable bracket from the

•

Vacuum hose from the elbow vacuum port

intake manifold

right-hand

line to the

O-ring, lubricate

it

Wiring to both ignition coils and

with clean

the Camshaft Position

Water pump. Tighten the bolts

15-22 Water

•

ft.

lbs.

pump

to

•

(20-30 Nm).

(CMP) sen-

•

2 bolts retaining the thermostat

bolts to

15-22

ft.

lbs.

(20-30 Nm).

position the upper hose and ther-

front cover nuts. Slide the ignition

mostat housing aside

Fill

7.

Operate the engine to normal operat-

and check

retain the intake manifold.

pulley

bolts

Intake manifold

alternator

•

7 stud bolts and the 4 bolts attaching the engine front cover to the

Alternator

•

Positive battery cable at the

engine

power •

Front cover

Retaining bolt from the positive

•

Both timing chains

battery cable bracket located on the

•

box

Vent hose from the canister purge

•

•

tion.

suspension, the •

LOWER REAR

Positive Crankcase Ventilation

removed due removal

secure the cylinder head bolt

conditioning compressor clutch electri-

connectors

pump

the bolts retaining the

to the cylinder

power

Wire the

Remove

not

pan and

pan gasket

Engine

•

Crankshaft pulley retaining bolt

•

Pulley

head

head gasket

’•The lower rear cylinder head bolt cannot be removed due to interference with the power brake booster. Use a rubber band to hold the bolt away from the cylinder blopk.

Remove

9.

•

oil

or disconnect the following:

Ground

strap,

1

stud and

1

bolt

retaining the heater return line to

the right-hand cylinder head

or disconnect the following:

•

oil

or

block and

come all the power steering pump aside. will

installation of the

damaging the cylinder block

power brake booster

to

the cylinder

head during removal and

7922RG02

cylinder head bolt to ease removal of the

in

cylinder head and to prevent the bolt from

power steering pump

support the rear

the vehicle.

10.

nector from the retaining bracket on

engine front cover. The front lower bolt on the

out.

is

Engine/transmission harness con-

Remove

7.

the

Use a rubber band

(PCV) valve from the cylinder head

in

in

to lack of clearance for

cover

cal

way

The lower

cylinder head until the cylinder head

and canister purge solenoid

6.

the cylinder head.

head bolt must stay

battery cable aside

Crankshaft Position (CKP) sensor,

steering

Remove

8.

rear cylinder

air

So

10 left-hand cylinder head-to-cylinder block bolts

solenoid and position the positive

the •

and gaskets

•

side of the right-hand cylinder head

the precautions in the beginning of this sec-

Use a rubber band

9 intake manifold-to-cylinder heads

junction block, fender apron and

•

Before servicing the vehicle, refer to

air

"•The 2 thermostat housing bolts also

•

Alternator wiring harness from the

distribution

•‘The cylinder head bolts are a torqueto-yield design and cannot be reused. Always use new cylinder head bolts for assembly.

equipped with

pump

Water

•

If

mounting studs

•

REMOVAL & INSTALLATION

2.

the

•

for leaks.

Cylinder Head

1.

off

to the intake

and from the vehicle

the cooling system.

6.

ing temperatures

brackets and ignition wire

assemblies

belt

manifold and

housing

Ignition coil brackets-to-engine

pulley. Tighten the

Accessory drive

body

sor

coil

•

throttle

the heater water hose

antifreeze prior to installation •

and position aside

Heated Oxygen (HO 2 S) sensors and

•

ignition coil bracket

connect the following: •

New

Accelerator and cruise control

cables coil

Bolt retaining the air conditioning

•

pump and •

•

brackets bolts

install:

Install or

der heads

from the

2 ignition wire tray-to-ignition

•

to the rear of the right-

Cylinder head covers to the cylin-

•

belt

from the spark plugs

cylinder head cover studs

4 water pump-to-engine bolts

•

5.

Accessory drive

• •

To water

•

Pulley

•

pressure sensor wiring

tube from the right-hand exhaust

pressure.

Remove

oil

Exhaust Gas Recirculation (EGR)

•

3.

and

connectors and position aside.

position before

raising the vehicle.

5.

Power steering control valve actua-

•

right-

luggage compartment,

of the

•

10 right-hand cylinder head-tocylinder block bolts

Remove

the cylinder head.

The lower

FORD MOTOR CO. CROWN head

rear cylinder

must stay

bolt

removed due removal

to lack of clearance for

secure the cylinder head bolt

head during removal and

to

cylinder

in the

installation of the

plus

3:

loosen

27-32 ft. lbs. (37-43 Nm). plus 85-95 degrees. again, plus 85-95

bolts at least

all

•

Step

4:

e.

Step

5:

f.

Step

6:

damaging the cylinder block

or head gasket.

17.

"••The lower rear cylinder

head

2 retaining bolts.

with the evaporator housing. Use a rub-

away from

tighten the retaining bolt

Exhaust pipes to the exhaust mani-

•

matched

at the center of the

both are

in

camshaft

time. Install

Camshaft Position-

T91P-6256-A, on the

EGR

•

the

flats of

Check

all

gaskets mating surfaces.

the cylinder heads

for flatness.

Check

and cylinder block

the cylinder heads for

combustion chambers

that

degrees

could provide

No.

for the

cylinder.

1

—The

crankshaft must only be rotated

in the

clockwise direction and only as

Rotate the crankshaft counterclock-

20.

should be

•

at the

from the front

9 o'clock position viewed

of the engine. This

tion

Install or

connect the following:

New head New

•

retain with rubber

•

bands as

new

cylinder head bolts,

rear bolts

in

and

install all bolts

Tighten the

16.

new

•

a.

Step 1:28-31

15-22

ft.

New

lbs.

bolts.

(20-30

ft.

lbs.

lbs.

(37-43 Nm).

d.

on the

Be sure the align-

in

•

•

LH CYLINDER

HEAD ASSY 21

7922RG03

Cylinder head torque sequence

SOHC

•

•

—4.6L

•

Please

visit

ft.

lbs

(20-30 Nm). compressor.

CKP

connectors

Engine/transmission harness con-

PCV

valve

in

the right-hand cylin-

der head cover and connect the

ft

(20-30 Nm).

canister purge solenoid vent hose

HO 2 S

•

on

Positive battery cable harness

the right-hand cylinder head •

Accelerator cable bracket on the

•

front

Bolt retaining the cable bracket to

the cylinder head Positive battery cable at the distribution

Accelerator and cruise control

•

Alternator

power

box and battery

and the 2 retaining

Tighten the bolts to 15-22

ft.

bolts. lbs.

(20-30 Nm).

to both places

cover meets the

•

2 bolts retaining the alternator brace to the intake manifold.

Cylinder head covers with

new gas-

on the cylinder heads. Tighten

our web

15-22

Air conditioning

nector on the power brake booster •

Vacuum hose to the throttle body adapter vacuum port

ket

in position

4 retaining bolts Tighten the bolts

electrical

•

cylinder heads.

engine

oil

sensor and canister purge solenoid

(20-30 Nm).

Apply silicone sealer

.

pan and a new gasket

Power steering pump

to

on the cylinder

Heater water hose and both

where the engine

connect the following:

•

cables to the throttle body

CYLINDER HEAD TIGHTENING SEQUENCE

Tighten an additional

Engine

intake manifold

RH CYLINDER HEAD ASSY

turn.

lbs

on the cylinder block

the cylin-

15—22

4:

Install or

sensors •

Step

•

Thermostat, O-ring, thermostat

lbs. •

ft.

85-95 degrees 24.

intake manifold gaskets

Intake manifold

35-39

(47-53 Nm).

Engine front cover and the

the 2 retaining bolts to ft.

(90

lbs.

Loosen one complete

housing and upper hose. Tighten

sequence, as follows:

ft.

Tighten to

15-22

hand-tight

Tighten to 66

3:

Tighten the bolts in sequence, to

cylinder head bolts,

:

2:

heads and the retaining bolts

remove the rubber bands from the lower

1

Step

der heads.

score the surface of the head face. Apply

Step

Step

aligned with the holes

the

a

Nm). b.

cedure

•

crankshaft pulley and

c.

ment tabs on the gaskets are

oil to

Install the

tighten the bolt as follows.

oil

to the

explained during the removal pro-

Position the cylinder heads on the

23.

points where the cover contacts the

cylinder heads.

cylinder block dowels, being careful not to

clean

engine

it

Nm).

bolts in the lower rear bolt

making

junction of the cylinder block and

Tighten to

holes on both cylinder heads and

15.

keyway on the

are aligned.

the cylinder heads.

gaskets on the cylinder

block •

of the

pan and cylinder block and

where the valves do not extend below

•

pressure sensor electri-

Pulley on the crankshaft,

engine front cover seal and

meets the junction

face.

the head face. 14.

New

lower corners of the cover where

Rotate the camshaft to a stable posi-

13.

oil

sure the crankshaft key and keyway

Both timing chains

gasket. Apply silicone sealer to the

ensures

pistons are below the top of the

engine block deck

•

connect the following

Install or

•

all

connectors

crankshaft pulley.

wise 45 degrees. The crankshaft keyway

that

and

cal

as TDC.

Install:

12.

tor

sealer in the rear of the far

To

line nut to

(35-45 Nm).

Apply a small amount of silicone

22.

leak paths.

lbs.

ft.

Power steering control valve actua-

•

Top

to position the crankshaft at

Dead Center (TDC)

scratches near the coolant passages and

26-33

Rotate the crankshaft clockwise 45

19.

tube to the right-hand exhaust

manifold and tighten the

camshafts to keep them from rotating Clean

crossmember. Adjust as nec-

until

essary.

ing Tools

11.

20-30

to

sure the exhaust system clears

the No. 3

the

cylinder block.

4 nuts

(27-41 Nm).

lbs.

ft.

—Be

Rotate the camshafts using the flats

to the

right-hand cylinder head and

folds. Tighten the

bolt 18.

motor wiring harness

Starter

Position the heater return hose and

install the

71-106

inch lbs. (8-12 Nm).

1

turn.

d.

19-5

GRAND MARQUIS

the bolts and stud bolts to

2:

Step

degrees.

cannot be removed due to interference

•

85-95 degrees.

Step

cylinder head and to prevent the bolt from

ber band to hold the bolt

TOWN CAR

b.

full

Use a rubber band

the vehicle.

in

is

•

c.

the

in

cylinder head until the cylinder head

VICTORIA

site at

www.chiltonsonline.com

Tighten to

Nm).

72-96

inch lbs. (8-12

FORD MOTOR CO.

19-6

CROWN

Water

•

pump

bolts to

TOWN CAR

•

GRAND MARQUIS

pulley. Tighten the

15-22

ft.

(20-30 Nm).

lbs.

and

Ignition coil brackets

•

•

VICTORIA

ignition

wire assemblies onto the mounting

and tighten

to

15-22

grommet and

lbs.

ft.

Remove

5.

CMP

and

sensor har-

•

Fuel lines

•

PSP

and tighten the retaining

on

ing unit

brake aside

vacuum booster and

Ignition wires

•

Ignition wire brackets

Engine

air

Ignition wire brackets

Wires

at the

26.

If

equipped with

air

suspension, turn

ON

posi-

Positive battery cable harness on

•

from the

the right cylinder head •

Bolt retaining the cable bracket to

the cylinder head

bottom

•

Positive battery cable at the

of its stroke

and position the camshaft lobe on the base circle.

tion. Refill the

Install

amount 28.

of oil

and replace the

Start the

to

the spring coils to

prevent valve seal damage.

filter.

engine and bring

valve spring spacer tool

T91P-6565-AH between

engine with the correct

normal

When

16.

Install a

8.

valve spring compressor

operating temperature while checking for

under the camshaft and on top

leaks.

spring retainer.

Road

test the vehicle

and check

for

proper engine operation.

Compress

9.

remove the

To

Ignition wire brackets

Wires

•

Windshield wiper module

•

42-pin and transmission harness

the valve spring and

roller follower.

Remove

tip

1 1

1

Before servicing the vehicle, refer to

.

the precautions

in

.

to the

on the studs

spark plugs

connectors Retaining bracket

PSP

•

switch and

pressure send-

oil

the valve ing unit harness. •

Fuel lines

•

Apply engine

oil to

the valve

and

Negative battery cable

stem 17.

and

camshaft

install:

10.

REMOVAL & INSTALLATION

left

•

of the valve

spring compressor and spacer.

Rocker Arms

installing the

•

•

29.

power

box and the battery

cover, install or connect the following:

7.

27.

CKP

sensor

distribution

the air suspension switch to the

on the studs

spark plugs

to the

Canister purge solenoid, air condi-

•

Position the piston of the cylinder

6.

camshaft

camshaft cover grom-

into the

•

Camshaft cover

being serviced

the cooling system.

installing the right

•

position

studs and position the wires aside •

cleaner outlet tube

Negative battery cable Fill

PCV

•

from the spark plugs

•

Fuel supply and return lines

Cooling fan and shroud

and stud bolts and tighten

inch lbs. (8-12 Nm).

When

Windshield wiper module

•

the

covers.

tioning compressor clutch and

shield wiper governor

•

•

and position the harness

from the retaining bracket on the

and the wind-

install the

cover, install or connect the following:

42-pin engine harness connector

•

bolt

head cover studs

•

25.

pressure send-

front

met

and the bracket onto the cylinder

belt

oil

aside

Ignition wires to the spark plugs

Accessory drive

72-106 15.

switch and

where the

new gaskets onto

Position

camshaft covers and

Air inlet tube

the right-hand ignition coil bracket

•

camshaft cover by

to

Air conditioning pressure line

•

left

Install the bolts

•

ness connectors

•

the

of the

cover meets the cylinder head.

removing or disconnecting the following:

Nm) Ignition coil

Clean the sealing surfaces

silicone sealer to the places

remove

compressor

the valve spring

camshaft covers and cylinder heads. Apply

14.

and

inch lbs. (8-12

Remove

the camshaft cover.

2 bolts retaining the ignition wire

71-106

position aside

Bolts and stud bolts and

•

tray to the ignition coil bracket

tighten to

valve from the camshaft cover

of

and spacer. 13.

PCV

bottom

at the

circle.

the wires aside •

must be

piston

stroke and the camshaft at the base

12.

(20-30 Nm)

•

from the spark plugs

Ignition wires

Ignition wire brackets from the

camshaft cover studs and position

brackets to the engine front cover

•

its

•

7 nuts retaining the ignition coil

•

^The

cable aside •

studs •

and position the positive battery

engine and check

Start the

for leaks.

roller follower contact surfaces.

Install

valve spring spacer tool

T91P-6565-AH between the spring coils. Compress the valve spring, and install the

the beginning of this sec-

Intake Manifold

REMOVAL & INSTALLATION

roller follower. tion. 2.

Relieve the fuel system pressure.

3.

Disconnect the negative battery

Before servicing the vehicle, refer to

1.

the precautions

in

the beginning of this sec-

cable. tion.

4 Remove the right camshaft cover by removing or disconnecting the following:

2. air

•

Positive battery cable at the battery

and •

at

the

equipped with

If

hand side

power distribution box

air

suspension, the

suspension switch, located on the of the

must be turned

right-

luggage compartment,

to the

OFF

position before

Retaining bolt from the positive raising the vehicle. battery cable bracket located on the 3.

Disconnect negative battery cable.

4.

Drain the engine cooling system.

5.

Properly relieve the fuel system

side of the right cylinder head •

Crankshaft Position (CKP) sensor, air

•

conditioning compressor clutch

7922RG04

pressure.

and canister purge solenoid con-

After installing the spring spacer,

nectors. Position the harness aside.

press the valve spring and remove the

Vent hose from the purge solenoid

rocker

arm

com-

Remove

6.

•

or disconnect the following:

Fuel supply and return lines

FORD MOTOR CO. CROWN •

VICTORIA

•

TOWN CAR

Windshield wiper governor (mod-

manifold. Tighten the tube nut to

ule)

26-33

•

Engine

air

cleaner outlet tube

•

Accessory drive

Ignition wires from the spark plugs

•

Ignition wire brackets

belt

Position •

•

Oil

from the •

Alternator. Tighten the bolts to

•

2 bolts retaining the alternator

15-22

and the Camshaft

(CMP) sensor

brace to the intake manifold and tighten to

2 bolts retaining the ignition wire

Nm) •

Alternator wiring harness from the

Nm

20-30

(15-22 t>*i

•

7922BGG6

manifold and the

Intake manifold torque sequence alter-

SOHC

nator to the cylinder block

•

Oil

7.

pressure sensor and power

Exhaust Gas Recirculation (EGR)

bracket to the ignition coil brackets.

replacing the intake manifold,

If

the necessary parts.

To install: Clean

9.

Position

all

Ignition wire brackets

gaskets mating surfaces.

new

on the

intake manifold gaskets

•

Wiring connectors to both ignition

•

Accessory drive

fold

the holes in the cylinder heads.

•

Air cleaner outlet tube

•

Windshield wiper governor

•

Fuel supply and return lines

Engine/transmission harness con-

Install the intake

manifold and the 9

from the front of the engine)

before final tightening, then tighten the

compressor (CKP)

sequence,

bolts, in

to

15-22

ft

lbs

(20-30

Nm). 1 1

Inspect and

.

necessary, replace the

if

O-ring seal on the thermostat housing

(PCV) valve from the cylinder head

Position the housing and upper hose and

cover

install the

PCV

15-22 12.

valve

ft.

2 retaining

bolts. Tighten to

connect the following

Fill

14.

If

the engine cooling system.

equipped with

air

suspension, turn

cables from the throttle body

•

HO 2 S

Accelerator cable bracket from the

•

Vacuum hose to the throttle body adapter vacuum port

•

Vacuum hose from

•

Accelerator cable bracket on the

and position aside

adapter port •

ON

posi-

tion.

15

Start the

16

Road

engine and check

test the vehicle

for leaks.

and check

for

Exhaust Manifold

•

Heated Oxygen (HO 2 S) sensor and

Negative battery cable

13.

Heater water hose

Accelerator and cruise control

body

sensor

belt

(20-30 Nm)

lbs.

Install or •

the throttle

CMP

proper operation

•

intake manifold

•

and the

the air suspension switch to the

Positive Crankcase Ventilation

Canister purge vent hose from the

coils

retaining bolts. Hand-tighten the right-rear bolt (viewed

power brake booster

Air conditioning

10

cylin-

der head cover studs

ment tabs on the gaskets are aligned with

noid wiring connectors

sensor

REMOVAL & INSTALLATION 1

Before servicing the vehicle, refer to

.

intake manifold

the precautions in the beginning of this sec-

Accelerator and cruise control

tion.

cables to the throttle body

2.

Drain the engine cooling system.

PCV

3.

Relieve the fuel system pressure.

cover

4.

Discharge the

position the upper hose and ther-

•

Canister purge solenoid vent hose

5.

Remove

mostat housing aside

•

Air conditioning

the heater water

hose

2 bolts retaining the thermostat

housing

to the intake

•

manifold and

valve in the cylinder head

**The 2 thermostat housing bolts are also used to retain the intake manifold.

•

9 bolts retaining the intake manifold to the cylinder

Intake manifold

heads

and gaskets

•

conditioning system

air

or disconnect the following:

compressor

•

Battery cables

sensor and canister

•

Engine

purge solenoid wiring connectors

•

Cooling fan and shroud assembly

Engine/transmission harness con-

•

Fuel supply and return lines

nector the retaining bracket on the

•

Upper

power brake booster

•

Windshield wiper governor and

clutch,

•

Ignition wires to the spark plugs

from the right-hand exhaust mani-

sensor and the canister purge sole-

•

Ignition wires to the ignition coils

• •

8.

inch

•

valve-to-exhaust manifold tube

clutch, Crankshaft position

•

71-106

(8-12 Nm).

on the cylinder heads. Be sure the align-

nector from the retaining bracket on

•

2 bolts retaining the ignition wire

engine

swap over

ness aside

•

•

—4 6L

lbs.

wiring and position the wiring har-

•

assembly on the

Ignition wire

Tighten the bolts to

steering control valve actuator

the

apron

engine

Bolts retaining the alternator brace

Alternator

(8-12

and junction block

and alternator

•

inch lbs.

alternator, right-hand fender

junction block at the fender apron

to the intake

71-106

Alternator wiring harness to the

assembly

•

•

(20-30 Nm).

lbs.

Ignition v^ires from both ignition

Ignition wire

•

ft.

coils

bracket to the ignition coil brackets

•

pressure sensor wiring connec-

tors

•

•

(35-45 Nm).

lbs.

tor •

cylinder head cover studs Ignition coils

ft.

Power steering control valve actua-

•

•

•

19-7

GRAND MARQUIS

•

EGR

CKP

is

covered

in Section

3

radiator

hose

support bracket

valve-to-exhaust manifold •

tube to the right-hand exhaust

Timing belt service

tube

air inlet

of this

manual

Compressor

outlet

hose

at

the

FORD MOTOR CO.

19-0

CROWN

VICTORIA

•

TOWN CAR

GRAND MARQUIS

•

15-22

tighten the bolts to

lbs.

ft.

(20-30 Nm) 1 1

Lower the engine onto the

.

front engine

support insulator and remove the jack. Install or

12.

connect the following:

Left-hand and right-hand engine

•

support insulator through-bolts and tighten to

15-22

lbs.

ft.

(20-30

Nm). Catalytic converter pipes to both

•

exhaust manifolds. Tighten he nuts to

20-30

(27-41 Nm).

lbs.

ft.

'•Be sure the exhaust system clears Left

the No. 3 crossmember. Adjust as nec-

exhaust manifold torque sequence

essary.

compressor and the hose assem-

the cylinder block and the 8 nuts

bly-to-right-hand ignition coil

retaining the exhaust manifold

bracket bolt. Plug both openings. •

the

power brake booster

Heater hose

•

Ground strap-to-right-hand

Install or

7.

Upper stud and lower

•

10. •

Heater blower motor switch resistor

To

Bolt retaining the right-hand front

•

•

to the

8.

Engine support insulator through-

33-48

•

Install or

•

kets.

to •

from

Front engine support insulator from

of the

lbs.

•

26-33

ft.

lbs.

15-22

ft.

and lbs.

Engine/transmission harness con-

•

Retaining bracket on the power

•

Air conditioning

•

in

sequence

compressor

outlet

compressor

Bolt retaining the

hose assembly

•

Upper radiator hose

•

Fuel supply and return lines

•

Windshield wiper governor and

line

to

retaining bracket

(35-45 Nm).

•

Left-hand front engine support insulator to the cylinder block

to the

the right-hand ignition coil bracket

valve and tube assembly to the

nut to

strap onto the stud

Heater hose

hose

(20-30 Nm).

exhaust manifold. Tighten the

with wire.

Left-hand exhaust manifold

EGR

Ground

brake booster

Tighten the bolts ft.

and

(20-30

nector

connect the following:

15-22

bolt

lbs.

ft.

•

Exhaust manifolds, using new gas-

Catalytic converter pipes from both

15-22

•

exhaust manifolds and cylinder heads.

fold.

crossmember

lbs.

Clean the mating surfaces

9.

it

ft.

(45-65 Nm).

lbs.

position

(20-30 Nm)

tube connector and tighten to

ft.

in

Nm)

(37-45 Nm). On

the

the •

27-33

sors

exhaust system and hang

Upper stud and lower

the exhaust manifolds are being

the right-hand exhaust manifold, transfer

exhaust manifolds. Lower the

Heater hose

•

tighten the nut to

Both Heated Oxygen (HO 2 S) sen-

from the right-hand exhaust mani-

•

•

replaced, transfer the heated 02 sensors and

EGR

Heater blower motor switch resistor

tighten to

Manifold and gasket

If

lbs.

using the 2 retaining screws

connect the following:

tighten to

Exhaust Gas Recirculation (EGR)

•

install:

valve-to-exhaust manifold tube nut

•

pan,

sub-frame

bolts •

oil

drain hole. Raise the

and right-hand exhaust manifold

head and position aside

engine support insulator

the engine

ft.

(20-30 Nm)

8 exhaust manifold retaining nuts

•

bolt retaining

the heater hose to the right cylinder

•

oil

to the

sub-frame. Tighten to 15-22

engine approximately 4 inches (100mm).

der head nut •

wood under

rearward of the cylin-

engine support insulator

Position an adjustable jackstand and

6.

a block of

•

Bolt retaining the right-hand front

2 manifold gaskets

nector from the retaining bracket on

sensors

Both

•

Left-hand exhaust manifold and the

•

Engine/transmission harness con-

HO 2 S

•

Engine cooling fan blade and fan

shroud

and

•

Engine

•

Battery cables

air inlet

tube

the cooling system.

13.

Fill

14.

Start the

15.

Properly evacuate and charge the

engine and check

for leaks. air

conditioning system. 16.

Road

test the vehicle

and check

for

proper operation.

Camshaft and Valve

Lifters

REMOVAL & INSTALLATION

1

.

Before servicing the vehicle, refer to

the precautions

Right exhaust manifold torque sequence

tion.

in

the beginning of this sec-

FORD MOTOR CROWN 2. air

equipped with

If

air

suspension, the

suspension switch, must be turned

OFF

tor

and

oil

•

TOWN CAR

control valve actua-

Loosen the camshaft bearing cap

17.

or until the heads of the bolts are free.

adapter

•

Oil filter

•

Cylinder head covers

Tighten

•

Engine front cover

71-106

4.

Drain the engine

5.

Remove

Timing chains

•

oil

or disconnect the following:

•

Negative battery cable

wise no more than 45 degrees from Top

•

Fan blade and fan shroud assembly

Dead Center (TDC)

Fuel supply and return lines from

tons are below the top of the engine block

the fuel injection supply manifold

deck

•

•

Windshield wiper governor (mod-

assembly from the vehicle

ule)

Ignition wires from the spark plugs

6565-AH between

belt

2 bolts retaining the ignition wire

and remove the rocker arm. Repeat the pro-

separator to the ignition coil brack-

cedure

and the

bolt retaining the air

right-hand ignition coil bracket.

their locations, they

Connectors from both ignition coils

same bore

(CMP)

Ignition coils with brackets attached

•

Electrical

connector from the

nator and at the

power

power

1 1

points near the upper bearing halves lift

the camshaft bearing cap

Repeat the removal procedure

.

Remove

12.

upward

Positive Crankcase Ventilation

13.

to

for the

related

damage.

To

Engine/transmission harness con-

14.

for

If

front

steering

will not

come

22.

Install

23.

pan

and crankshaft pulley Engine

install the

Clean and inspect the cylinder head

Apply clean engine

oil to

81-95

Install

Install

install

24

Valve Spring Spacer T91P-

Tighten the in

the rocker

until all rocker

arm Repeat arms

the pro-

45

Top

crankshaft must only be rotated

as TDC.

25.

Install or

connect the following:

Timing chains

individually.

•

Engine front cover

•

bearing cap cluster

tightened individually.

oil filter

covered

on

are installed.

to position the crankshaft at

•

is

is

sequence

inch lbs. (8-12 Nm). Be sure to

-Each camshaft

Be

the valve spring coils.

tighten each camshaft bearing cap cluster

Heater Core replacement

of the valve

the clockwise direction and only as

far

is

and

lbs.

Rotate the crankshaft clockwise

•The

and hand

camshaft cluster retaining bolts

assembly

ft.

base circle Compress the valve spring

its

the

and seat the camshaft bearing

start the retaining bolts

71-106

the flats of

spacers and

a valve spring compressor

Dead Center (TDC).

to

Crankshaft pulley bolt and washer

and

sure that the valve being compressed

out. Oil

T92P-6256-A on

spring retainer.

unusual wear or

install:

Install

adjusters

necessary, install Camshaft Posi-

camshafts on the cylinder heads 16.

the dial indicator.

install the lash

degrees

the

•

Remove

under the camshaft and on top

in

•

5:

6565-AH between

cap cluster assemblies.

all

in

end-play

and replace the cylinder

camshaft journals and lobes. Position the

and

lower bolt on the power

pump

15.

conditioning clutch harness

aside

If

to

cedure

pump

tight,

Install the bolts

sealing surfaces.

power steering

too

washers and tighten

Crankshaft Position (CKP) sensor

to the cylinder block

is

camshaft sprockets

and

Bolts retaining the

end-play

removed,

the camshafts

covers, engine front cover and cylinder head

wire the

•

21.

power brake booster

air

If

(110-130 Nm)

avoid bearing damage.

components

(PCV) valve from the cylinder head

If

tioning Tools

the camshaft straight

Clean and inspect the camshafts and

cover and position aside

pump

4:

binding or foreign material

in their original positions.

opposite cylinder head.

and position

connectors

"The

at

clusters from the cylinder head

nector from the bracket on the

•

for

Step

e.

20

head. Tap upward on the camshaft bearing

bracket located on the right-hand

and

is

excessive, check for worn camshaft

To remove each camshaft, unfasten

10.

and gradually

EVAP

camshaft forward

Specified end-play

head, as required.

Bolt from the positive battery cable

Fuel vapor hose from the

dial

locations tor installation.

caps

box

the positive battery cable aside

•

not mix the camshaft bearing

caps (cluster assemblies) to the cylinder

pulley

canister purge valve

•

check

thrust plate

cylinder head

•

it.

the camshaft thrust bearing.

• Do

distribution

Positive battery cable at the distribution

•

Step

d.

installed in the

they were removed from.

the 14 bolts retaining the camshaft bearing

pump

and zero the

0.0901—0.006 inch (0.025—0 190mm).

alter-

box

Push the camshaft toward

3: Pull the

caps. Note the camshaft bearing cap

•

Water

Step

c.

is

sensor

•

must be

2:

and release

out of their bores in the cylinder head. Note

so the

it

on the camshaft

indicator.

required, pull the lash adjusters

conditioning pressure line to the

and the Crankshaft Position

•

9.

Step

b.

the rear of the engine

the valve spring

rocker arms are removed.

until all If

is

resting

is

sprocket bolt or the front of the camshaft.

on

its

Compress

fol-

a dial indicator on

1: Install

indicator foot

the valve spring coils. Be

sure that the valve being compressed circle.

Step

a.

Valve Spring Spacer T91P-

Ignition wire brackets from the

base

Check camshaft end-play as

the front of the engine. Position

cylinder head cover studs

ets

•

Install

8.

camshafts should turn freely but

lows:

under the camshaft and on top of one of the

•

cleaner outlet tube

sequence, to

with a slight drag.

valve spring retainers.

Accessory drive

•

-The

pis-

valve spring compressor

•

•

all

19.

Install a

Engine

•

ensure that

bolts, again in

inch lbs. (8-12 Nm).

installation for the opposite cylinder head.

face.

7.

•

air

to

all

Repeat the camshaft bearing cap

18.

Rotate the crankshaft counterclock-

6.

Q_Q 3

1

cluster retaining bolts approximately 2 turns

pressure sensor

Properly relieve the fuel system

pressure.

CO.

GRAND MARQUIS

•

position before raising the vehicle.

3.

way

Power steering

•

to the

VICTORIA

in Section

Cylinder head covers. Tighten the cylinder head cover bolts to

71-106

2 of this manual

inch lbs. (8-12 Nm).

4 I

n y"i n U

ford motor co. CROWN

I

TOWN CAR

•

VICTORIA

•

GRAND MARQUIS the air suspension switch to the

ON

posi-

tion.

32.

Start the

33.

Road

engine and check

for leaks.

and check

test the vehicle

for

proper engine operation.

Valve Lash

ADJUSTMENT The valve lash

is

not adjustable.

collapsed lash adjuster clearance

check the camshaft,

rect,

If

the

incor-

is

roller follower

and

valve for wear or damage. 1.

8-12

Nm

(71.4-107.1 Lb-In)

Before servicing the vehicle, refer to the

precautions

in

the beginning of this section.

2.

Disconnect the negative battery cable.

3.

Remove

4.

Rotate the crankshaft until the

camshaft base

the camshaft covers.

circle is contacting the roller

follower. 5.

Use a suitable

lash adjuster. Slowly

tool to bleed

adjuster until the plunger 6.

Use a

feeler

down

compress the

gauge

bottomed.

is

to

check the clear-

ance between the camshaft and the follower.

the

lash

roller

The clearance should be

0.018-0.033 inch (0.45-0.85mm). Tighten the camshatt bearing cap cluster bolts

in

the sequence to avoid

damage

to the

camshaft or bearings

Starter Motor

Power steering control valve actua-

•

•

Positive battery cable harness on

•

connector

Oil

pressure sensor harness con-

•

Bolt retaining the battery cable

shaft

Apply silicone sealer

Evaporative emission hose to the

•

to the crank-

keyway

27.

crankshaft pulley and

•

Positive battery cable at the

tighten the bolt as follows:

Step

1:

distribution

Tighten to 66

ft.

Water

•

(90

lbs.

Nm).

bolts to

Step

b.

Step

c.

2: 3:

Loosen one complete Tighten to

35-39

ft.

•

turn.

Step

4:

Install or

• •

Engine

Tighten an additional

ft.

•

oil

pan

•

•

and

lbs.

to the ignition

sensor

and

2 upper bolts

•

1

Accessory drive

Evaporative emission canister

•

Windshield wiper governor

purge valve harness connector

•

Fuel supply and return lines

Engine/transmission harness con-

•

Fan and shroud assembly

nectors on the power brake booster

•

Negative battery cable

Install or

connect the following:

and lower mounting

•

Starter

•

2 upper mounting bolts. Tighten to

15-20

ft.

lbs.

bolt all

(20-27

Nm). Wires from solenoid and tighten the nut to

40-50

inch lbs.

•

Red solenoid

•

Negative battery cable

safety cap

belt

retaining bracket

29.

Fill

the engine cooling system.

PCV

30.

Fill

the crankcase.

31.

If

equipped with

lower bolt and starter

3 bolts

head cover studs •

safety cap

install:

bolt

sensor

der head cover

•

Ignition wires to the spark plugs

•

CKP

valve to the right-hand cylin-

Wires from solenoid

on

and the brackets onto the cylinder

Air conditioning clutch

Red solenoid

•

•

and the retaining

(20-30

or disconnect the following:

Negative battery cable

•

the right-hand ignition coil bracket

bolts. Tighten ft.

CMP

To 3.

(20-30 Nm).

and the

Remove

ignition

Air conditioning pressure line

Power steering pump on the engine

15-22

lbs.

coils

Nm).

•

(20-30 Nm)

lbs.

ft.

Harness connectors

connect the following:

the bolts to

•

15-22

Tighten the retaining nuts to 15-22

and the 4 retaining

•

pulley and tighten the

wires to the engine front cover.

lbs.

85-95 degrees. 28.

2.

•

Ignition coil brackets

(47-53 Nm). d.

power

box

pump

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

canister purge valve

Install the

a.

1.

bracket to the cylinder head

nector 26.

REMOVAL & INSTALLATION

the right-hand cylinder head

tor

air

Oil

Pan

REMOVAL & INSTALLATION 1.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

suspension, turn

tion.

1Q_11 *3

FORD MOTOR CO. CROWN 2.

Drain the engine cooling system

3.

Properly discharge the

air

Remove

7.

condition-

•

Remove

or disconnect the following:

•

Negative battery cable

•

Engine

•

Fuel supply and return lines at the

air

•

the front cover

sub-frame

and inspect the

Bolts retaining the left-hand and

the O-ring. 12.

If

pick-up tube and replace

oil

removed, position the

tube on the

oil

of

and cylinder block. Clean

pick-up

oil

pump and hand

2

start the

retaining bolts. Install the bolt retaining the

Cooling fan and fan shroud

Catalytic converter pipes from both

pick-up tube on the main bearing stud

•

Upper radiator hose

exhaust manifolds. Lower the

spacer,

•

Wiper governor and support

exhaust system and support

bracket

wire from the transmission cross-

bolts to

member.

tighten the pick-up tube-to-main bearing

•

•

A/C compressor

•

Engine/transmission electrical har-

•

•

outlet

hose

Position a jack and a block of

8.

with

hand

tight.

Tighten the pick-up tube-to-oil

13.

72-108

wood

stud spacer bolt to

drain

Nm).

15-22

bracket on the power brake booster

hole. 10. Raise the engine approximately 4

Heater water hose

(100mm) and insert 2 wood blocks approximately 2V2-2 3A inch (60-70mm)

Apply silicone sealer

the right-hand cylinder head

thick under each front engine support insu-

crankshaft rear

Upper stud and loosen the lower

lator.

to

blocks and remove the jack.

hose

right-hand cylinder head and

9.

and

ft.

lbs.

the

oil

oil

the bolt retaining the

pick-up tube to the main bearing stud spacer.

Remove

the pick-up tube.

ft.

new gasket on

Position a

(20-30

lbs.

the

where the

to

pan.

oil

front

cover meets the cylinder block and the seal

oil

and

and

meets

retainer

the cylinder block. Position the

oil

pan

(20 Nm), then rotate the bolts, in

to

install the retaining bolts.

Tighten the bolts in sequence, to 14

pan.

retaining the oil pick-up tube to the

(13-16 Nm)

14.

the engine

necessary, remove the 2 bolts

pump and remove

reinstall the

pan drain plug with a new gasket. Tighten

10-12

Remove If

Heater blower motor switch resistor

the plug to

oil

Lower the engine onto the wood

position aside

oil

pan, rearward of the

inches

Nut retaining the ground strap

Drain the engine

oil

pump

inch lbs. (8-12 Nm), then

under the

to the

•

it

ness connector from the retaining

bolt retaining the heater outlet

oil

support insulator to the lower front

supports

pan and inspect

oil

•

•

6.

Clean the engine

damage. Clean the sealing surfaces

for

mount

I

I

install:

.

Bolt retaining the right-hand engine

insulators to the engine

supply manifold

GRAND MARQUIS

•

To

or disconnect the follow-

right-hand front engine support

cleaner outlet tube

fuel injection

TOWN CAR

1 1

Relieve the fuel system pressure.

5.

•

ing:

ing system. 4.

VICTORIA

ft.

lbs.

pan retaining

oil

sequence an additional 60 degrees

within 4 minutes of applying the silicone sealer.

15

Position the jack and

under the engine drain hole,

and

remove

wood

the

16

blocks. Lower the engine

jack.

Install or

•

oil

engine enough to

raise the

and remove the

wood block

pan, rearward of the

oil

connect the following:

Left-hand and right-hand engine

support insulator through-bolts and

15-22

tighten to

ft.

lbs.

(20-30

Nm) •

Bolt retaining the right-hand engine

support insulator to the lower front sub-frame. Tighten the bolt to

15-22 •

lbs

ft

(20-30 Nm).

Exhaust system to the exhaust

manifolds and tighten the 4 retaining nuts to

Nm) Be

20-30

ft

lbs.

(27-41

sure the exhaust system

clears the

crossmember Adjust as

necessary. •

New engine

•

Heater blower motor switch resistor

oil filter

using the 2 retaining screws • •

Heater water hose

Upper stud and tighten the upper

and lower bolts

to

15-22

ft.

lbs.

(20-30 Nm) •

Ground

strap

tighten to

on the stud and

15-22

ft.

lbs.

(20--30

Nm)

To prevent

oil

leaks, tighten the

oil

pan bolts

in

the

sequence shown

Brake service

is

covered

in Section

4 of this manual

•

Heater water hose

•

Throttle valve cable,

if

equipped

10 19 Sr L 1

FORD MOTOR CO. CROWN

i

VICTORIA

•

TOWN CAR

•

Engine/transmission electrical har-

•

Harness connector on the power

•

Air conditioning

GRAND MARQUIS

•

ness connector

brake booster bracket

hose •

compressor

Bolt retaining the

hand

outlet

compressor

to the

hose

to the right-

ignition coil bracket

hose

•

Upper

•

Fuel supply and return lines

•

Wiper governor and retaining

radiator

7922RG13

bracket

Apply a continuous bead

•

Engine cooling fan and fan shroud

•

Engine

•

Negative battery cable

sealant to the back of the seal retainer

cleaner outlet tube

air

before installing

17.

Fill

the cooling system.

18.

Fill

the engine crankcase with engine

of silicone

8

i

-1

2

it

on the engine

Nm (71 .4 -107.1

Lb -In)

oil.

air

engine and check

for leaks.

19.

Start the

20.

Properly evacuate and recharge the

conditioning system. 21

Road

.

test the vehicle

and check

for

Oil

The

6.

Pump

REMOVAL & INSTALLATION

1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Remove

or disconnect the following:

•

Negative battery cable

•

Cylinder head covers

•

Engine front cover

•

Engine

•

Timing chains

is

mounted on tne crankshaft

Install or

engine

connect the following:

•

New engine

•

Timing chains

•

Engine

oil

oil filter 7922RG14

pan

To avoid leakage, be sure to tighten the

•

Engine front cover

•

Cylinder head covers

•

Negative battery cable

crankshaft rear

the crankcase.

7.

Fill

8.

Start the

tube to the

oil

attaching the

the retainer and immediately install

and proper engine 9.

Road

oil

engine block. Tighten the bolts

and check

for

to

oil

pick-up tube

to the

REMOVAL & INSTALLATION

oil

pump

to

pump

install:

3.

Rotate the inner rotor of the

to align with the flats

the

install

oil

pump

4.

72-106

Clean the

oil

oil

flush with the cylinder

pick-up tube and

start the

Install the bolt retaining

hand

tight.

pump

bolts

inch lbs. (8-12 Nm). Tighten the

pick-up tube to main bearing stud spacer bolt to

15-22

ft.

lbs.

with the spring side

•

bolts, in a crisscross pattern, to

the beginning of this sec-

•

Transmission

•

Flexplate or flywheel

With a sharp awl, carefully punch a

small hole

in

•

or disconnect the following:

•

connect the following:

Flexplate or flywheel. Tighten the

54-64

Remove

the installation tool.

Install or

ft.

lbs.

(73-87 Nm).

Transmission Negative battery cable

11.

Check the engine

12.

Start the

oil level.

engine and check

for leaks.

the metal portion of the seal.

Remove

the seal using a slide

ham-

mer with

a sheet metal screw attached.

'Hf the

oil

leak

is

Timing Chain, Sprockets, Front Cover and Seal

coming from around

REMOVAL & INSTALLATION

be removed and resealed.

2 retaining bolts.

Tighten the pick-up tube-to-oil

72-106

oil

the pick-up tube to

ihe main bearing stud spacer

to

in

the seal retainer, the retainer must also

Place the pick-up tube on the

pump and hand

3.

4.

and

inch lbs. (8-12 Nm).

replace the O-ring. 5.

the precautions

pump

on the crankshaft and

block. Install the 4 retaining bolts tighten to

Remove

9.

Before servicing the vehicle, refer to

2.

To

oil.

Install the seal

tion.

the cylinder block Oil

sequence

Lubricate the seal and the crankshaft

10. 1.

Pick-up tube

in

inch lbs. (8-12 Nm).

toward the engine.

the bolt

main bearing stud spacer

•

71-107

8.

pick-up

pump and

4 bolts retaining the

of

on the

proper engine operation.

Rear Main Seal

•

back it

pressure.

test the vehicle

7.

•

to the

for leaks

with clean engine

oil

seal retainer bolts in

Apply silicone sealant

6.

engine and check

oil

the correct sequence

pan

oil

2 bolts retaining the

•

pump

oil

at the front of the

proper engine operation.

(20-30 Nm).

To 5.

1

install: If

the seal retainer

was removed,

carefully clean the sealant from the retainer

and engine block using

Remove any

oil

a plastic scraper.

or grease residue from the

Before servfcing the vehicle, refer to

.

the precautions in the beginning of this section. 2.

Drain the engine

3.

Remove

oil.

or disconnect the following:

•

Negative battery cable

•

Cooling fan and shroud

sealing surfaces with a solvent.

CROWN COPPER TIMING

COPPER TIMING LINK

UNK RH CHAIN

LH CHAIN

FORD MOTOR CO. 1

VICTORIA

TOWN CAR

•

GRAND MARQUIS

•

Left-hand camshaft sprocket retain-

•

INSTALLTOOL

9 Q_1IO

CRANKSHAFT

ing bolt, washer, sprocket spacer, 8.

if

and

necessary

necessary, note the position of the

If

crankshaft sprockets and remove the crankshaft sprockets by sliding

them

off

the front

of the crankshaft.

Inspect the plastic running face on

9.

the tensioner

COPPER TIMING LINKS RH AND LH CRANKSHAFT GEARS

worn or damaged, inspect the engine

MARKS

pan

T922RG16

Be sure that the timing marks are aligned

when

the No.

1

piston

arms and chain guides.

TDC on com-

is at

the

for oil

contamination and thoroughly clean pan. Replace the

oil

pick-up tube.

To install: Examine the timing chains, looking

10. installing the timing chains

for the

copper

links.

the copper links are

If

not visible, lay the chain on a •

Accessory drive

pump

Water

4

belt

pulley

the

•

Power steering pump

•

Oil

•

oil

be

Install the crankshaft positioning tool to

sure the crankshaft does not turn while

pression

•

If

:

REMOVAL & INSTALLATION

CAUTION

1998—99 Models

There may still be residual fuel in the system, and a small amount of fuel

may

be released

Pump

gauge

an approved container.

into

for fuel leaks.

bleed hose into an

when

1

.

Before servicing the vehicle, refer to the

precautions

servicing fuel 2.

in

the beginning of this section.

Relieve the fuel system pressure.

lines or connections. In order to

reduce the chance cover the fuel line

of

3.

Drain the fuel tank.

4.

Remove

personal injury,

or disconnect the following:

fittings with a

shop towel before disconnecting to catch any fuel that may leak out.

•

Negative battery cable

•

Fuel tank

•

Evaporative Emissions (EVAP) pipe

•

Fuel Filter

filler

Quick connect

pipe

fuel lines

from the

fuel tank •

REMOVAL & INSTALLATION

•

Rear rubber exhaust hangers Fuel tank strap bolts, support the fuel tank

1.

•

Before servicing the vehicle, refer to

the precautions

in

•

the beginning of this sec-

Lockring and the

fuel

sender

assembly from the tank

tion. 2.

Fuel tank.

Disconnect the negative battery

cable.

>-»Note the direction the strainer

pointing and

3.

Relieve the fuel system pressure.

the

4.

Twist the quick connector 14 turn in

ing.

pump

remove the

by pulling

it

is

strainer from

down and

7922UG34

twistFuel

pump and

level

sender assembly

LE Torque the hose clamp lbs. (2.8

C & H-BODIES-GENERAL MOTORS CORPORATION PARK AVE. • EIGHTY EIGHT • LSS • REGENCY • BONNEVILLE

91 £

.1

C

25 inch

to

filler

pipe to the tank.

Torque the hose clamp lbs. (2.8

•

Nm).

Fuel tank

•

SABRE

25 inch

to

Nm).

Negative battery cable

•

the fuel tank.

8.

Refill

9.

Run the engine and check

for leaks

and proper engine operation.

Park Avenue And 1

2000-01 Models

All

Before servicing the vehicle, refer to

.

the precautions in the beginning of this section. 2.

Relieve the fuel system pressure.

3.

Drain the fuel tank.

4.

Remove

or disconnect the follow-

ing: •

Negative battery cable

•

Spare

•

Trunk lining

and jack

tire

•

Fuel sender access panel

•

Sender and quick connect

fittings

from the sender •

Electrical

connector from the

sender and position harness and

hoses aside

**

CAUTION

The

When removing

pump

service cover

is

located

in

compartment under the spare

the luggage

tire

— Park

the fuel sender from

the tank, the reservoir bucket of fuel.

fuel

Avenue shown others similar

Use caution

in

is full •

Lockring

•

Fuel line quick connectors

•

Sender

•

Fuel sender access cover

•

Trunk

liner

•

Spare

tire

containing the

Fuel Injectors

fuel.

•

Sender retaining ring

•

Sender and take note

•

of its position

Fuel sender O-ring and discard

connector

REMOVAL & INSTALLATION Before servicing the vehicle, refer to the

1

and jack

it

8.

7

—

GENERAL MOTORS CORPORATION N-BODY SKYLARK • ACHIEVA • ALERO • GRAND AM

9.

no

•

Fuel tank

•

Negative battery cable

Pressurize the fuel system and verity

leaks.

Fuel Injector

REMOVAL & INSTALLATION 2.4L Engine 1.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2. 3.

Relieve the fuel system pressure.

Remove • •

1

2

3 4

SNAP RING COVER - TAB

Fuel pressure regulator

vacuum

hose •

MODULAR UNIT WIRE HARNESS - ABOVE COVER

6

FUEL TANK TANK ISOLATION STRIPS

7

RUBBER ISOLATOR

5

or disconnect the following:

Air cleaner outlet resonator

Camshaft Position (CMP) sensor connector

electrical

(3)

•

Fuel injector electrical connectors

•

Fuel inlet pipe at the fuel

•

Fuel return pipe bracket screw and

rail

7922Z325

separate the fuel pipe from the

Exploded view

of the fuel

sender assembly mounting

to the tank

pressure regulator

assembly

•

Fuel

•

Fuel injector retaining clip

•

Fuel injector

rail

To

install:

4.

Lubricate the O-rings with engine

oil

prior to installation. 5.

Install or

connect the following:

Fuel injector with

•

Fuel injector retaining clip

•

Fuel to

rail

19

New

•

ft.

assembly. Torque the bolts

fuel pipe

22

2

CONNECTOR ASSEMBLY - FUEL SENDER WIRING

3

FUEL PIPES (3) COVER ASSEMBLY - FUEL SENOER SEAL - FUEL PUMP OUTLET

4

5 6

O-rings lubricated

oil

Fuel inlet pipe. Torque the

•

HARNESS ASSEM8LY (ABOVE COVER) - FUEL PUMP AND FUEL SENDER WIRING

(26 Nm).

lbs.

with engine

1

new O-rings

•

ft.

lbs.

fitting to

(30 Nm).

SUPPORT ASSEMBLY (THREE HOLLOW SUPPORT OR GUIDE PIPES) - FUEL PUMP RESERVOIR

- FUEL PUMP RESERVOIR CONNECTOR POSITION ASSURANCE (CPA) HARNESS ASSEMBLY (BELOW COVER) - FUEL PUMP 9 10 HARNESS ASSEMBLY (BELOW COVER) - FUEL LEVEL SENDER 7

RETAINER

8

2

11

12

13

14

15 16

17 18

19

14

20

RESERVOIR - FUEL PUMP FUEL SENSOR ASSEMBLY - FUEL LEVEL PUMP ASSEMBLY (JET PUMP ASSEMBLY) FUEL PUMP RESERVOIR STRAINER (EXTERNAL) - FUEL SENDER PAD (BUMPER) - FUEL SENDER

VALVE (SECONDARY UMBRELLA VALVE) FUEL PUMP RESERVOIR INLET CHECK

- FUEL PUMP FUEL BAFFLE (ISOLATOR CUP) - FUEL PUMP PUMP ASSEMBLY (ROLLERVANE) - FUEL OUTLET - FUEL PUMP

STRAINER

9306ZG10 7922Z326

Exploded view Exploded view

of the fuel

pump assembly

engine

of the fuel

injector— 2. 4L

07 OE L\J

N-BODY— GENERAL MOTORS CORPORATION SKYLARK

•

ACHIEVA

•

ALERO

£

GRAND AM

•

»

To install:

** WARNING If

the fuel injector O-rings are color

coded,

black O-ring

install the

in

the

upper position and the brown O-ring in the lower position. 4

Lubricate the O-rings with engine

oil

prior to installation. 5. 9306ZG12

Exploded view 3.4L engine

—

of the fuel rail

assembly—

3.1 L engine is similar

Exploded view engine

—

of the fuel injector

3.1 L engine

is

—3.4L

6

similar

Install

New

•

Fuel injector

•

Fuel injector retaining clip

•

Fuel injector electrical connectors

•

Fuel return pipe to the pressure

•

regulator.

Torque the screw

to

53

inch lbs. (6 Nm).

2.

Relieve the fuel system pressure.

3.

Remove •

CMP

connector

•

Fuel feed pipe

•

Fuel pressure regulator

vacuum

•

Fuel return pipe from the pressure

•

Main

Air cleaner outlet resonator

•

Negative battery cable

•

Main

• fuel injector wiring

connector harness

fuel injector wiring

electrical

connector

New

pipe O-rings lubricated

fuel

oil

•

Fuel feed pipe at the fuel

harness

Torque the pipe nut

connector

electrical

• electrical

assembly

Fuel

Fuel injector electrical connectors

•

Fuel injector-to-fuel

rail

ft.

lbs.

to

13

(17 Nm).

Upper intake manifold

• rail

clip

Before servicing the vehicle, refer to the •

Torque the pipe nut

regulator.

•

lbs.

ft.

Fuel return pipe to the pressure

connector

•

rail.

13

to

(17 Nm).

Engine Coolant Temperature (ECT) sensor

tor leaks.

in

(10 Nm).

electrical

regulator

•

precautions

lbs.

ECT sensor

with engine

3.1L and 3.4L Engines 1

O-rings

assembly. Torque the bolts

rail

89 inch

•

•

Re-pressurize the fuel system and

6.

Upper intake manifold

Fuel injector electrical connectors

hose

check

fuel injector

g:

•

electrical

Fuel to

or disconnect the follow-

•

sensor

or connect the following:

•

Re-pressurize the fuel system and

Fuel injector

the beginning of this section

check

for leaks

DRIVE TRAIN •

Transaxle

Wiring harness from the transaxle

mount bracket

REMOVAL & INSTALLATION

•

Upper transaxle mount

•

Clutch master cylinder from the

1998 1

MODELS Before servicing the vehicle, refer to

.

the precautions in the beginning of this section.

•

Ground wires from

•

Backup

•

Transaxle vent tube

•

light

the transaxle

switch connector

cable. 3.

Drain the transaxle fluid

4

Install

Rear transaxle mount

off

engine mounts.

Remove

5.

• •

or disconnect the following

Left side

sound

•

Left inner fender well

•

Anti-lock Brake System (ABS)

cal

Air cleaner throttle

•

Shift cable

lever

and duct work from the

from the manual

on the transaxle

• •

shift

55

ft.

mount Torque

lbs.

Flywheel housing cover. Torque the

89 inch

lbs (10

suspension support

Left side

Torque the nuts to 22

the transaxle

Nm).

•

•

Lett side

Ball joints

lbs (61

•

Left side stabilizer link

•

Left side

U-bolt from the sway bar

•

Left side

suspension support

•

Halfshafts from the transaxle

lbs

(120

U-bolt to the sway bar.

Flywheel housing cover Vehicle Speed Sensor (VSS) from

from the steering knuck-

ft.

Nm).

connectors

Ball joints

Nm).

Halfshafts to the transaxle

•

•

the

Nm)

(75

Torque the bolts to 89

electri-

les

body

Front transaxle bolts to

ft

Nm).

•

from the clutch pedal •

connect the following:

Transaxle Torque the bolts to 55

bolts to

splash shield

Wheel Speed sensor (WSS)

insulator

Clutch master cylinder pushrod

•

•

Front wheels

the

the transaxle from the

Install or

9.

•

•

an engine support fixture and

use the fixture to take the weight

Remove

lbs (75

the support fixture

Disconnect the negative battery

2.

8

vehicle.

Lower the powertrain assembly with

6.

mount

Front lower transaxle

Support the transaxle with a jack

To install:

slave cylinder

Manual

•

7

•

ft.

(30

Torque the nuts to 45

lbs.

ft

Torque the nuts to

(30 Nm).

•

WSS

•

Left inner fender well

For complete service labor times, order the Chilton Labor Guide

lbs.

Nm).

Stabilizer link

22

ft.

electrical

connectors splash shield

07/ "lO OR t

GENERAL MOTORS CORPORATION— N-BODY skylark

achieva

•

•

•

Front wheels

•

Vehicle Speed Sensor (VSS) to the transaxle. Torque the bolt to

80

alero

grand am

•

6.

Support the suspension crossmem-

7.

Remove

or disconnect the following:

inch lbs. (9 Nm).

•

Suspension crossmember bolts

•

Rear transaxle mount. Torque the

•

Rack and pinion bolts

•

Ground wires

•

Transaxle vent tube

•

Backup

•

Upper transaxle mount. Torque the

44

bolts to

55

(60 Nm).

lbs.

ft.

Raise the vehicle

8.

Remove

9.

(75 Nm).

•

Shift cable to the

manual

on the transaxle. Torque the nut

89 inch •

Shift linkage

Vacuum modulator

Lower the engine and transaxle

•

Front transaxle

•

Rear transaxle mount

sound

the bolt to 81

insulator •

the transaxle.

Refill

MODELS •

Remove

or disconnect the following:

•

Negative battery cable

•

Air cleaner

•

Clutch slave cylinder line and

ft.

assembly

bracket

Cable bracket

•

Vehicle Speed Sensor (VSS) electrical

•

connector

Backup lamp switch

electrical

con-

nector •

Starter

motor

Tie the radiator to the

3.

upper hood

latch panel.

an engine support

4.

Install

5.

Remove

the nuts to

22

Both outer

tie

fixture.

or disconnect the following:

•

Transaxle bolts

•

Lower closeout panel

ft.

180 degree

• •

lbs.

ball joints.

(20

Nm)

plus an

Torque the nuts

Lower

•

Both wheel well splash shields

•

Front wheels

•

Lower closeout panel

to

Remove

Untie the radiator support.

the engine support fixture.

66

and 32

Nm) on 2.4L engines (43 Nm) on 3.4L

•

Lower radiator support

engines.

•

Wheel Speed sensor (WSS)

ft.

(90 lbs.

to

Both outer

•

Both

•

Both stabilizer shaft links

•

Front transaxle

rod ends

ball joints

Backup lamp switch

mount

electrical

con-

•

VSS

•

Shifter cables

•

Clutch slave cylinder bracket and

bolts

Torque converter-to-flywheel bolts

connector

line

a scribe

mark the flywheel-to-

and

Oil level indicator

•

Transaxle cooler lines

fill

tube

•

Vehicle Speed Sensor (VSS)

•

Vacuum

reservoir tank

Position a jack under the transaxle.

Remove

6.

•

electrical

Heater core hose pipe brace-to-

•

5.

nector

•

tie

lbs.

motor

proper reassembly.

connect the following:

Both wheel well splash shields

•

Transaxle converter cover

torque converter relationship to assure

Wheels

electri-

•

•

Torque the bolts

connectors

Starter

transaxle nut and bolt

Starter motor.

cal

Engine-to-transaxle brace

•

•Using

14.

ft.

Both halfshafts

•

•

connectors

13.

frame

suspension support

Left side

•

radiator support

Install or

Left side stabilizer shaft

assembly

turn.

WSS

electrical

from the control

bushing clamp nuts

Nm).

lbs. (61

ball joints

Left side stabilizer shaft link pin

•

•

•

•

Torque

•

15.

84

rod ends. Torque the

nuts to 15

ft.

Both

arms

lbs.

ft.

(30 Nm).

lbs.

ft.

engine splash shields

nectors •

•

links.

additional

45

180

left

bolt

Both stabilizer shaft

Both

Anti-lock Brake System (ABS)

Wheel Speed Sensor (WSS) con-

bolts.

the front bolts to

•

•

Right and

•

(115 Nm).

lbs.

Right front brake hose

from the transaxle

Shifter cables

•

to

•

•

•

Nm) and

•

Torque the

Suspension crossmember

(245

tion.

Both front wheels

•

Torque

(110 Nm).

Torque the rear bolts

the precautions in the beginning of this sec-

engine bolts

(115 Nm).

bolts.

lbs.

ft.

bolts.

lbs.

ft.

Remaining upper transaxle-to-

•

mount

Rack and pinion bolts to 81

Before servicing the vehicle, refer to

84

or disconnect the following: (2) transaxle-to-engine bolts

Rubber hose from the transaxle

Torque

bolt.

(110 Nm).

lbs.

ft.

connector fixture.

vent pipe

mount

Front transaxle the bolts to

•

2000-01

Upper

•

Clutch master cylinder pushrod to

an engine support

Remove

4.

•

the clutch pedal

to the

ft.

(100 Nm).

connector

Shift solenoid electrical Install

3.

Transaxle. Torque the bolts to 74

Rear transaxle mount

Left side

2.

connect the following:

Halfshafts

Negative battery cable

1.

trical

•

•

12.

•

to

body

•

Park/Neutral position switch elec-

•

install:

lbs.

and duct work

•

sion from the vehicle.

(10 Nm).

from the

connector

electrical

Install or

line

Torque Converter Clutch (TCC)

•

Support and remove the transmis-

12.

from the transaxle

modulator

to clear the left side inner

•

Air cleaner throttle

•

lbs.

Air intake duct

•

.

To

shift lever

•

Halfshafts from the vehicle

body panel.

connect the following:

Negative battery cable

•

assembly enough

the engine support fixture.

mount

or disconnect the following:

•

•

cylinder

Install or

Remove

2.

Rear transaxle mount

Wiring harness to the transaxle

Remove

tion.

Front transaxle

•

10.

the front sus-

off of

•

10.

1 1

Before servicing the vehicle, refer to

.

•

Clutch master cylinder to the slave

11.

1

or disconnect the following:

•

mount bracket

MODELS

1998

the precautions in the beginning of this sec-

pension crossmember.

to the transaxle

switch connector

light

bolts to

lbs.

ft.

Automatic

ber.

or disconnect the following:

Transaxle mount-to-body bolts

•

Remaining engine-to-transaxle

•

Transaxle

bolts

'•-Transaxle cooler and lines should be

flushed whenever the transaxle has

•

Side transaxle mount nuts

•

Air cleaner

•

Rear transaxle mount stud

•

Negative battery cable

•

Right brake hose

assembly

been removed ment.

for overhaul or replace-

97.07'

N-BODY— GENERAL MOTORS CORPORATION SKYLARK *ACHIEVA*ALERO* GRAND AM To install:

1 1

11 ** I

N-BODY— GENERAL MOTORS CORPORATION SKYLARK

•

ACHIEVA

ALERO

•

GRAND AM

•

•

Front wheel

•

Halfshaft nut

•

Caliper from the steering knuckle

and support

and washer

it

aside

DO NOT

allow the caliper to hang unsupported from the brake hose. •

Brake rotor

•

3 hub/bearing assembly bolts

•

Halfshaft from the hub/bearing

assembly •

To

Hub/bearing assembly

install:

or connect the following:

Install

3.

•

Hub/bearing assembly onto the halfshaft,

making sure the splines

engage smoothly •

Hub/bearing assembly to the steering knuckle. Torque the bolts to 70

HUB AND BEARING ASSEMBLY STEERING KNUCKLE WASHER DRIVE AXLE NUT - 260 N-m (192 HUB AND BEARING RETAINING BOLT WASHER

1

2

3 4

5 6

ft.

• •

of the front

Caliper onto the steering knuckle.

Torque the bolts to 38

LBS. FT.)

ft.

lbs. (51

Halfshaft nut. Torque the

hub nut

Nm). •

74 N22ZM0

Exploded view

(95 Nm).

lbs.

Brake rotor

lbs (100

ft.

tional

hub/bearing assembly

40 degree

models, or

to

turn for

284

to

plus an addi-

ft.

lbs.

1998 (385 Nm).

1999-01 models.

for

•

Nm)

Front wheel. Torque the nuts to 100

5 ft.

lbs (140

Nm).

Rear

DRUM BRAKE Before servicing the vehicle, reler to

1.

the precautions in the beginning of this section.

2

Remove

or disconnect the follow-

ing •

Wheel

•

Brake drum

•

4 hub/bearing assembly to knuckle nuts

•The

top rear bolt will not clear the

brake shoes and must be removed with the bearing assembly. •

1

2 3 4

5

Anti-lock Brake System (ABS)

speed sensor wire from the

BOLT REAR AXLE ASSEMBLY BACKING PLATE HUB AND BEARING ASSEMBLY LOCKNUT

hub/bearing assembly •

Hub/bearing assembly

To install: 3.

Install or

connect the following:

•

Hub/bearing assembly on the

•

ABS

TO2ZM1

knuckle

Hub and bearing components

For Wheel Alignment specifications, see Section

1

of this

manual

wheel speed sensor

07I L •

flO GENERAL IV10T0RS CORPORATION— N-BODY SKYLARK • ACHIEVA • ALERO • GRAND AM Hub/bearing nuts. Torque the nuts to

44

ft.

lbs.

(60 Nm).

•

Brake drum

•

Wheel. Torque the nuts lbs.

to

100

ft.

(140 Nm).

DISC BRAKE 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

3.

Remove

or disconnect the following:

•

Wheel

•

Brake rotor

•

Parking brake cable from the lever

•

Wheel Speed Sensor (WSS) cal

•

Rear wheel bearing assembly with disc brakes

— 1999-01 models

electri-

connector

Hub/bearing assembly bolts from

To

install:

lbs.

connect the following:

Install or

ft.

(95

lbs.

the knuckle • •

to the

back-

els.

Torx® bolts from the rear of the ing plate. Tighten the Torx®bolts to

hub/bearing assembly •

Hub/bearing assembly

89 inch

Hub/bearing assembly from the •

lbs.

(10 Nm).

Hub/bearing assembly on the

Nm) on 1999 models or 62 Nm) on 2000-01 mod-

(85

•

WSS

•

Parking brake cable to the lever

electrical

connector

•

Brake rotor

•

Wheel assembly

backing plate knuckle. Torque the bolts to 70

ft.

f

GENERAL MOTORS CORPORATION—V-BODY 1998-01 Cadillac-Catera

DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM

28-13 28-2 28-12 28-2

PRECAUTIONS

Front Crankshaft Seal

Removal &

Air

Removal &

Bag

28-15

Disarming

28-15

Precautions

28-15

Rearming

28-15 28-2

Alternator

28-2

Installation

Axle Shaft, Bearing and Seal

&

Installation

28-14

Pump

Removal &

Installation

Relieving Fuel

Removal &

Installation

Installation

CV-Joints Outer Joint

Ignition

Removal &

Removal &

Installation

Lower

Removal &

Installation

Exhaust Manifold

Removal &

Installation

Rear Main Seal

Removal

28-12

Control

Steering Gear

Removal &

28-6

28-19 28-19

Starter

Removal &

Oil

Installation

Removal &

28-3 Oil

Installation

Pump Removal &

Installation

28-10

28-17

Strut

Removal &

Installation

Transmission Assembly

Removal

&

Installation

28-17

28-13

28-10 28-10

Adjustment

W Water

28-10

28-13

V

28-19 28-10

Pan

28-17

28-10

Motor

Valve Lash

28-20

Installation

28-17

Installation

28-19

Arm Bushing

Removal &

28-15

T

0

28-7

28-15 Installation

Shock Absorber Removal &

28-6

Installation

28-11

Power

S

Assembly

Replacement

28-4

28-7

28-11 Installation

Recirculating Ball

28-12

Installation

Lower Control Arm

28-14

28-3

&

28-12

28-3

Ball Joint

Removal &

E Engine Assembly

28-11

L

28-17

28-14 28-11

Positioning

28-12

28-3

Timing

Adjustment

28-4

Cylinder Head

&

Piston and Ring

28-13

I

28-8

28-14

28-12

28-12

Intake Manifold

28-17

Removal &

Removal

28-14 Installation

System Service

Precautions

28-8

Coil Spring

&

Installation

Fuel System Pressure

28-14

C Camshaft

Inner

Fuel

Pinion Seal

28-8

28-13

28-2

Removal Removal

Installation

Fuel Injector

A

28-8

28-12

Removal &

SUSPENSION

Installation

Fuel Filter

STEERING AND 28-15

P

F

Pump

Removal &

28-4 Installation

Wheel Bearings

28-10

Adjustment

28-10

Removal &

28-4

28-20 28-20

Installation

28-20

GENERAL MOTORS CORPORATION— V-BODY

28-2

CATERA

PRECAUTIONS eye

Before servicing any vehicle, please be

sure to read

of the following precautions,

all

which deal with personal of

prevention

safety,

component damage, and important points when servicing a

irritation persists, or

should always buy the correct type

tance IMMEDIATELY.

fluid for

The EPA warns

•

prolonged contact

that

may cause

to take into consideration

with used engine

motor vehicle:

skin disorders, including cancer!

Never open, service or drain the radia-

• tor or

cooling system

hot, serious

when

the engine

Observe

tions

all

applicable safety precau-

when working around

fuel.

Whenever

servicing the fuel system, always work

Do

well-ventilated area. or vapors to

effort to

used engine

to

come

in

in

a

not allow fuel spray

sure to used engine

You

oil.

water, or

•

new

All

now equipped

vehicles are

becomes contaminated, completely

Any brake

fluid.

flush the

Never reuse any

fluid.

removed

fluid that is

from the system should be discarded. Also,

come in condamage

fluid to

painted surface;

tact with a

will

it

the paint.

Never operate the engine without the

•

proper amount and type of engine

doing so WILL result

waterless hand cleaner should be used.

with an air bag system. The system

contact with a spark,

expo-

of brake

the brake fluid

If

do not allow any brake oil.

other exposed after

your vehicle.

system with new brake

Protective

Soap and

oil.

of

minimize your

soon as possible

skin areas as

number

a

when changing

gloves should be worn

Wash your hands and any

and hot coolant. •

oil

should make every

exposure

is

burns can occur from the steam

proper operation of the brake system. You

you have taken

if

brake fluid internally, seek medical assis-

oil;

severe engine

in

damage.

must be

Timing

•

belt

maintenance

Many models

extremely

is

disabled before performing service on or

important!

around system components, steering col-

ence-type, non-freewheeling engine.

extinguisher near the work area. Always

umn, instrument panel components, wiring

timing belt breaks, the valves

keep

and sensors. Failure

open flame or excessive heat light, for

(a hot

drop

example). Keep a dry chemical

fire

fuel in a container specifically

designed

for fuel storage; also,

to follow safety

disabling procedures could result

always

in

and

head may

acci-

tially

strike the pistons,

dental air bag deployment, possible per-

sonal injury and unnecessary system

maintenance

additional fuel system precautions later in

repairs.

this

Always wear safety goggles when

working with, or around, the

Fuel injection systems often remain

•

pressurized, even after the engine has been

When

turned OFF. The fuel system pressure must

sure the bag and trim cover are pointed

be relieved before disconnecting any fuel

away from your body. When placing

lines. Failure to

do so may

and/or personal

injury.

Brake

•

fluid often

deployed

result in fire

brake fluid

in

bag, be

fluid.

If

of the

module

it

if

system precautions

your eyes, flush your eyes

• If

away

is

is

recommended

interval for the timing belt,

cable on

some

vehicles

may

interfere

some

vehicles

may

the functions of the on-board

tem^) and may

require the

interfere with

computer sys-

computer

and

essential to the safe

When

is

servicing

with the operation of the on board puter system. The computer

com-

drum

brakes, only dis-

is

Alternator electrical connectors

•

Alternator

ence.

INSTALLATION

reconnected. 1.

Install or

•

Alternator

26

1

.

Negative battery cable intake air resonator

•

Drive belt

•

Coolant heater,

2.

erly. if

equipped

(40 Nm).

lbs.

Alternator electrical connectors

Coolant heater,

•

Drive belt

if

equipped

•

Intake air resonator

•

Negative battery cable

Perform a charging system

verify that the

system

to

the upper

•

or disconnect the following:

•

ft.

Nm) and

•

tion.

•

30

Torque the lower nut (35

Cooling duct

Before servicing the vehicle, refer to

Remove

lbs.

•

the precautions in the beginning of this sec-

2.

ft.

nut to

REMOVAL

connect the following:

Alternator.

is

test

and

operating prop-

at a time,

leaving the remaining side intact for refer-

may

undergo a relearning process once the negative battery cable

Alternator cooling duct

•

to

reconnected.

assemble and assemble one side

later in this section.

•

to the

Disconnecting the negative battery

cable on

ENGINE REPAIR ^Disconnecting the negative battery

replace-

and

inspection.

•

bag

Clean, high quality brake fluid from a

sealed container

causing poten-

interval charts in the front of

for the

ative battery cable

accidentally air

the

undergo a relearning process once the neg-

reduce the

deployed. Refer to the additional

you do get

with clean, running water for 15 minutes.

motion

will

If

the cylinder

timing belt section for belt replacement and

•

a non-

bag on a work surface, always

from the surface. This

contains polyglycol

and wash your hands thoroughly

handling brake

after

air

air

face the bag and trim cover upward,

ethers and polyglycols. Avoid contact with the eyes

carrying a non-deployed

manual

ment

bag system.

air

in

interfer-

expensive) engine damage. Refer to the

properly seal fuel containers to avoid the

•

an

serious (also time-consuming and

possibility of fire or explosion. Refer to the

this section.

utilize

Alternator mounting hardware

OQ tO O

ENGINE FRQTT

EMQNC LEFT

ENGINE R1CKT

MARK

A

OIL RING SPACER GAP (tanc in hole or slot

wrm

arc)

CAPS C 2N0 COMPRESSION RING GAP D TOP COMPRESSION RING GAP

B

OIL RINC RAIL

7S224G46

Piston ring end-gap spacing

—3.1L,

3.4L,

3.8L engines

CAM8HAFT TO BALANCE 8HAFT TO CRANKSHAFT CAMSHAFT 7922XG17

Balance shaft-to-camshaft and camshaft-to-crankshaft timing mark alignment— 3. 8L engine

Lower oil Upper oil 3 Top Ring

control

control ring

4

Piston and Ring

5.

POSITIONING

mg

1

2.

Ol

control nng expanoer Second nng

Piston ring end-gap positioning

—

3. 51-

engine

CONNECTING ROD

_

—

o ~\2>/

\C2y-

Piston positioning

— 3.5L engine

ARRO* TOWARDS FRONT Of ENGINE

I922AG5I

Piston positioning

Connecting rod and cap installation. Be

Otten the arrow

is

sure to matchmark the cap and rod prior to

Piston ring positioning— 3. 1 L. 3.4L, 3.5L

replaced by a notch, which also must lace

disassembly, as shown

and 3.8L engines

toward the front

ol the

and 3.8L engines

Heater Core replacement

is

covered

in

Section

2 of this manual

engine

— 3.1L, 3.4L

no no

GENERAL MOTORS CORPORATION— W-BODY

£

CENTURY

•

REGAL

IMPALA

•

LUMINA

•

MONTE CARLO

•

«

INTRIGUE

*

GRAND PRIX

FUEL SYSTEM Fuel System Service Precautions

accidental attempt

is

made

and torque the

to start the

Safety

is

the

most important

factor

when

performing not only fuel system mainte-

nance but any type to

manner may

safe

injury or death.

in

result in serious personal

Maintenance and testing

of

components can be

accomplished safely and

effectively

fitting to

connect

avoid spillage.

and per-

to the to the fuel

5.

bleed hose into an

Install the

approved container and open the valve

battery cable unless the repair or test proce-

bleed fuel system pressure. The fuel con-

dure requires that battery voltage be

nections are 6.

Always

system pres-

relieve the fuel

(injector, fuel rail,

ulator, etc.), fitting or fuel line

now

to

7.

in

the

gauge

Reconnect the negative battery cable

pressure reg-

unless addition service work

connection.

formed.

system pressure, to avoid exposing

skin, face

and eyes

to fuel spray. Please

advised that fuel under pressure trate the skin or

any part

of the

body

• 5.

Always place

around the

shop towel or

a

(should

it

occur)

is

all

10 seconds. Turn the ignition

cloth

fuel

ON

OFF and

for leaks.

Turn the ignition

OFF

and check

for

leaks.

Fuel

Pump

REMOVAL & INSTALLATION

Before servicing the vehicle, refer to

1.

REMOVAL & INSTALLATION

All

in

the beginning of this sec-

tion.

Models

2.

Relieve the fuel system pressure.

3.

Drain the fuel tank with a hand held

siphon Before servicing the vehicle, refer to

until the level is less

Remove

4.

than 14

•

Negative battery cable

tion.

•

Spare

tire

and jack

2.

Relieve fuel system pressure.

•

Floor trunk liner by pulling

3.

Remove

•

Fuel sender access panel

soaked

cloths or towels are deposited into a suit•

or disconnect the following:

Quick-connect

fitting at

the inlet of

•

full.

or disconnect the following:

the precautions in the beginning of this sec-

quickly removed from all

position

for

fuel spillage

engine surfaces. Ensure that

22

it

loosening to absorb any excess fuel due to

Ensure that

ON

two seconds then turn the ignition

6.

to

Nm)

Negative battery cable

the precautions

1.

spillage.

(30

lbs.

for

or connection prior to

fitting

the outlet side of

Turn the ignition to the

contacts. •

fitting to

and using a back up

Except Lumina

Fuel Filter

that

inlet

being per-

is

be

may pene-

on the

safe for servicing.

Drain any fuel remaining

Exercise extreme caution whenever relieving fuel

filter

fitting

filter

an approved container.

into

sure prior to disconnecting any fuel system

component

ft.

check

sonal injury, always disconnect the negative

applied.

(20

lbs.

ft.

wrench, torque the outlet nut

pressure

connection while connecting gauge to

Threaded the

a shop towel around the pressure test

lines.

•

•

charge into an approved gasoline container.

fitting

Quick-connect side of the

connection and another hose to dis-

test

Wrap

by

fire

•

to relieve

This procedure calls for a fuel pres-

4.

adhering to the following rules and guide-

To avoid the possibility of

cap

sure test gauge with a line equipped with a

a

the vehicle’s fuel system

•

fuel filler

tank pressure.

of maintenance. Failure

conduct maintenance and repairs

Loosen the

3.

15

bolt to

Nm)

engine.

it

back

Fuel tank pressure sensor electrical

able waste container. the fuel

Always keep

•

a dry

chemical (Class B) •

Threaded

fitting at

the outlet side of

•

Fuel sender electrical connector

•

Fuel sender assembly quick con-

extinguisher near the work area.

fire

the fuel

Do come •

to

connector

filter

filter.

not allow fuel spray or fuel vapors into contact with a

spark or open

^Have

nect fittings

a container available to •

retrieve any fuel remaining in the

flame.

Retaining snapring from the fuel

filter.

sender

Always use a backup wrench when

•

loosening and tightening

fuel line

tion fittings. This will prevent

connec-

•

unnecessary 4.

stress

and torsion

to fuel line piping.

from the mounting bracket

Filter

To install: Install or

•

Fuel

connect the following:

filter

into the

mounting bracket

Always follow the proper torque specifications.

Always replace worn

•

rings with new. or equivalent,

Do

fuel fitting Fi-

not substitute fuel hose

where

fuel pipe is installed.

Fuel System Pressure RELIEVING

1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

7922Z528

Disconnect the negative battery cable

to prevent possible

discharge of fuel

if

an

Remove

the fuel

pump from

removing the locking

ring

the tank after

W-BODY— GENERAL MOTORS CORPORATION. CENTURY

REGAL

•

IMPALA

•

LUMINA

•

MONTE CARLO

•

torque the nuts to 89 inch

lbs.

•

INTRIGUE

•

GRAND PRIX

OQ OO OU

(10

Nm)

When

the Lockring

is

removed from assembly

10. •

Trunk

liner

•

Spare

tire,

the fuel sender, the sender will

Downward pressure

spring up.

jack and spare

cover

tire

the fuel tank.

Refill

should be kept on the assembly and slowly released to ensure the sender

Lumina

assembly does not get damaged. 1

•

Modular

fuel

sender assembly

Install or

• •

New

connect the following:

O-ring on the fuel tank

2.

Relieve the fuel system pressure.

3.

Drain the fuel tank.

4.

Disconnect the negative battery

Fuel sender cable.

•

Snapring on the

•

Fuel sender electrical connector

•

sender

fuel

Remove

5.

Fuel tank pressure sensor electrical

Clean

6.

Quick connect

the fuel tank from the

vehicle.

connector •

the beginning of this sec-

in

tion.

To install: 5.

Before servicing the vehicle, refer to

.

the precautions

of pipe

all

Also clean

tions.

and hose connec-

areas around the con-

all

fittings at the fuel

nections.

sender

Disconnect the quick-connect

7.

•

Negative battery cable

Add

6.

a small

amount

at

fittings

the fuel sender assembly.

of fuel to the

Remove

8.

the fuel sender

assembly

fuel tank.

Turn the ignition to the

7 for

ON

retaining

ON

ring, the fuel

sender assem-

position

2 seconds then turn the ignition

10 seconds. Turn the ignition

snap

and the O-ring from the

bly

OFF

fuel tank. Dis-

for

and check

Exploded view

card the fuel sender assembly O-ring.

To

of the fuel injector

— 3.1L

and 3.4L engines

install:

for leaks.

Turn the ignition

8.

OFF

Position the

9.

and check

new

fuel

sender assem-

for

on the

bly O-ring

2.

fuel tank.

leaks. 3.

Install or

9. •

connect the following:

Fuel sender access panel and

••Make sure the fuel

pump

strainer

when

restrict fuel flow. Also,

pump

Remove

not to fold over or twist

ensure that the

strainer does not block

Upper intake manifold

•

Fuel inlet and return lines

•

Fuel injector electrical connectors

•

Coolant temperature sensor

arm. sender assembly and

Install the fuel

10.

the 1. fuel sender

assembly retaining snap

1

Connect the quick-connect

.

fittings at

•

Fuel

•

Fuel injector retaining clips

•

Fuel injectors

tank and add fuel

12.

Install the fuel

13.

Pressurize the system as follows to

check

4

5.

for leaks: a.

Turn the ignition switch

ON

for

2

seconds. b.

Turn the ignition switch

OFF

for

10

Coat the new

Install or

c.

Turn the ignition switch to the

d.

Check

Upper O-ring

•

Lower O-ring

•

Fuel injector

•

Fuel injector retaining clips Fuel

•

•

3 4

5

FUEL PIPES (ABOVE COVER) RESERVOIR - FUEL PUMP FUEL SENSOR ASSEMBLY - FUEL LEVEL 7922XG19

Fuel

pump and sending

assembly

unit

•

rail

lbs.

and torque the bolts

(10

Fuel injector electrical connectors Fuel inlet and return lines with

13ft. lbs. (17 •

3.1L and 3.4L Engines

module

the precautions

in

the beginning ot this sec-

6.

repair tion.

Brake service

is

covered

in

Nm)

Section 4 ol this manual

ft

lbs.

(25

Nm)

Negative battery cable

Start the vehicle if

new

fittings to

Upper intake manifold and torque the bolts to 18

•

Before servicing the vehicle, refer to

electri-

connector

O-rings and torque the

REMOVAL & INSTALLATION

to 7

Nm)

Coolant temperature sensor cal

SUPPORT ASSEMBLY - FUEL SENOER COVER ASSEMBLY - FUEL SENDER

connect the following

•

ft.

Fuel Injector

O-rings

Lower backup O-ring

ON

for fuel leaks.

fuel injector

oil.

•

•

seconds.

1

rail

with clean engine

the fuel sender assembly.

2

connector

To install:

ring. 1

electri-

full

cal

travel ot float

or disconnect the following:

•

installing

the fuel sender assembly, as this will

fuel

Relieve the fuel system pressure.

necessary.

and check

for leaks,

OO £

GENERAL MOTORS CORPORATION— W-BODY CENTURY

REGAL

*

•

IMPALA

LUMINA

•

3.5L and 3.8L Engines 1

Before servicing the vehicle, refer to

.

the precautions in the beginning of this section.

MONTE CARLO

•

Relieve the fuel system pressure.

3.

Remove

Fuel injector retaining clips

snap-lock tabs retainers, push

Fuel injectors

down

install:

4.

Coat the new

•

Fuel injector sight shield

•

Fuel feed and return lines

•

Fuel pressure regulator

•

vacuum

connection •

Ignition coil wires from the coil

•

Fuel injector electrical connectors

Fuel

fuel injector

O-rings

•

oil.

connect the following:

Ignition coil wires to the coil

•

Fuel pressure regulator

vacuum

connection

•

Upper O-ring

•

Fuel feed and return lines

•

Lower O-ring

•

Negative battery cable

•

Fuel injector

•

Fuel injector retaining clips

•

Fuel

rail

into

Fuel injector electrical connectors

•

Lower backup O-ring

(10

Nm)

bolt retainers.

it

repair

If

to

7

equipped with

equipped with

and check

Start the vehicle

6.

and torque the bolts

rail

lbs.

ft.

•

snap

until the retainers

place.

Install or

or disconnect the following:

GRAND PRIX

•

To

5.

•

•

with clean engine

2.

INTRIGUE

•

if

for leaks,

necessary.

Install the fuel injector sight shield

7.

and torque the nuts

27 inch

to

lbs. (3

Nm).

DRIVE TRAIN Transaxle Assembly

Torque converter cover

•

Starter

•

Torque converter bolts

•

Oil

•

Drive axles and secure them to the

les

steering knuckles and struts

(85

REMOVAL & INSTALLATION

~These

transaxles were used

in a

variety of General Motor’s vehicles. •

Due

to

model

installed

model and options, the removal and year, vehicle

•

procedures may vary The procedures given here

installation slightly.

should suffice for most using these transaxles.

all

vehicles

1

in

the beginning of this sec-

an engine support

Install

4.

Remove •

fixture.

or disconnect the following:

Negative battery cable

•

Throttle

•

Engine mount struts

•

Wire harness connectors from the

body

air inlet

duct

Front wheels

Vehicle Speed Sensor (VSS) con-

•

Fluid

Remove

•

connect the following:

Install or

•

Transmission

•

Lower transmission bolts and

(25

(75

Nm)

selector cable with the

(20

Range

ft.

Nm)

selector cable to the

PNP

•

New

lbs.

ft.

(75

Nm)

•

frame to body bolts and

125

to

ft.

lbs.

Wire harness connectors

Vacuum hose and

pipe to the

bolts to

Remove

(170

37

ft.

Ibs.

(50

Nm)

•

Throttle

•

Negative battery cable

VSS

35

lbs.

ft.

(47

Nm)

connector

•

WSS

•

Fluid

filler

tube

•

Drive axles to the transmission

•

Upper transmission bolts

•

Oil

•

Wire harness grounds

•

Torque converter bolts and torque

•

Both front wheels

•

Engine splash shields

•

Both

electrical

electrical

air inlet

duct

the transmission with fluid.

10.

Fill

11.

Start the

engine and check the oil level.

Add

oil

if

necessary.

cooler hoses

them

to

46

ft.

lbs.

(63

4T65-E Transmission

Nm) 1

•

body

engine and transaxle

connectors

Nm)

the engine support fixture.

Transmission brace and torque the bolts to

mod-

Engine mount struts and torque the

•

pipe from the

to the

ulator

switch

Starter

Before servicing the vehicle, refer to

.

motor and torque the bolts the precautions in the beginning of this sec-

to

rod ends from the steering

Power steering gear from the frame and secure it to the body of the

32

ft.

lbs.

(43

Nm) tion.

•

knuckles

Torque converter cover and torque

89 inch

the bolts to •

Lower

lbs.

(10

2.

Drain the transmission

3.

Install

4.

Remove

Nm)

ball joints to the steering

fluid.

an engine support

fixture.

or disconnect the following:

knuckle and torque the nuts to 40

vehicle

Power steering cooler

line

ball joints

knuckles

ft.

clamps

Engine mount lower nuts

Lower

Ibs.

ft.

Ibs.

transmission •

PNP

•

Range

•

install:

8.

Park/Neutral Position (PNP) switch

•

•

Ibs.

the transmission from the

•

•

Nm)

switch and torque the bolts to

vehicle.

•

•

and torque

PNP

ft.

switch

Range selector cable from the

tie

bolts

•

55

bracket and torque the nut to 15

7.

Ibs.

to

Frame-to-body bolts

torque them

Vacuum hose and

ft.

tube

filler

Upper transaxle

18

Lower the frame from the

To

knuck-

63

to

them

table to support

6.

torque them to 55

modulator •

Engine splash shields

Lower transmission bolts

ibs.

Nm)

•

Transmission brace

ft.

to the steering

•

9. •

59

and torque the nuts

nectors

• •

ends

Tie rod

Wheel Speed Sensor (WSS) con-

•

transmission •

•

frame.

Drain the transmission fluid.

3.

cooler hoses

frame

to the

bolts to

Nm)

(80

the transmission.

tion. 2.

and torque the

Use a transmission

5.

Before servicing the vehicle, refer to

.

the precautions

•

motor

nectors

4T60-E Transmission

Power steering gear

•

•

lbs.

(55

Nm)

•

Negative battery cable Throttle

•

Engine mount struts

•

Wire harness connectors from the

Engine mount lower nuts and torque them to 32

from the steering

•

•

Power

ft.

lbs.

(43

steering cooler line

Nm)

body

clamps transmission

to the

frame

air inlet

duct

OQ OE OU

W-BODY— GENERAL MOTORS CORPORATION. CENTURY •

REGAL

•

IMPALA

Range selector cable from the Park Neutral Position

•

Range

•

PNP

•

•

•

(PNP) switch

selector cable and bracket

•

Power steering gear

frame

to

•

•

Fluid

filler

tube

•

MONTE CARLO

32

lbs.

ft.

(43

lbs.

Nm)

Brake rotor

Wheel Speed Sensor (WSS)

Lower

ball joints to the steering

•

Engine splash shields

•

Both

it

torque them to 35

body

to the

Power steering cooler

vehicle

•

Engine mount lower nuts

les

•

Lower

(85

•

from the steering

ball joints

clamps

line

59

to

ft.

to the steering

and torque the nuts

63

to

Torque converter cover

•

Front wheels

•

Starter

•

Fluid

•

Torque converter bolts

•

Upper transmission bolts and

•

Oil

•

PNP

•

Wheel Speed Sensor (WSS) cal

•

18

Vehicle Speed Sensor (VSS) elec•

table to support •

Engine mount lower nuts

•

Transmission brace

•

Lower transmission bolts

•

Frame-to-body bolts

•

• •

from the vehicle.

Remove

the transmission.

Install or

•

the •

connect the following:

Transmission

assembly

New

lbs.

ft.

(75

Nm)

to the

pull

on the axle

37

ft.

body

seated

6. ft.

strut

to the

Install or

Do

the snapring

(50

•

Front wheel driveshaft bearing and

•

•

•

Nm) New

lbs.

Adjust the wheel alignment.

13.

Start

engine and check the engine if

neces-

sary.

if

and torque

lbs.

ft.

lbs.

(200

80

Nm) and ft.

lbs.

Front wheel

•

Negative battery cable

7.

Check the transaxle

8

Check the

front

fluid level.

necessary

REMOVAL & INSTALLATION

to

55

ft.

lbs.

(75

Nm) •

Transmission brace and torque the transmission bolts

Nm) and (63

lbs.

to

32

ft.

lbs.

the engine bolts to

46

VSS

•

WSS

•

Drive axles to the transmission

•

Oil

•If equipped with Antilock Brake System (ABS) brakes, use care to avoid

(43

damage age

connector

electrical connectors

cooler hoses

set a 1

ABS toothed ring Dammay cause the selffeature of the ABS system to

to the

to the ring

diagnostic

Nm)

•

electrical

Lumina and 1998-99 Monte Carlo

ft.

system

fault

code.

Before servicing the vehicle, refer to

Use

the precautions in the beginning of this sec-

a puller to press the axle shaft

through the hub/bearing assembly

tion.

For complete Engine Mechanical specifications, see Section

1

of this

manual

148

alignment and adjust

Lower transmission-to-engine bolts and torque them

to

(108 Nm)

•

Nm) •

to

the caliper

Halfshaft (180

it

Nm)

frame-to-body bolts and

torque them to 133

(70

Brake caliper and attaching bracket

bolts to

the transmission with fluid

12.

(215

lbs.

Brake rotor

ft.

Negative battery cable

oil

driveshaft nut ft

ft.

and torque the bracket bolts

duct

Fill

connector

torque the bolts to 52

Nm)

11.

Add

connect the following:

electrical

frame and raise

into position

not is

WSS

PNP

and torque the

air inlet

oil levels.

If

•

159

lbs.

pull outward.

shaft.

properly seated, the axle will remain in

the engine support fixture.

Throttle

is

place.

Nm)

Engine mount

and

of the axle shaft

Nm)

Wire harness connectors to the

and transaxle

install:

9.

Halfshaft into the transaxle

with a prying tool. Grasp the inner housing

Range selector cable

Remove

10.

Lower the transmission and frame

8.

(25

Bearing-to-knuckle bolts, loosely

•

Verify that the snapring

5.

Range selector cable with the

bolts to

engine. 7.

lbs.

•

transmission

Separate the transmission from the

6.

lbs.

switch and torque the bolts to

(20

connect the following:

Halfshaft/bearing assembly

transaxle

switch

the transmission. •

•

tube

filler

ft.

lbs.

connectors

trical

ft.

bracket and torque the nut to 15

Use a transmission

5.

•

electri-

connectors

Install or

properly by tapping on the inner groove

torque them to 55

Drive axles and secure them to the

install:

4.

Nm)

•

steering knuckles

To

knuck-

Engine splash shields

•

assem-

through the knuckle and into the

ends

Tie rod

the halfshaft/bearing

bly through the steering knuckle.

lbs.

•

cooler hoses

Remove

3.

steering gear to the frame

knuckles

motor

Axle shaft using an appropriate

Nm)

(80

Power steering cooler

clamps

Wheel hub/bearing

•

puller

Nm)

(47

frame

Power

•

line

lbs.

ft.

and torque the bolts

of the

•

Engine mount lower nuts and

to the

and secure

Nm)

(55

lbs.

electri-

connector

cal

Both front wheels

•

Brake caliper and bracket assembly

•

•

Power steering gear from the frame

Drive shaft nut

• •

knuckle and torque the nuts to 40

knuckles

•

Torque converter cover and torque

ft.

•

or disconnect the following:

Front wheel

the bolts to 89 inch lbs. (10 Nm).

Upper transmission bolts

rod ends from the steering

£

GRAND PRIX

•

Remove

2.

motor and torque the bolts

ft.

Wire harness grounds

tie

INTRIGUE

•

•

•

•

Nm)

(63

•

•

To

46

to

Starter to

retaining bolts

•

Torque converter bolts and torque

them

switch

LUMINA

•

90 90 L.3“00

GENERAL MOTORS CORPORATION CENTURY

REGAL

*

IMPALA

•

•

LUMINA •

Century, Regal, Impala, Intrigue, Gran Prix and 2000-01 Monte Carlo 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

•

*

GRAND PRIX

it

CV-joint boot by sliding

Tri-pot

it

away

tri-pot joint

housing from the

tri-pot

spider

Remove

or disconnect the following:

•

Front wheel

•

Stabilizer shaft link

•

Drive shaft nut

•

Outer

•

•

•

9306XG17

Inboard spacer ring slide

rear-

it

Pliers Tool

measurement— Inner

Boot

(tri-pot) joint

J-8059

•

Outboard retaining ring using

•

Tri-pot joint spider

•

Inboard spacer ring and CV-joint

from the steering knuckle

Ball joint

bushing from the

ward on the shaft using Snapring

rod end from the steering

tie

Trilobal tri-pot

housing

knuckle

3.

INTRIGUE

*

—

Large CV-joint boot clamp, cut and

from the

tion. 2.

MONTE CARLO

•

discard •

—

— W-BODY

Snapring Pliers Tool J-8059

Press the axle shaft through the hub.

assembly

boot

To prevent

damage

CV-

to the inner

do not pull on the axle shaft remove it from the transaxle.

joint,

Throughly clean and inspect

3.

to

To

install:

4. 4.

5.

Install or

connect the following:

Place a drain pan under the transaxle

to catch

when

all

parts.

any transaxle

the axle shaft

Remove

fluid that leaks out

removed.

is

Crimping the large CV-joint boot ring

the axle shaft from the

Inner (tri-pot) joint

transaxle by prying between the transaxle

and the inner CV-joint housing.

To install: 6.

connect the following:

Install or

•

Axle shaft that

the

housing •

Axle shaft through the hub/bearing

Exploded view

of the inner (tri-pot) joint

Ball joint ft.

•

22

lbs.

ft.

tional •

New 118

Nm)

(30

lbs.

(160

if

fol-

ft.

all

it

lbs.

WARNING

8.

Check the

front

Make

sure that there are no pinch

points on the inboard seal.

Positioning the inner CV-joint boot seal

Check the transaxle

the lower half.

Nm)

Front wheel

7.

Position the outboard of the half-

(215

and torque the

(23

the lower half of Tool J-

a vise.

41048 onto

to

except

lbs.

in

Position the upper end of Tool J-

c.

and torque

Impala models

ft.

Mount

shaft in the tool.

plus an addi-

Nm) on

Stabilizer shaft link

nut to 17 •

clamp on the boot.

ring

Secure the swage ring clamp as

6.

b.

to

turn

drive shaft nut

Nm) on

swage

41048

Impala models or 159

•

Position the CV-joint boot seal into

a.

40

Nm)

120 degree

ft.

to

end and torque the nut

Tie rod

clamp

7.

and torque the nut

(55

lbs.

ring

lows:

assembly •

CV-joint boot

the axle shaft's joint seal groove and align

seated by pulling on the

is

it

Swage

5.

the transaxle. Verify

in

•

•

fluid level.

and swage ring— Inner

(tri-pot) joint

alignment and adjust,

d.

hand e.

necessary.

Insert both bolts until

and tighten by

snug.

Tighten each bolt 180 degree

turn) at a time, alternating J

(Vfe

between the

41048

bolts, until

CV-Joint

f.

both sides are bottomed.

Remove Install or

•

OVERHAUL

the tool.

connect the following:

Inboard spacer ring, slide

it

rear-

ward on the shaft using Snapring

J-8059

Pliers Tool

Inner (Tri-Pot) Joint

•

the shaft

Before servicing the vehicle, refer to

1.

the precautions

in

Tri-pot joint spider

•

the beginning of this sec-

assembly onto

r

Outboard retaining ring

into the

axle shaft groove using Snapring

tion.

Remove

2. •

Pliers Tool

or disconnect the following: •

Front wheel

•

Halfshaft

•

Swage

ring using a

View

of the

swage

Inner (tri-pot) joint

hand grinder

ring crimping tool

J-8059

Tri-pot joint spider assembly, slide it

against the outboard retaining

ring

07 OQ Of

W-BODY— GENERAL MOTORS CORPORATION. CENTURY* REGAL Inboard spacer ring, seat

•

it

•

IMPALA

•

LUMINA

•

MONTE CARLO* INTRIGUE* GRAND PRIX

the

in

groove •

V2 kit grease

•

Vz

kit

New

large seal

joint

boot

Lubricate the parts with a light coat

of grease.

Assemble the CV-joint cage and

7. it

inner race, as follows:

over the 9306XG19

assembly

CV-joint boot/clamp, slide

bushing with the seal

lip in

into

the cage centerline.

Disconnecting the outer CV-joint from the axle shaft

lies flat

against

Insert the cage/inner race into the

d.

it

mea-

Assemble the chrome

8.

(125mm).

Using the Crimp Tool J-35910, a

clamp

to

130

ft.

Position a brass

a.

CV-joint cage and tap

lbs.

to

tilt

(176 Nm).

b.

connect the following:

Halfshaft

•

Front wheel

drift it

against the

with a

hammer

the cage. Insert the 1st

chrome

alloy ball into

the cage. Tilt

c.

the cage in the opposite direc-

tion.

Insert the opposite

d.

Outer Joint

chrome

alloy

ball.

Repeat the procedure

e

Before servicing the vehicle, refer to

1.

alloy balls into

the CV-joint cage, as follows:

torque wrench and a breaker bar, crimp the

•

cage

outer race.

Position the CV-joint boot so

Install or

inner

by rotating the inner race downward.

trilobal bushing. the10.

large CV-joint boot

windows with

Insert the inner race into the

c.

’•Make sure the boot

9.

Align the cage

b.

race lands.

the

groove

in.

Rotate the inner race 90 degrees to

a.

it

place, over the trilobal tri-pot

8.

all

install:

6.

clamp onto the CV-

tri-pot joint spider

sures 4.9

from the cage.

Throughly clean and inspect

To

bushing flush with

Tri-pot housing, slide

•

it

the cage from the outer race.

parts.

Trilobal tip-pot

•

Rotate the inner race upward and

5.

the tri-pot housing face •

Remove

d.

remove

into the boot

grease into the tri-pot hous-

ing •

c.

until all

6

balls are inserted.

the precautions in the beginning of this sec-

Install or

9.

connect the following:

tion.

Remove

2.

grease into the CV-joint

•

Vfe kit

•

%

•

Swage

•

CV-joint boot

or disconnect the follow-

boot

ing:

Front wheel

• •

Halfshaft

•

Swage

•

Large boot clamp, cut and discard

ring using a

hand grinder

—Outer CV-

it

10

into the axle shaft's joint seal

CV-joint boot from the axle shaft

a.

Position a brass

CV-joint cage and tap the cage.

b.

Chrome

c.

Tilt

41048 b.

drift it

Position

against the

with a

of seal

hammer

edge

here

c. SVOS22

Positioning the

alloy ball

boot— Outer

the lower half of tool J-

a vise.

Position the outboard of the half-

Position the upper end of tool J-

41048 onto

the lower half.

CV-joint

from the cage.

the cage in the opposite direc-

Disassemble the CV-joint cage and

4.

Make

inner race as follows:

Remove

in

shaft in the tool

tion.

d

Mount

it

Disassemble the chrome alloy balls

tilt

fol-

lows:

from the CV-joint cage as follows:

to

Secure the swage ring clamp as

1 1

Tool J-8059

a.

groove

boot.

ring ears using Snapring Pliers

3.

Position the CV-joint boot seal

and align the swage ring clamp on the

inner race-to-axle shaft retaining

and discard

clamp

groove

away from

CV-joint assembly by spreading the

•

ring

the retaining ring seats into the

the CV-joint •

grease into the CV-joint

CV-joint onto the axle shaft until

•

joint

it

CV-joint boot, slide

•

View the cage and inner race

kit

the opposite

chrome

a.

Pivot the cage

sure that there are no pinch

points on the inboard seal.

alloy

and race 90 degrees

ball.

to the center line of the outer race. e.

Repeat the procedure

until all

d.

6 b.

balls are

Align the cage

windows with

outer

hand

removed.

Insert both bolts until

race lands.

For Accessory Drive Belt

illustrations,

see Section

1

of this

manual

snug.

and tighten by

OO

*3

a

GENERAL MOTORS CORPORATION— W-BODY CENTURY

•

REGAL

Tighten each bolt 18Q degree

e

IMPALA

•

(V2

LUMINA

•

Remove

f.

Install or

12. •

CV-joint boot/clamp, slide

•

seal

large seal

boot

lip in

it

INTRIGUE into

•

GRAND PRIX

torque wrench and a breaker large CV-joint boot

clamp

to

bar,

130

crimp the ft.

lbs.

(176 Nm).

the groove

i->Make sure the boot

connect the following:

New

•

place, over the outer race with the

bottomed.

the tool.

joint

MONTE CARLO

)

turn at a time, alternating between the bolts, until both sides are

•

lies flat

14.

against

Install or

connect the following:

•

Halfshaft

•

Front wheel

the outer race.

clamp onto the C VUsing the Crimp Tool J-35910, a

13.

STEERING AND SUSPENSION Air

ing column.

Bag

The

driver’s side air

bag

is

now

disabled.

**

CAUTION

The vehicles are equipped with the Supplemental Inflatable Restraint (SIR) or air bag system. The SIR system must be disabled before performing service on or around SIR system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary SIR system repairs.

6.

Remove

1. 7.

Detach the

connector

at

the right side

CPA and

sound

insulator.

air

bag

is

now

disabled.

Inflatable Restraint (SIR)

CPA

yellow 2-way SIR

the base of the steering wheel.

The passenger's side

Attach the yellow 2-way

2. tal

tor

at the

After

air

bag system as follows:

Be sure the ignition key

is

4.

Attach the yellow 2-way SIR connec-

Several precautions

at the

multi-use bracket

module

is

locked and the

removed.

inflator

7.

Turn the ignition switch to the

the AIR

flashes 7 times, then shuts

off.

the

module. •

When

carrying a live inflator module,

3 4

that the

bag and trim cover are pointed

CONNECTOR POSITION ASSURANCE (CPA) CONNECTOR, STEERING COLUMN WIRING HARNESS

away. •

Place the inflator module on a bench

or other surface with the

SRS 2-way connector

location

—

SRS 2-way connector

location

— passenger’s side

driver’s side

bag and trim cover

facing up. •

With the

inflator

module on

the bench,

never place anything on or close to the

module which may be thrown of

in

the event

an accidental deployment.

DISARMING

1.

Turn the steering wheel so the vehicle

wheels are pointing straight-ahead. 2.

Turn the ignition key to the

position and 3.

remove the

Remove

the AIR

LOCK

key.

BAG

fuse from the

fuse block. 4.

Remove

5.

Detach the Connector Position Assur-

the

left

side sound insulator.

ance (CPA) and yellow 2-way Supplemental Inflatable Restraint (SIR)

connector

at the

multi-use bracket near the base of the steer-

base

insulator.

fuse.

BAG

wires or connector on the underside of the

hold securely with both hands, and ensure

BAG

position and verify the AIR

to avoid

module by

sound

Install

sonal injury.

Never carry the

side

Install the left

6.

accidental deployment and possible per-

•

at the

5.

must be observed

the inflator

insulator.

and Connector Position Assurance

PRECAUTIONS

when handling

sound

side

Install the right

the column.

necessary repairs are made, re-

enable the

of the steering wheel.

3.

(CPA)

ARMING

base

Supplemen-

connector and

light

RUN

of

W-BODY— GENERAL MOTORS CORPORATION. CENTURY

•

REGAL

•

Power Rack and Pinion Steering Gear

IMPALA

•

LUMINA

•

MONTE CARLO

•

INTRIGUE

Negative battery cable

•Set

Front wheels

block tooth on the upper steering shaft

CAUTION

is at the 12 o’clock position. The wheels should be straight ahead. Set

tion. 2.

Remove

or disconnect the following:

stub shaft

may

result in

the steering gear. This

the steering shaft so that the

ignition key lock to the the 3.

Failure to disconnect the intermediBefore servicing the vehicle, refer to

could result

damage to damage may

in

damage

Common

3.4L

Remove

Tire,

Wheel and Ball Joint

to the

SIR

coil

or disconnect the follow-

ing:

ONLY

rack and pinion steering gear mounting

For

posi-

procedures

assembly.

cause a loss of steering control and may cause personal injury.

SHIELD. STEERING GEAR HEAT

LOCK

tion. Failure to follow these

i

16

OQ OQ 3 03

•

ate shaft from the rack and pinion 1.

GRAND PRIX

•

REMOVAL & INSTALLATION

the precautions in the beginning of this sec-

•

specifications, see Section

1

of this

manual

GENERAL MOTORS CORPORATION— W-BODY

29-40

CENTURY

REGAL

•

IMPALA

•

INTRIGUE

•

GRAND PRIX

stub shaft

tion.

REMOVAL & INSTALLATION

•

Both

1

.

Before servicing the vehicle, refer to the

rear.

precautions

>*D0 NOT lower the frame too far. Engine components near the firewall may be damaged.

2.

in

3.

Scribe the strut to the steering

Torx®

or disconnect the following:

Three upper

Lower

bolts from the rear of the

•

Power steering pressure

To

from

line

strut nuts •

Strut

Install or

hose

•

Magnasteer Variable Assist

•

connect the following:

•

Power steering gear through the

5.

to

Power steering gear through

bolts

59

(80

and torque them

24

ft.

lbs.

•

Nm) on Impala models.

Lower

strut bolts

to

Align the strut to the scribe mark on

ft.

lbs.

6.

Install

7.

Road

connector to the power

Power steering

if

lines with

new 0-

rings to the steering gear. Torque the fasteners to

20

(27

lbs.

ft.

•

•

and check the if

necessary.

torque

its

"•The Chevrolet Lumina and 1998-99 Monte Carlo utilize a replaceable cartridge housed within the strut assembly. The cartridge can be replaced without removing the strut assembly from the vehicle.

New

rear to

Tie rod

(30 •

10. •

ends

ft.

lbs.

lbs.

ft.

(110

and

Nm)

the shaft into the car-

ment

(180

rod. Install

9.

service the strut cartridge

to the steering

and torque the nuts

to

spring could result

ft.

mount

insulator as

Step 1:Use a soap solution

is

in

Step

to lubri-

necessary, install an

2:lf

alignment rod tool

on

com-

personal injury.

knuck-

22

the strut

follows:

partially installed

after the

bushing

and position the

as required to assist

is

strut

the bushing

in

installation.

pressed. Otherwise the released coil

Nm)

bumper

Strut

Raise the strut and remove the align-

8.

a.

vehicle keeps the coil spring

frame bolts and torque

133

82

to

cate the bushing for ease of installation.

unless the weight of the vehicle

original

connect the following:

them

it

Compress

•

Front Strut Cartridge

housing

Strut cartridge closure nut

•

the suspension. The weight of the

les

Self-contained replacement car-

b.

Install or

connect the following:

Install or

the front wheel. test the vehicle

end alignment, adjust

DO NOT

position. 8.

the strut housing

install:

•

CAUTION

hose

return

Raise the rear frame to

7.

To

(123 Nm).

Nm).

Power steering

oil in

using a suction pump.

tridge with a strut alignment tool

equipped

•

Strut cartridge

Remove any

Nm)

steering gear assembly,

•

90

front

Mounting

trical

or

wrench

left

Magnasteer Variable Assist elec-

•

closure nut using a Strut Cap Nut

all

tridge into the strut

the

wheel opening

lbs.

and torque

Nm) on

7.

connect the following:

strut into

or disconnect the following:

the steering knuckle. Torque the lower bolts

To install:

ft.

lbs. (41

left

wheel opening

•

strut nuts

ft.

6.

•

•

30

models except Impala (33

Steering gear mounting bolts

Install or

to

if

•

tool in the

Strut closure nut by unscrewing the

•

Three upper

them

equipped

6.

Remove

5

Strut

electri-

connector from the power

steering gear assembly,

Alignment

compress the

install:

•

return

bumper

Strut

Install a Strut

the cartridge. 4.

Power steering

insulator by prying

bladed tool

flat

correct position and

the steering gear •

mount

Strut

strut bolts 4.

50

bit

with a

•

removing the three

Strut shaft nut by using a No.

•

Front wheel

•

•

cal

Strut cover by

or disconnect the follow-

frame. Lower the frame slightly •

•

cover nuts

ing:

Frame

Wheel

the beginning of this section.

Remove

or disconnect the following:

•

knuckle for proper installation.

•

Remove

Remove

3.

center

at the

Scribe the strut cover to body to

2.

Front Strut

Support the frame

the beginning of this sec-

in

assure proper camber adjustment.

rod ends from the steering

tie

knuckles

•

Before servicing the vehicle, refer to

Strut

the precautions

Intermediate steering shaft

5.

•

pinch bolt from the steering gear

•

4.

MONTE CARLO

•

1.

Intermediate steering shaft lower

•

LUMINA

•

Install or

•

connect the following:

Strut shaft nut using the No.

Torx®

bit

tighten

it

to

59

ft.

50

lbs.

(80

Nm)

lbs.

Nm)

Intermediate steering shaft to the steering gear stub shaft and torque the lower pinch bolt to

(48 •

ft.

lbs.

Front wheels

• 9.

35

Nm)

Negative battery cable Fill

and bleed the power steering

system. 10. repair

Start the vehicle if

and check

for leaks, Strut closure nut removal

necessary.

7922Z532

7922Z537

11.

Check the

adjust as needed.

front

end alignment and Strut shaft nut

removal

Strut closure nut

removal

W-BODY— GENERAL MOTORS CORPORATION. OQ_>11 CENTURY

•

REGAL

•

IMPALA

LUMINA

•

MONTE CARLO

•

•

INTRIGUE

•

C-

GRAND PRIX

3

*T

I

To install: connect the following:

Install or

5.

•

Strut

the bolts to •

90

Nm)

and wheel

•

Rear

•

Three strut to body mount nuts and

tire

torque them to 30

ft.

test the vehicle

wheel alignment

rear

(122

lbs.

ft.

Stabilizer shaft link to the strut

Road

6.

and torque

Strut to knuckle bolts

•

if

Nm)

lbs. (41

and adjust the

needed.

LUMINA 1.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Remove

Negative battery cable

.

Wheel

•

Brake hose bracket

•

Strut

• (1) Front Stabilizer Shaft Insulator (2) Front Stabilizer Shaft Link Nut

Clamp Bolt/screw

Mount Nut

Front Suspension Strut

(4)

Front Suspension Spring

(12)

(5)

Front Suspension Stmt

(13)

(6)

Strut

(7)

Front Steering Knuckle

(8)

Strut

(11)

To Knuckle Nut

(16)

3.

suspension without replaceable

Install or

Strut

•

37

ft.

lbs.

Nm)

(50

Strut/stabilizer shaft bracket to the

knuckle

strut cartridge

Strut-to-knuckle bolts and nuts

• •

connect the following:

mount-to-body nuts and

tighten to

*

of the front

from

Strut

•

732225

Exploded view

at the strut

body nuts

To install:

Clamp

Front Stabilizer Shaft

to

Strut/stabilizer shaft bracket

•

Lower Control Arm Bolt/screw Front Lower Cotrol Arm Nut Frame

Front

(14) Front Stabilizer Shaft Insulator (15) Front Stabilizer Shaft

To Knuckle Bolt/screw

mount

the knuckle

(9) Front Stabilizer Shaft Link] (10) Front Lower Control Arm

(3)

or disconnect the following:

•

Tighten the nuts to 82

Strut cover while aligning scribe

marks and torque the

bolts to

ft.

lbs.

(112

Nm).

24

ft.

lbs. (33 Nm) A 4-wheel alignment is recommended after any steering/suspension

11

•

Brake hose bracket

•

Wheel

Coil Spring

repairs are performed.

Rear Strut

REMOVAL & INSTALLATION

EXCEPT LUMINA 1

Except Models Equipped With A Front

Before servicing the vehicle, refer to

.

the precautions

in

the beginning of this sec-

Strut Cartridge

tion.

1

Remove

2.

3.

•

Negative battery cable

•

Three

•

Rear

•

Stabilizer shaft link

(2) (3) (4) (5)

From Suspension Slrui Mourn Retainer From Spring Upper Insulator From Spring Front Spnng Seat Front Suspension Strut Bumper

strut to

tire

tion.

2

and wheel

3.

from the

strut

has

if

4 its

to the

the knuckle

strut

that the strut

mounting holes

compressor

drilled for specific

vehicle lines.

the strut to knuckle bolts have been

ball joint or drive axle

Remove the strut from the vehicle. Mount the strut assembly into a strut

compressor. Note

knuckle must be retained after

removed. Damage may occur

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

body nuts

Scribe the strut to the knuckle.

•The (1)

or disconnect the following:

is

Compress

height after

the strut approximately

initial

contact with the top

cap.

not retained.

WARNING

79222531

4.

Remove

or disconnect the following:

Knuckle and strut assembly with replace-

•

Strut to knuckle bolts

able strut cartridge

•

Strut

For Wheel Alignment specifications, see Section

Never bottom the spring rod!

1

of this

manual

or

damper

V4

OO AO

GENERAL MOTORS CORPORATION— W-BODY CENTURY

*

REGAL

*

IMPALA

LUMINA

•

MONTE CARLO

•

*

INTRIGUE

•

GRAND PRIX

forcing screw while the guiding rod centers 3

When

the assembly.

the threads on the

damper

shaft are visible,

rod and

install

ft.

(85

lbs.

Nm) on

models

or

52

strut or

55

ft.

1 1

the guiding

63

models except Impala

all

lbs.

ft.

(70 Nm), for a front

Nm)

(75

lbs.

Remove

.

remove

the nut. tighten the nut to

(for a rear strut)

the strut from the

compres-

sor. Install the strut to the vehicle.

12.

Models Equipped With A Front

Strut

Cartridge 1

.

Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2.

Remove

the strut assembly from the

vehicle.

2

STRUT ASSEMBLY INSTALL LOCKING PINS THROUGH STRUT ASSEMBLY

3

TIGHTEN NUTS UNTIL FLUSH WITH

4

STRUT COMPRESSOR COMPRESSOR FORCING SCREW

1

h

CAUTION

Do not over compress the Only compress the spring

comes away from

coil spring. until

it

the seat.

7922YG24

3.

View in

a

of a typical strut

Compress

mately Vfunch

assembly mounted

compressor

3

4.

5

7

9 TO

Relieve the spring tension and

remove the spring.

To

install: •

2 3

Exploded view

of the front strut

strut

and make certain

upper and lower seats are

positioned correctly •

assembly

•

and torque

Strut rod nut lbs.

WRENCH SOCKET STRUT ASSEMBLY

Spring to the that the

7922YG27 1

Discard the nut

rotate. 5.

SPRING SPRING LOWER INSULATOR STRUT

8

or disconnect the following:

Strut rod nut with the proper socket

while not allowing the rod to rod to

JOUNCE BUMPER STRUT DUST SHIELD

6

Remove •

SPRING SEAT SPRING UPPER INSULATOR

4

a spring

compressor.

STRUT MOUNT NUT STRUT MOUNT RATE WASHER

1

2

the coil spring approxi-

(13mm) using

(85

to

63

ft.

Nm)

Strut

7922YG25

Use

a socket

damper

and

a

wrench

to

com-

Remove

5.

remove the

shaft nut spring cap while

damper

shaft

the nut from the strut

ing rod on top of the damper shaft. Use the 10. rod to guide the damper shaft straight down

pressing the spring

Lower

Ball Joint

and place an alignment/guid-

REMOVAL & INSTALLATION

through the spring cap while compressing 1

the spring.

To

Remove

.

Before servicing the vehicle, refer to

the components. the precautions

in

the beginning of this sec-

install:

6.

Mount

tion.

the strut assembly

in

the strut 2.

compressor, using the bottom locking pin 3.

Remove Remove

the wheel. the lower control

arm from

only. 7.

Install the

spring over the damper

the vehicle. 4.

and swing the assembly up so the upper

Remove

control

arm by

the ball joint from the lower drilling out the

4

rivets

locking pin can be installed. 8.

Install all shields,

bumpers and

insulators on the spring seat. 1

2

Install the rod to

straight

guide the damper shaft

down through

the spring cap while

compressing the spring

Use an Vs

in. drill bit

through the

STRUT COMPRESSOR STRUT ASSEMBLY

7922YG26

retaining the ball join^to the control arm.

9.

spring. the

Install the

strut

to

make

a pilot hole

Finish drilling the rivets

spring seat on top of the

The spring seat

same

rivets.

using a Vz flat

should be facing 5.

in. drill bit.

Remove

the ball joint.

direction as the centerline of the

assembly spindle.

To install: 6.

Install the

guiding rod and turn the

Install or

connect the following:

^

AO OQ m ‘w

W-BODY— GENERAL MOTORS CORPORATION. CENTURY Ball joint to the control

•

Bolts with the heads facing

50

to

REGAL

•

IMPALA

arm

•

and torque them

•

LUMINA

•

MONTE CARLO

INTRIGUE

•

models tighten the control arm-to-

down

frame nuts to 52 •

(68

lbs.

ft.

•

lbs.

ft.

is

Front wheel

Nm) •

Lower control arm

•

Wheel

to the vehicle

bushing

until the

pressed into the control arm. 11.

Disassemble the

12.

Install or

CONTROL ARM BUSHING REPLACEMENT 1

**A 4-wheel alignment is recommended after any steering/suspension

Tighten the screw

10.

(70 Nm).

GRAND PRIX

•

tools.

connect the following:

•

Lower control arm

•

Front wheel

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

Wheel Bearings

tion.

repairs are performed.

Remove

2.

or disconnect the follow-

ADJUSTMENT

ing:

Lower Control Arm REMOVAL & INSTALLATION

3.

•

Front wheel

•

Lower control arm

The wheel bearings are not adjustable. a wheel bearing

Lubricate the threads of a bushing

must be replaced. Using a

driver with high pressure lubricant. 1

.

9. 4.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

Assemble the

check

for looseness.

(0.127mm) on drum bearing wear

5

2.

Remove

or disconnect the following:

•

Front wheel

•

Anti lock Brake

To

speed sensor connector and jumper harness from the retainer

until the

•

Stabilizer shaft link

•

Cotter pin from the ball stud and

7.

Disassemble the

tools.

4.

Remove

Lubricate the

new bushing

outer cas-

install

a

new bushing

into the control

1

arm.

Before servicing the vehicle, refer to the

.

precautions driver/installer

set onto the control arm.

from the steering knuckle.

bolts.

Do

lower control arm and

Front wheel

•

Wheel Speed Sensor (WSS)

not tighten the nuts

at this

time

electri-

connector

•

Brake caliper and bracket

•

Rotor

•

Driveshaft nut

a front hub removal tool to the

Install

3.

beginning of this section.

or disconnect the following:

•

cal

the lower control arm.

Install the

in the

Remove

2.

To install: 5.

excessive and the hub and

REMOVAL & INSTALLATION

the ball stud nut counterclockwise to separate the ball stud

is

bearing should be replaced.

Front 8

removal tool over

in.

or disc brakes the

is

and lower control arm. Rotate

the ball joint

dial indicator,

exceeds 0.005

install:

Assemble a bushing

Install a ball joint

bushing

ing.

loosen the nut 3.

Tighten the tool

pressed from the control arm. 6.

System (ABS) wheel

If it

If

it

tool onto the control

arm bushing.

tion.

out of specification,

is

wheel bearing/hub assembly with three

'•Align the ball stud cotter pin hole

wheel nuts. Use the tool to push the drive-

parallel to the knuckle to ease the cot-

shaft out of the

Remove

4.

ter pin installation.

wheel bearing/hub. the wheel bearing/hub

assembly and discard the bolts 6.

Install or

•

connect the following:

the nut to

Monte

40

Carlo,

To install:

knuckle and torque

Ball stud to the ft.

lbs.

Grand

Nm)

Prix,

15

to

Install or

Nm) on

(55

Century

ft.

lbs.

Removing

the bushing from the lower con-

arm

(20

degrees on Impala models. On

lbs. •

63

cotter pin

Make

wheel speed

wheel speed sensor wire har-

ness

to the retainer clips

•

ABS

wheel speed sensor connector

•

Lower control arm nuts and torque

them

to

83

ft.

lbs.

(113

Nm) on

all

models except Lumina. On Lumina

ft.

and torque

(160 Nm) on ft.

it

to

except

all

lbs.

(215

Impala models

lbs (185

Stabilizer shaft link

ABS

•

lbs

torque the bracket bolts to 137

sensor •

%

Front caliper with the bracket and

•

ends do not make

ABS

to

Brake rotor

•

contact with the

and torque them

Nm)

drive shaft nut ft.

Nm) on

and bend the ends.

certain the

(130

Impala models or 159

ft.

(85 Nm).

New

bolts

lbs.

118

J 21474-19

tighten to

new

New

•

plus an additional 120

Lumina models

connect the following

Wheel bearing/hub assembly using

• trol

and Regal models. On Impala models, tighten

5

Nm) and

mounting bolts

to

•

WSS

connector

•

Front wheel

electrical

ft.

the caliper

63

ft

lbs.

(85

Nm)

Rear Installing the bushing to the lower control

The

arm

into

the

For Maintenance Interval recommendations, see Section

1

rear

one

hub

wheel bearing/hub

unit.

The

or bearing is

of this manual

is

integrated

unit is non-serviceable.

damaged, the com-

If

903 £ plete

ii

A GENERAL• CENTURY

hub and bearing

unit

(V10T0RS CORPORATION— W-BODY REGAL • IMPALA • LUMINA • MONTE CARLO

.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

3.

Remove

To

•

Rear wheel

•

Brake drum,

•

Rear caliper and bracket,

if

WSS Brake

•

Rear wheel hub to knuckle bolts

•

•

Parking brake lever bracket and

torque the bracket bolts to 92

parking brake actuator

lbs.

if

•

•

Anfilock Brake System (ABS) Wheel

if

2

KNUCKLE ASSEMBLY, REAR SUSPENSION HUB AND BEARING ASSEMBLY

3

BOLT/SCREW, WHEEL

is

bolted to the knuckle

rotor,

if

connector

equipped

Brake caliper with the bracket and

(125

bolts to

connect the following:

Parking Brake lever bracket and

Hub and

Nm) and

32

ft.

lbs.

•

Brake drum,

•

Rear wheel

if

ft.

the caliper

(44

Nm)

,

if

equipped

A 4 wheel alignment bearing assembly and

torque the bolts to 55

7922Z535

The rear hub/bearing assembly

electrical

equipped

actuator •

equipped

Brake

1

4.

install:

equipped •

rotor,

electrical

Rear wheel hub from the knuckle

Install or

equipped

GRAND PRIX

•

•

or disconnect the following:

*

•

tion. 2.

INTRIGUE

connector

Speed Sensor (WSS)

must be

replaced. 1

«

ft.

lbs.

(75

after

Nm)

is

recommended

any steering/suspension repairs have

been performed.

GENERAL MOTORS CORPORATION — Y-BODY 1998-01 Chevrolet-Corvette

30-18 30-2 30-16 30-2

DRIVE TRAIN.. ENGINE REPAIR FUEL SYSTEM

PRECAUTIONS STEERING AND SUSPENSION

30-28 30-28

Arming

30-28

Disarming

30-28

Precautions

30-28

C Installation

Installation

30-16

Removal &

Installation

Hydraulic Clutch System

30-23

Removal &

Installation

Lower

Removal &

Lower Control Arm Control

30-3

Removal &

30-3

Installation

30-8

Exhaust Manifold Installation

30-8

Fuel Filter Installation

Installation

30-32

Removal &

Installation

Pump Removal &

30-10 30-11

P Piston and Ring

Steering Gear

30-16

Removal &

Removal &

Installation

Transmission Assembly Installation

Removal

&

Installation

30-13 30-18 30-18

Installation

30-30

U 30-31

Ball Joint

Removal &

Installation

Upper Control Arm

30-31

30-32

Arm Bushing 30-32

Replacement

Removal &

Installation

30-32

V 30-10

Valve Lash

30-10

W Water

Pump

30-6

Removal & 30-28

30-13

30-30

Transverse Spring

30-15

30-28

30-10

Timing Chain, Sprockets,

Adjustment

30-15

Positioning

30-16 30-17

30-10 Installation

30-11 Installation

30-29

T

Control

30-10

Pan

Power Rack and Pinion

F

Installation

Motor

Removal &

Upper

30-33

0

Oil

Engine Assembly

30-32

Arm Bushing

Removal & Oil

E

Starter

&

30-32

Replacement

30-2

Distributor

Installation

30-7

30-29

Shock Absorber

Removal & 30-32

Ball Joint

30-6

D

30-7

L

30-6

Cylinder Head

30-7

Installation

30-13 30-7

Installation

Front Cover and Seal

30-24

Overhaul

Removal &

30-23 30-23

Bleeding

30-24

CV-Joints

Installation

Rocker Arms

Removal 30-23

Halfshaft

30-9

30-23

Removal &

S

H

30-22

Adjustment

Removal &

30-16

Intake Manifold

30-22

Clutch

Fuel Injector

30-16

30-13

Rear Main Seal

Fuel System Service

30-9

Camshaft

Removal &

30-16

30-2

Removal

Removal &

Installation

Fuel System Pressure

30-2

Alternator

Removal &

Removal &

R

30-17 30-16

Precautions

Bag

Removal &

Installation

Pump

Relieving

A Air

Removal & Fuel

Installation

30-6

Wheel Bearings 30-33

Adjustment

Removal

&

Installation

30-33

GENERAL MOTORS CORPORATION— Y-BODY

30-2

CORVETTE

PRECAUTIONS eye

Before servicing any vehicle, please be sure to read

following precautions,

of the

all

which deal with personal of

prevention

safety,

component damage, and important points

to take into consideration

when

servicing a

Never open, service or drain the radia-

when

cooling system

tor or

the engine

Observe

all

applicable safety precau-

when working around

tions

fuel.

Whenever

servicing the fuel system, always work

Do

well-ventilated area. or vapors to

fluid for

The EPA warns

•

with used engine

oil

that

prolonged contact

may cause

should make every to

used engine

gloves should be worn

come

in

in

a

not allow fuel spray

sure to used engine

oil.

Soap and

expo-

water, or

waterless hand cleaner should be used. •

new

All

vehicles are

If

now equipped must be

of brake

the brake fluid

becomes contaminated, completely Any brake

fluid.

flush the

Never reuse any

fluid.

removed

fluid that is

from the system should be discarded. Also,

do not allow any brake oil.

other exposed after

your vehicle.

system with new brake

Protective

oil.

with an air bag system. The system

contact with a spark,

of

You

when changing

soon as possible

skin areas as

number

a

minimize your

effort to

Wash your hands and any

and hot coolant. •

should always buy the correct type

tance IMMEDIATELY.

exposure

is

burns can occur from the steam

hot; serious

proper operation of the brake system. You

you have taken

if

skin disorders, including cancer!

motor vehicle: •

irritation persists, or

brake fluid internally, seek medical assis-

fluid to

tact with a painted surface;

come in condamage

will

it

the paint.

Never operate the engine without the

•

proper amount and type

of

doing so WILL result

severe engine

in

engine

oil;

damage. Timing

•

belt

maintenance

Many models

extremely

is

disabled before performing service on or

important!

around system components, steering col-

ence-type, non-freewheeling engine.

extinguisher near the work area. Always

umn, instrument panel components, wiring

timing belt breaks, the valves

keep

and sensors. Failure

or excessive heat (a hot drop

open flame

example). Keep a dry chemical

light, for

fuel in a

designed

fire

container specifically

for fuel storage; also,

to follow safety

disabling procedures could result

always

in

and

head may

acci-

tially

strike the pistons,

sonal injury and unnecessary system

maintenance

additional fuel system precautions later in

repairs.

this

working with, or around, the 3.

Fuel injection systems often remain

•

pressurized, even after the engine has been

OFF. The

turned

fuel

system pressure must

be relieved before disconnecting any lines. Failure to

do so may

and/or personal

injury.

•

brake fluid

in

fluid.

carrying a non-deployed air bag, be

air

from the surface. This

If

of the

module

will if

it

accidentally

system precautions

your eyes, flush your eyes

• If

air

is

causing poten-

interval charts in the front of

for the

recommended

interval for the timing belt,

replace-

and

to the

inspection.

Disconnecting the negative battery

cable on

some

vehicles

may

the functions of the on-board

tem^) and may

interfere with

computer sys-

require the computer to

When

is

servicing

reconnected.

drum

brakes, only dis-

assemble and assemble one side

later in this section.

essential to the safe

ative battery cable •

bag

Clean, high quality brake fluid from a

sealed container

the

undergo a relearning process once the neg-

reduce the is

deployed. Refer to the additional

you do get

with clean, running water for 15 minutes.

motion

away

If

the cylinder

in

timing belt section for belt replacement and

•

bag on a work surface, always

face the bag and trim cover upward,

and wash your hands thoroughly

handling brake

bag system.

sure the bag and trim cover are pointed

deployed

result in fire

Brake fluid often contains polyglycol

after

When

air

manual

ment

away from your body. When placing a non-

fuel

ethers and polyglycols. Avoid contact with the eyes

Always wear safety goggles when

interfer-

expensive) engine damage. Refer to the

dental air bag deployment, possible per-

possibility of fire or explosion. Refer to the

•

an

serious (also time-consuming and

properly seal fuel containers to avoid the

this section.

utilize

and

at a time,

leaving the remaining side intact for refer-

ence.

ENGINE REPAIR To

Distributor All

5.7L (VIN G) engines use a Direct

Ignition

System.

•

install: Install or

•

Alternator

•

Alternator

Alternator rear

(50

mounting bolts and

torque them to 37

ft.

lbs.

(50

Nm)

.

2.

in

• •

Regulator connector and battery to

or disconnect the following:

Negative battery cable Regulator connector and battery to

from the

rear of

the alternator •

Accessory drive

•

Rear mounting bracket

•

Alternator

•

Alternator

belt

9306ZG24

mounting bolts Exploded view

of the

alternator— 5. 7L engine

lbs.

Drive belt

the beginning of this section.

alternator terminal

ft.

•

Before servicing the vehicle, refer to the

Remove

37

•

REMOVAL

1

to

Nm)

Alternator

precautions

mounting bracket

and torque the bolts

connect the following:

Y-BODY— GENERAL MOTORS CORPORATION

30-3

CORVETTE alternator terminals

and torque the

alternator terminal nut to lbs.

•

(13

•

10 inch

Nm)

•

Negative battery cable

Intake Air Temperature (IAT) sensor

connector

Mass

Flow (MAF) sensor elec-

REMOVAL & INSTALLATION

•

and

cleaner

•

Air intake duct

•

Upper

•

Radiator

•

Electronic Brake Control Traction

air

•

radiator support

Electric throttle

motor

Throttle Position

electrical

•

(EBTCM/BPMV) and

Engine Coolant Temperature (ECT) sensor

•

bracket

Sensor (TPS)

connector

electrical

Module/Brake Pressure Modulator Valve

Evaporative Emission (EVAP) sole-

connector

connector

trical

Engine Assembly

Air

•

noid electrical connector

electrical

electrical

A/C compressor

connector electrical

connec-

tor

Before servicing the vehicle, refer to

1.

•

Brake pipes

•

Accessory drive

•

Fuel line from the connector at the

the precautions in the beginning of this sec-

belt

•

Alternator electrical connectors

•

Alternator

•

Brake booster vacuum hose

tion.

The following tools

will

be required

in

front of the

dash

•

Intermediate shaft to steering gear

addition to the basic hand tools: •

Transverse spring compressor and

•Cap

adapters

fuel

and plug

all

openings

bolt

for the •

system

to

prevent contaminants

from entering the system.

•

Ball joint separator

•

Engine support table

• •

Driveshaft support strap

•

Fuel pressure

gauge

2.

Relieve the fuel system pressure.

3.

Drain the cooling system.

4.

Drain the engine

5.

Evacuate the A/C system.

6.

Remove

Fuel

•

Fuel line at the fuel

•

Radiator hoses from the water

•

oil.

•

or disconnect the follow-

ing:

covers

•

•

rail

Intermediate shaft from the steering

gear

Secondary from the

rail

Air Injection (AIR)

left

•

Both front wheels

•

Heated Oxygen (HO2S) sensor con-

pump

nectors from the intermediate

Heater hoses from the water

exhaust pipes

pump

•

Intermediate exhaust pipes

Fuel injector electrical connectors

•

Close-out panel

Ignition coil

main harness connec-

tor

hose

exhaust manifold

•

Starter

motor

•

Starter

motor

•

Oil level

•

Crankshaft Position (CKP) sensor

•

connectors

sensor connector

connector

electrical

•

electrical

A/C compressor hose assembly Engine trical

oil

temperature sensor elec-

connector

Heated Oxygen (HO2S) sensor

•

Left

•

Front stabilizer shaft

•

Connectors from the cooling fans

•

Cooling fan assembly

•

Tie rod

ends from the steering

knuckles •

Antilock Brake System (ABS) electrical

connectors from the cross-

member, •

if

equipped

Electronic Variable Orifice (EVO)

connector clips from the cross-

member, •

if

Real Time tor clips

equipped

Damping (RTD) connec-

from the crossmember,

if

equipped •

Shock absorber lower mounting bolts

•

Front transverse leaf spring

•

Automatic transmission cooler pipes

at

the flywheel housing junc-

tion •

Automatic transmission cooler pipe

clamps from the engine Use a compressor such as engine

J

33432-A

to

compress the

front transverse spring

— 5 7L (VIN G)

•

oil

pan

Automatic transmission cooler pipe

from the radiator

For complete service labor times, order the Chilton Labor Guide

GENERAL MOTORS CORPORATION— Y-BODY

30-4

CORVETTE

CAUTION Failure to use the

minimum

fastener

length specified will prevent the

proper retention

of the propeller shaft

during assembly. For vehicles with an automatic trans-

7.

mission, perform the following steps:

Remove

a.

the two plug bolts

the

in

driveline support assembly. b.

Install

M10

an

55

x

bolt, or longer,

each plug location. Torque the bearing

in

support bolts to 26

On

8.

remove the

sion,

bell

housing inspection

cover, then turn the flywheel

access the bolt and loosen

Remove

9.

(35 Nm).

lbs.

ft.

vehicles with automatic transmis-

hub

collar to

it.

the engine flywheel housing

access plug. Rotate the automatic transmission

10.

collar so that the bolt 1 1

Loosen the

.

is

bolt

facing down.

and unclip the wire

harness from the engine and reposition

it

to

the driveline. 12.

Install a driveline

support tool to the

close out panel flange. 7922Z603

CAUTION On automatic transmission vehicles, remove the plugs from the driveline support assembly and install 2

M10

Never use a driveline support

x 1.5 bolts into the plug holes

tool to

support the weight of the engine

assembly. 13.

It

equipped with a manual transmis-

sion, perform the following steps:

Unclip the clutch actuator hose

a.

from the engine flywheel housing b.

Using a hydraulic clutch

rator tool,

clip.

line

sepa-

depress the white release ring

on the actuator hose and

pull lightly

on

the master cylinder hose. c.

Remove

the flywheel housing bolts

from the driveline support.

Support the engine and crossmem-

14.

ber assembly.

Remove

15. •

Front

or disconnect the following:

crossmember nuts BY

HAND

and lower the engine assembly slightly •

Secondary

Air Injection (AIR) tube

bracket bolt and reposition the bracket to gain access to the

ground strap •

Ground left

•

Engine cal

•

•

bolt

on the flywheel hub collar after turning

for

access

pressure sensor electri-

Camshaft Position (CMP) sensor connector

Manifold Absolute Pressure (MAP)

sensor it

oil

connector

electrical

7922Z604

Loosen the

strap f/om the rear of the

cylinder head

electrical

connector

Y-BODY— GENERAL MOTORS CORPORATION

30-5

CORVETTE •

Front transverse spring and torque

46

the bolts to •

(62

lbs.

ft.

Nm)

Shock absorber lower mounting nuts and torque them to 21

•

lbs.

ft.

Nm)

(28

Front stabilizer shaft and torque the

53

bolts to

ft.

(72

lbs.

Nm)

•

ABS EVO RTD

•

Tie rods to the steering knuckle

•

•

connector

electrical electrical

connector

electrical

connector

torque the nuts to 33

ft.

and

(45

lbs.

Nm). •

•

Radiator

Cooling fan assembly to the radia-

and attach the

tor

electrical

connec-

tors to the fans •

Ground wires

to the

left

side of the

engine •

HO 2 S

•

Engine

sensor connectors temperature sensor con-

oil

nector •

A/C compressor hoses

com-

to the

pressor

Install a Driveline

Support tool

•

•

42203

to the

under cover flange

nector

•

CMP sensor electrical MAP sensor electrical

Front driveline support assembly

•

KS

bolts

•

Install or

Engine from the driveline, by plac-

•

Front driveline support bolts and

Knock Sensor (KS)

•

J

ing a

electrical

con-

•

of the driveline

and the flywheel

•

housing

bolt to

engine away from the pro-

Pull the

16.

•

Raise the vehicle

7.

off of

•

the engine

18. Remove member nuts. 19. Remove

•

the engine mount-to-cross-

•

member.

To

•

Install the

engine on the crossmem-

ber and torque the nuts to

40

ft.

lbs.

Install or

•

•

•

(50

Wire harness

(if

Nm)

Ground

(25

Nm)

strap to the rear of the

•

24

ft.

lbs.

Engine cal

oil

(32

Nm)

pressure sensor electri-

•

connector

visit

the

ft.

lbs (50

ft

lbs (20

Nm) and Nm)

to the rear of the

to

Automatic transmission cooler

•

37

the nuts to 15

•

(if

equipped)

fittings to

26

ft

lbs.

Nm)

(35

MlOx 55mm

•

bolts from

in

AIR hose to the

left

exhaust mani-

after

removing the to

M10 37

x

at the

and torque them

(27

Nm)

to

20

and

site at

bolts to

rear of the oil

•

•

Automatic transmission cooler pipes

pan

www.chiltonsonline.com

Nm)

Alternator bracket

lbs

equipped)

(48

•

cooler

ft.

lbs.

Brake booster vacuum hose

ft

flywheel housing junc-

tion

(if

oil

ft.

•

•

Automatic transmission

Intermediate steering shaft to the steering gear and torque the bolt to

35

the driveline support

Nm)

(50

our web

Nm)

Intermediate exhaust pipe and

and torque the

the driveline support tool.

to the front

Please

and

fold

Two plugs

pipes

left

Nm)

lbs (50

Front wheels

equipped)

lbs.

lbs.

motor and torque the bolts

ft

•

to the clutch

on the engine and torque the bolts ft.

to the

engine

pipes to the radiator

Master cylinder hose

connector

hangers and torque the bolts

Nm)

equipped)

(if

electrical

Driveline close out panel

(12 •

Clutch actuator hose to the flywheel

assembly

connect the following

cylinder head and torque the bolt to

•

lbs.

ft.

37

connector

electrical

sensor

torque the bolts to 106 inch lbs

nuts and torque

55 bolts and torque them

18

•

Nm)

(110

Starter to

Nm)

(50

lbs.

sensor

right side of the

•

Power steering pump and reservoir

to

Wire harness ground wires

the driveline support assembly

Lower the vehicle onto the

engine/crossmember assembly. 22.

37

to

Remove Remove

24.

21.

•

engine 23.

(54

Nm).

ft.

(50

lbs.

ft.

actuator hose

install:

20.

lbs.

ft.

81

housing the engine from the cross-

Oil level

Flywheel housing bolts and torque

them

and crossmember.

CKP

•

and bracket and torque the

37

to

•

connect the following:

New crossmember them

peller shaft. 1

Air tube

A/C compressor line retaining bolt and torque it to 26 ft. lbs. (35 Nm)

connector

connector

electrical

torque them to 37

blade tool between edge

flat

connector

•

•

37

ft.

and torque the (50

lbs.

Nm)

Alternator

and torque the bolts

37

(50

ft.

lbs.

to

Nm)

Alternator connectors

and torque

the nuts to 10

(13

ft.

lbs.

Nm)

Fuel injector electrical connectors Ignition coil

nectors

main

electrical

con-

GENERAL MOTORS CORPORATION— Y-BODY

30-6

CORVETTE

EVAP solenoid

•

connec-

electrical

tors

motor

connector

•

Throttle

• •

ECT sensor electrical connector TPS electrical connector

•

A/C compressor

electrical

connec-

electrical

tor

pump pump

•

Heater hoses to the water

•

Radiator hoses to the water

•

Fuel line to the fuel

•

Fuel

rail

•

Drive belt

•

EBTCM/BPMV 20

the bolts to

bracket and torque

Nm)

(27

lbs.

ft.

EBTCM/BPMV

•

rail

covers

and

to the bracket

torque the nuts to 89 inch

lbs.

(10

Nm) Upper radiator hose

• •

Upper

•

Air cleaner

•

IAT sensor electrical connector

radiator support

and

air intake

•

MAF

•

Negative battery cable

sensor

electrical

duct

connector

new

25.

Fill

the engine with

26.

Fill

the cooling system.

27.

Evacuate and recharge the A/C sys-

oil.

To

install:

4.

Install or

New

•

Water pump. Torque the bolts to 11 ft.

On

vehicles with an automatic trans-

mission, start the engine and allow for

10 minutes. Torque the hub

96

ft.

lbs.

(130

Nm) and

it

to idle

•

collar bolt to

install the

flywheel

Check the vehicle

30.

if

for leaks

and

Water Pump REMOVAL & INSTALLATION

.

to

(if

lbs.

ft.

lbs.

(25 Nm).

pump

pump

Accessory drive

•

Air intake duct

•

MAF

3.

from the rear if

of

removing the

side

Cylinder head

install:

f»New Mil cylinder head bolts must be used when installing the cylinder

•

IAT sensor electrical connector

•

Negative battery cable

5.

connector

Install the

new

6.

the cooling system.

Place the cylinder head on the engine

d.

Mil Mil Mil Mil

e.

M8

a.

and check

cylinder head gasket

onto the locating pins.

and tighten the bolts

b.

for leaks,

necessary.

c.

Cylinder Head

bolts:

in

22

sequence ft.

to:

(30 Nm).

lbs.

90 degrees.

bolts: plus

bolts 1-8: plus

90 degrees.

bolts 9-10: plus bolts (11-15):

50 degrees.

22

(30

lbs.

ft.

Nm).

tion. 2.

To

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

bolt

if

side

belt

electrical

Start the vehicle

left

side

left

bracket,

head assembly.

•

6.

Ground wire

left

•

(10

Radiator inlet and outlet hoses to

if

•

equipped).

89 inch

•

Fill

repair 1

pulley

5.

removing the

if

the cylinder head,

then to 18

sensor

it,

Power steering pump removing the

ft.

Heater hoses to the water

the water

necessary.

then to 22

•

the engine and

been removed from the vehicle.

repair

Nm) and

pump

Water

Nm) and

A wheel alignment is recommended crossmember have

29.

(15

•

(30 Nm).

Torque the bolts

inspection plug.

when

gasket with the tabs facing up

lbs.

lbs.

Power steering pump and reposition

•

tem. 28.

•

connect the following:

Remove

Negative battery cable Intake Air Temperature (IAT) sensor

1

electrical

connector

Mass

Flow (MAF) sensor elec-

• •

Air intake duct

Accessory drive Inlet

and

water

outlet

belt

hoses from the

Heater hoses from the water

•

Water (if

• •

pump

pulley bolts and pulley

pump Water pump

2.

in

the beginning of this sec-

24 •

to the rear of the

lbs.

ft.

Nm)

3.

Relieve the fuel system pressure.

4.

Remove

•

or disconnect the following:

if

Rocker arm cover

•

Exhaust manifold from the cylinder

•

head

•

Vapor vent pipe

•

removing the

left

side

pulley,

if

(50

ft.

lbs.

(25

Nm)

,

if

t

Power steering pump

pulley,

if

Exhaust manifold and torque the

sequence,

Nm), then

Power steering pump

lbs.

removed •

Intake manifold

ft.

Power steering pump and torque removed

•

removed

removed

the bolts to 18

Negative battery cable

•

if ,

bolts, in

retaining bolts

(32 Nm),

Power steering pump bracket and torque the bolts to 37

Drain the engine coolant.

pump

equipped)

Six water

Before servicing the vehicle, refer to

•

pump

•

.

the precautions tion.

connector

trical

•

connect the following:

Ground wire

cylinder head and torque the bolt to

•

Air

Install or

•

or disconnect the following:

•

•

7.

REMOVAL & INSTALLATION

Drain the cooling system.

•

to

18

ft.

to 11 lbs.

ft.

(25

lbs.

(15

Nm)

Valve rocker arm cover and torque

Y-BODY— GENERAL MOTORS CORPORATION

OU" 7I Ofl

CORVETTE

9.

With the engine

in this position,

tighten the exhaust valve rocker

on cylinders No.

1

,

7 and 8

2.

arm

to

bolts

22

lbs.

ft.

(30 Nm), then, tighten the intake valve

arm

rocker

and 5

bolts on cylinders No. 1. 3, 4

22

to

lbs.

ft.

(30 Nm).

Rotate the crankshaft

10.

1

revolution

(360 degrees). 1 1

With the engine

.

in this position,

tighten the exhaust valve rocker

on cylinders No.

arm

5 and 6 to 22

3. 4.

bolts ft.

lbs.

(30 Nm), then, tighten the intake valve

arm

rocker

and 8

22

to

12.

on cylinders No.

bolts

new gasket and torque lbs.

7

arm cover using

the rocker

Install

2. 6.

(30 Nm).

lbs.

ft.

the bolts to

a

106 inch

(12 Nm).

13.

Negative battery cable.

14.

Start the vehicle

repair

if

and check

for leaks,

necessary.

Intake Manifold

REMOVAL & INSTALLATION Be sure the tab on the edge

ot the

gasket

is

closer to the front ot the engine

when

installed

•The

intake manifold, throttle body,

and rail may be removed from the engine as an assembly. fuel injectors

15

13

^ 3

k 7 xl •

106 inch

Intake manifold

bolts in

Nm)

(12

Nm)

and torque the

sequence

to

to •

lbs.

8

4 ./S\_

(S/

Nm)

the precautions in the beginning of this sec-

Relieve the fuel system pressure

Remove

3.

boll

Nm)

Rocker arm cover

•

Rocker arm

necessary

4.

If

removed,

install the

installed in their original positions.

rocker

piston

Fuel injector electrical connectors

Knock Sensor (KS) connector

KS jumper

arm mounting rocker

PCV

•

Engine cooling

fuel rail

covered

tube Irom the throttle body

in Section

bleed hose from

body heater

Throttle

•

Intake manifold

bolts

air

body

•

and

outlet

hose

fuel stop

bracket

arms but do not

Top Dead Center (TDC).

is

from the

Positive Crankcase Ventilation

To install: 5.

Apply a 0.20

1

in.

(5mm) bead

of

threadlock to the threads of the intake manifold bolts.

Timing belt service

pigtail

•

oil.

Rotate the crankshaft so the No. is at

Sensor (TPS)

connector

the throttle

Lubricate the flange and washer sur-

Install the

Throttle Position

rail

hose

arm covers

arm

tighten the bolts at this time. 8.

Before servicing the vehicle, refer to

•

ventilation

stop bracket

Lubricate the rocker arms and

•Always keep

7.

Vacuum

install:

face of the rocker

6.

•

neces-

if

dud

(PCV) valve pipes from the rocker

pushrods with clean engine

the rocker arms and order so they can be

connector

Air intake

•

REMOVAL & INSTALLATION

in

Flow (MAF) sensor elec-

Air

Fuel line from the fuel

•

pivot support. 5.

pushrods

connector

Mass

•

•

sary

To

Rocker Arms

electrical

electrical

Rocker arm pivot support,

for leaks,

or disconnect the following:

Intake Air Temperature (IAT) sensor

•

•

or disconnect the following

•

Rocker arm, push rods and pedestals

and check

Remove

•

•

Start the vehicle

Relieve the fuel system pressure.

4

rv2B>\!

•

9.

3

•

the cooling system

Fill

Drain the cooling system.

trical

2.

beginning of this section.

in the

2

j>y

Negative battery cable

8.

if

(12

5

tion.

44 inch lbs (5

then to 89 inch lbs. 910

106 inch

precautions

5.7L engine

Vapor vent pipe and torque the

•

repair

lbs.

—

Before servicing the vehicle, refer to the

1

2

1. Cylinder head bolt torque sequence

the bolts to

^

'll

6 _/o\

14

12

11

3 of this manual

1

GENERAL MOTORS CORPORATION— Y-BODY CORVETTE make

sequence

— 5.7L

fc

The

CAUTION

fuel rail stop bracket

must be

installed on the intake manifold in

may

Negative battery cable

•

Left

result in fuel spray

•

Engine coolant

•

Heated Oxygen (HO 2 S) sensor

•

PCVtube

•

Alternator electrical connector

•

PCV

•

•

•

Accessory drive

•

KS sensor jumper pigtail KS electrical connector TPS electrical connector

•

Alternator

•

Fuel injector electrical connectors

•

•

Vacuum

air

(10

outlet

hose

valve pipes

•

IAT sensor electrical connector

•

MAF

•

Negative battery cable

and reposition

Fill

Start the vehicle

connector

and check

Exhaust Manifold

•

Spark plug wires

•

Sparkplugs

•

Exhaust manifold

To

install:

4.

Apply threadlock

Install

5.

new

the exhaust manifold using a

Beginning with the center 2

torque the bolts to 11 Left Side

to the threads of the

gasket.

6.

new gas-

it

bolts.

connect the following:

Intake manifold with a

of

the cylinder head and reposition

for leaks,

necessary.

it

AIR pipe retainer from the rear

•

the cooling system.

7.

hose

Air Injection (AIR)

AIR pipe from the exhaust manifold

•

Fuel line Air intake duct

electrical

belt

from the check valve

•

sensor

connector

electrical

Secondary

vent hose

REMOVAL & INSTALLATION •

Engine Coolant Temperature (EOT) sensor

•

if

nuts from the exhaust manifold studs

bleed hose

causing personal injury. Install or

hand intermediate pipe flange

body heater

lbs.

its

original position. Failure to reinstall this part

•

Throttle

8.

repair

Nm)

•

engine 6.

second pass and tighten the

89 inch

•

Intake manifold torque

a

bolts to

lbs.

ft.

(15

nating from side-to-side until

all

bolts,

Nm)

alter-

the bolts

ket • •

1

Fuel stop bracket Intake manifold bolts

the bolts

Nm)

in

first to

the

and torque

44 inch

.

precautions 2.

lbs. (5

sequence shown, then

Before servicing the vehicle, refer to the

3.

in

the beginning of this section.

Relieve the fuel system pressure.

Remove

or disconnect the following:

same

are tight. Torque the bolts again in the

sequence

18

lbs.

ft.

(25 Nm).

Bend over the exposed portion

7.

gasket 8.

to

at

Install or

•

connect the following:

Spark plugs and torque them ft.

Spark plug wires

•

AIR pipe retainer bolt the cylinder head bolt to

15

to

1

Nm)

(15

lbs.

•

•

of the

the rear of the cylinder head.

lbs.

ft.

to the rear of

and torque the (20

Nm)

AIR pipe with a new gasket and torque the bolts to 15

ft.

lbs.

(20

Nm) •

AIR hose torque

it

to the to

15

check valve and

ft.

lbs.

(20

Nm)

•

Alternator and torque the bolts to

•

Accessory drive

•

Alternator electrical connector

37

ft.

lbs.

(50

•

EOT sensor

•

HO 2 S lbs.

•

•

Nm) belt

electrical

connectors

sensor and torque

(42

it

to

30

ft.

Nm)

Fuel lines

Intermediate pipe flange-to-exhaust

manifold nuts and torque them to

15 • 9.

ft.

lbs.

(20

Nm)

Negative battery cable

Start the vehicle

and check

for leaks,

'

repair

if

necessary.

Right Side 1.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

Re sure

to reinstall the fuel stop bracket

when

installing the intake manifold

tion.

Y-BODY— GENERAL MOTORS CORPORATION

Qfl-O OU 3

CORVETTE

AIR pipe using a new gasket and

•

torque the bolts to 15

lbs.

ft.

(20

Nm)

HO 2 S

•

sensor

torque

it

to

in

30

the manifold and

ft.

lbs.

Nm)

(42

Intermediate pipe flange-to-exhaust

•

manifold nuts and torque them to

15

8.

repair

ft.

lbs.

(20

Nm)

Negative battery cable

•

Start the vehicle if

and check

for leaks,

necessary.

Camshaft REMOVAL & INSTALLATION Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section.

2

Drain the cooling system

3.

Relieve the fuel system pressure.

Remove

4.

Exploded view

Remove

2.

of the

exhaust manifold— 5. 7L engine

or disconnect the following:

•

Fuel lines from the fuel

•

Rocker arm covers

•

Rocker arms and pushrods

•

Both cylinder heads

•

Valve

•

Radiator

lifter

guides and the

or disconnect the following:

•

Negative battery cable

•

Right side intermediate exhaust

pipe nuts from the manifold studs •

Heated Oxygen (HO 2 S) sensor

•

Secondary

Air Injection (AIR) pipe

from the exhaust manifold •

Spark plug wires

•

Sparkplugs

•

Oil level indicator

•

Exhaust manifold

To

install:

3.

Apply threadlock

and tube

to the threads of the

bolts. Install the

4.

new

exhaust manifold using a

gasket.

Beginning with the center 2

5.

tighten the bolts to 11

ft.

lbs.

nating from side-to-side until

(15 all

bolts,

Nm)

alter-

the bolts

are tight. Then, tighten the bolts again in the

same sequence to 18 ft. lbs. (25 Nm). 6. Bend over the exposed portion of gasket 7.

at

connect the following:

Oil level indicator

the bolt to 12 •

ft.

tube and torque

lbs.

(16

Nm)

Spark plugs and torque them ft.

•

the

the rear of the cylinder head

Install or

•

lbs.

(15

to

1

Nm)

Spark plug wires

Install three

Heater Core replacement

M8-1.25

is

x

100mm

covered

long bolts into the camshatt to use as a handle

in Section

2 of this manual

rail

lifters

on

U OU“ in

GENERAL MOTORS CORPORATION— Y-BODY CORVETTE

I

•

Engine front cover

•

Oil

pan

•

Oil

pump

•

Camshaft sprocket and timing chain

•

Camshaft Position (CMP) sensor

all

Camshaft

•

•

ADJUSTMENT Oil

The rocker arms on the 5.7L (VIN G)

and sensor

bolt

fold nuts to

Valve Lash

engine are bolted

into position

is

possible.

noisy, suspect low

oil

If

the valves are

Install

M8

3

x

100mm

long bolts

Carefully

6.

remove the camshaft from

the engine, be sure not to

damage

the

To 7.

Negative battery cable

Before servicing the vehicle, refer to

1.

tion.

Starter Motor

REMOVAL & INSTALLATION 1.

Before servicing the vehicle, refer to

the precautions

2.

install:

in

the beginning of this sec-

2.

Drain the engine

3.

Remove

•

or disconnect the following:

Negative battery cable

•

Intermediate exhaust pipe

oil.

•

Starter electrical connectors

Negative battery cable

•

Alternator

•

Washer

•

Engine Coolant Temperature (EOT)

connect the following:

Install or

100mm

long

•

Starter bolts

•

Starter

bolts in the front of the camshaft to

use as a handle

Camshaft

•

Camshaft

•

ket

engine and

Tie rods from the steering linkage

•

Real Time

(25

CMP

Starter to

new gas-

retainer using a

18

to

• •

ft.

Nm)

•

37

connect the following:

•

motor and torque the bolts

ft.

lbs.

(50

Starter electrical

connectors

Intermediate exhaust pipe and

Nm) Timing chain and sprocket and

•

torque the sprocket bolts to 26

Nm) Oil pump and torque the bolts lbs. (25 Nm) Oil pan with a new gasket and lbs.

•

ft.

(35

to

18

ft.

•

torque the bolts pan-to-rear cover

106 inch

bolts to

10.

(25 •

Nm) and

(12

lbs.

the remaining bolts to

18

lbs.

ft.

Nm)

Front cover with a

new gasket and

torque the bolts to 18

ft.

lbs.

(25

Nm) •

Radiator

•

Valve

lifters

and

guides and

lifter

torque the bolts to 106 inch (12

Cylinder heads

•

Pushrods and rocker arms

•

Rocker arm covers with new gaskets

and torque the bolts

inch lbs. (12

9.

Fuel lines to the fuel

•

Negative battery cable Refill

if

to

106

Nm)

•

rail

the cooling system.

Start the

repair

lbs.

Nm)

•

engine and check

Intermediate shaft from the steering

for leaks,

necessary.

Exploded view

of the starter

assembly

Electronic Brake Control

(EBCM/BPMV)

reposition

(25

lbs.

Damping (RTD) sensor

equipped

Stabilizer shaft

Valve

sensor with a new O-ring and ft.

connector

Module/Brake Pressure Modulator

Nm)

torque intermediate pipe-to-mani-

torque the bolt to 18

if

electrical

gear

Install or

•

connector

•

install:

bolts

and torque the bolts

lbs.

•

3.

into the

remove the 3

To

motor

electrical

Headlamp

•

Three M8-1. 25 x

•

reservoir

•

links, 8.

oil.

or disconnect the following:

•

sensor

Remove

Lubricate the camshaft with clean

engine

Nm) and (50 Nm)

Pan

tion.

camshaft bearings.

lbs.

the precautions in the beginning of this sec-

in

the front of the camshaft to use as a handle.

ft.

pressure or worn

All

5.

(20

lbs.

37

REMOVAL & INSTALLATION

valve train components.

camshaft bearings are the same diameter, extreme care must be taken during camshaft removal or installation to avoid damaging them.

ft.

so that no

retainer plate

adjustment

15

other bolts to

—5.7L engine

•

Power steering gear

bracket and

Y-BODY— GENERAL MOTORS CORPORATION 3Q_-|

9346ZGG1

Separate the upper

and lower

(1)

(3) oil

pans 4.

Lower shock absorber mounting

.

bolts

Transverse

.

spring using a suit-

leat

able compressor

Lower control arm bolts trom the suspension crossmember

•

Engine mount lower nuts

•

Wheel Speed Sensor (WSS) wiring harness trom the crossmember

.

Brake

.

Apply sealant

to the

covers attach areas where the tront and rear

engine

from the crossmember

line

Support the suspension crossmember. Crossmember mounting nuts

•

crossmember

•

Front

•

Oil filter

•

Automatic transmission cooler rear retaining

and

front

line

clamp bolts

equipped) Enqine flywheel housing-to-oil pan

(if

.

bolts

Engine flywheel close out bolts • Engine oil level sensor . Engine oil temperature sensor elec-

.

trical

connector

pan assembly

•

Oil

•

Lower

pan bolts and separate

oil

the pans

p*To remove the

necessary it

necessary)

(if

pan gasket

oil

to drill out 3 rivets

it

is

securing

to the pan.

To 5.

lower

install: If

oil

separated, connect the upper and pans with a new gasket and torque

the bolts to 6.

106 inch

Apply a 0.20

sealant directly

lbs. in.

(12 Nm). of

RTV

of the front

and

(5mm) bead

on the tabs

rear cover gaskets that extend

onto the

oil

pan mounting surface following: 7. Install or connect the •

New

gasket on the

necessary to

on the

oil

oil

rivet the

pan.

It

is

not

new gasket

Exploded view

ot

the

oil

pan mounting— 5 7L engine

pan.

Brake service

is

covered

in

Section 4 of this manual

to the

engine block

5 7L

-|

— "3

•

•

I

•

pan-to-engine bolts and torque

Oil

18

to

Nm)

(25

lbs.

ft.

repair

pan-to-rear cover bolts and

Oil

•

Oil

pan

Negative battery cable

•

Oil

•

Oil

pump pump

if

new

oil.

and check

To

tor leaks,

necessary.

5.

Check and adjust

11.

the front

end align-

Nm)

125

Torque the lower control arm bolts lbs.

ft.

to

•

37

to

and

Left

Engine trical

and bolts

Oil

REMOVAL & INSTALLATION

(12

(25

connector

Engine it

8.

•

torque

clamp

2.

Drain the engine

3.

Drain the cooling system.

oil.

(12

lbs.

4.

Nm)

Remove •

Negative battery cable

•

22 inch

to

it

clamp

Engine front cover

to

it

22

Engine front cover

•

Negative battery cable

ft.

lbs.

plug and torque

Oil drain

it

to

18

Fill

the cooling system.

8.

Start the vehicle

necessary.

ft.

Raise the suspension crossmember into position. •

Crossmember mounting torque them to 81

•

(110

Nm)

Engine mount lower nuts and torque them to 48

•

nuts and

lbs.

ft.

WSS

(65

lbs.

ft.

Nm)

wiring harness to the cross-

member •

Brake

•

Transverse

•

at this

(28

DO NOT

and torque them

74

(100

lbs.

ft.

EBCM/BPMV

lbs.

Be sure

to seat the

tube into the

pump

before installing the bolt

Nm)

c£>

bracket and torque

20

(27

lbs.

ft.

Nm)

Intermediate shaft and torque the

Outer to

18

tional •

ft.

Power steering gear and torque the

pinch bolt to 25 •

to 21

Nm)

the bolts to •

to the cross-

torque the bolts

time

bolts to •

spring

Lower shock absorber mounting bolts

•

leaf

Lower control arm

member,

•

crossmember

line to the

ft.

ft.

lbs.

(35

Nm)

rods and torque the nuts

tie

(25

lbs.

Nm)

plus an addi-

180 degree turn

RTD sensor

electrical connector,

it

equipped •

Stabilizer shaft

nuts to 53

clamp

ft.

and torque the

lbs-.

bolts to

43

link

Nm) and the lbs. (58 Nm)

(72 ft.

•

Alternator and torque the bolts to

•

Washer

37

ft.

lbs.

(50

Nm)

reservoir and torque the

nuts to 66 inch lbs. (7.5 •

EOT sensor

electrical

Nm)

connector

Oil

pump assembly mounting— 5. 7L engine

new

the engine with

7.

Nm)

(25

lbs.

ft.

lbs.

lbs.

pan

Fill

it

new 0-ring

106 inch

the nut to 18

Oil

Nm)

(30

Nm) and Nm)

bolt to

•

Nm)

lbs. (3

and torque

Oil filter

screen with a

6.

repair

and

bolt

pump

•

or disconnect the following:

Automatic transmission cooler pipe

torque

•

the beginning of this section.

and

bolt

106 inch

to

it

rear retaining

•

in

Automatic transmission cooler pipe front retaining

•

Before servicing the vehicle, refer to the

precautions

Nm)

(35

lbs.

ft.

.

sensor and torque

oil level

26

to

Oil

and torque the

temperature sensor elec-

oil

drive gear are aligned prop-

Pump •

1

•

pump

106 inch

to

Nm)

(12

lbs.

•

the bolts to 18

erly.

right close outs

and torque the bolts

connect the following:

pump and torque lbs. (25 Nm)

Nm)

(50

lbs.

ft.

Oil

K»Be sure the crankshaft sprocket and

(170 Nm). oil

them

Install or

•

ft.

12.

Flywheel housing bolts and torque

screen

install:

ment.

(12

lbs.

the engine with

Start the vehicle

10.

Nm)

(25

lbs.

ft.

Front headlamp electrical connector

Fill

pan-to-front cover bolts and

Oil

torque them to 106 inch

•

9. •

pan and hand tighten the bolts

Oil

torque them to 18 •

—

I

i

them •

GENERAL MOTORS CORPORATION— Y-BODY CORVETTE i.m^— « a—

o L

1

UUw

oil.

and check

for leaks,

Y-BODY— GENERAL MOTORS CORPORATION Ofl-I CORVETTE

OU

I

Q J

Rear Main Seal REMOVAL & INSTALLATION

•The

rear main seal is a 1-piece unit. can be removed or installed without removing the oil pan or crankshaft. It

1

.

Before servicing the vehicle, refer to the

precautions 2.

in

Remove • •

the beginning of this section.

or disconnect the following:

Transmission Clutch and pressure plate,

if

equipped with a manual transmission

3.

•

Flywheel inspection cover

•

Flywheel

Using a pry

tool, carefully pry the old

seal out.

7.

To install: 4.

Inspect the crankshaft for nicks or

burrs, correct as required. 5.

Clean the area and coat the seal and

crankshaft with engine 6.

Install or

Flywheel torque sequence

oil.

connect the following:

•

Seal, using a seal installer

•

Flywheel and torque the bolts

sequence

to

then to 37 finally to •

ft.

74

15

ft.

(20 Nm) Nm) and (100 Nm)

Flywheel inspection cover and torque the bolts 18

ft.

lbs.

(25

if

Timing Chain, Sprockets, Front Cover and Seal

sion

(50

lbs.

Clutch and pressure plate

equipped with a manual transmis-

lbs.

ft.

lbs.

• in

•

Transmission

Start the vehicle

repair

if

and check

for leaks,

REMOVAL & INSTALLATION

necessary.

Nm)

Before servicing the vehicle, refer to

1

the precautions in the beginning of this section.

Drain the cooling system.

2. 3.

Drain the engine

4

Remove

oil.

or disconnect the follow-

ing: •

Negative battery cable

•

Engine

•

Oil

pan

Oil

pump

•

front

cover

Rotate the crankshaft until the timing

5

marks are aligned. The marks should face each

other.

Remove

the camshaft sprocket

bolts.

•Do

not turn the crankshaft after the

timing chain has been removed.

age

to the pistons or

Remove

6.

valves

may

Damoccur.

or disconnect the following:

Camshaft sprocket and timing

•

chain •

Crankshaft sprocket using a suitable puller

To 7.

install:

Be sure the timing mark on the

crankshaft sprocket

is at

the 12 o'clock

79222634

position.

Use a seal

installer to press the seal

on the crankshaft

For complete Engine Mechanical specifications, see Section

If

not rotate the crankshaft to the

correct position.

1

of this

manual

fl

1

4

GENERAL MOTORS CORPORATION— Y-BODY CORVETTE Install or

8.

•

connect the following:

Crankshaft sprocket with a Crankshaft Balancer

and Sprocket

Installer tool

Timing chain on the camshaft

•

sprocket.

Timing chain and sprocket assem-

•

marks are

bly so the timing

aligned and torque the camshaft (

sprocket bolts to 26

ft.

•

Nm) Oil pump and torque ft. lbs. (25 Nm)

the bolts to 18

•

Oil

•

Front cover with a seal

lbs.

(35

pan with a new gasket

new gasket and

and hand tighten the bolts

at

this time 9.

Install the oil

pan

and hand-tighten them

certain that the front cover

aligned and torque the

cover bolts to 18

ft.

cover bolts

to

at this time.

oil

lbs.

pan-to-front

(25

the remaining bolts to 18

Make

properly

is

ft.

Nm) lbs.

then

(25

Nm). 10.

Connect the negative battery

cable.

A

puller is

needed

to

remove the crankshaft sprocket

11.

Fill

the cooling system.

12.

Fill

the engine with

13.

Start the vehicle

repair

if

new

oil.

and check

for leaks,

necessary.

J 41665-1

7922Z639

Timing chain alignment

—5.7L engine

Be sure

to install the crankshaft

sprocket properly

Y-BODY— GENERAL MOTORS CORPORATION CORVETTE

1

Piston

o

and Ring

POSITIONING

2.

0

ENGINE LEFT

Upper compression

ENGINE FRONT

1I

R J

»

ENGINE RIGHT

piston ring

3 Lower compression piston

ring

4 Oil control piston ring 5 Oil control ring spring w/spacer

C

2rwJ

comoression

ring

gap

D Top compression nng gap 792AG«

7922AG43

Piston ring positioning

OH OU

—5 7L engine

Piston ring end-gap spacing

1

.

— 5.7L engine

Piston

2 Connecting rod LH 3 Connecting rod bearing A Connecting rod 5.

RH

Connecting rod bearing cap

6 Connecting rod bearing cap bolt 7 Crankshaft Piston and connecting rod positioning

— 5.71 engine

For Accessory Drive Belt

illustrations,

see Section

1

of this

manual

GENERAL MOTORS CORPORATION— Y-BODY

Qfl IK IO OU"

CORVETTE

FUEL SYSTEM 4.

Fuel System Service Precautions

5.

Safety

is

most important

the

factor

when

performing not only fuel system mainte-

nance but any type to

of

maintenance. Failure

conduct maintenance and repairs

manner may

safe

a

Maintenance and testing

injury or death.

of

of the fuel

rail

fuel

spray and connect a fuel pressure

and guide-

to the following rules

6.

70

Nm)

(95

lbs.

ft.

6.

Connect the negative battery cable.

7.

Turn the ignition switch

OFF

ignition switch

open the valve

and torque the nuts

Stabilizer shaft to

onds, then

for

back

ON

2 sec-

for

10 seconds. Turn the

ON

and inspect

for

leaks.

to bleed the

system pressure.

Pump

Fuel

Close the valve and disconnect the

gauge. Drain any remaining

fuel

gauge

the

To avoid the possibility of

assembly) to catch any

Place the bleed hose into a suitable

container, then fuel

7.

lines.

•

end

by

effectively

(located on the side or

fitting

gauge.

system components can be

accomplished safely and

•

fuel

pressure valve

result in serious personal

the vehicle's fuel

adhering

in

Remove the left fuel rail cover. Wrap a shop towel around the

from

fuel

REMOVAL & INSTALLATION

into the bleed container.

and per-

fire

These models have 2 sonal injury, always disconnect the negative

Fuel Filter

and

The

left).

battery cable unless the repair or test proce-

sender assembly dure reguires that battery voltage be

REMOVAL & INSTALLATION

fuel

pump

fuel

in

the

is left

tanks (right

part of the fuel fuel tank.

right fuel tank contains a fuel

The

sender

applied.

Always

•

assembly with a siphon

system pres-

relieve the fuel

sure prior to disconnecting any fuel system

component

pressure reg-

(injector, fuel rail,

ulator, etc.), fitting or fuel line

connection.

Exercise extreme caution whenever relieving

system pressure,

fuel

skin, face

and eyes

advised that

exposing Please be

under pressure may pene-

fuel

trate the skin or

to avoid

to fuel spray.

any part

of the

body

that

1

.

Before servicing the vehicle, refer to

around the

a

shop towel or

sender feed pipe. Although there are 2

2.

Relieve the fuel system pressure.

3.

Clean the

(should

Ensure that

quick-connect 4.

it

occur)

is

Remove

•

to

fuel

•

soaked

•

able waste container.

Do come •

to

•

•

spark or open

•

flame.

Always use a back-up wrench when

•

loosening and tightening fuel line connection fittings. This will prevent

stress

and torsion

unnecessary

to fuel line piping.

Always

To

Always replace worn

rings with new. or equivalent,

Do

fuel fitting

0-

5.

3.

Drain the fuel tank(s).

Intermediate pipe-to-muffler bolts

4.

Remove

left

•

muffler

•

Fuel feed and return quick connect

from the

fuel filter

mount

Mark each

6.

nut

Fuel filter/pressure regulator and

them during

fuel

Remove

7.

fuel line to

help identify

installation.

or disconnect the follow-

ing: •

Quick connect

fittings

from the

fuel

sender

Fuel system ground strap Fuel filter/pressure regulator from

•

the bracket

•

Fuel sender electrical connector Fuel tank strap and properly support the fuel tank

•

connect the following:

plastic quick

ers on the inlet •

Fuel tank shield(s)

sender assembly.

Fuel feed pipe from the outlet side

New

or disconnect the following:

Both rear wheels

Clean the area around the

5.

Fuel filter/pressure regulator

Install or

•

connector retain-

and

Fuel sender attaching bolts and

discard them

outlet tubes

Fuel filter/pressure regulator into the bracket

not substitute fuel hose

where

cradle

install:

follow the proper torque specifications. •

Properly relieve the fuel system

2.

pressure.

bracket

not allow fuel spray or fuel vapors into contact with a

for both.

the precautions in the beginning of this sec-

of the fuel filter/pressure regulator

Always keep a dry chemical (Class B)

extinguisher near the work area.

fire

removal and installation

same

tion.

filter.

or disconnect the following:

bracket

cloths or towels are deposited into a suit-

•

the

Before servicing the vehicle, refer to

1.

Rear stabilizer bar from the rear

fittings

quickly removed from all

from the

and lower the

fuel spillage

engine surfaces. Ensure that

fittings

is

it

• all

connections, then

filter

units, the

procedure

depress the locking tabs and detach the

loosening to absorb any excess fuel due to spillage.

pump which

sending

cloth

connection prior

fitting or

jet

tank through the fuel

tion.

contacts.

Always place

left

the precautions in the beginning of this sec-

• •

supplies fuel to the

•

Fuel system ground strap

•

Fuel feed pipe to the outlet side of

fuel pipe is installed.

the fuel filter/pressure regulator

Fuel System Pressure •

Fuel filter/pressure regulator and

bracket to the mounting stud and

RELIEVING

torque the nut to 40 inch

lbs. (4.5

Nm) 1

.

Before servicing the vehicle, refer to

•

the precautions in the beginning of this section.

Fuel return and feed quick connect fittings

•

Muffler and torque the hanger nuts

2.

Disconnect the negative battery cable.

to

3.

Loosen the

mediate pipe bolts

the tank pressure.

fuel filler

cap

to relieve

12

Nm)

ft.

lbs.

(16

Nm) and to

37

the inter-

ft.

lbs.

(50

These models have 2

fuel tanks

by a fuel sender feed pipe

connected

Y-BODY— GENERAL MOTORS CORPORATION CORVETTE •

arm

Float

retaining clip

arm

float

(left

7 If

OU

and the

side sender only)

Fuel sender and gasket

•

To install:

••Always

new

install a

fuel strainer

before installing the fuel sender

assembly. A strainer that has been

exposed to fuel will not unfold comand may interfere with the full

pletely

arm.

travel of the float 9. 8.

a

Install

new gasket on

the fuel

sender.

Do not damage the

float

arm during

installation.

Fold the long strainer over hold the strainer

itself

and

position.

in this

Pinch both strainers upward toward

10.

each other. 1 1

Install

.

the float

arm through

the fuel

tank opening with the folded strainers. ••It

may be necessary

sender

Look

12.

make If

it

is

to rotate the

proper installation.

for

into the fuel tank

opening and

certain that the long strainer

visible.

is

not visible, rotate the fuel sender until

the strainer

is

free

Align the fuel sender gasket tab

13.

with the fuel sender cover

mark and

mark with the

align the cover

fuel tank

mark.

new break away head

Install the

14.

attaching bolts to the fuel sender and

hand

tighten them.

**

CAUTION

The upper hex head portion of the fuel sender attaching bolts is designed to shear off the lower sec-

when

tion of the bolt

torque

is

bolts after the

off of

Fold the strainer on

head

Tighten the

15.

bolts in

the proper

reached. Do not tighten the

sequence

sheared

is

new break away until the

attaching

hex head shears

Install or

•

Fuel sender electrical connector

•

Fuel tank strap and torque the bolts

18

ft.

lbs.

•

ft.

It

will

lit

Into the

opening

Fill

the fuel tank

and

install the fuel

cap.

lbs.

(25

ON for 2 seconds, then ON again and

Turn the ignition

the tuel tank

tor

10 seconds,

Relieve the fuel system pressure

3.

Remove

Fuel Injector 4.

REMOVAL & INSTALLATION

•

Both

•

Fuel feed hose from the fuel

•

Fuel injector electrical connectors

•

Fuel

rail

•

Fuel

rail

1

fuel rail

Spread the

injector

5

Both rear wheels

or disconnect the follow-

ing:

Nm)

from the

precautions

Tire,

in

Wheel and Ball Joint

the beginning of this section.

specifications, see Section

1

covers rail

mounting bolts

injector clip to release the fuel rail.

Fuel injector by spreading the retain-

Before servicing the vehicle, refer to the ing clip.

Negative battery cable

For

in

2.

Nm)

Fuel tank shield and torque the bolts to 18

•

(25

3 times so

inspect the system for leaks

Fuel feed and return pipes

to

7.

OFF

connect the following:

•

•

1

filler

18.

the lower section.

16.

itselt

off.

of this

manual

Oft 1 Q GENERAL MOTORS CORPORATION «jU" BO corvette

**The

Fuel injector into the fuel

•

To install: fuel injector is

stamped with

—Y-BODY •

rail

number identification, manufacturweek code and plant number. Make certain the correct injector is ordered when replacing them.

CAUTION

ing date,

The

•

must be onto the engine. The

fuel rail stop bracket

clean 7.

new

injector seals with

oil.

installed

• •

New New

connect the following:

and personal

fire

on the

the bracket

is

not installed,

fuel could spray possibly

0-ring seals on the injectors retainer clip

If

(10

Nm)

89 inch

fuel

lbs.

connectors to the injec-

•

Fuel feed hose to the fuel

•

Negative battery cable

•

Left

and

right fuel

rail

covers

rail

ON for 2 seconds, then ON again and

Turn the ignition

causing a

OFF

injury.

attaching bolts to

tors

fuel rail in the event of a frontal

crash.

Install or

to the

and torque the

rail

Electrical

8.

bracket serves as protection for the Lubricate the

and ground strap

rail

intake manifold

a

part

6.

Fuel

socket

for

10 seconds,

inspect the system for leaks.

injector

DRIVE TRAIN 5.

Right side muffler and

•

Transmission Assembly

tie

the

Driveline tunnel closeout panel

•

Rear

bell

Automatic

plug

housing access plug and

matchmark the

flexplate to the

torque converter •

Flexplate-to-torque converter bolts

•

2 plug bolts from the front of the

•

Propeller shaft hub clamp bolt

•

Shift cable bracket nuts

•

Shift control cable

driveline support

tion. Install

Disconnect the negative battery

2.

bolts to Shift the transmission into N.

Remove

4.

or disconnect the following:

•

Rear wheels

•

Intermediate exhaust pipe

M10

x 1.5 x

55mm

26

ft.

must remain

remove them

lbs.

the lower control or

Outer

•

Shock absorber lower mounting

tie

bolts

Lower

•

order to maintain the posi-

tion of the input shaft bearing.

arms

rod ends from the knuckle

•

(35 Nm). These bolts

installed until instructed to in

shift

Rear transverse spring and support

•

assembly

longer bolts into the bolt holes. Torque the

cable. 3.

two

from the

lever

Before servicing the vehicle, refer to

1.

the precautions in the beginning of this sec-

or disconnect the following:

Engine flywheel housing access

•

•

REMOVAL & INSTALLATION

Remove

6.

left

side muffler to the underbody

Install

7.

ball joints

from the knuckles

a transmission support fixture

to the transmission.

Wiring harness and brake pipe

•

retainers from the rear

clip

crossmem-

ber •

Lower transmission-to-differential

•

Transaxle mount-to-rear cross-

nut

member

nut

Rear crossmember retaining nuts

•

while supporting the crossmember •

Crossmember

•

Transaxle mount bracket

Separate the axle shafts from the

8.

ferential

and

tie

them

to the

dif-

underbody.

Release the retainer securing the

9.

wiring harness from the “L” shaped brack-

along the driveline support and move

ets

the harness out of the way.

Lower the driveline

10. it

to

slightly

and

tilt

gain access to the electrical connec-

tors. 1 1

Remove

.

•

trical

•

or disconnect the following:

Vehicle Speed Sensor (VSS) elec-

connector

Wire harness retainer from the ferential rear

•

dif-

cover stud

Wire harness retainer

clip

from the

top of the differential •

Transmission harness 20 way connector

•

Park Neutral Position (PNP) switch electrical

Remove

the inspection plug, then

remove the flexplate-to-torque converter

bolts

connectors

OH_1 Q 13 OU

Y-BODY— GENERAL MOTORS CORPORATION CORVETTE •

Bolt securing the wire harness to

the

side of the case

left

Lower the

12.

and angle

driveline

it

while observing the top rear of the differential

and the lowest

ment

compart-

part of the rear

The engine Positive

floor panel.

Crankcase Ventilation (PCV) pipes

not to 13.

will

most

dash panel. Make certain

likely contact the

damage the dash. Remove or disconnect

the following:

•

Wire harness from the retainer

•

Transmission rear

along the top of transmission oil

from the junction

cooler pipes

fittings at the fly-

wheel housing •

5 driveline

to flywheel

housing

bolts after supporting the rear of

the engine

Bend

14.

away from

the wiring harness bracket

the driveline, toward the tunnel

wall to have access to

remove the

driveline.

Separate the driveline from the

15.

engine by prying them apart with a

flat

blade tool

Lower the driveline and

16.

from the engine

tilt it

away

until the input shaft clears

the flywheel housing TO22M3

Remove

the plugs and install two

MIO

x

1.5 x

55mm

Remove

17 •

or longer bolts into the bolt holes to

•

secure the bearing— 5. 7L engine

or disconnect the following:

Driveline

Transmission

from the

oil

cooler rear pipes

fittings

•

Transmission to driveline bolts

•

Separate the transmission from the driveline with a

Using a

18

blade tool

flat

device, place the

lifting

assembly on a bench. •

Rear transmission

oil

cooler fittings

from the transmission •

Transmission-to-driveline assembly

support bolts •

Driveline from the transmission

while supporting the torque converter

To

•

Differential-to-transmission bolts

•

Differential

from the transmission

install:

19

Install or

•

connect the following:

Differential to the

transmission and

torque the bolts to 37

lbs (50

ft

Nm) •

•

Transmission to the driveline support

and torque the bolts

lbs.

(50

Rear transmission

oil

to the transmission fittings to

20.

30

Using a chain

to

gain access to the clamp bolt, then loosen it— 5.7L engine

For Wheel Alignment specifications, see Section

21

1

of this

.

37

ft.

ft

cooler fittings

and torque the

lbs (40

Nm)

hoist, place the

assembly on a transmission Rotate the flywheel

to

Nm)

jack.

Carefully raise the assembly into the

manual

.

GENERAL MOTORS CORPORATION— Y-BODY

30-20

CORVETTE Remove

2.

or disconnect the following:

•

Negative battery cable

•

Both rear wheels

•

Folding top stowage compartment lid

extension panel (on convertible

models)

7922Z645

Transmission-to-differential mounting bolt locations

— 5.7L engine

•

Traction control/ride control switch

•

Console retaining nut covers

•

Console retaining nuts

•

Accessory plug

•

Fuel door release electrical connector

•

Console

•

Shift control

knob button

•

Shift control

knob

•

Shift control

knob

•

and torque the nuts

vehicle while placing the wiring harness

46

the bolts to

Nm)

(62

lbs.

ft.

Wiring harness into the “L" shaped

•

Shift control boot

by grabbing both

sides and pulling

it

assembly

Transmission cable and bracket and

•

connect the following:

Driveline

torque the nuts to 15

the vehicle.

in

toward the

Ashtray

•

Trim plate

•

Retaining screws located behind the

Install or

in

•

brackets

are the same.

•

lbs.

Rear transverse spring and torque

•

driveline will slide into

the rear of the engine as long as the angles

23.

ft.

retainer

lever

22. Align the assembly for installation

The

15

connector

plus an additional 160 degrees

loosely into the harness retaining slots.

into the engine.

to

electrical

ft.

lbs.

•

grill

and behind the ashtray

grill

Instrument panel accessory trim

(20 plate

Nm)

Reposition the wiring harness

•

made during removal and torque the bolts to 47 ft. lbs. (63 Nm)

them

Oil

37

to

ft.

Nm)

•

cooler lines and torque the

tings to

20

ft.

lbs.

Wiring harness to the

left

22 inch

Shift rod

•

Shift control

mounting bolts

•

Shift control

assembly

•

Courtesy lamp

it

side of

•

Remove

25.

the two

M10

x

55mm

Install or

•

•

PNP

switch electrical connector

Left side lower

Transmission harness 20 way con-

port

nector

to

Clutch master cylinder pushrod

connect the following:

Wiring harness

•

clip to the top of

the differential •

VSS

electrical

height. •

Axle shafts

•

Transmission mount

to the cross-

Suspension crossmember and ft.

lbs.

(110

Lower transmission-to-differential it

to

37

ft.

lbs.

(50

Nm)

Lower

clip

crossmember

lbs.

ft.

(50

•

Nm)

Both rear wheels

•

•

Driveline closeout panel

•

Rear transverse spring

•

Outer

•

Lower shock absorber

•

Lower

Negative battery cable Start the vehicle

and allow

it

to reach

engine OFF. Allow the engine to cool

to

ambient temperature, then tighten the

fly-

wheel hub collar bolt 28.

Intermediate exhaust pipe and

secure the mufflers out of the way

Install the bell

to

96

ft.

lbs.

rod ends bolts

ball joints

Support the transmission •

(130 Nm).

housing inspection

tie

Wiring harness and brake lines

from the suspension crossmember •

Lower transmission-to-differential

lbs.

suspension

(70

(220

Outer

Flush the automatic transmission

•

Transmission mount-to-crossmem-

•

Rear suspension crossmember nuts

•

Transmission mount and bracket

oil

cooler.

tie

A front end alignment is recommended when the crossmember is removed. 30.

Nm)

Shock absorber lower mounting bolts and torque them to 162 ft. lbs.

29.

ber nuts ball joints to the

knuckles and torque the nuts to 52

•

Intermediate pipe and torque the

hose

Rear wheels

nut

Wiring harness and brake pipe

ft.

•

•

Right hand muffler assembly

Clutch actuator hose from the master cylinder

plug.

retainers to the •

•

3.

nut and torque

•

and (10

lbs.

normal operating temperature. Turn the

Nm) •

Driveline tunnel closeout panel

37

Clutch actuator cylinder hose from the retainer clip

•

27.

torque the nuts to 81

•

Nm)

•

•

the nuts to 37

ft.

•

(50

torque the bolts to 89 inch

bolts to

member and torque lbs. (50 Nm)

lbs.

Nm)

connector

Raise the transmission to installation

24.

ft.

and the pushrod from the

pedal

assembly and torque the bolts

37

closeout panel while

the hole •

2 plug bolts to the driveline sup-

•

bolt

bolts

from the input shaft front bearing. 26.

clamp

guiding the courtesy lamp through

retainer •

and boot

is

finger tight

Nm)

lbs. (2.5

housing access plug

bell

Propeller shaft hub bolt until

•

fit-

the transmission and torque the bolt to

Rear

Nm)

(27

•

ing nuts

Driveline support-to-flywheel hous-

(50

Shift control closeout boot retain-

torque

converter using the matchmarks

lbs.

•

to the

ate hole in the driveline assembly.

ing bolts and torque

•

Transmission flexplate

•

bracket to align with the appropri-

•

Nm) rod ends to the knuckles

from the

Manual 1

tion.

Axle shafts from the differential and

•

Wiring harness from the driveline

position them out of the

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

differential

•

support assembly

way

00-91 Cl OU

Y-BODY— GENERAL MOTORS CORPORATION CORVETTE

Reverse lockout solenoid

•

electrical

connector

Gear select (skip

•

Transmission

•

sensor

shift)

solenoid

connector

electrical

fluid

electrical

temperature

connector

(if

equipped)

Support the rear of the engine

6. •

Driveline support-to-bell housing bolts

Driveline support

•

assembly out

of

moving the

the bell housing while

assembly rearward Carefully lower the assembly

7.

away

from the vehicle while simultaneously adjusting the angle. Attach a chain hoist to the assembly,

8.

then remove

it

from the jack and place

on

it

a workbench.

Remove

9.

•

or disconnect the following:

Driveline support-to-transmission

mounting

bolts. Carefully pry the

assembly away from the

driveline

transmission while guiding the

shift

rod through the opening in the driveline support

Transmission

• Insert a flat bladed tool

transmission assembly

between the

shifter bracket

and brake

liner retainer before lowering the

shift

rod from the

transmission

—5.7L engine

•

mount-

Transmission-to-differential

ing bolts and separate the differential

from the transmission

To install: 10.

Install or

•

connect the following:

Differential to the

5.

transmission and

torque the bolts to 37

ft.

lbs.

(50

Nm) •

Transmission

•

Driveline support to the transmis-

shift

rod

sion and torque the bolts to 37 lbs (50

To aid

11

m

ft

Nm) later installation

rubber band around the

shift

place a

rod then tape

the shift rod to the driveline support

assem-

bly.

Place the assembly on the transmis-

12.

sion jack with a chain hoist

Begin to raise the assembly into the

13

vehicle while loosely installing the wiring

mounting— 5. 7L engine

Driveline support-to-transmission

harness along the driveline assembly retaining slots.

•

Harness

clip

from the top

Lower the transmission enough

4

of the

remove the wiring harness from the top

differential

Do not lower the top rear portion

of

storage compartment or the will hit the

ing

PCV

damage.

or disconnect the follow-

the

same angle as

to install

ing:

•

Vehicle Speed Sensor (VSS) electrical

pipe

dash panel possibly caus-

Be sure the driveline assembly

15

Remove

•

16.

connect the following:

Input propeller shaft into the clutch

disc

electrical con•

nector

For Maintenance Interval recommendations, see Section

is at

the engine before trying

it.

Install or

•

connector

Backup lamp switch

front of

the driveline support to the bell housing.

of

the assembly.

the differential past the bottom of the

Have an assistant guide the

14

to

1

Wiring harness bracket

of this manual

to align

GENERAL MOTORS CORPORATION— Y-BODY

30-22

CORVETTE

7922Z649

Pull the shift rod up to break the tape

and

hook the rubber band on the rear stud— 5.7L engine

Clutch master cylinder pushrod

•

retainer •

Left

•

Courtesy lamp

17.

Pull

lower closeout panel

up the

rod to break the tape

shift

and hook the rubber band on the on the top •

Shift control

the bolts to

the nuts to

— 5.7L

engine

with the appropriate hole

•

lbs.

(50

and torque them

to

37

tt.

•

fluid

electrical

•

temperature

connector

•

solenoid elec-

connector

trical

•

shift

Reverse lockout solenoid electrical

•

Backup lamp switch

•

Wiring harness to the top of the

electrical

•

•

•

VSS

•

Axle shafts

•

Transmission mount on the

electrical

lbs.

•

in

connector the differential

and torque the bolts

(50

•

differ-

to

37

ft.

Nm)

•

Rear suspension. crossmember and torque the nuts to 81

ft.

lbs.

•

(70

and torque them

Nm)

Outer

tie

to

162

ft.

rod ends and torque the

Nm)

nuts to 15

ft.

additional

160 degrees

lbs.

(20

106 inch

Shift control boot Shift control

knob

•

Shift control

knob

•

Console Fuel door release electrical connector

•

Accessory plug

•

Console retaining nuts and torque to

89 inch

Nm)

•

Traction control/ride control switch

•

Folding top stowage compartment

•

Rear wheels

•

Negative battery cable

18.

lid

Bleed the clutch system.

Clutch

Transverse spring and torque the to

46

ft.

lbs.

(62

ADJUSTMENT

Clutch actuator hose to the master 1

.

Before servicing the vehicle, refer to

Clutch actuator hose to the retain-

the precautions in the beginning of this sec-

ing clip

tion.

Driveline tunnel closeout panel

and

2.

Remove

torque the bolts to 89 inch

(10

3.

FHave an assistant depress the clutch

lbs.

the flywheel inspection cover.

Nm)

pedal until the tension

Muffler assemblies

stepped adjusting

Intermediate exhaust pipe and ft.

lbs.

(50

4.

is

released from the

ring.

Using 2 screwdrivers,

rotate the

stepped adjusting ring counterclockwise until fully

adjusted out.

Continue

Clutch master cylinder pushrod to

tion

the clutch pedal

clutch pedal.

Nm)

(10

connector

Console retaining nut covers

•

(50

lbs.

electrical

•

ber nuts and torque lbs.

and button

•

Rear wheels

ft.

retainer

plus an

Nm) 37

Nm)

•

•

to

Nm)

•

Transmission mount-to-crossmem-

them

(12

lbs.

(30

boot and torque

extension panel

Nm)

(220

torque the bolts to 37

(110

Nm) •

and torque the

lbs.

lbs.

Instrument panel accessory trim plate

them

cylinder hose

dif-

ferential

ential

ball joints ft.

line

Nm)

con-

nector

(50

lbs.

ft.

crossmember

mounting bolts

connector •

37

Shock absorber lower mounting

lbs.

•

Gear select/skip

Lower

bolts

(if

equipped)

to

Wiring harness and brake

nuts to 52

and

attach the connectors

sensor

•

retainers to the

Wiring harness to the retainer on

it

Nm)

Nm)

Transmission

Lower transmission-to-differential nut and torque

the top of the transmission

•

•

Driveline support-to-flywheel housing bolts

•

the dri-

in

assembly

veline

ft.

• 7922Z648

Place a rubber band on the shift rod, then tape the rod to the driveline support assembly

assembly and torque

22

Shift control closeout

•

rear stud

of the driveline tunnel.

5.

to

hold them

in this

posi-

and have the assistant release the

tO OU 9Q

Y-BODY— GENERAL MOTORS CORPORATION Ofl CORVETTE

Hydraulic Clutch System BLEEDING

1

Before servicing the vehicle, refer to

.

the precautions in the beginning of this section. 2.

Fill

the clutch master cylinder with

clean clutch hydraulic fluid.

Raise and safely support the vehicle

3.

with an assistant in

it.

Remove

the intermediate exhaust

5.

Remove

the driveline tunnel cover.

6.

Have the assistant depress and hold

4 pipe.

the clutch pedal down.

Loosen the bleeder screw on the

7.

actuator cylinder to release the

air,

then

tighten the screw

Do not allow the clutch pedal to be until the bleeder screw is closed or air will be drawn into the released

system. Repeat the prior two steps

8.

air

Rotate the stepped adjusting ring counterclockwise

to

the master cylinder fluid level and

compress the springs

until the

has been purged from the system. Check refill

as

needed 6. 7.

Remove Install

the screwdrivers.

•

the inspection cover. Torque

the bolts to 18

ft.

lbs.

(25 Nm).

Install

the driveline tunnel cover.

10

Install

the intermediate exhaust pipe.

11

Lower the

9.

Negative battery cable

•

Exhaust system

•

Driveline support and transmission

vehicle.

as an assembly

REMOVAL & INSTALLATION 1

.

•

Flywheel inspection cover

•

Pressure plate bolts.

Before servicing the vehicle, refer to

access

tion.

•

Remove

or disconnect the follow-

ing:

Halfshaft be nec-

REMOVAL & INSTALLATION

essary to rotate the flywheel to

the precautions in the beginning of this sec-

2.

It

will

To 3.

all

the bolts

Pressure plate and disc

Install or

• i

•

the precautions in the beginning of this sec-

connect the following

tion.

Clutch disc and pressure plate on

2

the flywheel

3.

Apply the parking brake.

Remove

Clutch disc alignment tool through the disc to keep

•

Before servicing the vehicle, refer to

1

install:

in

place

•

Axle nut Rear transverse spring

Turn the flywheel to access

•

Outer

•

Antilock Brake System (ABS)

Torque the bolts

it

all

the

in the

to

52

sequence

ft

lbs.

(70

Inspection cover and torque the

•

ft.

lbs.

(25

~Be

Driveline support and transmission

it

is

Park brake cable Irom the lever and

sure

to

support the halfshaft until

removed. Do not

let

it

hang by the

CV-joint.

•

Exhaust system

•

Negative battery cable

4

Bleed the clutch system.

and

For Tune-up, Capacities and Firing orders, see Section

Wheel

electrical

bracket

Nm)

assembly

5.

rod end from the knuckle

connector •

bolts to 18

tie

Speed Sensor (WSS)

Nm). •

or disconnect the following

•

shown, using 3 steps

Clutch assembly torque sequence

Wheel

Pressure plate bolts finger-tight

bolt holes 4.

•

1

Attach a puller on the wheel studs start to

of this

push the axle

manual

shaft into the

hub

GENERAL MOTORS CORPORATION— Y-BODY

30-24

CORVETTE Rear transverse spring and torque

•

the bolts to •

46

ft.

(62

lbs.

Halfshaft retaining nut

the nut to

118

ft.

lbs.

Nm)

and torque

(160

Nm)

Wheel

.

CV-Joints

OVERHAUL

Inner Joint 1

.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2. 3.

Remove axle Wrap a shop

shaft.

towel around the axle

shaft. 4.

Place the wheel drive shaft horizon-

tally in a 5.

bench

vise.

Remove

the large seal retaining

clamp from the C V joint 6. Use a side cutter tool

seal.

or other suitable

and discard the clamp. 7.

Remove

the small seal retaining

clamp from the 8.

joint seal.

Use a side

cutter or other suitable

7922Z653

tool Insert a large drift through the cooling fins to

ing the retaining

assembly. This ball joint to

keep the hub assembly from turning while remov-

nut— 5.7L engine

and discard the clamp. 9.

Separate the seal from the joint outer

race at the large diameter end.

provide clearance for the

will

be separated from the knuckle

assembly. 5.

Remove

or disconnect the following:

from the knuckle

•

Ball joint

•

Axle shaft from the hub

•

Halfshaft

assembly from the

differ-

by inserting a suitable tool

ential

between the CV-joint and differential

and prying them apart

To install: 6.

Install or •

shaft.

on the

Use

differential

light force to

output

be sure

it

is

ym

seated

fully

•

connect the following:

Halfshaft

Halfshaft through the

hub assembly

V

but do not install completely. This will

provide clearance for installing

53]'Oj w

the ball joint •

•

Ball joint to the

knuckle and torque

the nut to 41

lbs.

ft.

(55

Halfshaft through the

Nm)

ZjjSSS

hub assembly

II

completely •

Park brake cable

to the bracket

\Y/*y \JL-frA

and

!

the lever •

WSS

•

Tie rod

electrical

end

connector

to the

knuckle and

torque the nut to 15

Nm)

ft.

lbs.

(20

plus an additional 160

degrees

7922Z654

Exploded view

of the halfshaft

mounting— 5. 7L engine

Y-BODY

— GENERAL MOTORS CORPORATION OU CORVETTE

LJ

To install:

•Protect the wheel drive shaft boots, seals and clamps from sharp objects

when

servicing on or near the wheel

Damage

drive shaft(s).

to the boot(s),

the seal(s) or the clamp(s)

Remove

to

shaft-inner joint

Position the seal behind the joint

face.

wheel drive

1 1

at the large

joint outer race

diameter end-inner

joint

Position the wheel drive shaft verti-

.

cally in the

bench vise so the inner

Slide the joint outer race

12.

toward the

joint is up.

down

vise.

driver

bladed screw-

between the retaining ring and the

outer race.

away from

may fall race when

balls

and inner removed.

the outer race

Lift

the outer race

Engage the inner race splines onto

is

seal to catch

b

any balls

c

the outer race oft the axle shaft

and inner

balls

from the axle

by the seal

e

vise.

you

the outer race retaining ring

Align the cage lands with the inner

race ball tracks.

21

.

Reposition the cage along the axle

Wipe

23.

Remove

the grease from the inner race.

25.

26.

Remove Remove Remove

Reposition the

Work evenly around

the cage from the axle shaft

using a three jaw puller-inner joint

Clean

al

the wheel drive shaft from

Inspect to be sure that the axle shaft is

exposed

Install

37.

Position the cage so the cage lands

the snap ring to the axle shaft

38

Install the

39

Position the cage

parts thoroughly with clean

Thoroughly

Insert

41

dry

all

windows

race.

to align

approximately 60 percent of kit

into the outer

Position the wheel drive shaft verti-

bench vise so the inner

cally in the

joint

end

up.

42

Apply a small amount

from the service

43 service

air

cage onto the inner

race.

is

solvent.

28.

the inner race

to drive the inner race, until

36

40

the seal from the axle shaft.

•All traces of old grease and any contaminates must be removed. 27.

block along

the inner race seat fully onto the

leel

and inner race the inner race from the axle shaft

wood

the grease from the service

the bench vise.

Remove

to begin to drive the

with the inner race ball tracks

the inner race from the axle

shaft using a three jaw puller

24.

hammer

align with the inner race ball tracks

away from the inner race

22.

a

snap ring groove

shaft.

shaft

block squarely

axle shaft

35

the snap ring from the axle

shaft-inner joint

20.

Use

and continue

shaft.

Remove

wood

axle shaft

balls caught

bench

Remove

first.

Position a

the face of the inner race to avoid the

race.

Position the wheel drive shaft hori-

zontally in the

d

from

17.

19.

to install

inner race onto the axle shaft.

Remove any

the snap ring from the axle

Be sure

the axle shaft splines

16.

18.

onto the axle

over the end of the inner race

Remove any remaining

the cage

the end of the axle

Install the inner race

a.

out of the cage

the outer race from the axle

Use the

b.

9346ZGB6

inner race spline relief must

34.

which are not retained by grease

15.

end faces the vise

shaft as follows:

shaft as follows: a.

cage onto the axle shaft so

away from

axle shaft

shaft-inner joint

shaft.

the inner race spline relief side onto the

Remove

14.

Remove

Install the

•The

934GZGB4

934SZG85

33.

the smaller diameter

Position the retaining ring along

the axle shaft

•The

Install

shaft.

outer race. c.

seal retaining

the seal onto the axle shaft.

32.

face

Pry the retaining ring from the

b.

new small

Install a

clamp onto the wheel drive

Insert a small flat

a.

a bench vise.

31.

ring as follows:

the outer race from the axle

shop towel around the axle

a

Place the wheel drive shaft horizon-

30. tally in

Disengage the outer race retaining

13.

Remove

Wrap

29.

shaft.

shaft.

9346ZG03

Separate the seal from the

and lead

increased noise and possible failure

of the

10.

may cause

lubricant to leak from the joint

the cage from the axle

to the

remaining grease from the

into the seal.

the parts.

For complete service labor times, order the Chilton Labor Guide

of the grease

cage windows

ball tracks.

Insert the kit

kit

GENERAL MOTORS CORPORATION— Y-BODY

30-26

CORVETTE Slide the outer race

c.

down over

the

balls.

Position the wheel drive shaft hori-

49.

zontally

in

bench

the

vise.

Engage the outer

race retaining ring as follows:

Slide the outer race toward the

a.

vise.

Insert the outer race retaining ring

b.

groove along the outer edge of

into the

the outer race.

Position the outer race retaining

c. 9346ZGB8

so the opening

ring

Use a hammer and

a block of

wood

in

the ring aligns

to

with an outer race land (not a ball track). drive the inner race onto the axle

Position the large diameter end of

50. shaft-inner joint

the seal onto the outer race.

clamp onto the neck

of the

omega shape has

a

(2-3mm), with

a difference in the gap

width from side to side no greater than

Measure the distance between the and the edge

of the seal

base

gap width between 0.079-0.118 inch

to the axle shaft.

53.

axle shaft groove closing to

until the

of the seal.

Position the seal and small retaining

52.

clamp edge

Tighten the small seal retaining clamp

Position the small seal retaining

51.

0.016 inch (0.4mm)-inner

joint

of the last

edge and adjust

fit

0.10 inch (2.5mm).

»The

seal retaining clamp must not be

over-tightened or under-tightened.

Crimp

54.

6D percent

Insert approximately

grease from the service

kit into

the small seal retaining

clamp

using tool J 42572. Tighten the small seal

of the

clamp

retaining

the outer

shape has

race-inner joint

inch

a

until the

base

of the

omega

gap width between 0.079-0.118

(2-3mm), with

a difference

in

the gap

width from side to side no greater than

Measure the distance between the end

0.016 inch (0.4mm). The clamping hold time

and adjust the plunging motion

must be no

to

less than 2 seconds.

Measure the distance between the

55.

end

of the seal

and the end

of

the seal and the end of the joint outer race

8.90 inch within 0.16 inch

within

4mm-inner

of the joint

(226mm

joint

of the joint outer

race and adjust the plunging motion of the

8.90 inch within 0.16 inch

joint to

within 56.

Position the large seal retaining

clamp onto the 57.

clamp Measure the distance between the edge the seal and the

edge

of the last axle shaft

groove closing edge and adjust

(2.5mm)-mner

inch

of

fit

to

0.10

joint

Install

the outer race retaining ring

seal.

Position the seal and large retaining to the joint outer race.

Measure the

distance between the edge of the seal and the

edge

of the joint outer race last

closing edge and adjust

fit

to

groove

0.03 inch

seal must not be dimpled,

Measure the distance between the edge

stretched or out of shape in any way.

45.

Position the retaining ring below the

46.

Install

windows

the balls through the cage

to the inner race ball tracks.

Use the

47.

position 48.

if

seal to keep the balls in

necessary.

Install the

outer race onto the axle

shaft as follows: a.

in

Be

careful not to allow the grease

58.

Inspect the seal for proper shape.

the seal

is

NOT shaped

the pressure in the seal

If

If

correctly, equalize

dam-

the seal has been cut or punctured

Align the outer race ball tracks to

the balls.

to

0.03 inch (0.8mm)-inner joint

retaining

clamp

until the

base

of the

0.079-0.118 inch (2-3mm), with

replace the seal.

ence

’•The seal retaining clamp must not be over-tightened or under-tightened.

omega

shape has a gap width between

during assembly, you must discard and

the outer race to leak out. b.

race last groove closing edge and adjust fit

and shape the seal

properly by hand. Inspect the seal for age.

of

the seal and the edge of the joint outer

onto the axle shaft.

cage, toward the vise.

60.

(0.8mm).

•The 44.

(226mm

4mm).

in

the

gap width from side

a differ-

to side

greater than 0.016 inch (0.4mm).

no

The

clamping hold time must be no less than 2 seconds.

59.

Crimp the

large seal retaining

clamp

using tool J 42572. Tighten the small seal

Remove the bench vise.

the wheel drive shaft from

Y-BODY— GENERAL MOTORS CORPORATION CORVETTE Distribute the grease within the inner

61.

CV

Plunge the

62.

joint

Inspect the inner

63.

CV

joint

Hold the wheel drive shaft

a.

cally, b.

follows:

Large ring clamp on the

•

Outer joint onto the axle shaft

in a circular

Compress

Disassemble the chrome alloy balls

boot

the retaining ring using a

from the CV-joint cage as follows:

verti-

Position a brass

a.

to

Install

CV

•

CVboot

Rotate the wheel drive shaft four or

times

retaining ring on the half-

•

CV-joint cage and tap

five

New shaft

Axle shaft retaining ring

with the outer joint at the bottom.

64.

block

•

and wheel

smooth operation as

hammer and wood

using a

10.

back and forth four

or five times.

drive shaft for

•

Outer joint from the axle shaft

• 3.

joint.

00-97 CI OU

the cage.

b.

Remove

motion.

tilt

drift it

against the

with a

chrome

the 1st

hammer alloy ball

from the cage.

the axle shaft.

the cage

Tilt

c.

Outer Joint

the opposite direc-

in

tion. d.

Remove

the opposite

chrome

alloy

Repeat the procedure

until all

6

Before servicing the vehicle, refer to

1.

ball.

the precautions in the beginning of this sece.

tion.

Remove

2.

balls are

or disconnect the follow-

removed.

Disassemble the CV-joint cage and

4

3M6ZGC7

ing: •

Axle shaft from the vehicle

•

Large

•

Small

•

CV

CV CV

inner race as follows: Install the axle shaft retaining a.

boot retaining clamp

Pivot the cage and race 90

ring-outer

joint

degrees to the center

boot retaining clamp

line of the outer

race.

boot from the joint

b.

Align the cage

windows with outer

4

3

race lands.

Remove

c.

the cage from the outer

race. d.

Rotate the inner race upward and

remove

from the cage.

it

To install: Lubricate the parts with a light coat

5.

of grease.

Assemble the CV-joint cage and

6.

2

inner race, as follows:

90 degrees

Rotate the inner race

a.

to

b.

KMWGC5

Separate the outer shaft using a

joint

Align the cage

windows with

inner

Insert the inner race into the

c.

the distance

between the edge

groove closing edge and adjust inch

race lands.

from the axle

Measure

tit

to 0

10

(2.5mm)

cage

by rotating the inner race downward.

hammer and wood

d.

block-outer joint

Insert the cage/inner race into the

outer race.

Assemble

7.

the

chrome

alloy balls into

the CV-joint cage, as follows

Position a brass

a.

CV-joint cage and tap to

tilt

b.

drift it

against the

with a

hammer

the cage. Insert the 1st

chrome

alloy ball into

the cage.

the cage in the opposite direc-

Tilt

c.

tion. d.

Insert the opposite

chrome

alloy

ball. e.

Repeat the procedure

until all

6

balls are inserted. Install

8.

V20

f

the CV-joint.

cage and tap cage-outer

it

drift

with a

against the CV-joint

hammer

to

tilt

joint

Please

visit

•

Small

•

CV

base

ol the

connect the following:

CV

boot retaining ring

site at

a difference in the

gap

width Irom side to side no greater than 0 016 inch

boot on the halfshaft

our web

omega shape has

gap width between 0.07!M).118 inch

(2-3mm), with

Install or

9.

the

Tighten the small seal retaining clamp until the

the grease provided, into

9346ZGC6

Position a brass

of

the seal and the edge ol the last axle shaft

the cage centerline.

www.chiltonsonline.com

(0.4mmH>uter

joint

a

9Q

0U ӣ O

GENERAL MOTORS CORPORATION— Y-BODY CORVETTE 3

Measure the distance between the edge the seal

and the edge

groove closing edge and adjust inch

small

(8mm)— outer flat

of

of the last axle shaft fit

to

0.3

joint

bladed tool while pushing the

outer joint onto the axle shaft. 11.

Seat the outer joint on the shaft

hammer and

using a

Install the

12.

CV

block of wood.

remaining grease into the

boot.

13.

Position the

CV

boot and the small

boot clamp. 9346ZGD2

14. 15.

Crimp the small boot clamp. Position and crimp

in

place the large

of the

between 0.079-0.118 inch (2-3mm), with a difference

boot clamp. 16.

Tighten the small seal retaining clamp until the base

omega shape has

gap width

a

the gap width from side to side no

in

greater than 0.016 inch (0.4mm)-outer joint

Install the Halfshaft in the vehicle.

STEERING AND SUSPENSION Air

3.

Bag

Place the inflator module on a bench

or other surface with the

**

1.

vehicles are equipped with an air

bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system

inflator

module which may be thrown

the

in

the

then

.

Before servicing the vehicle, refer to

the precautions

side lower trim panel,

SIR fuse

to the fuse block.

Turn the ignition switch

to the

RUN

in

the beginning of this sec-

7-9

Verify the SIR indicator light flashes

times, then turns OFF.

system

If

not, inspect

for malfunction.

tion. 2.

3.

Turn the steering wheel to align the in

the straight-ahead position.

Turn the ignition switch

to the

4.

Remove

the AIR

BAG

Power Rack and Pinion Steering Gear

LOCK

position.

PRECAUTIONS

of the steer-

position. 5.

1

Install the left install the

4.

DISARMING

base

at the

column.

ing

3.

event of an accidental deployment.

LOCK

Engage the yellow 2-way connector

and the CPA device

module on the

bench, never place anything on or close to

wheels

repairs.

2.

With the

Turn the ignition switch to the

position.

facing up.

CAUTION

4.

All

bag and trim cover

REMOVAL & INSTALLATION fuse from the

fuse block.

Several precautions must be observed

when handling

the inflator

module

to

5.

avoid

accidental deployment and possible per-

.

the

left

side lower trim panel,

then unplug the Connector Position Assur-

ance (CPA) device and the yellow 2-way

sonal injury. 1

Remove

SIR harness wire connector

Never carry the

inflator

module by

the

at the

base

of

the steering column.

wires or connector on the underside of the

module. 2.

ARMING

When

.

Before servicing the vehicle, refer to

tion. 2.

Drain the powensteering

3.

Remove

bag and trim cover are pointed away.

Negative battery cable

•

Brake Pressure Modulator Valve

(BPMV) After the

necessary repairs have been

made, re-enable the

air

bag system as follows:

fluid.

or disconnect the following:

•

carrying a live inflator module,

hold securely with both hands, and ensure that the

1

the precautions in the beginning of this sec-

bracket,

if

equipped

•

Both front wheels

•

Intermediate shaft shield

90-90 wU

Y-BODY— GENERAL MOTORS CORPORATION CORVETTE

0

Exploded view

of the front

shock absorber

—5.7L engine

mounting

•

Negative battery cable

•

Wheel

• 79227B56

Exploded view

power steering gear mounting

ol the

Real Time

Damper (RTD)

electrical

connector

—5.7L engine

•

Upper mounting nut

retainer

and

insulator •

•

•

Intermediate shaft lower coupling

coupling to the steering gear and

from the power steering gear

torque the bolt to 25

Power steering

•

Magnasteer

Steering cooler pipe from the steer-

•

Wire harness clips to the cross-

•

Power steering cooler

•

Both outer

tie

rod ends from the

Cooler

•

Cooler pipe

to the

•

Stabilizer shaft

ber

torque the

•

Wire harness clips from the cross-

Nm)

electrical

connector

(27

from the crossmem-

•

20

fitting to

a

gear lbs

ft

to the steering fitting to

20

ft

gear and lbs.

(27

c

Remove the tool from the shock. Remove the shock absorber install: Install or

Power steering gear through the

left

4.

Install or

Nm)

•

Both front wheels

•

Negative battery cable

Refill

•

crossmember to

Check and adjust the

front

end align-

•

Shock Absorber

•

6

(110 Nm)

Brake pipe

•

Stabilizer shaft

to the

tie

ing knuckle ft.

tional

lbs.

Front

crossmember

rod ends to the steer-

and torque the nuts

(25

insulator, retainer

and nut

19

to

ft

lbs.

(26

If

RTD

to

21

ft

electrical

lbs.

(28

Nm)

connector

equipped with heavy duty shocks

(FE3) pertorm the following steps

1

Both outer

upper shock

Lower mounting bolts and torque

them

REMOVAL & INSTALLATION

•

Upper

and torque the nut

Torque the crossmember mounting

18

•

lbs.

(100 Nm)

lbs.

to the

Nm)

and torque the nuts

ft.

Shock absorber tower

connect the following:

Steering gear to the

ft.

•

ment.

74

connect the following:

Retainer and insulator to the shock

absorber

and bleed the power steering

system. 7.

compressed

the shock from the

d.

5

6.

is

vehicle

To

Steering gear mounting bolts and

a shock support tool to the it

Remove

(3.5

wheel opening

•

Install

shock while

torque the clamp to 32 inch lbs

install:

•

b

the shock absorber from

upward

ber

To

nuts 81

Compress

the bottom

Brake pipe from the crossmem-

nuts

•

equipped with heavy duty shocks

4

•

loosen the crossmember mounting

•

hose

Inlet

If

Intermediate shaft shield and

member

•

to the steering

Nm)

Magnasteer

tower 3.

crossmember

and torque the

knuckles

Shock absorber from the upper

(FE3) pertorm the following steps:

•

•

•

connector

member

ing gear

5.

•

steering gear

electrical

Shock absorber lower mounting bolts

Nm)

hose from the

inlet

•

(34

lbs.

ft

Nm)

the precautions in the beginning of this sec-

to

plus and addi-

180 degrees

a

Before servicing the vehicle, refer to

tion. 2.

Remove

or disconnect the follow-

a shock support tool to the

b

Install the

shock

to the vehicle.

c.

Install the

upper

insulator,, retainer

and nut and torque the nut

to

19

ft.

lbs

(26 Nm).

ing:

Intermediate shaft lower steering

Timing belt service

Install

shock absorber

d.

is

covered

in

Section

3

of this

manual

Remove

the support tool from the

^

1

Of! GENERAL MOTORS CORPORATION— Y-BODY

OU"Oll shock and

CORVETTE

install a

spring compressor to

bolt

the spring. 7.

Raise the lower control arm and

install the

bolts

and torque them

to 21

ft.

lbs.

Step

Remove

6:

the spring

(28

Before servicing the vehicle, refer to

8.

Install

the precautions

in

•

Negative battery cable

•

Remove

2.

Rear

Negative battery cable Front wheels

Lower

•

.

Cam

Before servicing the vehicle, refer to

the precautions

arm

the beginning of this sec-

in

tion. 2.

Remove

•

Transverse spring bolts and retain-

Transverse spring and the

Negative battery cable

Wheel Rear position sensor electrical connector,

To if

install: Install or

equipped •

•

Lower mounting

•

Upper mounting bolts

bolt •

Shock absorber from

New

the lower to

arm and shock tower

Upper insulator and

retainer

from

the shock absorber

front spring adjuster bolt

Install or

connect the following:

Upper insulator and

gap

height— front

•

assembly

removed

if

Shock absorber

to the

shock tower

and lower control arm •

Upper mounting bolts and torque

them •

to

22

ft.

lbs.

(30

Nm)

Lower shock absorber mounting bolt

(220

and torque

it

to

162

ft.

lbs.

Nm)

•

Rear position sensor electrical con-

•

Wheel

•

Negative battery cable

nector

Exploded view absorber

of the rear

—5.7L engine

shock Exploded view

46

ft.

lbs.

(62

Nm)

Lower control arm

to the cross-

Cam

bolts to the

matchmarks made

during the removal procedure.

retainer to the

shock absorber,

spring retainers and bolts to

crossmember and torque them

member

ease the installation procedure and set-

ting the proper vehicle trim

To install:

•

Measure the to

•

connect the following:

Spring to the crossmember

the

control

com-

pressor tool

•

•

matchmarking them

Lower control arm

6.

3.

bolts from the lower control after

ers

•

•

from the steering

•

•

•

ball joint

or disconnect the follow-

ing: •

from the lower

knuckle •

1

of the lower control

arm

control

•

one

Stabilizer shaft link

or disconnect the following:

•

it.

arms

tion.

Wheel

and compress

or disconnect the following:

bolts from

the beginning of this sec-

or connect the following:

•

spring compressor tool J

to the spring

Lower shock absorber mounting

•

com-

pressor tool.

front spring adjuster

ease the installation procedure

Remove

5.

1.

to

Install a

4.

33432-A Front

a.

gap

and setting the proper vehicle trim height.

REMOVAL & INSTALLATION

shock absorber lower mounting

Nm).

Measure the

3.

Transverse Spring

of the front transverse

spring— 5. 7L engine

Y-BODY— GENERAL MOTORS CORPORATION Ofl

wU U

CORVETTE Hand

cam

tighten the

bolts at this

•

Lower control arm

ball joint

stud to

the steering knuckle

and torque the

nut to 15

Nm)

additional

ft.

lbs.

(20

plus an

210 degrees

•

Shock absorber

•

Shock absorber lower mounting bolts

(28 •

and torque them

ft.

ft.

33432-A

arm and torque (72

degree turn

it.

the spring mounting bolts,

•

Remove

the spring from the vehicle

Front wheels

•

Negative battery cable

Perform a front end alignment.

Torque the control arm cam bolts

WSS

•

Brake rotor

•

Spring to the vehicle

•

Brake caliper and torque the

•

Spring spacers, insulators and

and torque the bolts

to

46

ft.

.

Spring to the lower control arm

•

Lower control arm

to spring bolts

lbs.

ft.

(170

Nm)

tool

125

bolts to

ft.

Wheel front alignment.

Rear

and insulators and release the

compressor

connector

Check and adjust the

5

lbs.

ft.

Nm)

(175

lbs.

lbs.

Nm)

•

to

electrical

mounting bracket

crossmember

1

125

53

to

Nm)

(72 •

to the

(25

Stabilizer shaft link to the control

verse spring

(62

11.

lbs.

turn •

tool.

connect the following:

mounting bolts

Adjust the front trim height.

ft.

plus an additional 180 degree

Spring compressor to the trans-

•

tool

10.

rod to the steering knuckle

tie

arm and torque the nut

Install or

7.

connect the following:

•

Outer

Nm)

and remove the compressor

ft.

210

plus an additional

ber and control arm.

lower control arm supports.

9.

and compress

Nm)

(20

lbs.

and torque the nut to 18

the nut to

compressor

ball joint to the steering

spacers and insulators from the crossmem-

Nm)

the spring

Install or

to the spring

Remove

5.

Lower

knuckle and torque the nut to 15

a spring compressor tool J

Install

from the transverse spring and move the

8.

•

To install:

lbs.

Remove

4.

6.

lbs.

Nm)

control

7.

to 21

Stabilizer shaft link to the lower

53

height to ease the installation procedure and setting the proper vehicle trim height.

time

I

.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

•

Rear wheel

•

Negative battery cable

tion. 2.

Rear

8.

Adjust the trim height and place the

retainers 1

.

on the control arm

bolts.

Before servicing the vehicle, refer to 9.

the precautions in the beginning of this sec-

Check and adjust

the alignment,

3.

Wheel Speed Sensor (WSS)

•

or disconnect the following:

•

Negative battery cable

•

Rear wheels

Measure

•

cal

needed.

Remove

electri-

connector

Ball Joint

REMOVAL & INSTALLATION

Damping (RTD)

Real Time sensor,

Upper

the transverse spring stud

or disconnect the following:

Wheel

if

tion. 2.

Remove •

if

•

Brake caliper

•

Brake rotor

•

Shock absorber solenoid connector,

•

Front

Outer

tie

position

equipped

if

electrical

equipped

rod from the suspension

knuckle Before servicing the vehicle, refer to

•

Axle shaft nut

the precautions in the beginning of this sec-

•

Upper control arm from the knuckle

tion.

•

Lower

•

Suspension knuckle from the

1.

2.

Remove

or disconnect the following

•

Wheel

•

Brake caliper

•

Brake rotor

•

3.

from the lower

arm

Wheel Speed Sensor (WSS)

electri-

connector

Outer

tie

knuckle

3.

install:

4

Press the

Upper

•

Steering knuckle from the vehicle

Install or

ball joint

Measure the transverse spring stud height to

ease the installation procedure and set-

ting the proper vehicle trim height

assembly

— rear

install: Install or •

•

•

Lower

•

knuckle

ball joint to the control

to

15

•

lbs.

(55

Nm)

Upper control arm

to the knuckle

and torque the nut

to

15

ft.

lbs.

(20

plus an additional 250 degree

ft.

arm

lbs.

turn

•

(20

covered

in Section

lbs (160

Outer

tie

it

to

1

18

Nm)

rod to the knuckle and

torque the nut to 15

ft

lbs.

(20

Nm)

plus an additional 160 degree turn •

is

Axle shaft nut and torque ft.

plus an additional 250 degree

Heater Core replacement

knuckle and

It.

turn

connect the following

and torque the nut

Nm)

to the vehicle

ball joint to the

torque the nut to 41

from the steering

Ball joint to the steering

Upper

suspen-

connect the following

Knuckle

Nm)

4

Irom the

ball joint into the

•

knuckle.

To

ball joint

sion knuckle

from the control arm

•

Press the

To

5.

rod from the steering

ball joint

Press the upper

knuckle

Stabilizer shaft link

cal •

from the knuckle

vehicle

control •

ball joint

Brake rotor

2 of this manual

nn m nr 0 U OC •

GENERAL IVIOTORS CORPORATION— Y-BODY CORVETTE

Brake caliper and torque the

mounting bracket bolts lbs.

(175

WSS

•

Shock absorber solenoid

electrical

connector,

6.

to

•

RTD

Wheel

ft.

Nm)

•

•

125

if

Negative battery cable

•

Front wheel

•

Real Time link

connector

position sensor,

ing

is

connect the following:

Front

•

Upper control arm

•

Upper control arm shims and bolts

48

to

Before servicing the vehicle, refer to

lbs.

ft.

the precautions in the beginning of this sec-

Nm)

(65

tion.

Ball joint stud into the

•

upper con2.

arm and torque the nut

trol

Before servicing the vehicle, refer to

15

to

Remove •

Nm)

(20

lbs.

the beginning of this sec-

plus an additional

tion.

RTD sensor

•

the lower control

arm from

250 •

Front transverse spring

•

Wheel Speed Sensor (WSS) cal

•

Front wheel

•

Negative battery cable

•

Press the

ball joint

from the control 4.

Real

Time Damping (RTD)

Check and adjust the

front

Support the lower control arm with a

jack stand ball joint into the control

Press the

•

Rear

arm.

Shock absorber from the lower control

the control

arm

in

the vehicle.

1

.

Before servicing the vehicle, refer to

•

the precautions in the beginning of this sec-

2.

Remove

or disconnect the following:

Rear wheel

•

Wheel Speed Sensor (WSS) cal

link,

if

4.

position

equipped

•

Upper control arm bolts

•

Upper control arm

Support the lower control arm with a

bolts to the position

match

dure and hand tighten the bolts •

Lower control arm

ball joint

stud to

the steering knuckle and torque the

Install or

connect the following:

nut to 15

Upper control arm and torque the bolts to 81

ft.

lbs.

(110

Suspension knuckle

additional

ft.

lbs.

(20

Nm)

plus an

210 degrees

Nm)

ball joint

stud

nut into the upper control arm.

may

Cam

marked during the removal proce-

install:

set-lower ball joint

connect the following:

Lower control arm

jack stand •

Ball joint stud

tool

after

Lower control arm from the vehicle

Install or

from the control arm

•

•

from the knuckle

washers and nuts

bolts,

install:

• 5.

Support the lower control arm with a

•

removal and installation

To 4.

Damping (RTD)

jack stand.

To

Cam

•

electri-

connector

Real Time

sensor 3.

Ball joint stud

•

matchmarking them

•

•

from the lower

arm

•

Negative battery cable

•

arm

Stabilizer shaft link

control

tion.

Ball joint

electrical

equipped

wheel 3.

Install

if

alignment.

To install:

5.

electri-

connector

connector,

arm.

4.

Front wheel

link

the vehicle. 3.

or disconnect the following:

ft.

degrees

Remove

is

Lower Control Arm

1

Front and Rear

2.

arm

REMOVAL & INSTALLATION

and torque the bolts

in

control

install: Install or

3.

REMOVAL & INSTALLATION

the precautions

new

arm

Upper control arm

•

To

.

a

shims

wheel

alignment.

1

when

replaced

installed.

Upper control arm bolts and

•

Ball Joint

The manufacturer does not provide a bushing replacement procedure. The bush-

from the upper

ball joint

control

equipped

rear

Damping (RTD) sensor

and support the lower control

Upper

•

if

CONTROL ARM BUSHING REPLACEMENT

arm

electrical

equipped

Check and adjust the

Lower

•

It

be necessary to use an Allen

wrench

to

keep the

ball joint

stud

from spinning while tightening the

Upper Control Arm

ball joint

to

REMOVAL & INSTALLATION

15

ft.

tional •

WSS

•

RTD

Front

stud nut. Torque the nut

lbs.

(20

Nm)

plus an addi-

250 degrees electrical

connector

position sensor link,

if

equipped 1.

Before servicing the vehicle, refer to

the precautions

in

the beginning of this sec-

tion. 2.

5.

Remove

or disconnect the following:

•

Rear wheel

•

Negative battery cable

Check and adjust the

alignment.

rear

7922Z661

wheel

Lower engine

control

arm mounting

bolts

— 5.7L

OH QQ OU OO

Y-BODY— GENERAL MOTORS CORPORATION CORVETTE CONTROL ARM BUSHING REPLACEMENT

Stabilizer shaft link to the lower

•

arm and torque the nut

control

53

lbs.

ft.

Nm)

(72

The manufacturer does not provide a

•

Transverse spring and remove

bushing replacement procedure. The bush-

•

Shock absorber lower mounting

ing

and torque them

bolts

21

to

ft.

lbs.

is

when

replaced

a

new

control

arm

RTD

Brake rotor

•

Stabilizer shaft link

control

is

•

installed.

electrical connector,

if

3.

Wheel Bearings

WSS

Front wheQl

•

Negative battery cable

connector

electrical

ADJUSTMENT

Perform a front wheel alignment.

7.

Tighten the lower control arm nuts to

periodic wheel bearing adjustment

is

To

necessary. The wheel bearings are a sealed unit that

(170 Nm).

•

stud from the

ball joint

Wheel hub mounting

•

Wheel hub/bearing assembly from

must be replaced

if

loose or noisy.

install: Install or

•

connect the following:

Hub/bearing assembly to the steering knuckle.

Front

the precautions in the beginning of this sec1

tion.

Remove

or disconnect the following:

•

Negative battery cable

•

Rear wheel

•

Make

certain that the

•

2.

arm

Shock absorber from Lower

Before servicing the vehicle, refer to

the lower

Remove

•

mounting bolts

to

Lower control arm

to

or disconnect the following: •

•

Negative battery cable

•

Front wheel

•

Wheel Speed Sensor (WSS) cal

ball joint

and torque the

96

ball

55

Outer

ft.

tie

lbs.

(75

•

Cam

and torque the nut •

connector

to

WSS

electrical

after

matchmarking them •

3.

Lower control arm from the vehicle

install:

connect the following:

Install or

•

Lower control arm

•

Cam

bolts to the position

match

marked during the removal procedure and hand tighten the bolts •

Lower

ball joint

stud to the steering

knuckle and torque the nut to 15 lbs.

(20

Nm)

ft.

plus an additional 210

degrees •

Stabilizer shaft link to the lower

control to •

53

lbs.

5.

lbs.

(72

the link nut

Nm)

and torque the bolts

to

162

ft

(220 Nm)

Transverse spring trol

4.

arm and torque

Shock absorber lower mounting bolts

•

ft.

to the

lower con-

arm

•

Rear wheel

•

Negative battery cable

Perform a rear wheel alignment

Torque the lower control arm front

cam

bolt to

rear

cam

107

bolt to

ft.

70

lbs. ft.

(145

lbs.

Nm) and

(95 Nm).

the

Exploded view

Brake service

is

of the front

covered

hub/wheel bearing and knuckle assembly

in Section

4 of this manual

33

ft.

connector

from the lower

washers and nuts

stud to the

Nm)

electri-

arm

bolts,

(130

Nm)

stud nut from the

Stabilizer shaft link

control

lbs.

rod to the steering knuckle

knuckle •

ft.

is

steering knuckle and torque the nut

arm

control •

.

the precautions in the beginning of this sec-

facing rearward

Nm)

tion.

Transverse spring from the lower control

To

bolts

speed sensor cable connection Before servicing the vehicle, refer to

2.

Lower

•

REMOVAL & INSTALLATION

Rear .

rod ball stud

the knuckle

No

6.

1

tie

steering knuckle

•

lbs.

Separate the outer

the lower

from the steering knuckle

•

ft.

from the lower

arm and support arm

control

equipped

125

Brake caliper

•

Nm)

(28 •

•

to

— 5.7L engine

lbs.

(45

Qfl OA tl UU"U •

GENERAL MOTORS CORPORATION— Y-BODY CORVETTE

Stabilizer shaft link to the-lower

speed sensor cable connection

is

arm and torque

facing rearward and torque the

hub

control

55

ft.

(75

lbs.

the nut to

mounting bolts

Nm)

Brake rotor

•

Brake caliper and torque the

•

bracket mounting bolts to 125

(175

lbs.

to

96

Upper control arm

Nm)

(65

lbs.

•

•

Front wheel

•

Negative battery cable

to the steering

Lower control arm

stud to

ball

the suspension knuckle and lbs.

ft.

(75

Nm) •

Axle nut and torque

it

to

1 1

8

ft.

lbs.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

Exploded view

tion.

ing

2.

ft.

Nm)

torque the nut to 55

.

(130

knuckle and torque the bolt to 49

ft.

Rear 1

lbs.

ft.

Nm)

•

Remove

of the rear

and knuckle assembly

hub/wheel bear-

— 5.7L engine

•

or disconnect the following:

3.

33

Negative battery cable

•

Axle nut

•

Rear wheel

•

Separate the upper control arm

•

Wheel Speed Sensor (WSS)

• •

•

•

link,

if

•

rod ball stud to the steer-

Brake rotor

Shock absorber solenoid

tie

lbs.

arm

ball joint

stud

and torque the nut

(45

Brake rotor Brake caliper and torque the

mounting bracket bolts (175

to

125

•

if

electrical

equipped

rod end from the suspen-

sion knuckle

To

WSS

•

Shock absorber solenoid

electrical

connector electrical

Hub/bearing bolts Hub/bearing from the knuckle

•

RTD

position sensor link,

install:

equipped Install or

•

connect the following:

Hub/bearing assembly ing knuckle.

Make

•

Rear wheel

•

Negative battery cable

to the steer-

certain that the

ft.

Nm)

•

Suspension knuckle

to

Nm)

connector

•

Outer

tie

Steering knuckle from the lower control

•

Brake caliper

connector,

ft.

lbs.

equipped

•

•

from the suspension knuckle

Time Damping (RTD) position

sensor •

electri-

connector

Real

Outer

ing knuckle

•

cal

Nm)

(160

if

GEO/CHEVROLET 1998-01 Metro

DRIVE TRAIN... ENGINE REPAIR FUEL SYSTEM

PRECAUTIONS STEERING AND SUSPENSION

•

31-19 31-2 31-17 31-2

Exhaust Manifold

31-10

Removal &

31-10

31-27

Fuel Filter

Front Crankshaft Seal

Removal &

31-27

Disarming

31-27 31-27

Precautions

31-3

Installation

Removal & Fuel

Installation

31-11

Fuel System Pressure

31-18 31-17 31-17 31-17

Relieving

31-14 Installation

Removal &

&

Ring

31-16

Positioning

31-16

Piston

Rack and Pinion Steering Gear. ...31-28

Removal &

Installation

Removal &

Installation

Rocker Arms/Shafts

Removal &

Removal &

Installation

Installation

Installation

Installation

Ignition

31-3

Removal &

Installation

31-2

Lower Control Arm

Starter

31-9 31-9

31-14

Motor

Removal &

Installation

31-2

Control

Removal &

Installation

31-4 31-4

31-30

Pan

Front Cover

&

Removal &

Seal Installation

Transaxle Assembly

Removal & 31-33 31-33 31-34

Installation

31-33

Installation

31-14

31-15 31-15 31-19

31-19

V 31-13

Valve Lash

31-13

Adjustment

W Water

Pump

Removal &

31-7 Installation

Wheel Bearings

0 Oil

Timing Chain, Sprockets,

Arm Bushing

Removal &

Removal &

Installation

Replacement

E

Engine Assembly

31-14

31-30

Strut

31-33

Ball Joint

Removal &

Installation

31-9

L

31-7

Removal

31-9

Intake Manifold

Lower

31-2

Installation

31-23

31-3

Timing

Adjustment

D Distributor

31-15

T

31-7

Cylinder Head

31-23 31-23

Bleeding

31-24

Overhaul

Removal &

Hydraulic Clutch System

31-32 31-24

CV-Joints

Installation

31-22 31-32

Coil Spring

Removal &

Removal &

31-22

Adjustment

31-23

Halfshaft

31-12 31-21

Clutch

31-28

31-15

Rear Main Seal

S 31-12

Installation

31-14

P

C Camshaft

31-14

31-17

31-17 Installation

Installation

Pump

31-11

31-18

Pump

Removal &

31-3

Removal

Installation

Fuel Injector

31-3

Alternator

Installation

Removal & Oil

Removal &

31-17

Removal &

Bag

Installation

F

A Air

Prizm

Adjustment

31-7

31-35

31-35

O Qi "4 0

GEO/CHEVROLET METRO

1

PRIZM

•

PRECAUTIONS eye

Before servicing any vehicle, please be

sure to read

of the following precautions,

all

which deal with personal of

prevention

safety,

component damage, and important points consideration when servicing a

irritation persists, or

fluid for

The EPA warns

•

prolonged contact

that

may cause

with used engine

motor vehicle:

skin disorders, including cancer!

Never open, service or drain the radiacooling system

tor or

hot; serious

when

the engine

Observe

applicable safety precau-

all

when working around

tions

fuel.

Whenever

servicing the fuel system, always work

Do

well-ventilated area. or vapors to

to

effort to

used engine

gloves should be worn

come

in

a

in

not allow fuel spray

(a hot

oil.

You

Soap and

expo-

water, or

•

new

All

vehicles are

now equipped must be

disabled before performing service on or

drop

becomes contaminated, completely

Any brake

fluid.

flush the

Never reuse any

fluid.

removed

fluid that is

from the system should be discarded. Also,

come in condamage

fluid to

painted surface;

tact with a

will

it

the paint.

Never operate the engine without the

•

proper amount and type of engine

doing so WILL result

waterless hand cleaner should be used.

of brake

the brake fluid

If

do not allow any brake oil.

other exposed after

your vehicle.

system with new brake

Protective

oil.

with an air bag system. The system

contact with a spark,

open flame or excessive heat

sure to used engine

of

minimize your

soon as possible

skin areas as

number

a

when changing

Wash your hands and any

and hot coolant. •

oil

should make every

exposure

is

burns can occur from the steam

should always buy the correct type

medical assistance.

to take into

•

proper operation of the brake system. You

you have taken

if

IMMEDIATELY seek

brake fluid internally,

oil;

severe engine

in

damage. Timing

•

belt

maintenance

Many models

important!

extremely

is

an interfer-

utilize

around system components, steering col-

ence-type, non-freewheeling engine.

extinguisher near the work area. Always

umn, instrument panel components, wiring

timing belt breaks, the valves

keep

and sensors. Failure

example). Keep a dry chemical

light, for

fuel in a

designed

fire

container specifically

for fuel storage; also,

to follow safety

disabling procedures could result

always

in

and

head may

acci-

tially

strike the pistons,

sonal injury and unnecessary system

maintenance

additional fuel system precautions later

repairs.

this

5. working with, or around, the

Fuel injection systems often remain

•

Always wear safety goggles when

•

air

pressurized, even after the engine has been

When

turned OFF. The fuel system pressure must

sure the bag and trim cover are pointed

be relieved before disconnecting any fuel

away from your body. When placing

lines. Failure to

do so may

and/or personal

injury.

•

Brake

fluid often

handling brake

after

brake fluid

in

fluid.

If

of the

module

system precautions

your eyes, flush your eyes If

vehicles

if

it

is

accidentally air

sealed container

is

require the

ative battery cable •

bag

interfere with

computer

When

is

to

reconnected.

drum

servicing

brakes, only dis-

assemble and assemble one side

later in this section.

essential to the safe

may

on-board computer sys-

undergo a relearning process once the neg-

Clean, high quality brake fluid from a

•

some

tem^) and may

reduce the

deployed. Refer to the additional

you do get

with clean, running water for 15 minutes.

motion

to the

Disconnecting the negative battery

cable on

and trim cover upward, away will

replace-

and

inspection.

the functions of the

from the surface. This

and wash your hands thoroughly

recommended

interval for the timing belt,

timing belt section for belt replacement and

•

a non-

causing poten-

interval charts in the front of

for the

bag on a work surface, always

air

face the bag

contains polyglycol

ethers and polyglycols. Avoid contact with the eyes

carrying a non-deployed air bag, be

deployed

result in fire

manual

ment

bag system.

the

expensive) engine damage. Refer to the

dental air bag deployment, possible per-

possibility of fire or explosion. Refer to the

this section.

If

the cylinder

serious (also time-consuming and

properly seal fuel containers to avoid the

in

in

and

at a time,

leaving the remaining side intact for refer-

ence.

ENGINE REPAIR Remove

Distributor

the distributor from the

Timing Disturbed

engine.

REMOVAL

INSTALLATION

1.

Remove

2.

Place a

hole. 1

.

Before servicing the vehicle, refer to

the precautions

in

tion. 2.

Remove

or disconnect the follow-

Negative battery cable

•

Distributor electrical connector

•

Spark plug wires from the distribu-

mark the position

of the distributor

body and

of the distributor

body

relation to the cylinder head. 4.

2.

Distributor cap

Mark the position

Remove

the distributor

made dur-

and be sure the drive gear engages

properly within the

cap

rotor in relation to the distributor

Align the reference marks

ing removal. Position the distributor care-

•

•

bolts.

ley, until .

fully

tor

3.

Timing Not Disturbed 1

ing:

in

3.

Install or

4.

3.

a

spark plug. the spark plug

rotate the

engine by

wrench on the crankshaft pul-

compression

is felt.

Align the timing mark on the crank-

shaft pulley with the

0 degrees mark on

the timing scale attached to the front of

Dead Center (TDC) on

•

Hold-down

•

Distributor electrical connector

»

Spark plug wires

rotor points to the No.

•

Distributor cap

on the cap.

•

Negative battery cable

bolts but

1

the engine. This places the engine at

slot.

connect the following:

do not tighten

Check and/or adjust the

the

Top

compression

stroke. 4.

5.

ignition tim-

Turn the distributor shaft

Install or

•

y spark

until the

plug tower

connect the following:

Distributor,

by aligning the distrib-

utor housing-to-cylinder head

ing.

hold-down

Have someone

hand using

the beginning of this sec-

the No.

thumb over

Tighten the distributor hold-down

bolts to 11

ft.

lbs.

(15 Nm).

marks made during the removal procedure

01.0 O O

GEO/CHEVROLET METRO

•

PRIZM

I

1

93066Z28

Exploded view 1

Distributor

2

Distributor

of the alternator

— Metro

A

and Prizm models

mounting bolts

Blank (cavity

1)

B Diagnostic request terminal (cavity 2)

7922Z701

C •

Be sure

to tighten the distributor

mounting

belt

— Prizm

•

(cavity 3)

D Ground terminal(cavity 4) E Test switch termmaJ( cavity F Duty check terminai(cavity

Alternator electrical connectors

then torque the alternator bolts to •

Spark plug wires and

•

Distributor cap

•

17

lbs.

ft.

electrical wires

Nm)

(23

assembly

Check and/or adjust

7.

Tighten the distributor hold-down

bolts to 11

ft.

lbs.

ignition timing.

(15 Nm).

2 Jumper

•

Air cleaner

•

Negative battery cable

7922Z7Q2

Jumping terminals

Prizm 1

DLC Install

.

the alternator

Install the alternator belt

2.

and adjust

the tension until a deflection of 0.24-0.31

(6-8mm)

inch

REMOVAL

deflection with

kg) of pressure exerted

used

Metro

belt.

On

a

new

when

22

lbs.

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

belt the belt deflection

Install or

3.

Remove • •

•

Upper and lower mounting bolts

•

belt

.

7.

Connect a tachometer

timing light to the No. idle

1

spark plug wire.

8

Refer to the vehicle emission control

for ignition timing specifications.

Negative battery cable

belt

9

Remove

the cap from the diagnostic

check connector, located next coil or

Timing

left

to the ignition

side strut tower and insert a

fused jumper wire between appropriate the terminals

On

4 terminal connectors, hold

the connector with the locking tab is

top and

jump

11

1

On 6

•

Accessory drive

tion.

•

Alternator electrical connectors

•

Alternator

the engine until

it

reaches nor-

mal operating temperature. Stop the engine,

tion for approximately

5 seconds.

ON

posi-

Start the

engine again.

Run

3.

connect the following

Alternator

and the

bolts,

allow

do not

tighten the bolts at this time

4.

it

the engine at

2000

RPM

for

to run at idle speed.

Be sure

top

and

all

accessories are turned

left

(D

E).

Loosen the

distributor

bolt

and

rect

timing marks are aligned.

13. bolt to

hold-down

rotate the distributor until the cor-

Tighten the distributor hold-down 1

1-15

ft

lbs.

(15-20 Nm) and

recheck the timing. Be sure the timing

approximately 5 minutes. After 5 minutes, •

at the

inals at the lower

12.

Run

2.

but keep the ignition switch in the

Install or

the

terminal connectors, hold the

Before servicing the vehicle, refer to

.

the precautions in the beginning of this sec-

Metro

at

the lower 2 terminals (C and

D

Metro

Negative battery cable

INSTALLATION

if

Accessory drive

•

belt

Connect a

speed and adjust,

connector with the locking tab or disconnect the following:

nega-

to the

tive terminal of the ignition coil.

Nm)

(23

Before servicing the vehicle, refer to

Remove

in

•

lbs.

tion. 2.

placed

depending on

•

ft

••The ignition timing on the Prizm

the precautions in the beginning of this sec-

shift lever is

PARK

information label (located under the hood)

17

not adjustable. 1

r

transaxle type

10

Prizm

o

Alternator electrical connectors

ADJUSTMENT

Alternator

NEUTRAL

Alternator bolts to

Ignition

Accessory drive

•

Be sure the

needed

connect the following

Alternator electrical connectors

•

Fully

•

or disconnect the following:

assembly

engage the parking brake.

5.

6.

•

Negative battery cable Air cleaner

the 6 terminal

— Metro models

Check the engine

(10 kg) of pressure exerted.

tion. 2.

(10

the

installing a

should be 0.20-0.27 inch (5-7mm) with 22 lbs.

in

and hand-tighten

the bolts.

Alternator

.

6)

DLC

Duty check

1

5)

Negative battery cable

6.

1

Diagnostic output terminal

and adjust as

necessary

bolts to prevent the timing from chang-

ing

Accessory drive

advances according

to

engine speed.

Remove the diagnostic check jumper. Remove the timing light and 14

tachometer.

OFF

For complete service labor times, order the Chilton Labor Guide

GEO/CHEVROLET

31-4

METRO

•

PRIZM

Prizm

•

Engine Assembly

Engine Coolant Temperature (ECT) sensor

‘—If the ignition timing is out ot specifi-

cation, a possible engine electrical

•

REMOVAL & INSTALLATION

electrical

may have occurred. The followprocedure may be used to check

failure

ing

•

Metro

the timing: Before servicing the vehicle, refer to the

.

precautions

in

Warm

2.

the beginning of this section.

the engine to normal operating

temperature. Turn

all

electrical

accessories

OFF.

sure

Connect a tachometer or engine scan and check the engine is

it

speed and be

650-750 rpm.

Connect a timing

4.

idle

light.

Remove

the

cap on the Data Link Connector (DLC).

Using a fused jumper wire, connect terminals El and

TE1.

Before servicing the vehicle, refer to

1.

should be

at

10 degrees Before Top Dead

Center (BTDC).

Remove

6.

DLC and 7.

the

jumper wire from the

Drain the cooling system.

4.

Drain the engine

5.

Drain the transmission fluid,

OFF

•

electrical

Pleated

Oxygen (HO 2 S) sensor

•

connector

Body

Throttle

Injection (TBI) unit

connector

Early Fuel Evaporation (EFE) heater electrical connector,

if

Oil

Alternator connectors

Air cleaner

Coil wire from the distributor

•

•

Radiator and cooling fan assembly

•

•

Evaporative emissions (EVAP)

equipped

pressure switch electrical con-

•

•

elec-

connector

electrical

•

•

sensor

trical

hood

nector

purge solenoid

and disconnect

oil.

or disconnect the following:

ground wires

Manifold Absolute Pressure (MAP)

•

if

connector

•

Flood after scribing the hood hinge to the

Speed Control (ISC) motor

Intake manifold

equipped with an automatic transmisson.

reinstall the cap.

Shut the engine

test

3.

Idle

•

pressure.

Remove

Exhaust Gas Recirculation (EGR)

electrical

Properly relieve the fuel system

•

With the jumper wire connected, the timing

•

tion.

6.

Sensor (TPS)

connector

valve electrical connector

the precautions in the beginning of this sec-

engine and check timing.

Start the

5.

all

ENGINE

2.

3.

tool

1.0L

connector

Throttle Position electrical

• 1

connector

electrical

Coolant Temperature Sending unit

electrical

Starter solenoid electrical

connec-

tor

connector

•

Distributor electrical connector

equipment.

A/C compressor clutch

coil electri-

equipped

cal connector,

if

•

EVAP

vacuum hose

•

MAP

canister

sensor vacuum hose

•

Brake booster hose

•

Accelerator cable from the throttle

body equipped

•

Clutch cable,

•

Gear select cable

if

automatic

for

transmissions •

Speedometer cable

•

Heater

•

Fuel feed and return hoses

inlet

and

outlet

hoses

Support the engine.

7.

•

•

Exhaust pipe from the manifold Gearshift control shaft and exten-

sion rod from the transmission •

Backup lamp switch

electrical

con-

nector •

Crankshaft Position (CKP) sensor electrical

•

Ht

is

connector

Both halfshafts

not necessary to disconnect the

halfshaft from the knuckle. •

A/C compressor without disconnecting the hoses

•

Power steering hoses from the

pump, Attach a

8.

+B El

FP TE1

W MO

SYSTEM VOLTAGE GROUND TERMINAL FUEL PUMP TERMINAL DIAGNOSTIC REQUEST TERMINAL MALFUNCTION INDICATOR LAMP (MIL) TERMINAL DATA LINK CONNECTOR (DLC) (UNDER HOOD) 7922Z703

DLC

pin locations

— Prizm models

if

equipped

lifting

device to the engine.

transmission mount

•

Left side

•

Right side and rear engine

•

Engine/transmission assembly

mount

To install: Install or

9.

• •

connect the following:

Engine/transmission assembly Left

transmission mount and torque

the nut to 41

ft.

lbs.

(55

Nm)

OH C O U

GEO/CHEVROLET METRO •

10.

Right and rear engine

mounts and

torque the bolts to 41

ft.

Nm) Remove

lbs.

device and

lifting

Exhaust pipe

to the

1 1

the bolts to

20

if

electrical

cal •

connector

Direct clutch

and second brake

solenoid electrical connector

equipped. 12.

Fill

the engine with clean

•

Brake booster hose

Nm)

13.

Fill

the cooling system.

•

Accelerator cable

Gearshift control shaft and exten-

14.

Fill

the transmission.

•

Clutch cable,

sion

15.

Fill

the

•

Shift select cable,

•

Backup lamp switch

16.

Start the

•

Speedometer cable

•

Halfshafts

•

Heater

•

Power steering hoses

•

Fuel feed and return hoses

•

A/C compressor and torque the

torque the bolts to 33

•

bolts to

(45

lbs.

ft.

repair

37

ft.

lbs.

(50

•

Speedometer cable

•

Gear select cable, Clutch cable,

•

Accelerator cable

if

power steering

oil.

reservoir.

engine and check

for leaks,

necessary.

pump

ENGINE

1.3L

Nm)

equipped

Install

8.

equipped

if

and

inlet

if

•

Left

tion.

•

Rear engine mount

Properly relieve the fuel system

2.

10.

transmission mount

•

Exhaust pipe from the manifold

•

Gearshift control shaft and exten-

•

Heater inlet/outlet hoses

3.

Dram

•

Engine vacuum lines

4

Evacuate and recover the A/C sys-

•

•

Alternator and torque the bolts to

•

Power steering pump

Drain the engine

•

A/C compressor,

17

(23

lbs.

ft.

Nm)

the cooling system

5.

oil.

•

Fuel return and feed lines

6.

Drain the transmission

•

Distributor electrical connector

7.

Remove

•

Starter solenoid electrical

connec-

tor •

CKP

sensor

•

MAP

sensor electrical connector

•

EVAP purge solenoid

electrical

connector

electrical

Positive

•

Hood

•

Radiator and cooling fan assembly Air cleaner

•

Engine Coolant Temperature (ECT)

•

Coolant temperature sending unit electrical

•

•

•

ISC motor

•

Fuel injector connectors

•

HO 2 S

electrical

valve electrical connector electrical

•

connector

connector

•

sensor connector

ground wires

electrical

•

Alternator electrical connector

•

Fuel injector electrical connectors

•

A/C Compressor clutch

•

Manifold Absolute Pressure (MAP)

cal connector, •

if

coil electri-

equipped

Starter solenoid electrical

connec-

•

MAP

sensor

•

EVAP

canister

electrical

connector

•

vacuum hose Map sensor vacuum hose Brake booster vacuum hose

•

Accelerator cable

•

Clutch cable,

•

Speedometer cable

•

if

•

lbs.

(10

Nm) •

Air cleaner

assembly

visit

lbs (55

Nm)

•

A/C compressor and torque

the bolts to

bolts to 18

25

ft

ft.

lbs

lbs (25

(35

Nm) the

Nm)

•

Both halfshafts

•

Gearshift control shaft and exten-

sion rod

if

Oil

•

A/C compressor clutch

electrical

Exhaust pipe to the manifold and torque the bolts to 37

pressure switch electrical con-

Nm) 15 Remove •

Park/Neutral Position (PNP) switch

•

Heater

•

Accelerator cable

connector

inlet

and

outlet

Ignition coil connectors

•

Clutch cable,

•

Alternator electrical connector

•

Shift select cable,

•

Starter solenoid electrical

•

Speedometer cable

•

Brake booster hose

our web

site at

www.chiltonsonline.com

lbs.

(50

Fuel feed and return hoses

•

connec-

ft

the engine support fixture.

equipped

if

tor

Please

ft

Power steering pump and torque

Power steering pump pressure

electrical

Radiator and cooling fan and

torque the bolts to 89 inch

lbs (55

sensor electrical connector

connector, •

ft.

•

connector

nector •

Nm)

mount and

Rear engine mount and torque the bolts to 41

Heated Oxygen (HO 2 S) sensor elec-

equipped

equipped

•

•

connector

switch electrical connector,

tor •

lbs (55

ft

Right side engine

torque the bolts to 41

Speed Control (ISC) motor

trical

connect the following:

transmission mount and torque

Nm)

Oil

nector

Left

the bolts to 41

connector

•

Idle

electrical

•

Install or

•

Crankshaft Position (CKP) sensor

EFE heater

pressure switch electrical con-

14

•

Intake manifold

•

under the vehicle.

table,

Lower the vehicle onto the

13

connector

•

connector

Place the engine/transmission

12.

connector

•

electrical

the engine support fixture.

engine/transmission assembly.

Camshaft Position (CMP) sensor

electrical

equipped

engine/transmission.

Evaporative emissions (EVAP)

electrical

f

equipped

Raise the vehicle from the

assembly on the

connector

Throttle Position (TPS) sensor

purge solenoid

connector

if

To install:

assembly

electrical

electrical

connector

TPS EGR

•

•

Remove

battery cables

•

equipped

vehicle.

11

sensor

ECT sensor connectors

and negative

if

Both halfshafts

Place an engine table under the

9.

fluid.

or disconnect the following:

•

connector •

sion rod,

tem.

fixture.

mount

the precautions in the beginning of this sec-

pressure.

hoses

and engine support

Right side engine

Before servicing the vehicle, refer to

.

equipped

outlet

•

1

equipped

•

if

if

to the

con-

Vehicle Speed (VSS) sensor electri-

•

gear select cable and accelerator cable play,

manifold and

I

nector

Adjust the clutch pedal free-play,

.

PRIZM

Backup lamp switch

•

ft.

Nm)

(27

Negative battery cable

•

the engine

properly support the engine assembly. •

Hood and torque

•

(55

lbs.

•

if

hoses

equipped if

equipped

Q-1 £ OI"U • • •

GEO/CHEVROLET METRO

PRIZM

•

•

Accelerator cable

connector

•

Intake Air Temperature (IAT) sensor

•

Air cleaner

•

Upper

Drive belt tensioner,

if

32

manual transmission

with

•

•

CMP

•

CKP

•

ISC motor

•

HO 2 S

•

Windshield washer reservoir

•

Fuel injector electrical connectors

•

Oxygen (O 2 S) sensor

•

MAP

•

•

Power steering pump pressure

sensor

sensor

connector

electrical

electrical

sensor

sensor

electrical

connector

electrical

connector connector

electrical

connector

electrical

•

Oil

•

if

pressure switch electrical con-

A/C compressor clutch connector,

electrical

equipped

it

•

PNP

•

Ignition coil connectors

•

Alternator electrical connector

•

Starter solenoid electrical

switch electrical connector

Backup lamp switch

•

VSS

•

Direct clutch

sensor

electrical

electrical

con-

•

Starter

motor

•

Starter

motor

•

Torque converter

equipped

Power steering pump, do not

•

Upper

•

Air cleaner

radiator

Exhaust pipe from the manifold

•

Accelerator cable to the throttle

•

Transmission-to-engine bolts

•

Manifold Absolute Pressure (MAP)

•

Accessory drive

sensor hose

•

A/C compressor and torque

lever

Fill

the engine

Evacuate and recharge the A/C sys-

the transmission fluid.

Fill

20.

Start the

•

for

•

Fuel feed and return hoses Shift select cable

Prizm

9.

Remove

Front and rear transmission

•

Right engine

•

Engine assembly

bolt to

mounts

mount

Fuel return hose

•

Fuel feed pipe to the fuel

ft.

lbs.

(64

Nm)

ft.

lbs.

nuts to 42

Alternator

Crankshaft pulley,

ft.

front

equipped

hoses

to the intake

Radiator and cooling fan and

mount

•

ft.

Nm) and lbs.

(52 ft.

Nm) and lbs.

Remove

11.

•

the 12.

(87

the

(87

the engine hoist and sup-

port the engine. if

outlet

Nm) Hood and torque lbs. (27 Nm)

Nm).

ft.

lbs.

(13

the bolts to

20

ft.

Negative battery cable Adjust the clutch pedal free-play,

gear select cable and accelerator cable play, if

equipped. 13.

Recharge the A/C7system.

14.

Fill

the engine with clean

15.

Fill

the cooling system.

16.

Fill

the transmission.

•

Both halfshafts

17.

Fill

the

•

Front exhaust pipe and torque the

18.

Start the

equipped with

manual transmission

Nm)

and

torque the bolts to 9

rear transmission

lbs.

through-bolt to 64

belt if

(64

lbs.

ft.

Nm). Torque the

Ignition coil electrical connectors

•

47

through-bolt to 64

hood

A/C compressor,

(29

inlet

using

if

Remove or disconnect the following: Hood after scribing the hood hinge

Accessory drive

lbs.

(54

Front and rear transmission

mounts and torque the bolts to

•

ft.

rail,

the bolt to

manifold and fender •

oil.

•

Nm)

Shift cable

22

mount and

Right side engine

(29

•

Engine ground wires

torque them to 47

(69

lbs.

equipped with

(142

•

equipped.

to the

lbs.

Engine-to-transmission bolts and

•

lbs. ft.

•

Nm)

Evacuate the A/C system,

ft.

•

torque the bolts to 40

6.

105

Heater

Drain the cooling system.

Drain the transmission fluid.

if

•

pressure.

equipped

ft.

the nut to 21

Engine assembly

•

the lower

Ignition coil electrical connectors

connect the following:

Install or

Properly relieve the fuel system

Drain the engine

(if

• tion.

5.

lbs.

new gaskets and torque

Before servicing the vehicle, refer to

4.

Nm) and (54 Nm)

(25

•

To install:

the precautions in the beginning of this sec-

the

Nm)

manual transmission, and toque the

or disconnect the follow-

•

10.

ft.

Crankshaft pulley,

•

Attach an engine hoist to the engine.

proper

40

Nm) and Nm)

hoses

ing:

engine and check

lbs.

ft.

torque the bolt to 51 outlet

8.

operation.

18

Drive belt tensioner

and fenders and

(25

lbs.

ft.

with manual transmission) and

the intake mani-

Heater

inlet

18

belt

Alternator and torque the upper bolt

•

•

•

oil.

tem. 19.

bolts to

sensor

Ground wires from fold

18.

Nm)

(10

lbs.

•

nesses

17.

89 inch

IAT sensor electrical connector

•

the cooling system.

hose

•

Nm)

(10

assembly and torque

the bolts to

dis-

bolt to

Fill

•

if

to

16.

•

bolts,

A/C pressure switch wiring har-

Positive and negative battery cables

lbs.

Nm)

connect the hoses

lbs.

Hood

Nm)

torque the bolts to 89 inch

Data Link Connector (DLC) and

assembly

(23

lbs.

ft.

MAP

•

•

Windshield washer reservoir and

•

•

7.

•

•

(10

3.

Engine wiring harness Alternator and torque the bolts to

Radiator and cooling tan assembly

Air cleaner

Nm)

(10

lbs.

hose

•

solenoid electrical connector

89 inch

89 inch

radiator

Brake booster hose

to

Nm)

(30

•

connectors

electrical

lbs.

ft.

Lower

17

Both halfshafts

Nm)

(35

lbs.

ft.

Engine splash shields and torque

•

•

2.

22

26

motor and torque the bolts

the bolts to

hose from the ther-

radiator

Splash shields

connector

and second brake

and torque the bolts

.

to •

•

Lower

to

Starter

Engine wiring harness and place

•

connec-

nector

•

•

with an automatic transmission

tor •

them

hose

radiator

•

•

Torque converter bolts and tighten

•

assembly

mostat housing

nector •

connector

aside

equipped

O 2 S sensor and torque the nuts to ft. lbs. (40 Nm) Power steering pump and torque the bolts to 27 ft. lbs. (37 Nm)

•

•

switch electrical connector,

1

equipped

ECT sensor electrical congector TPS sensor electrical connector EVAP purge solenoid electrical

bolts to

46

ft.

lbs.

(62

Nm)

repair

if

power steering

oil.

reservoir.

engine and check

necessary.

for leaks,

GEO/CHEVROLET METRO Crankshaft pulley and torque the

•

Water Pump

12

bolts to

ft.

lbs.

(16

Nm)

•

Water pump/alternator drive

belt

•

Lower alternator cover

and

REMOVAL & INSTALLATION

plate

torque the bolts to 89 inch

Metro 1

.

Before servicing the vehicle, refer to

tion.

•

Water

or disconnect the following:

Negative battery cable

pump 18

A/C compressor suction pipe

17

bolt to

bracket,

if

•

lbs.

ft.

Water

pump

but do not remove the bolts

pump

Nm)

Right side lower splash shield

•

A/C compressor

drive belt,

if

Lower

•

Water pump/alternator drive

•

Crankshaft pulley

pump

Water

•

Timing

•

Oil level indicator

assembly

Negative battery cable the cooling system.

6.

Refill

7.

Start the if

engine and check

for leaks,

necessary.

belt

1.

pulley

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

belt

2.

Drain the engine coolant.

Remove

•

pump pump Water pump

3.

water

bolts

and nuts

install:

connect the following

Install or

pump

with a

new gasket and

torque the bolts to 115 inch

•

Nm) New rubber

•

Upper

To

lbs.

4

(13

17

bolt to

ft.

Intake manifold

•

Exhaust manifold

•

Rocker arm cover

•

Timing

•

Camshaft

•

Valve

•

Distributor

•

Cylinder head bolts

•

Cylinder head

lbs.

Negative battery cable

Accessory drive

•

Right side lower splash shield

•

Water

•

Water

pump pump

lifters

To install: 3.

Install

or connect the following:

Cylinder head with a

new gasket in

3 even

bolts

install: Install or

Water

connect the following

pump

with a

new O-ring and

torque the bolts to 8

lbs. (11

ft.

Nm)

(23

Nm)

•

Right side lower splash shield

Oil level indicator

•

Accessory drive

•

Timing

•

Negative battery cable

tube

belt 5.

Fill

belt

Cylinder head torque

the cooling system.

engine

1922170*

To ensure a tight seal, be sure gasket sur-

prepared— Metro

and tensioner

belt

•

faces are properly

belt

or disconnect the following

•

alternator adjusting bracket

and torque the

•

and torque the bolts

•

•

seals

or disconnect the following:

Negative battery cable

•

tion.

tube

Upper alternator bracket from the

Water

Remove •

Prizm

•

Water

2.

alternator cover plate

•

•

tion.

equipped

•

Before servicing the vehicle, refer to

if

•

•

1.

the precautions in the beginning of this sec-

drive belt ten-

Air cleaner

repair

4.

(24

•

equipped

To

lbs.

A/C compressor suction pipe

pulley bolts, loosen

•

Cylinder Head

(23 Nm).

equipped bracket,

•

for leaks,

Metro

pulley and torque the

ft.

Adjust the water

assembly

Air cleaner

•

and check

necessary.

(10

sion and torque the alternator adjustment

•

*

if

Right side lower splash shield

5.

•

belt,

•

Drain the cooling system.

Remove

7

REMOVAL & INSTALLATION

bolts to 3.

Start the vehicle if

O-f

PRIZM

equipped

the precautions in the beginning of this sec-

2.

lbs.

Nm) A/C compressor drive

•

6.

repair

•

—

Cylinder head torque sequence

Timing belt service

is

covered

1

3L engine

in Section

3

of this

manual

sequence— 1. 01

— GEO/CHEVROLET

31-8

METRO

•

PRIZM

A CRANKSHAFT PULLEY SIDE 6053

CYLINDER HEAD GASKET 79222708

Cylinder head gasket positioning

— 1.0L Cylinder head bolt torque

engine

sequence— Prizm

•

Alternator

•

Crankshaft pulley

•

Accelerator cable from the throttle

•

Crankshaft Position (CKP) sensor

body

•

Drive belt tensioner

Intake Air Temperature (IAT) sensor

•

Right side engine

•

Timing chain tensioner

•

Timing chain cover

•

electrical

connector

hose

•

Air cleaner

•

Throttle Position (TPS) sensor

mount bracket

9.

electrical • 1

.

2.

Cylinder

head gasket

Cylinder block

• 7922Z799

Cylinder head gasket positioning

Control (IAC) valve electri-

Idle Air

cal

connector

connector

Manifold Absolute Pressure (MAP)

sensor

electrical

connector

•

Crank sensor reluctor

•

Timing chain slipper

•

Crankshaft sprocket

•

Timing chain

•

Camshaft sprockets

•

Camshaft bearing caps

•

Coolant bypass hoses

•

Camshafts

•

Fuel injector electrical connectors

•

Valve

•

Fuel injector harness from the

•

Intake manifold

1.3L

4.

lifters

engine

54

stages, in sequence, to

(73 lbs.

•

ft.

lbs.

Nm) onl.OL engines or 49 (68 Nm) on 1.3L engines

Valve

ft.

intake manifold

•

Exhaust manifold

•

Intake manifold support bracket

•

Cylinder head

•

Oxygen (O 2 S) sensor

•

•

Camshaft

•

Rocker arm cover and torque the bolts to

• • •

Timing

Install

44 inch belt

Nm)

lbs. (5

17

ft.

and torque the

lbs.

(23

Nm)

Exhaust manifold and torque the

17

ft.

lbs.

(23

Nm)

Negative battery cable

Start the

engine and allow

it

to reach

normal operating temperature. Check

and adjust the

ignition timing,

if

clamp and move

receiver pinch

for leaks

necessary.

in

mount

a.

18

ft.

lbs.

(25 Nm).

b.

36

ft.

lbs.

(49 Nm).

•

Fuel line at the fuel

c.

Plus an additional 90 degrees.

•

Spark plug wires

«

Ignition coils

rail 1 1

Properly relieve the fuel system

Install or

.

•

Fuel

•

Ground wires from

rail

the cylinder head

Drain the engine coolant.

4.

Drain the engine

5.

Remove

oil.'

Negative battery cable

•

Washer tank and pump

•

Accessory drive

belt

ft.

lbs.

(13

Nm)

Camshaft sprockets and torque the

40

Nm)

•

Heater hose from the cylinder head

•

Water bypass pipe

•

Timing chain

•

Camshaft Position (CMP) sensor

•

Timing chain cover and torque the

•

Engine Coolant Temperature (ECT)

•

bolts to

bolts to 14 •

Positive Crankcase Ventilation

1

Dead

Center (TDC) and align the camshaft timing

Remove

8.

•

•

•

105

Power steering

oil

lbs.

ft.

(55

(18

Nm)

ft.

lbs.

(142

Nm)

89 inch

lbs.

(10

Nm)

•

ECT sensor

•

Camshaft sensor and torque the

•

Water bypass

bolt to 11

or disconnect the following:

lbs.

Rocker arm cover and torque the bolts to

piston to Top

ft.

Crankshaft pulley and torque the bolt to

•

Rocker arm cover Set the No.

or disconnect the following:

•

connect the following:

•

sprockets.

3.

the

Camshafts and torque the bearing cap bolts to 10

•

7.

pressure.

in

Ignition coil connectors

(PCV) valve and hoses

the beginning of this sec-

Torque the cylinder head bolts

10.

Right side engine

•

tion.

new

cylinder head with a

following sequence:

sensor

the precautions

Install the

gasket.

•

Before servicing the vehicle, refer to

2.

fixture.

•

Prizm 1.

A/C

an engine support

the receiver aside

and tensioner

Intake manifold

bolts to •

•

Distributor

bolts to •

Exhaust pipe from the manifold

lifters

6.

To install:

pressure switch

bolt to 11

connector

•

Right side lower engine splash

•

ft.

ft.

lbs.

(15

pifre

lbs.

Nm)

and torque the

(15

Nm)

Heater hoses

Ground wires

to the cylinder

shield

and torque the bolts

Power steering pump

(15

Nm)

to 11

ft.

head lbs.

OH O _Q 3

GEO/CHEVROLET METRO •

Fuel ft.

and torque the bolts

rail

lbs.

•

Fuel line to the

•

Ignition coils to

10

rail

Nm)

(14

lbs.

ft.

mount and

torque the bolts to 40

ft.

(54

lbs.

Nm) •

12.

A/C receiver pinch clamp Remove the engine support

•

Rocker arm cover

•

Battery

•

Timing

•

Both battery cables

•

Camshaft sprocket

•

Camshaft Position (CMP) sensor

•

Camshaft

•

•

If

Metro

necessary, remove the rocker

the rocker shafts. Note the order in

ft.

Nm)

lbs. (41

bled

Fuel injector harness brackets

•

Vacuum hoses

•

Intake manifold support bracket ft.

lbs.

and

(50

Nm)

intake and exhaust rocker

shafts are

NOT

the

manifold and torque the bolts

106 inch

lbs.

(12

Upper

Fuel injector connectors

•

Coolant bypass hoses

hose

radiator

MAP

•

IAC valve

•

TPS sensor

•

arm

•

same. Both can be at the ends of

•

arm

3.

shaft with the

disassembled

Lubricate the rocker

lbs.

(10

Nm)

•

Accessory drive

•

Negative battery cable

belt

new

Fill

the engine with

14.

Fill

and bleed the cooling system.

15.

Start the vehicle

and check

Road

necessary.

oil

test

for leaks,

and check

•

97 inch

lbs.

43

ft

lbs.

(60

•

•

Nm)

body

EGR Modulator EGR valve

for

proper operation.

Rocker Arms/Shafts REMOVAL & INSTALLATION The

1

0L and

1

8L engines do not use

rocker arms/shafts, the camshaft directly

actuates the valves.

1.3L Engine 1

Before servicing the vehicle, refer to

the precautions in the beginning of this section.

—

Rocker arm shaft retaining bolts tightening sequence

Heater Core replacement

is

covered

in Section

2

of this

1

equipped

Coolant hoses from the

body

Nm)

if

Fuel feed and return hoses from the throttle

•

Camshaft sprocket and torque the bolt to

connector

Early Fuel Evaporative (EFE) heater electrical connector,

sensor and torque the bolts to lbs. (11

electrical

sensor electrical connector •

bolts, in the

•

CMP

97 inch

13.

oil.

Nm).

Camshaft

body

Manifold Absolute Pressure (MAP)

and torque the

•

the intake mani-

fold

shafts in their original posi-

•

connector

Ground wires from Throttle

correct sequence, to (11

Speed Control (ISC) motor

•

and torque the bolts

the bolt

Idle

•

(23

tions

connector

Exhaust Gas Recirculation (EGR)

Posi-

17

Washer pump and torque

Throttle Position (TPS) sensor

and exhaust rocker

Alternator

arm

•

arms and

Accelerator cable to the throttle body to

connector

unit connector

valve electrical connector •

to the

connect the following

•

Nm)

electrical

ECT sending

electrical

Install or

•

connector

arms on

Engine Coolant Temperature (ECT)

electrical

assemble the

earlier,

tion the intake

89 inch

•

•

shafts with clean engine

lbs.

•

rocker shafts.

4

connector

electrical

If

or disconnect the following:

Air cleaner

sensor

stepped end toward the distributor side.

springs, washers and rocker

sensor electrical connector electrical

the intake rocker

IAT sensor electrical connector

if

Remove

distinguished by looking

•

repair

Drain the cooling system.

4.

To install;

•

•

to

Nm)

•

to

3.

the shafts, which are different. Install

Fuel injector harness to the intake

ft.

Relieve the fuel system pressure.

2.

posi-

tion.

•The

torque the bolts to 37

same order and

in the

Before servicing the vehicle, refer to

.

tion.

removed; they must be re-assem-

30

to

1

ENGINE

the precautions in the beginning of this sec-

which the components are

•

•

1.0L

torque the bolts to 46

(62

REMOVAL & INSTALLATION

and rocker

arms, washers and springs from

lbs.

Nm)

arm

Exhaust pipe with a new gasket and ft.

lbs. (5

Intake Manifold

bolts. Lift out

shafts, with the springs

02sensor and torque the nuts

•

Rocker shaft retaining

the exhaust and intake rocker

(35

lbs.

44 inch

bolts to

arms attached.

ft.

belt

Battery

Exhaust manifold support bracket

26

Rocker arm cover and torque the

•

and torque the

bolt to

Timing

•

•

belt

I

•

Both battery cables

Nm) •

or disconnect the following:

PRIZM

•

fixture

Nm) •

Remove

2.

and torque the bolts

Right side engine

•

10

to

Nm)

(14

•

31 engines

manual

throttle

O

" 1I

1

•

U

METRO

•

PRIZM •

Evaporative Emissions (EVAP) canister

•

GEO/CHEVROLET

fl

vacuum hose

MAP

sensor hose from the intake

Fuel feed and return hoses

•

Intake manifold

(PCV) vacuum hose

•

Canister purge hose

To

Accelerator cable from the throttle

•

Accelerator cable

5.

body

•

Intake manifold bolts

•

Intake manifold

Intake manifold/throttle

body

unit

To connect the following:

Intake manifold with a

and torque the bolts

to

17

PCV hose

•

EVAP

canister

•

MAP

sensor vacuum hose

•

Brake booster

•

Coolant hoses

•

Fuel feed and return hoses

•

ECT sensor

vacuum hose

vacuum hose

electrical

connect the following:

Intake manifold with a

•

new gasket to

•

17

•

Canister purge hose

•

•

Brake booster hose

•

•

Coolant hoses

ft.

Fuel inlet pipe to the fuel fitting to

22

Fuel return hose

Fuel feed and return hoses

•

Wiring harness

ft.

lbs.

Upper

hose and support

radiator

bracket and torque the bolt to 13

Ground wires

to the intake

mani-

lbs.

•

Engine wire harness

to the intake

MAP

lbs.

equipped

•

TPS sensor

ECT switch electrical connector TPS sensor electrical connector EGR solenoid valve electrical con-

•

IAC valve

•

EVAP

nector

•

sensor

Coolant bypass hoses

connector

•

MAP

Accelerator cable

•

IAC valve

•

TPS sensor

•

Air cleaner

Air cleaner

•

Negative battery cable

•

Throttle

•

Wiring harness to the retaining

clamps

injectors

assembly

•

connector

the cooling system.

6.

Fill

7.

Start the vehicle

and check

for leaks,

•

Negative battery cable

1

.

7.

Start the vehicle

connector

•

Throttle valve cable,

if

and torque the bolts

to 11

98 inch

bolts to

(15

Before servicing the vehicle, refer to •

the cooling system.

Fill

electrical

assembly

IAT sensor electrical connector

the precautions in the beginning of this sec6.

connector

Accelerator cable and torque the

assembly

Air cleaner

connector

electrical

electrical

•

Prizm

body and adjust as needed

sensor

•

repair as necessary.

Accelerator cable to the throttle

•

ft.

•

canister purge valve electrical

ISC motor electrical connector

electrical

9

Fuel injector connectors to the fuel

connector

Ground wires body

connector

to

Nm)

(13

•

electrical

electrical

•

manifold

connector

electrical

ft.

Nm)

(18

•

to the intake

(18

Nm) •

to the retaining

fold

if

and

Intake manifold support bracket

manifold and torque the bolt

electrical connector,

(29

lbs.

Fuel injector electrical connectors

EFE heater

and

rail

ft.

•

connector

lbs.

Brake booster vacuum hose

torque the bolts to 13

•

•

13

Nm)

clamps

connector

new gasket

to

Nm)

torque the

Nm)

(23

lbs.

connect the following:

Intake manifold with a

and torque the bolts

•

•

Install or

•

and torque the nuts and bolts

lbs.

Coolant temperature sending unit electrical

•

•

ft.

•

•

ft.

install:

(18

Install or

5.

new gasket

throttle

install:

Nm)

(23

•

Coolant hoses from the

Brake booster hose

Install or

•

•

Upper radiator hose and support bracket

•

Positive Crankcase Ventilation

•

Fuel feed and return hoses

Brake booster vacuum hose

•

•

•

Intake manifold support bracket

•

To install: 5.

•

•

Brake booster vacuum hose

•

•

clamps

body

manifold •

•

Wiring harness from the retaining

lbs. (11

Nm)

equipped ft.

lbs.

Nm)

Negative battery cable the cooling system.

6.

Fill

7.

Start the vehicle

tion.

and check

for leaks, 2.

repair

1.3L

if

Relieve the fuel system pressure.

necessary.

repair

ENGINE

3.

Drain the cooling system.

4.

Remove

.

for leaks,

Exhaust Manifold

Before servicing the vehicle, refer to the

precautions

•

Accelerator cable from the throttle

•

Throttle valve cable from the

the beginning of this section.

in

REMOVAL & INSTALLATION

body 2.

and check

necessary.

or disconnect the follow-

ing: 1

if

Relieve the fuel system pressure.

3.

Drain the cooling system.

4.

Remove

throttle body,

if

equipped

or disconnect the following: •

•

Air cleaner

•

Ground wires from the

electrical

intake

connector

assembly

•

Air cleaner

•

Throttle Position (TPS) sensor

fold

Fuel injector electrical connectors

•

Manifold Absolute Pressure (MAP)

electrical • •

electrical

Throttle Position (TPS) sensor •

Control (IAC) valve electri-

connector

•

tor

electrical

.

Before servicing the vehicle, refer to

2.

Remove

Manifold Absolute Pressure (MAP)

• •

electrical

in

the beginning of this sec-

tion.

or disconnect the follow-

connector

Coolant bypass hoses

Negative battery cable Front pipe from the exhaust manifold

•

Fuel injector electrical connectors

•

•

Wiring harness from the intake

•

Exhaust manifold heat shield

manifold

•

Exhaust manifold

Evaporative Emissions (EVAP) can-

purge valve

1

the precautions

sensor

connector

connector

ister

ENGINE

ing:

Idle Air Control (IAC) valve electri-

cal •

Idle Air

connector

connector cal

electrical »

I.OL

mani-

•

sensor

Metro

Intake Air Temperature (IAT) sensor

connec-

Heated Oxygen (HO 2 S) sensor

01.11 O

GEO/CHEVROLET METRO To install:

•

Install or

3.

•

Exhaust manifold with a new gasket

17

ft.

•

I

I

Heated Oxygen (HO 2 S) sensor and

Front exhaust pipe from the

exhaust manifold

lbs.

Nm)

(23 •

to

PRIZM

sub-oxygen sensor

connect the following:

and torque the bolts

•

•

Exhaust manifold heat shield and

•

Exhaust manifold support bracket

Exhaust manifold upper heat

3.

torque the bolts toll

•

• •

new 33

HO 2 S and (45

lbs.

4.

shield

(15

Front pipe to the exhaust manifold

bolts to

•

lbs.

Nm) with a

•

ft.

seal ft.

and torque the

lbs.

necessary

if

To install: 7922Z713

torque the bolts to 33

connect the following:

Install or

ft.

Nm)

•

Lower heat

shield,

torque the bolts to 11

and check

•

1

ENGINE

(48 •

Before servicing the vehicle, refer to

.

and torque the bolts (15

or disconnect the follow-

•

•

Negative battery cable

•

Front pipe from the exhaust mani-

and torque the bolts (62

•

Oxygen (O 2 S) sensor

electrical

•

Low

side

A/C

line bracket

position aside, •

To 3.

•

if

and

4

equipped

24

ft.

ft.

lbs.

ft.

A/C

line bracket,

lbs.

lbs. (41

ft.

(15

37

and check

(15

to 11

ft.

lbs.

(50

1

.

O2S

Negative battery cable

electrical

in

Remove •

4.

Accessory drive

•

Alternator cover plate and torque

12

ft.

lbs.

Nm)

(16

belt

49 inch

lbs. (5.5

•

Right side splash shield

•

Air cleaner

•

Negative battery cable

assembly

Fill

Start the vehicle if

new

the engine with

7.

oil.

and check

for leaks,

necessary.

Before servicing the vehicle, refer to

.

tion.

Remove

2.

oil.

Negative battery cable

assembly

Air cleaner

•

Right side engine splash shield

•

Lower

Accessory drive

•

Crankshaft pulley

•

Water

•

Timing

pump

seal

belt

Negative battery cable

•

Accessory drive

•

Right side splash shield

•

Crankshaft pulley

•

Crankshaft front seal

4

Rotate the Crankshaft to align the tim-

•

Crankshaft

belt

To

install:

5.

Lubricate the

clean engine

Brake service

Is

oil

seal

lip of

covered

the

new

Install or

In

new

oil

connect the following:

New

•

Crankshaft pulley and torque the

oil seal

105

using a seal driver

ft.

Section 4 of this manual

lbs.

(142

•

Right side splash shield

•

Accessory drive

•

Negative battery cable

Start the vehicle

seal with repair

oil.

the

•

bolt to

tion.

oil to

lubricate the lip of the oil seal with

multi-purpose grease

pulley

ing marks.

Timing

belt

Apply clean engine

and

cover

belt

or disconnect the following:

•

To install: 3.

alternator cover

•

Negative battery cable

Nm)

(24

•

8

or disconnect the following:

the precautions in the beginning of this sec-

or disconnect the follow-

lbs.

Prizm

•

•

Prizm

Remove

ft.

the bolts to

necessary

the beginning of this sec-

Drain the engine

connector

ing:

Nm)

lbs. (11

pulley and torque the

Crankshaft pulley and torque the

for

Before servicing the vehicle, refer to

3.

lbs.

Before servicing the vehicle, refer to

Nm)

the precautions in the beginning of this sec-

2.

Nm)

•

97 inch

pump 18

(27

lbs.

Nm)

Metro

Nm)

•

•

if

ft.

•

Nm)

if

ft

Water

20

cover and torque the

belt

5.

Nm) to

•

lbs.

REMOVAL & INSTALLATION

Front pipe and torque the bolts to

37

2.

ft

Negative battery cable

Start the vehicle

Exhaust manifold stiffener bracket

(50

1.

46

tion.

and torque the bolts

•

30

the precautions

side

Timing

bolts to

1

equipped and torque the bolts

•

to

and torque the ten-

belt

lbs.

lbs.

Exhaust manifold heat shield and

Nm) Low

— Metro

connect the following:

bolts to ft.

Nm)

torque the bolts to 11

•

24

connect the following:

to

•

repair

Exhaust manifold with a new gasket

(32 •

to

Front Crankshaft Seal

and torque the bolts

shown

oil seal

lbs.

Exhaust manifold

Install or

•

ft.

Nm)

exhaust leaks, repair

install:

Timing

H02sensor and torque the fasteners to

Exhaust manifold heat shield

to 11

Nm)

Exhaust manifold stiffener bracket

connector

•

Front pipe to the exhaust manifold

fold

•

New

sioner bolt to

Exhaust manifold support bracket

(32 •

36

•

bolts to

•

•

seal protector as

Install or

6.

lbs.

Nm)

and torque the bolts

ing:

to

ft.

Exhaust manifold upper heat shield

the precautions in the beginning of this sec-

Remove

oil

(15

Nm)

tion. 2.

lbs.

Exhaust manifold with a new gasket

and torque the bolts

1.3L

ft.

Nm)

for

necessary.

if

to the lip of the seal

removed, and

if

use an

Start the vehicle

damage

To prevent

Negative battery cable

exhaust leaks, repair

Lower heat shield from the exhaust manifold,

Nm)

(45

Exhaust manifold

if

necessary.

Nm)

belt

and check

for leaks,

Q1 " 1 C 9 O

GEO/CHEVROLET METRO

I

I

•

PRIZM

O

Camshaft

•

engine

REMOVAL & INSTALLATION

^3 — ENGINE

I.OL 1

A

-

B

-

Before servicing the vehicle, refer to

.

Remove

2.

or disconnect the following:

•

Negative battery cable

•

Rocker arm cover

•

Distributor

•

Timing

•

in

—

and housing

belt sprocket.

rod inserted into the hole

during this procedure. Place a clean

shop cloth between the rod and mating surfaces and use care not to

of the

left

until the is

for the

camshaft journal and

all

oil to

the

the engine

oil

to

pump

or disconnect the following:

Camshaft caps from the cylinder

around the cam,

.

2.

lifter

through the camshaft

holes and check that engine

out from the

oil

holes

in

oil

the valve

Install

Camshaft timing

camshaft journal.

•

Camshaft Position (CMP) sensor

nal positions, 7.

Apply silicone sealant

surface of the No.

which

will

1

to the

mating

and No. 3 bearing cap,

mate with the cylinder head.

Install

'Camshaft bearing cap No. installed

first.

It

Loosen

if

lifters in their

•

Camshaft

To

install:

4.

Apply clean engine

the camshaft

in

the cylinder

oil

ing bolts (11

and torque them

to

freely.

oil to

journals and the

5.

Install or

the

oil

seal.

•

connect the following:

Camshaft Camshaft housings and torque the bolts in

oil

move

1 is

retains the camshaft in

Apply clean engine

valve adjusting screws to

Camshaft housings

camshaft,

the proper position and thrust direc-

11.

belt pulley

•

origi-

being re-used.

all

allow the rocker arms to

There are marks provided on each

for installation. Install the

belt

and housing 3.

tion. the valve

or disconnect the following:

Negative battery cable

•

•

bores.

6.

Remove

surface of each bearing cap against the

bearing cap as indicated by the marks.

install:

Before servicing the vehicle, refer to

Rocker arm cover

and direction

comes

purged and

until the air is

ENGINE

•

the sliding

camshaft bearing cap indicating the position

lifters

oil

to the retain-

97 inch

lbs.

sequence

Nm) New camshaft

to

97 inch

(11 •

oil

seal

Nm).

© ©

©

©

© ©

7922Z714

Position the crankshaft as

shown before

removing the camshaft— Metro with I.OL engines

a

oper-

is

Timing

oil to

Camshaft

oil

may make

the engine

•

Apply clean engine

Valve

journal

when

tion.

is at

•

Pour engine

air is

if

•

8.

10.

head

5.

is started,

the Hydraulic Valve Lash

the precautions in the beginning of this sec-

•

To

engine and check the igni-

Start the

in

1.3L

position the camshaft so the camshaft tim-

9.

•

belt

camshaft bearing

— Metro with I.OL engine

head. After applying engine

crank-

60 degrees

arrow mark on the

Remove

Negative battery cable

trapped

1

case. 4.

»

'When

the lower position.

the

Timing

2000 rpm

ing sprocket pin hole in the camshaft

when loosening.

mark

Distributor

•

the tapping sound ceases.

The mating surface of the cylinder head and cover must not be damaged

shaft sprocket timing

lbs. (5

ated. In such a case, run the engine at

cap bolts

Turn the crankshaft

Nm)

Distributor housing

tapping sound

Torque sequence

3.

(60

lbs.

(HVL) adjuster, the valve in.

the camshaft, before loosening

the rod

ft.

•

13.

the sprocket retaining bolt.

bump

44

tion timing. Adjust the timing as necessary.

Lock the camshaft with a 0.39

(10mm)

Valve cover using a new gasket and

•

Metro with I.OL engine

belt

Camshaft timing

•

Nm)

7922Z715

bearing caps

lip

Camshaft sprocket and torque the

torque the bolts to 44 inch

Indicates direction to timing belt

Directional markings for the camshaft

tion.

seal after applying

the seal

•

Indicates position from timing belt

the precautions in the beginning of this sec-

oil

oil to

bolt to

Metro

connect the following:

Install or

12.

Camshaft

9346XGB1

Camshaft housing torque sequence

lbs.

OH O 19 O

GEO/CHEVROLET METRO •

ft.

bearing cap bolts to 17

(60

lbs.

ft.

Nm) •

•

belt 4.

to adjust

dead b.

ft.

lbs.

(23

number one

Set the

cylinder to top

center.

Ensure the camshaft

is in

phase.

if

and

Adjust valves

d.

Rotate the crankshaft one revolu-

valves. Record the clearance

torque the bolt to 40

for all valves that are not within specifica-

ft.

(55

lbs.

Nm)

tion, in

Timing chain

replacement shims.

•

Negative battery cable

•

Adjust valves

CMP

3, 4, 7,

and

5.

der intake and exhaust valves. Record the

Valve Lash

determine the required replacement shims.

Nm)

lbs. (11

CMP

•

Rocker arm cover and torque the

Nm)

Negative battery cable

camshaft and valve stems, are used to

matically at

b

Insert tool

camshaft and

Prizm and 1.3L Metro

Before servicing the vehicle, refer to

camshaft

J-3987-1 between the

lifter

adjustment shim, to

•

•

Camshaft sprocket

Camshaft bearing cap sequence, by starting

bolts, in at the

ends

and working towards the center

of

the camshaft •

Camshaft from the cylinder head

Install or

•

Camshaft

•

Camshaft bearing caps

to the cylinder

head

in

sequence

to

lifter.

Disconnect the ignition wires.

magnet, remove the adjustment shim

4

Remove

from the top

5

Turn the crankshaft

No.

1

the negative battery cable

the rocker

cylinder

is at

d.

arm cover until the

piston

Top Dead Center

Using a small screwdriver and a

Use

e

of the lifter

the micrometer to

measure the

thickness ol the removed shim Deter-

(TDC) on the compression stroke Align the

mine the thickness

groove

using the formula below For the pur-

in the

crankshaft pulley with the 0

mark on the timing

belt

cover Be sure the

poses

camshaft gears are aligned

The intake valve clearance should be

0 006—0.010

in.

7.

in.

Using a

new shim T =

ol the following formula,

Valve clearance measured;

(0.15-0.25mm) and the

A= N = Thickness

+

gauge, measure the

clearance between the camshaft and valve

For the intake camshaft valves

A—0 008 A

10

in.

(0

N

—0 010

in.

Select a

= T

20mm)

For the exhaust camshaft valves:

11

T +

a jwe’i

new shim

of the required

10.

(0.25-0 35mm).

feeler

of the

Thickness ol the shim removed;

proper location and direction and torque the bolts

on the

of the tool

3.

0.010-0.014

in their

lifter

Remove

exhaust valve clearance should be

connect the following:

to hold the

lifter,

2.

6.

install:

J-39871-2 between the

bottom edge

in

•

Insert tool

camshaft and the

tion.

Negative battery cable

•

Before servicing the vehicle, refer to

away from the camshaft Position the

or disconnect the following:

Timing chain

.

the

down

the precautions in the beginning of this sec-

tion.

Remove

lifter c.

1

the precautions in the beginning of this sec-

3.

of the

directly over the valve (camshaft

lobe pointing away from the valve).

not

is

is

compress the valve spring and push

camshaft.

To

times. Adjustment

required or possible.

the

ft

lbs.

left

fender well

(16

Nm)

Suspension support cage nuts from

Powertrain/frame assembly from

Install or

• •

connect the following:

Powertrain/frame assembly

New frame-to-body

bolts

do not

tighten at this time

Suspension supports with new bolts

and torque the suspension

support and frame bolts to 74

Purge solenoid

•

Rear Heated Oxygen (HO 2 S) sensor

•

Frame-to-body attachment fasten-

Raise the powertrain into the vehicle.

•

•

•

body

install:

and intake duct assem-

Purge hose from the

exhaust manifold and torque

the bolts to 12

the

connector

Air cleaner

electrical

Exhaust from the catalytic converter to the

to the fuse block

•

belt

from the struts

from the steering

Properly support the powertrain and

bly

Heater hoses

Accessory drive

•

Nm)

•

•

electrical

motor and torque the bolts

ball joints

the vehicle

Coolant reservoir hose

lbs.

Suspension support assemblies

•

fluid.

•

ft.

•

or disconnect the following:

To

33

Lower

ers

10.

to

Stabilizer bar links

•

•

Steering gear-to-intermediate shaft

Starter

•

oil.

Both battery cables

them

Tie rods from the steering knuckles

frame assembly.

pressure.

•

•

•

9.

•

(65

A/C compressor without removing

the

Upper and lower radiator hoses

lbs.

•

•

Metal power steering line

ft.

Exhaust system from the catalytic

knuckles

Before servicing the vehicle, refer to

•

torque them to 48

mount

transmission mount

converter to the exhaust manifold

•

•

Left side

MANUAL TRANSMISSION 1.

the

the hoses Start the engine,

2.

Engine mount bracket and torque the bolts to

Right side engine

tion.

hand-tighten them •

•

•

install:

and align

wood blocks between

•

10

mission with a jack

repair

push pin from

pulley and frame.

oil.

•

16.

Install

8.

fluid.

5 seconds and

liner

transmission case and frame and the crank

12.

new

wheel

Left front

the frame

fender well

left

hoses

Secure the radiator to the upper radi-

7.

•

IAT sensor electrical connector

hoses

lower cowl

radiator

•

•

radiator

at the

ator support.

and intake duct assem-

Lower engine-to-transmission bolts lower cowl

shaft lever to the transmission

bly

•

at the

Retaining clips connecting the control

nector

the hoses

To

SW2

connector and hose

•

throttle

lifting

•

Torque the upper

.

connector

electrical

SW1

•

throttle

electrical

body

connector

lbs.

•

electrical

•

ft.

plus 45 degrees

Ball joint to the steering

(100

connec-

Nm)

and torque the nuts

connector

Back-up switch

(100

to

knuckle

74

ft.

lbs.

Nm)

Stabilizer links to the struts

tor

torque the fasteners to 50

Front dash cover

(65

Nm)

ft.

and lbs.

00.7

SATURN LW

•

SCI

•

SC2

•

SL

SL1

•

SL2

•

SW1

•

vC.

SW2

•

I

•

IAT sensor electrical connector

•

Ground wire

•

Main wire feed

•

Battery

•

Steering gear-to-intermediate shaft

to the

fender well

left

to the fuse block

and both cables

and torque the pinch bolt

to

15.

Fill

the engine with coolant.

16

Fill

the engine with

17.

Fill

the power steering fluid.

18.

Prime the

ON

ignition

new

ft.

oil.

system by cycling the

fuel

5 seconds and

for

22

Nm)

(30

lbs.

OFF

10

for

seconds a few times without cranking the engine. Start the engine,

19. repair

if

check

for leaks,

and

necessary

3.0L Engine 1

Before servicing the vehicle, refer to

.

the precautions in the beginning of this section.

Properly relieve the fuel system

2.

pressure.

Powertrain/frame assembly with

table-2. 2L engine

lifting

3.

Drain the engine coolant.

4.

Drain the engine

5

Drain the power steering

6

Remove

Both battery cables

•

Air cleaner

•

Mass

and torque the new nuts lbs.

(65

45

ft.

to the

exhaust

ft.

lbs.

(16

Nm)

A/C compressor and torque the bolts to 18

•

Rear

HO 2 S

tt,

(25

lbs.

sensor

Nm)

electrical

torque the bolts to 41

tt

lbs.

(55

Nm) •

Left

side transmission mount and

torque the bolts to 41

Nm) Remove

12.

Move

lbs.

(55

it

in

connector

(12

Nm)

14

Install

wood

blocks.

place

Black engine harness connector

from under the fuse block panel •

Fuse block

•

Engine harness connector to the

•

Battery tray

•

Evaporative Emissions (EVAP)

of the fuse

•

Fuse block

•

the engine harness to the engine

block

purge connector

Fuel feed and return lines

•

FVAP purge solenoid

•

Upper and lower

•

Heater hoses

•

Brake booster vacuum hose

electrical

connector

boot to the cowl

•

Right front speed sensor connector

•

Front Oxygen (0;S) sensor from the

electrical

•

connector and hose

hoses •

•

•

Purge hose

•

Air cleaner

Timing belt service

is

•

connector

•

Transmission main

electrical

con-

Transmission

shift control electrical

connector

to the throttle

body

•

and intake duct assembly

covered

pipe

nector

Transmission back-up switch electrical

rod as follows:

down

Transmission ground electrical connector

Main harness connector near the master cylinder

rod into the shift

Lower weather pack connector from inside the fuse block and secure

•

•

Install the shift

A/C pressure connector

•

Fuse block

Cowl cover

a.

•

Fuse block and battery trays

•

linkage assembly.

connector by the brake

•

Both front wheels

shift control

inline

•

•

Shift control rod

TCM

Cruise control and throttle cables

•

Adjust the

connector from under

•

Right front splash shield

radiator

lbs

It

or connect the following

Left

push pins

mam

master cylinder

plus 180 degrees

•

liner

•

and use a 3/8 inch punch

PCM PCM

front wheel

Transmission Control Module

the cowl cover

the shift lever to the 5

bottom the

boot

Tighten the pinch bolt to 9

e

assembly

Flow (MAF) sensor elec-

Battery ground cable from the fuse

(TCM)

shift lever

•

•

13.

ft.

d

to hold

mount and

Right side engine

Pull

(reverse gate)

con-

nector •

up the

c.

Air

block •

on the case

lock pin

manifold and torque the bolts to 12

•

clockwise and depress the

trol shaft

spring loaded transmission shift linkage

Exhaust system

•

to

Nm)

•

fluid.

or disconnect the following

•

trical

Rotate the transmission shift con-

b

Tie rods to the steering knuckles

•

oil.

in

Section

3

of this

Rear connector on the Engine Control

manual

Module (ECM)

SATURN

32-8

LW

SCI

•

•

SL1

•

SL2

Brake booster

•

Fuel lines

•

EVAP purge hose and

•

connector

solenoid •

motor

•

Starter

Torque converter bolts

SW2

•

Right front speed sensor electrical

•

•

SW1

Transmission main connector

•

vacuum hose

•

•

SL

•

SC2

•

O 2 S sensor

Front

electrical

connec-

tor

Exhaust system from the catalytic

•

converter to the exhaust manifold

•

Right front speed sensor

EVAP purge solenoid

electrical

connector

•

Transmission nose bracket

•

A/C compressor without removing the hoses

Torque the upper

11. to

48

ft.

lbs.

housing bolts

bell

(65 Nm).

•

Heater hoses at the lower cowl

•

Battery tray

•

Lower engine-to-transmission bolts

•

Fuse block and route the engine

•

Upper and lower radiator hoses

•

coolant reservoir hose

•

•

Metal power steering line

•

Main wire feed

•

Power steering reservoir from the

•

A/C pressure connector

radiator support

•

TCM TCM

Attach an engine

7.

harness

7922Z801

Water pump

Lower weather pack connector

•

device to the

lifting

to the block

to the fuse block

torque the bolts inline

lifting

sequence

main connector under the

cowl cover and secure

eyes.

mount and •

Positive

it

•

13.

Fill

the engine with

14.

Fill

the

15.

Prime the

30

ft.

lbs.

Nm)

(40

30

ft.

lbs.

Nm) and the (55 Nm)

(40 ft.

lbs.

torque the bolts to 30

Nm) Remove

ft.

lbs.

(40

ignition

Metal power steering line

Power steering reservoir

•

Coolant reservoir hose

•

Lower transmission bolts and torque them to 48

ft.

lbs.

(65

(40

ft.

lbs.

(65

Nm)

2.2L Engine

fluid.

1

system by cycling the

5 seconds and

for

if

OFF

for

10

check

for leaks,

and

necessary.

Nm)

.

ft.

(20

(40

to the

Nm) exhaust

•

Fuel feed and return lines

•

Brake booster

Remove

ECM

or disconnect the following:

•

Negative battery cable

•

Air cleaner

•

Exhaust manifold heat shield

assembly

the beginning of this sec-

•

Accessory drive

•

Right front wheel

belt

•

Inner wheel well splash shield

•

Water

pump

the pulley to

pulley bolts and allow

hang

freely

pump hub Water pump flange Water pump

on the

water

vacuum hose

rear connector

or disconnect the following:

Negative battery cable

•

Transmission

in

•

EVAP purge solenoid and hose

•

tion.

Drain the cooling system.

Nm)

•

Before servicing the vehicle, refer to

tion.

Nm)

lbs.

Exhaust system

.

the precautions in the beginning of this sec-

Before servicing the vehicle, refer to

the precautions

manifold and torque the nuts to 15

•

To

install:

4.

Install or

bolts

9346ZG12

shift control electrical

connector • •

fuel

Start the engine,

16.

A/C compressor and torque the 30

for leaks,

oil.

Drain the cooling system.

Heater hoses at the lower cowl

bolts to

and check

necessary.

Remove

3.

lbs.

power steering

if

3.

2. lbs.

Start the vehicle

2.

motor and torque the bolts

ft.

the cooling system.

6.

1.9L Engines

Torque converter and torque them

ft.

Negative battery cable

Fill

engine.

1

•

Right front wheel

•

REMOVAL & INSTALLATION

Upper and lower radiator hoses

•

•

belt

Water Pump

radiator support

•

Right front wheel well splash shield

to the

•

30

Accessory drive

•

seconds a few times without cranking the

repair

•

Starter

ON

new

the engine lifting device.

•

to

(25

connector

electrical

Engine mount bracket and torque

Transmission nose bracket and

•

sensor

the engine with coolant.

lower bolt to 41

•

MAF Fill

48

lbs.

•

5.

repair

12.

to

ft.

fuse

and intake duct assem-

hand-tighten them

bolt to

•

Nm)

hub and

bly •

Engine mount and torque the upper

•

at the

and both cables

Air cleaner

connect the following:

the bolt to •

Battery

•

Upper transmission bolts and

•

10.

•

into the vehicle

on the pins on the transmission.

Install or

9.

main feed cable

(30

pulley to the

housing

Lower the engine

and align

crisscross

lbs.

Nm)

Battery ground cable at the wheel

•

Engine from the vehicle

To install: 8.

pump

ft.

block

Upper transmission bolts

•

22

to the

engine

bracket •

it

Water

to

torque the bolts to 19

Right front engine

•

in a

connector •

engine

sequence-1 .9L

bolt torque

engines

Transmission ground connector

Water

connect the following:

pump

with a

new gasket and

Water pump holding engine

tool

J43651-2.2L

SATURN LW

•

SCI

•

SC2

SL

•

•

SL1

•

2. 3.

SL2

SW1

•

•

32-9

SW2

Drain the cooling system.

Remove

or disconnect the following:

•

Negative battery cable

•

Air cleaner

•

Lett front

•

Wheel

•

Loosen the water pump pulley and

assembly

wheel

well splash shield

power steering pulley

bolts, but

do

not remove them 4.

Install

an engine support

fixture.

mount

•

Right front engine

•

Accessory drive

•

Release the retaining tabs on the

belt

wiring harness channel and remove the front cover

To

-

6

5.

,r

•

Wiring harness from the channel

•

Water

•

Power steering pump pulley

•

Drive belt tensioner Front timing belt cover

•

Water

of the

Install or

•

Thermostat housing

•

Water

•

Water

pump pump

from the Install a

4.

Water

connect the following:

pump

with a

new O-ring and

torque the bolts to 18

ft

lbs.

(25

Nm) Front timing belt cover and torque the bolts to 71 inch lbs (8

water pump-2. 2L engine

•

pump

install:

•

Exploded view

pulley

•

\ritp

) V-

pump

Nm)

feed pipe

sprocket access plate

front

cover

Water

Pump

pump pump

retaining bolts

Holding Tool

J43651. •

Water

•

Water

To

install: Install or

5.

connect the following

•

pump and torque the bolts to lbs. (25 Nm) 18 Water pump sprocket and torque the bolts to 89 inch lbs. (10 Nm) Water pump sprocket access plate

•

Water feed tube

Water

•

ft.

•

after lubricating

the

0-ring

Thermostat housing and torque the

•

bolts to

89 inch

(10

Nm)

Exhaust manifold heat shield

•

Air cleaner

•

Negative battery cable

assembly

the cooling system.

6.

Fill

7.

Start the vehicle

repair

lbs.

•

if

and check

for leaks,

necessary.

3.0L Engine 1

3MUGI)

Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

Timing

belt cover bolt locations— 3

0L engine

tion.

Heater Core replacement

is

covered

in Section

2

of this

manual

1

SATURN

f£

U

I

LW

SCI • SC2

•

•

SL

•

SW1

SW2

«

bolts to

30

ft.

lbs.

(40

pump

Water

bolts to

15

pulley's

ft.

lbs.

removing the

and torque the

(20

Nm) '

Wiring harness into the channel

• •

Wiring harness channel front cover

•

Accessory drive

Remove

Right front wheel

•

Wheel

•

Crankshaft pulley

•

and

torque the bolts to 44 inch

lbs. (5

Front exhaust pipe from the

•

Crankshaft gear retaining and

removal

tool

oil

pan

with the

shown— be

crankshaft tool with the

Front cover

flat

Air cleaner

•

Negative battery cable

side toward the sprocket.

sure to install the

flat

Front tour

oil

side toward oil

•

crankshaft gear retainer tool

Install a

7.

•

Nm) Front wheel

well splash shield

6.

well splash shield

•

lines

•

exhaust manifold

belt

the engine support fixture.

Wheel

•

Power steering pump without

•

Nm)

the bolts to 71 inch lbs. (8 •

front bracket

without removing the hoses

Nm)

Power steering pump and torque

•

A/C compressor and

•

Drive belt tensioner and torque the

•

6.

SL1 • SL2 •

pan bolts and cut the

pan seal away from the front

the gear

cover

and intake duct •

Front cover

Reposition the wire harness out of the cooling system.

7.

Fill

8.

Start the vehicle

^Position the crankshaft 90 degrees off of Top Dead Center (TDC) to make

the way. repair

if

and check

for leaks, •

Spark plug wires

•

Evaporative Emissions (EVAP)

necessary.

purge valve •

certain that the pistons do not touch the

valves during assembly.

vacuum hose

Positive Crankcase Ventilation

(PCV) vacuum hose body connector

•

Throttle

•

Brake booster vacuum hose

•

Upper radiator hose from the cylin-

the engine result

is

cold.

the cylinder head

if

while the engine

is

removed

is hot.

Before servicing the vehicle, refer to

1.

the precautions in the beginning of this section.

Drain the cooling system.

2. 3.

Drain the engine

4.

Properly relieve the fuel system

•

•

Loosen and uniformly remove the

•

Deaeration hose from the intake

in

several

Cylinder head from the dowels on the engine block

To

install:

Heater hose from the intake manifold

•Before

Fuel supply line

should be cleaned and inspected for

Engine torque axis mount

•

Accessory drive

•

Drive belt tensioner

•

Drive belt idler pulley

•

Rocker arm cover

•

Deaeration line from the cylinder

head water

installing the cylinder head,

it

excessive wear or damage.

•

oil.

Camshaft sprocket

•

10 cylinder head bolts

manifold

when Warpage may

Only remove the cylinder head

Timing chain, tensioner and guides

•

passes

der head outlet •

•

belt

8.

Clean the gasket mating surfaces. Be

careful not to

damage

the

aluminum com-

ponents and be sure the block bolt holes are clean of any residual sealer,

oil

or for-

eign matter.

outlet

9.

Using a

dial

gauge, check that the

pressure.

Remove

5.

or disconnect the following:

•

Negative battery cable

•

Air cleaner

•

Rocker cover fresh

•

Accelerator cable from the throttle

body and •

• •

7

10

6

2

4

8

9

5

1

hose

intake manifold bracket electri-

connector

Fuel injector connectors Idle Air cal

•

air

Coolant temperature gauge cal

3

assembly

Control (IAC) valve electri-

connector

Throttle Position (TPS) sensor electrical connector-

•

A/C compressor

electrical

connec-

tor •

Manifold Absolute Pressure (MAP)

sensor •

electrical

connector

Oxygen (O 2 S) sensor

electrical

connector •

Exhaust Gas Recirculation (FGR)

7922Z803

solenoid Gradually remove the cylinder head bolts

in

the sequence

shown

to

prevent warping the head

90-1

SATURN LW

•

SCI

•

SC2

•

SL

•

SL1

•

SL2

•

SW2 vJC

•

I

I

Coat the cylinder head bolts with

13.

clean engine

hand

SW1

and thread the bolts by

oil

until finger-tight.

14.

cylinder head bolts, in

Install the

sequence, as follows: a.

Tighten the bolts to 22

ft.

lbs.

(30

Tighten the bolts to 33

ft.

lbs.

(45

Nm). b.

Nm) for SOHC engines or to 37 (50 Nm) for DOHC engines.

lbs.

ft.

Tighten each bolt an additional 90

c.

degree turn. 15.

Install

the timing chain, sprockets,

guides and tensioners, using the following

procedure Verify that the crankshaft

a.

tioned

is

posi-

90 degrees clockwise past TDC.

The crankshaft key way sprocket timing mark must be aligned with the cylinder block main bearing cap vent piston and valve 10. b.

If

to No.

will

be

at 3 o'clock) to

to

90 degrees past TDC (the crankshaft sprocket timing mark

required, rotate the camshaft

1

TDC

up

position.

90 degrees

Rotate the crankshaft

c.

Rotate the crankshaft clockwise

split line to pre-

damage

counterclockwise to No.

1

TDC

position.

The crankshaft sprocket timing mark

prevent valve damage during assembly

must align with the cylinder block timing cylinder liners are flush or do not deviate

more than 0.0005

in.

(0.013mm).

Be sure the crankshaft degrees past

1 1

TDC and

that the

is still

.

Install the cylinder

carefully guide the

head

head gasket and

into place over the

mark.

16

Install or

•

90

dowels.

camshaft(s)

12.

If

sprocket and under the crankshaft

the head bolts and/or the block

were replaced,

pin(s) at the 12 o'clock position to prevent

in

valve damage.

proper clamp load; then, remove the bolts

sequence

to

install the bolts

48

ft

lbs.

(65

sprocket Slide the camshaft

and tighten

are properly positioned with the dowel

Nm)

connect the following

Timing chain over the camshaft

sprocket onto the camshaft with the

to insure

letters

FRTfacing away from the

cylinder head • •

Camshaft sprocket timing pin Camshaft washer and torque the bolt to 74

bolt

and

lbs.

ft

(100

Nm) •

Fixed chain guide and torque the fastener to 19

ft.

lbs (26

Nm) The

timing chain should be snug against the fixed guide •

Pivoting chain guide making cer-

between the

tain there is clearance

block and head and torque the bolts to •

19

Nm)

(26

168 inch

the bolts to •

lbs

ft

Timing chain tensioner and torque lbs.

(19

Nm)

Crankshaft timing gear retainer tool to align the gerotor oil

pump

to the

front cover •

Front cover and torque the perimeter

bolts to

22

ft.

lbs

(30

the lower center bolt to

(10 •

Oil

Nm) pan and torque the bolts

inch lbs. (9 •

Brake service

is

covered

in

Section 4 of this manual

Nm) and

89 inch lbs

Water

pump

to

80

Nm) pulley and torque the

SATURN

32-12

LW

bolts to 19

lbs.

ft.

•

SC2

(25

Nm)

SCI

•

SL

•

•

SL1

•

SL2

Remove

53 inch

the crankshaft timing gear

retaining tool.

Apply RTV across the cylinder head

18.

and

and

front cover T-joints

install a

new

rocker cover gasket •

Crankshaft pulley and torque the

•

Rocker cover and torque the bolts

159

bolt to

to •

22

•

22

cable

ft.

20

lbs.

ft.

Nm)

(27

Make

not

is

(25 Nm).

lbs.

Fill

the cooling system.

Fill

the engine with

21

Prime the

ON

for

Intake manifold

•

Exhaust manifold flange bolts

new

oil.

•

Fuel lines

•

A/C compressor switch

system by cycling the

5 seconds and

Start the engine, if

check

OFF

for

10

•

for leaks,

and

bolts to

Nm) (if removed) Power steering pump and torque the bolts to 22 ft. lbs. (30 Nm) A/C compressor and torque 18

35

Nm)

(47

Coolant

•

Upper

Accessory drive

•

Upper mount and torque the bracket nuts to

belt

37

bolts to •

Wheel

•

Wheel

37

lbs.

ft.

hose from the

Ignition coil electrical connectors

•

Knock Sensor (KS)

electrical

when Warpage may

Only remove the cylinder head the engine

is

cold.

•

if

the cylinder head

while the engine

is

removed

Before servicing the vehicle, refer to

the precautions

in

connector

hot. •

1.

connector

Front Oxygen (O 2 S) sensor electrical

is

electrical

Fuel injector jumper harness

•

Ignition coil

Power steering pump and secure to the

the beginning of this sec-

lines

2.

Drain the cooling system.

3.

Drain the engine

Properly relieve the fuel system

Remove

•

Camshaft cover ground strap

•

Camshaft cover

•

Upper timing chain guide

oil.

or disconnect the following:

•

Upper timing chain tensioner

•

Camshaft sprocket bolts

cover

well splash shield

•

EVAP

•

Throttle

canister purge

hose

body vacuum harness hose

•

PCVhose

•

Brake booster

•

Upper

•

Heater hose

•

Ground wire

•

O 2 S sensor

•

Fuel injector electrical connectors

•

IAC valve

•

EGR valve electrical connector TPS sensor electrical connector EVAP canister purge valve connec-

vacuum hose

radiator

hose

connectors

electrical

connector

electrical

electrical

connector

tors •

MAP

•

Alternator electrical connectors

sensor connectors

•

Starter

•

A/C compressor

motor

electrical

connectors

electrical

connec-

tors •

Intake manifold support bracket

torque the bolts to 22

ft.

lbs.

and

(30

Nm) •

Deaeration line and torque the cylinder head nut to

80 inch

Nm) and

bracket nut to

97 inch •

the rear

lbs. (11

Fuel feed

and

lift

lbs. (9

9306ZG43

Nm)

return lines with

new

it

engine without removing the

Nm)

(50

con-

Engine Coolant Temperature (ECT) sensor

Nm)

to

cylin-

•

•

5.

(50

lbs.

ft.

bleed hose

nector

pressure.

and then torque the mount

air

radiator

der head

necessary.

2.2L Engine

4.

•

Crankcase vent hose from the

•

tion.

(25

the front bracket bolts to

lbs.

ft.

the

lbs.

ft.

electrical

camshaft cover

•

and torque the

to the

connector

seconds a few times without cranking the

22.

Exhaust manifold down pipe catalytic converter

(32

lbs.

ft.

Nm) and

•

19.

fuel

Negative battery cable

•

•

20.

result

rear bracket bolts to

•

Negative battery cable

hose

air

certain that the

routed properly and

is

Alternator

24

•

•

repair

binding and torque the bolts to 18

•

Fresh

•

Accelerator linkage bracket and the throttle cable.

•

•

Drive belt idler pulley and torque the fastener to

•

Nm)

(30

lbs.

ft.

assembly

Air cleaner

.

to

Nm)

engine.

Drive belt tensioner and torque the fastener to

and torque the fastener lbs. (6

•

ignition

Nm)

(30

lbs.

ft.

Nm)

(215

lbs.

ft.

SW2

•

retainers

(if

removed) 17.

SW1

•

90-10 OL O

SATURN LW •

Camshaft sprockets

•

Plug to gain access to the fixed

•

•

to

may be

It

INTdiamond

com-

A/C suction

line retaining clips

away

install

a crankshaft pulley holder tool.

Crankshaft pulley

•

Front cover bolts except for the one

proceeding

to the next

the timing chain

front

not

is

•

•

•

Front cover

•

Adjustable timing chain guide

Nm)

lbs (85

Fixed timing chain guide lower bolt

(40

To install:

•

to

applying Loctite

12

New

•

•

ft.

•

line

clamps

Camshaft cover and torque the

89 inch

lbs.

it

-

•

to the

to

30

ft

ft

(10 •

Timing chain tensioner and torque ft.

lbs (60

•

Tap the top of the timing chain

•

All

component

89 inch

electrical

Upper

Crankcase ventilation hose

hose

radiator

•

Fuel pressure regulator hose

•

Brake booster vacuum hose

(30

Fuel lines to the bracket and torque the bracket bolt to

89 inch

lbs.

(10

Nm)

Front 4 cylinder head bolts coated

•

with Loctite' and torque them to 18

Exhaust

Nm)

ft.

and

the intake camshaft with the offset slot in

down

pipe to the exhaust

manifold and torque the bolts to 25

Position the exhaust camshaft with

the offset slot in the 2 o’clock position

Nm)

connections

•

plus 155 degrees

(22

(10

lbs.

•

Fuel lines

lbs.

lbs.

Engine wiring harness and torque

•

ft.

89 inch

Wiring harness to the intake mani-

the fasteners to

on the

lbs

new gasket

to

fold bracket

Nm)

cylinder head bolts and torque ft

Nm)

Nm)

New

22

(25

assembly and

Intake manifold with a

EVAP purge hose

to

lbs.

Ignition coil/module

and torque the bolts

lbs

OBENfacing up

sequence

Nm)

Power steering pump and torque

•

in

(10

Camshaft cover ground strap and

torque the bolts to 71 inch lbs (8

Nm)

cylinder head gasket with the

it

Nm)

(100

lbs.

•

Nm)

9.

74

dowels

them •

Crankshaft damper and torque the

the bolts to 18

prevent con-

Cylinder head and align

(55

Nm)

connect the following

side imprinted

lbs.

Right front wheel

plus a

between the pistons and valves. Install or

ft.

•

Nm)

the bolts 44

60 degrees

Top Dead Center (TDC)

lbs (10

threads and torque

Before Top Dead Center (BTDC) or after

Nm)

Engine mount to the bracket and

Right wheel splash shield

connect the following

89 inch

and lbs.

Fixed timing guide bolt access plug after

to

ft.

torque the bolt to 89 inch lbs. (10

Fixed timing guide and torque the bolt to

bolt

Nm)

(90

A/C

•

Install or

1 1

cover bolt which was

'•Set the crankshaft

ft.

lbs.

ft.

torque the fasteners to 41

bolts to

63

66

•

•

30 degree turn

blocked by the mount bracket

pump

to

Nm)

(40

•

Torque the intake and exhaust

Engine mount bracket

Water

marks

links are aligned prop-

camshaft bolts

18

• Accessory drive belt

•

it

lbs.

ft.

rail

bolt to

do not

engine mount

•

•

certain that all timing

If

to

Nm)

** CAUTION

step.

30

Engine mount to the side

10.

Make

it

Engine mount bracket and torque

torque the bolts to 41

age may occur. bolt but

Support the engine and remove the

Upper

new

torque

Drive belt tensioner and torque the

(55 •

aligned properly, severe engine dam-

bracket

•

•

but do not tighten a

Install

(25

lbs.

ft.

pump bolt and (25 Nm)

the bolts to

Nm)

sprocket bolt

erly before

blocked by the engine mount

right side

(10

lbs.

bolts to •

camshaft sprocket with the silver

and colored

•

remove

•

Timing chain around the exhaust

and

Position the crankshaft 60 degrees

Before Top Dead Center (BTDC) and

Water ft.

cylinder head and torque the bolt to

to allow clearance to the

Loosen water pump

•

through the opening on top of the

lbs.

(10

lbs.

Nm)

link aligned with the offset slot.

crankshaft pulley bolt

•

engage

to

new gasket and

torque the bolts to 18

Adjustable timing chain guide

Right front wheel and splash shield

the line

sprocket bolt but do

the timing mark

not be

89 inch

•

Front cover with a

•

with the offset slot

sprocket and align the silver link to

the timing chain can be sup-

Drive belt and tensioner

8.

I

Upper timing chain guide and

•

to

perform the remaining

to

•

tact

SW2

•

between the camshaft sprockets

Timing chain around the crankshaft

•

recommends

•

•

SW1

the tensioner.

not tighten

the crankshaft pulley.

•

•

camshaft sprocket with the copper

New camshaft

ported without slipping or moving on

7.

SL2

•

Timing chain around the intake

it

•

Cylinder head

necessary

•

SL1

Nm)

•

6.

•

Sprocket to the camshaft and align

•

perform the remaining steps

move

SL

torque the bolts to 89 inch

plete this procedure.

•

•

link aligned with the

Cylinder head bolts using the

if

SC2

timing mark