Haynes Buick, Oldsmobile & Pontiac FWD Models 1985 thru 2002 Automotive Repair Manual [19020] 156392479X, 9781563924798
“1 v. (various pagings) : 27 cm "Models covered: Buick, Oldsmobile, and Pontiac full-size front-wheel drive models
120 107 33MB
English Pages 260 Year 2003
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- Author / Uploaded
- Mike Stubblefield
- John H. Haynes
- Categories
- Technique
- Transportation: Cars, motorcycles
Citation preview
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Buick, Oldsmobile & Pontiac
FWD Models
Automotive Repair Manual by Mike Stubblefield and John H Haynes Member of the Guild of Motoring Writers
Models covered: Buick, Oldsmobile and Pontiac Full-size front-wheel drive models (C and H body types) 1985 through 2002 Does not cover diesel engine and related information, supercharger information or rear-wheel drive models
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AUTOMOTIVE
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A
PaARPES Ciessonnss MEMBER AC Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA
:
:
Acknowledgements Wiring diagrams originated exclusively for Haynes North America, Inc. by Valley Forge Technical Information Services. Technical writers who contributed to this project include Jon La Course, Jeff Killingsworth and Ken Freund. ©
Haynes North America, Inc. 1990, 1992, 1995, 1998, . 1999, 2000, 2003 With permission from J.H. Haynes & Co. Ltd.
A book in the Haynes Automotive Repair Manual Series
Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.
ISBN 1 56392 479 X Library of Congress Control Number 2002114286 While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. 03-256
0-3
Contents Introductory pages About this manual Introduction to the Buick, Oldsmobile and Pontiac full-size, front-wheel drive models Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting Anti-theft audio systems Jacking and towing Automotive chemicals and lubricants Conversion factors Fraction/decimal/millimeter equivalents Safety first! Troubleshooting
Oo oa T
LOSOO 1
SPEPPPPEPP DARONN owsCOON ok ek ek IND
Chapter 1 Tune-up and routine maintenance
Chapter 2
PartA
Engines
Chapter 2
PartB
General engine overhaul procedures
Chapter 3 Cooling, heating and air conditioning systems
Chapter 4 Fuel and exhaust systems
Chapter 5 Engine electrical systems
Chapter 6 Emissions and engine control systems
Chapter 7 Automatic transaxle
7-1
|
Chapter 8 Driveaxles
Chapter 9 Brakes
Chapter 10 Suspension and steering systems
Chapter 11 Body
11-1
Chapter 12 Chassis electrical system
12-1
Wiring diagrams
12-15
Index
IND-1
IND
Haynes mechanic, author and photographer with Oldsmobile Delta 88
0-5
‘Abo thisut manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It _ can do so in several ways. It can help you _ decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic _ and repair procedures to follow when trouble occurs. We hope you use the manual to tackle _ the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a _ shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop
must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.
Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within
that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, “see Section 8” means in the same Chapter. References to the left or right side of the vehicle assume you are sitting in the driver’s seat, facing forward. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.
NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.
CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.
WARNING A Warning provides a special procedure or special steps which must be taken while completing the
procedure where the Warning is found. Not heeding a Warning can result in personal injury.
Introduction to the Buick, Oldsmobile and Pontiac full-size, front-wheel drive models The full-size General Motors models covered by this manual are front engine/front-wheel drive “C” and “H” body vehicles only. Most are four-door sedans,
although some two-door models are available.
All models are powered by a transversely mounted V6 engine which drives the front wheels through an automatic transaxle and independent driveaxles. Independent suspension, featuring coil springs and struts or shock absorbers, is
used at all four wheels. The rack and pinion steering unit is mounted behind the engine. The brakes are disc at the front and drums or discs at the rear, with power assist
standard.
0-6
Vehicle identification numbers Modifications are a continuing and unpublicized part of vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly identify the component required.
Service parts identification label
plate contains the name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR) and the certifi-
This label is located inside the trunk (see illustration). It lists the VIN number, wheelbase, paint number, options and other information specific to your vehicle. Always refer to this label when ordering parts.
cation statement.
Body identification plate
Vehicle Identification Number
(VIN) This very important identification number is stamped on a plate attached to the left side of the dashboard and is visible through the driver’s side of the windshield (see illustration). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was manufactured, the model year and the body style.
Vehicle Certification Plate The Vehicle Certification Plate (VC label) is affixed to the rear of the left front door. The
The body identification plate is located in the engine compartment on the upper surface of the radiator support. Like the VIN, it contains valuable information concerning the production of the vehicle, as well as information on the options with which it is equipped. This plate is especially useful for matching the color and type of paint for repair work.
Transaxle identification number The transaxle identification number is located on the right rear side of the transaxle (see illustration).
Engine identification number
Vehicle Emissions Control Information label
The engine ID number is located on a pad at the drivebelt (right) end of the engine block, adjacent to the water pump or on the front surface of the block at the transaxle (left) end, adjacent to the starter (see illustration).
The Vehicle Emissions Control Information label is under the hood, often attached to the left shock tower (see Chapter 6 for more information and an illustration of the label).
a “ FRONT OF VEHICLE
The vehicle Identification Number (VIN) is on a plate attached to the top of the dashboard on the driver’s side of the vehicle - it can be seen through the windshield
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The engine identification number is in one of two places: at the right end of the block adjacent to the water pump, or at the front side of the block adjacent to the starter
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The service parts identification label is located on the inside of the trunk lid
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The transaxle identification number is on the right rear side of the transaxle
0-7
Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned
parts on an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general accessories, have convenient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are
unique to the vehicle and not generally available elsewhere (Such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: lf the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.
Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.
this task, as well as other repair procedures,
be replaced exactly as removed. Replace any
such as the repair of threaded holes that
damaged washers with new ones. Never use
have been stripped out. Flat washers and lockwashers, when removed from an assembly, should always
a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic.
Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either a lockwasher, locknut, locking tab or thread adhesive. Ail threaded fasteners
Grade 5
Grade 1 or 2
Grade 8
should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should be treated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works quite well. After applying the rust. penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose. Most automotive machine shops can perform
Boit strength marking (standard/SAE/USS; bottom - metric)
Grade
Identification
Grade Hex Nut
Grade'5
Ydoig
Identification : r-
y
Arabic 9
Hex Nut
Hex Nut
Pi
Grade 8
Class%
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Class
Class
Class
10.9
9.8
8.8
Arabic 10
Standard hex nut
Metric hex nut
strength markings
strength markings
Metric stud strength markings 00-1 HAYNES
0-8
Maintenance techniques, tools and working facilities
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Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important to be able to tell the difference between
Metric thread sizes
Ft-lbs 6to9 14 to 21 28 to 40 50 to 71 80 to 140
Nm 9 to 12 19 to 28 38 to 54 68 to 96 109 to 154
etn
5 to 8 12 to 18
7 to 10 17 to 24
Sane.
22 to 33
30 to 44
Anion
25 to 35
34 to 47
es
6 to9
9 to 12
Bend
12 to 18
17 to 24
Seely Ra Ee eas eRe
14 22 27 40 40
19 30 37 55 55
lente aa Banehon ere Cie eee
standard (sometimes called U.S. or SAE) and
metric hardware, since they cannot be inter-
changed. All bolts, whether standard or metric, are sized according to diameter, thread pitch and
N/a
length. For example, a standard 1/2 - 13 x 1
sraceseanc vesntSy cuurs aaa anes cavemen aCe
bolt is 1/2 inch in diameter, has 13 threads per
inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm in diameter, has a thread
pitch of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard bolt head is measured in inches, while the same dimension on a metric bolt is sized in millimeters (the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt and a metric wrench should not be used on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to it. The greater the number of slashes, the greater the strength of the bolt. Grades 0 through 5 are commonly used on automobiles. Metric bolts have a property class (grade) number, rather than a slash, molded into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and 10.9 are commonly used on automobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped into one side, while metric nuts are marked with a number. The greater the number of dots, or the higher the number,
the
greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade. It should be noted that many fasteners, especially Grades 0 through 2, have no distinguishing marks on them. When such is the case, the only way to determine whether it is standard or metric is to measure the thread pitch or compare it to a Known fastener of the same size. Standard fasteners are often referred to as SAE, as opposed
to metric.
However,
it
should be noted that SAE technically refers to
a
non-metric
fine
thread
Coarse thread non-metric referred to as USS sizes.
fastener fasteners
only. are
Since fasteners of the same size (both standard and metric) may have different
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to to to to to
20 32 38 55 60
55 to 80
to to to to to
27 43 51 74 81
75 to 108
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12-26 HOT
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12-27
Chapter 12 Chassis electrical system HOT
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12-28
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12-32
Chapter 12
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12
Courtesy light circuit - 1988 and later models
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Chassis electrical system
Chapter 12
12-34
HOT IN RUN, BULB
TEST OR START
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Chapter 12
Chassis electrical system
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Chassis electrical system Chapter 12
12-44
IND-1
index. B About this manual, 0-5 Accelerator cable, removal and installation, 4-11 Acknowledgements, 0-2
Air conditioner accumulator, removal and installation, 3-7 compressor, removal and installation, 3-8
condenser, removal and installation, 3-8 Air conditioning system, check and maintenance, 3-7 Air filter
housing assembly, removal and installation, 4-5 replacement, 1-16
Airbag, generai information and precautions, 12-13 Alignment, general information, 10-16 Alternator brushes, replacement, 5-6 removal and installation, 5-6 Antenna, removal and installation, 12-10 Antifreeze, general information, 3-2 Anti-lock Brake System (ABS) and Traction Control System (TCS), general information, 9-23 Anti-theft audio systems, 0-14 Automatic transaxle, 7-1 through 7-8 diagnosis, general, 7-2 differential seals, replacement, 7-5 fluid and filter change, 1-19 fluid level check, 1-9 general information, 7-1 neutral start switch, replacement and adjustment, 7-3 park/lock cable, removal and installation (floor shift models only), 7-4 removal and installation, 7-5 shift cable, replacement and adjustment, 7-4 Throttle Valve (TV) cable (1985 through 1991 models), replacement and adjustment, 7-2 Automotive chemicals and lubricants, 0-16
Balljoint, check and replacement, 10-4 Battery cables, check and replacement, 5-2 check and maintenance, 1-10 emergency jump starting, 0-13 removal and installation, 5-2 Body, 11-1 through 11-10 center console, removal and installation, 11-10 door glass regulator, removal and installation, 11-8 handles, removal and installation, 11-8 lock cylinder, removal and installation, 11-9 lock striker, removal and installation, 11-9 removal, installation and adjustment, 11-9
window glass, removal and installation, 11-7 door trim panel, removal and installation, 11-7 general information, 11-1 hinges and locks, maintenance, 11-5 hood latch cable, replacement, 11-5 hood, removal and installation, 11-5 maintenance, 11-1 outside mirror, removal and installation, 11-10
repair major damage, 11-5 minor damage, 11-1 seats, removal and installation, 11-10 trunk latch and striker, removal and installation, 11-10
lid, removal, installation and adjustment, 11-9 lock cylinder, removal and installation, 11-9 upholstery and carpets, maintenance, 11-1 vinyl trim, maintenance, 11-1 windshield and fixed glass, replacement, 11-5 Booster battery (jump) starting, 0-13 Brake rotor (disc), inspection, removal and installation, 9-6
IND-2 ee
Index em
ne
a
SR
TLL
SORE
Brakes, 9-1 through 9-24
Anti-lock Brake System (ABS) and Traction Control System (TCS), general information, 9-23 brake light switch, removal, installation and adjustment, 9-23
brake rotor (disc), inspection, removal and installation, 9-6 brake shoes, rear, inspection and replacement, 9-7 check, 1-15 disc brake caliper, removal, overhaul and installation, 9-4 pads, replacement, 9-2 general information, 9-2 hoses and lines, inspection and replacement, 9-19
master cylinder, removal, overhaul and installation, 9-16 parking brake, 1-16 adjustment, 9-20 cables, removal and installation, 9-21
power brake booster, inspection, removal and installation, 9-22 system bleeding, 9-20 wheel cylinder, rear, removal, overhaul and
installation, 9-16 Bulb replacement, 12-8 Buying parts, 0-7
C Camshaft and balance shaft, installation, 2B-21
Camshaft, balance shaft and bearings, removal and inspection, 2B-11 Catalytic converter, 6-16 Center console, removal and installation, 11-10 Charcoal canister replacement, 6-16 Charging system check, 5-5 general information and precautions, 5-4 Chassis electrical system, 12-1 through 12-44 airbag, general information and precautions, 12-13 bulb replacement, 12-8 circuit breakers, general information, 12-3 cruise control system, description and check, 12-12 door lock system, power, description and check, 12-13 electrical troubleshooting, general information, 12-1 fuses, general information, 12-2 fusible links, general information, 12-2 general information, 12-1 headlight adjustment, 12-8 removal and installation, 12-7 switch, replacement, 12-6 horn, check and replacement, 12-12
SSC
NS
A
SSE
TRA
I
SRT
SE
ES
SE
LS
ignition switch/key lock cylinder, replacement, 12-6 instrument cluster, removal and installation, 12-10
multi-function/turn signal lever (1996 and earlier models only), replacement, 12-4 multi-function/turn signal switch assembly, replacement, 12-4 radio and speakers, removal and installation, 12-9 antenna, removal and installation, 12-10 relays, general information and testing, 12-3 turn signal/hazard flashers, check and replacement, 12-4 window defogger, rear, check and repair, 12-10 window system, power, description and check, 12-13 windshield wiper motor/washer pump, removal and installation, 12-11 wiring diagrams, general information, 12-14 Chassis lubrication, 1-13 Circuit breakers, general information, 12-3 Control arm, removal and installation front, 10-5" rear, 10-10 Conversion factors, 0-17 Coolant
reservoir, removal and installation, 3-4 temperature sending unit, check and replacement, 3-5 Cooling system check, 1-10 servicing (draining, flushing and refilling), 1-19 Cooling, heating and air conditioning systems, 3-1 through 3-18 accumulator, removal and installation, 3-7 air conditioning system, check and maintenance, 3-7 antifreeze, general information, 3-2 compressor, removal and installation, 3-8 condenser, removal and installation, 3-8 coolant reservoir, removal and installation, 3-4 coolant temperature sending unit, check and replacement, 3-5 engine cooling fans, check and replacement, 3-2 general information, 3-1 heater and air conditioner blower motor, removal and installation, 3-5 control assembly, removal and installation, 3-6 heater core, removal and installation, 3-6 radiator, removal and installation, 3-3 thermostat, check and replacement, 3-2 water pump check, 3-4 removal and installation, 3-4 Crankshaft front oil seal, replacement, 2A-13 inspection, 2B-17 installation and main bearing oil clearance check, 2B-20
a
SS
: LESS
LSNG
rear oil seal installation, 2B-21 replacement, 2A-18 removal, 2B-13 Cruise control system, description and check, 12-12 Cylinder compression check, 2B-4 Cylinder head cleaning and inspection, 2B-9 disassembly, 2B-8
- _ reassembly, 2B-11 removal and installation, 2A-11 Cylinder honing, 2B-15
Disc brake caliper, removal, overhaul and installation, 9-4 pads, replacement, 9-2 Distributor cap and rotor check and replacement (1985 models only), 1-23 | Distributorless ignition coil and module (1986 and later models), removal and installation, 5-4 Door
glass regulator, removal and installation, 11-8 handles, removal and installation, 11-8 lock assembly, removal and installation, 11-7 cylinder, removal and installation, 11-9 striker, removal and installation, 11-9 system, power, description and check, 12-13 removal, installation and adjustment, 11-9 window glass, removal and installation, 11-7 Door trim panel, removal and installation, 11-7 Driveaxle boot check, 1-14 Driveaxles, 8-1 through 8-8 boot, replacement, 8-2 removal and installation, 8-1 Drivebelt check, adjustment and replacement, 1-16 Driveplate, removal and installation, 2A-18
E Electrical troubleshooting, general information, 12-1 Electronic Control Module (ECM)/Programmable Read Only Memory (PROM)/CALPAK/MEMCAL/Powertrain Control Module, 6-9 Electronic Spark Control (ESC) system, 6-14 Electronic Spark Timing (EST), 6-13 Emissions control systems, 6-1 through 6-16 catalytic converter, 6-16
charcoal canister replacement, 6-16
Index
eh
IND-3 cid
Electronic Control Module (ECM)/Programmable Read Only Memory (PROM)/CALPAK/MEMCAL/Powertrain Control Module, 6-9 Electronic Spark Control (ESC) system, 6-14 Electronic Spark Timing (EST), 6-13 Evaporative Emission Control System (EECS), 6-15 Exhaust Gas Recirculation (EGR) system, 6-14 general information, 6-1 information sensors, 6-10 camshaft position sensor, 6-13 crankshaft position sensor, 6-13 engine coolant temperature sensor, 6-10
Manifold Absolute Pressure (MAP) sensor, 6-11 Manifold Air Temperature (MAT) sensor or Intake Air Temperature (IAT) sensor, 6-11 oxygen sensor, 6-12 Park/Neutral (P/N) switch, 6-12 Throttle Position Sensor (TPS), 6-12 Vehicle Speed Sensor (VSS), 6-12 knock sensor replacement, 6-14 oxygen sensor, replacement, 6-13 Positive Crankcase Ventilation (PCV) system, 6-16 self-diagnosis system and trouble codes, 6-4 Transaxle Converter Clutch (TCC), 6-16 Engine cooling fans, check and replacement, 3-2 Engine electrical systems, 5-1 Hirer gn 5-8 alternator brushes, replacement, 5-6 removal and installation, 5-6 battery cables, check and replacement, 5-2 emergency jump starting, 5-2 removal and installation, 5-2 charging system check, 5-5 general information and precautions, 5-4 distributorless ignition coil and module (1986 and later models), removal and installation, 5-4 HEI coil and ignition module (1985 models only), removal and installation, 5-3 HEI distributor (1985 models only), removal and installation, 5-3 ignition system check, 5-3 general information, 5-1 starter motor removal and installation, 5-8 testing in vehicle, 5-7 starter solenoid, removal and installation, 5-8 starting system, general information and precautions, 5-7 Engine oil and filter change, 1-12 Engines, 2A-1 through 2A-20 crankshaft front oil seal, replacement, 2A= 43
crankshaft rear oil seal, replacement, 2A- 18 cylinder heads, removal and installation, 2A- 11
IND
IND-4
Index
driveplate, removal and installation, 2A-18 exhaust manifolds, removal and installation, 2A-10 general information, 2A-3 intake manifold, removal and installation, 2A-7 mount, check and replacement, 2A-19 oil filter adapter and pressure regulator valve, removal and installation (1986 and later models only), 2A-15 oil pan, removal and installation, 2A-17 oil pump pickup tube and screen assembly, removal and installation, 2A-17 removal, inspection and installation, 2A-15 rear main oil seal carrier (VIN K engine), removal and installation, 2A-19 repair operations possible with the engine in the vehicle, 2A-3 rocker arm covers, removal and installation, 2A-4 rocker arms and pushrods, removal, inspection and installation, 2A-5 timing chain and sprockets, removal and installation, 2A-16 timing chain cover, removal and installation, 2A-14 Top Dead Center (TDC) for number one piston, locating, 2A-3
valve lifters, removal, inspection and installation, 2A-9 valve springs, retainers and seals, replacement, 2A-6 vibration damper, removal and installation, 2A-13 General engine overhaul procedures,
2B-1 through 2B-24 block cleaning, 2B-14 inspection, 2B-15 camshaft and balance shaft, installation, 2B-21 balance shaft and bearings, removal and inspection, 2B-11 crankshaft inspection, 2B-17 installation and main bearing oil clearance check, 2B-20 rear oil seal, installation, 2B-21 cylinder compression check, 2B-4 cylinder head cleaning and inspection, 2B-9 disassembly, 2B-8
reassembly, 2B-11 cylinder honing, 2B-15 engine overhaul disassembly sequence, 2B-7 reassembly sequence, 2B-19 engine rebuilding alternatives, 2B-7 engine, removal and installation, 2B-5 main and connecting rod bearings, inspection, 2B-18 oil pressure check, 2B-3
piston rings, installation, 2B-19 pistons and connecting rods inspection, 2B-16 installation and rod bearing oil clearance check, 2B-22 removal, 2B-12
vacuum gauge diagnostic checks, 2B-4 valves, servicing, 2B-10 Evaporative Emission Control System (EECS), 6-15 Evaporative emissions control system check, 1-21 Exhaust Gas Recirculation (EGR) system, 6-14 Exhaust Gas Recirculation (EGR) system check, 1-21 Exhaust manifolds, removal and installation, 2A-10 Exhaust system’ check, 1-14 removal and installation, 4-11
— Fluid level checks, 1-6
automatic transaxle, 1-9 battery electrolyte, 1-7 brake fluid, 1-7 engine coolant, 1-6 engine oil, 1-6 power steering, 1-9 windshield washer fluid, 1-7 Fraction/decimal/millimeter equivalents, 0-18 Front fender liner, removal and installation, 11-6 Front fender, removal and installation, 11-6 Fuel and exhaust systems, 4-1 through 4-12
accelerator cable, removal and installation, 4-11 air filter housing assembly, removal and installation, 4-5 exhaust system, removal and installation, 4-11
filter replacement, 1-18 fuel injection system check, 4-6 general information, 4-6 fuel pressure relief procedure, 4-1 general information, 4-1 lines and fittings, repair and replacement, 4-3 Port Fuel Injection’ (PFI), component removal and installation, 4-7 pump, removal and installation, 4-4 pump/fuel pressure, testing, 4-2 tank cleaning and repair, general information, 4-4 Fuel injection system check, 4-6 general information, 4-6
Fuel system check, 1-16 Fuses, general information, 12-2 Fusible links, general information, 12-2
index
G Gear boots, steering, replacement, 10-12 Gear, steering, removal and installation, 10-11 General engine overhaul procedures, 2B-1 through 2B-24
block cleaning, 2B-14 inspection, 2B-15 camshaft and balance shaft, installation, 2B-21 balance shaft and bearings, removal and inspection, 2B-11
IND-5
HE! coil and ignition module (1985 models only), removal and installation, 5-3 HEI distributor (1985 models only), removal and installation, 5-3 Hinges and locks, maintenance, 11-5 Hood latch cable, replacement, 11-5 removal and installation, 11-5 Horn, check and replacement, 12-12 Hub and wheel bearing assembly, removal and installation front, 10-7 rear, 10-10
crankshaft inspection, 2B-17 installation and main bearing oil clearance check, 2B-20 rear oil seal, installation, 2B-21
removal, 2B-13 cylinder compression check, 2B-4 cylinder head cleaning and inspection, 2B-9 disassembly, 2B-8 reassembly, 2B-11
cylinder honing, 2B-15 engine overhaul disassembly sequence, 2B-7 general information, 2B-3 reassembly sequence, 2B-19 engine rebuilding alternatives, 2B-7 engine, removal and installation, 2B-5 initial start-up and break-in after overhaul, 2B-24 main and connecting rod bearings, inspection, 2B-18 oil pressure check, 2B-3 piston rings, installation, 2B-19 pistons and connecting rods inspection, 2B-16 installation and rod bearing oil clearance check, 2B-22
Ignition switch/key lock cylinder, replacement, 12-6 Ignition system check, 5-3 general information, 5-1 Ignition timing check and adjustment (1985 models only), 1-23 Information sensors, 6-10 camshaft position sensor, 6-13 crankshaft position sensor, 6-13 engine coolant temperature sensor, 6-10 Manifold Absolute Pressure (MAP) sensor, 6-11 Manifold Air Temperature (MAT) sensor or Intake Air Temperature (IAT) sensor, 6-14 oxygen sensor, 6-12 Park/Neutral (P/N) switch, 6-12 Throttle Position Sensor (TPS), 6-12 Vehicle Speed Sensor (VSS), 6-12 Initial start-up and break-in after overhaul, 2B-24 Instrument cluster, removal and installation, 12-10 Intake manifold, removal and installation, 2A-7 Introduction to the Buick, Oldsmobile and Pontiac full-size, front-wheel drive models, 0-5
removal, 2B-12
vacuum gauge diagnostic checks, 2B-4 valves, servicing, 2B-10
J Jacking and towing, 0-15
H Headlight adjusiment, 12-8 removal and installation, 12-7 switch, replacement, 12-6 Heater and air conditioner blower motor, removal and installation, 3-5 control assembly, removal and installation, 3-6 Heater core, removal and installation, 3-6
K Knock sensor, replacement, 6-14
L Lens assembly, rear, removal and installation, 11-10
IND
IND-6
Index
Mi Main and connecting rod bearings, inspection, 2B-18 Maintenance schedule, 1-5 techniques, tools and working facilities, 0-7 Master cylinder, removal, overhaul and installation, 9-16 Mount, engine, check and replacement, 2A-19
Multi-function/turn signal lever (1996 and earlier models only), replacement, 12-4 switch assembly, replacement, 12-4
N Neutral start switch check, 1-18 replacement and adjustment, 7-3
Positive Crankcase Ventilation (PCV) system, 6-16 valve check and replacement, 1-20 Power brake booster, inspection, removal and installation, 9-22 Power steering fluid level check, 1-9
pump, removal and installation, 10-12 system, bleeding, 10-13
R Radiator grille, removal and installation, 11-6 removal and installation, 3-3 Radio and speakers, removal and installation, 12-9
Rear brake shoes, inspection and replacement, 9-7 Rear main oil seal carrier (VIN K engine), removal and installation, 2A-19
Relays, general information and testing, 12-3 Repair operations possible with the engine in the vehicle, 2A-3 Rocker arm covers, removal and installation, 2A-4
O Oil filter adapter and pressure regulator valve, removal and installation (1986 and later models only), 2A-15 Oil pan, removal and installation, 2A-17 Oil pressure check, 2B-3 Oil pump pickup tube and screen assembly, removal and installation, 2A-17 removal, inspection and installation, 2A-15 Outside mirror, removal and installation, 11-10 Oxygen sensor, replacement, 6-13
=) Parking brake adjustment, 9-20 cables, removal and installation, 9-21 Piston rings, installation, 2B-19 Pistons and connecting rods installation and rod bearing oil clearance check, 2B-22 removal, 2B-12 inspection, 2B-16 Port Fuel Injection (PFi), component removal and installation, 4-7
Rocker arms and pushrods, removal, inspection and installation, 2A-5
S Safety first!, 0-19 Seat belt check, 1-18
Seatback latch check (two-door models only), 1-18 Seats, removal and installation, 11-10 Spare tire and jack check, 1-18 Spark plug replacement, 1-21 wire check and replacement, 1-23 Springs and insulators, rear, removal and installation, 10-9 Stabilizer bar and bushings, removal and installation front, 10-3 rear, 10-8 Starter motor removal and installation, 5-8 testing in vehicle, 5-7 Starter solenoid, removal and installation, 5-8 Starting system, general information and precautions, 5-7 Steering knuckle and hub, removal and
installation, 10-8
Steering system
alignment, general information, 10-16
IND-7
Index EE
gear boots, replacement, 10-12 gear, removal and installation, 10-11
general information, 10-11 power steering pump, removal and installation, 10-12
system, bleeding, 10-13 steering wheel, removal and installation, 10-13 tie-rod ends, removal and installation, 10-11 wheel studs, replacement, 10-15 _ wheels and tires, general information, 10-15 Steering wheel, removal and installation, 10-13 Strut and spring assembly, front, removal, inspection and installation, 10-5 cartridge, replacement, 10-6 rear, removal and installation, 10-9 _ Suspension adjustment link (rear), removal and installation, 10-10 Suspension and steering check, 1-14 Suspension and steering systems, 10-1 through 10-16 Suspension system balljoint, check and replacement, 10-4 control arm, removal and installation front, 10-5 rear, 10-10 hub and wheel bearing assembly, removal and installation front, 10-7 rear, 10-10 springs and insulators, rear, removal and installation, 10-9 stabilizer bar and bushings, removal and petaliation front, 10-3
rear, 10-8 steering knuckle and hub, removal and installation, 10-8 strut and spring assembly, front, removal, inspection and installation, 10-5 cartridge, replacement, 10-6 rear, removal and installation, 10-9 suspension adjustment link, rear, removal and installation, 10-10
~
Tire rotation, 1-14 Tools, 0-9 Top Dead Center (TDC) for number one piston, locating, 2A-3 Transaxle, automatic, 7-1 through 7-8 diagnosis, general, 7-2 differential seals, replacement, 7-5 fluid and filter change, 1-19 fluid level check, .1-9 general information, 7-1 neutral start switch, replacement and adjustment, 7-3 park/lock cable, removal and installation (floor shift models only), 7-4 removal and installation, 7-5 shift cable, replacement and adjustment, 7-4 Throttle Valve (TV) cable (1985 through 1991 models), » replacement and adjustment, 7-2 Transaxle Converter Clutch (TCC), 6-16 Troubleshooting, 0-20 Trunk latch and striker, removal and installation, 11-10 lid, removal, installation and adjustment, 11-9 lock cylinder, removal and installation, 11-9 Tune-up and routine maintenance, 1-1 through 1-24 Tune-up general information, 1-6 major tune-up, 1-6 minor tune-up, 1-6 Turn signal/hazard flashers, check and replacement, 12-4
U Underhood hose check and replacement, 1-11 Upholstery and carpets, maintenance, 11-1
V Vacuum gauge diagnostic checks, 2B-4 Valve lifters, removal, inspection and installation, 2A-9 Valve springs, retainers and seals, replacement, 2A-6 Valves, servicing, 2B-10 Vehicle identification numbers, 0-6
Vibration damper, removal and installation, 2A-13 Thermostat, check and replacement, 3-2
Throttle Valve (TV) cable (1985 through 1991 models), replacement and adjustment, 7-2 Tie-rod ends, removal and installation, 10-11 Timing chain and sprockets, removal and installation, 2A-16 cover, removal and installation, 2A-14 Tire and tire pressure checks, 1-8
Vinyl trim, maintenance, 11-1
W Water pump check, 3-4 removal and installation, 3-4
IND-8 Wheel cylinder, rear, removal, overhaul and installation, 9-16
Wheel studs, replacement, 10-15 Wheels and tires, general information, 10-15 Window defogger, rear, check and repair, 12-10 system, power, description and check, 12-13
Index Windshield and fixed glass, replacement, 11-5 Windshield wiper
blade inspection and replacement, 1-11 motor/washer pump, removal and installation, 12-11
Wiring diagrams, general information, 12-14 Working facilities, 0-12
~Haynes Automotive Manuals NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information. ACURA 12020 12021
t
;
Integra ’86 thru 89 & Legend *86 thru ’90 Integra ’90 thru ’93 & Legend ’91 thru ’95
AMC 14020 14025
Jeep CJ - see JEEP (50020) Mid-size models ’70 thru ’83 (Renault) Alliance & Encore ’83 thru ’87
AUDI 15020 4000 all models ’80 thru ’87 15025 5000 all models ’77 thru ’83 15026 5000 all models ’84 thru ’88
AUSTIN-HEALEY Sprite - see MG Midget (66015)
18021 18025 18050
3/5 Series not including diesel or all-wheel drive models ’82 thru ’92 3-Series incl. Z3 models ’92 thru ’98 320i all 4 cyl models ’75 thru ’83 1500 thru 2002 except Turbo ’59 thru ’77
BUICK *49010 *49020
18025
19030
Buick Century ’97 thru ’02 Century (front-wheel drive) - see GM (38005) Buick, Oldsmobile & Pontiac Full-size (Front-wheel drive) ’85 thru ’02 Buick Electra, LeSabre and Park Avenue; Oldsmobile Delta 88 Royale, Ninety Eight and Regency; Pontiac Bonneville Buick Oldsmobile & Pontiac Full-size (Rear wheel drive) Buick Estate ’70 thru '90, Electra’70 thru ’84, LeSabre ’70 thru ’85, Limited ’74 thru ’79 Oldsmobile Custom Cruiser ’70 thru ’90, Delta 88 ’70 thru ’85,Ninety-eight ’70 thru ’84 Pontiac Bonneville ’70 thru ’81, Catalina ’70 thru ’81, Grandville ’70 thru ’75, Parisienne ’83 thru ’86 Mid-size Regal & Century all rear-drive models with V6, V8 and Turbo ’74 thru ’87 Regal - see GENERAL MOTORS (38010) Riviera - see GENERAL MOTORS (38030) Roadmaster - see CHEVROLET (24046) . Skyhawk - see GENERAL MOTORS (38015) Skylark - see GM (38020, 38025) Somerset - see GENERAL MOTORS (3802)
CADILLAC 21030
Cadillac Rear Wheel Drive all gasoline models ’70 thru ’93 Cimarron - see GENERAL MOTORS (38015) DeVille - see GM (38031 & 38032) Eldorado - see GM (38030 & 38031) Fleetwood - see GM (38031) Seville - see GM (38030, 38031 & 38032)
CHEVROLET *24010
Astro & GMC Safari Mini-vans ’85 thru ’02,
24015 24016
Camaro V8 all models ’70 thru ’81 Camaro all models ’82 thru ’92
24017
Camaro & Firebird ’93 thru ’00 Cavalier - see GENERAL MOTORS (38016) Celebrity - see GENERAL MOTORS (38005) Chevelle, Malibu & El Camino ’69 thru ’87 Chevette & Pontiac T1000 ’76 thru ’87 Citation - see GENERAL MOTORS (38020)
24020 24024 24032 24040 24041 10305 24045 24046
*24048 24050
Monte Carlo all models ’70 thru ’88 Monte Carlo '95 thru ’01 - see LUMINA (24048)
24059 24060 24064
Nova all V8 models ’69 thru ’79
Nova and Geo Prizm ’85 thru ’92 Pick-ups ’67 thru ’87 - Chevrolet & GMC, all V8 & in-line 6 cyl, 2WD & 4WD ’67 thru ’87; Suburbans, Blazers & Jimmys ’67 thru ’91 Pick-ups ’88 thru ’98 - Chevrolet & GMC, full-size pick-ups ’88 thru ’98, C/K Classic ’99 & 00, Blazer &
24065
Jimmy ’92 thru ’94; Suburban ’92 thru ’99; Tahoe & Yukon ’95 thru ’99 Pick-ups ’99 thru ’01 - Chevrolet Silverado
*24066
& GMC Sierra full-size pick-ups ’99 thru ’01, Suburban/Tahoe/Yukon/Yukon XL ’00 thru ’01
24070
S-10 & S-15 Pick-ups ’82 thru ’93, Blazer & Jimmy ’83 thru 94, $-10 & S-15 Pick-ups ’94 thru ’01, Blazer & Jimmy ’95 thru ’01, Hombre ’96 thru ’01 Sprint ’85 thru ’88 & Geo Metro ’89 thru ’01 Vans - Chevrolet & GMC ’68 thru ’96
*24071
BMW *18020
24055
Corsica/Beretta all models ’87 thru ’96 Corvette all V8 models ’68 thru ’82 Corvette all models ’84 thru 96 Chevrolet Engine Overhaul Manual Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons ’69 thru ’90 Impala SS & Caprice and Buick Roadmaster ’91 thru ’96
Impala Lumina Lumina Lumina
- see LUMINA (24048) ’90 thru ’94 - see GM (38010) & Monte Carlo ’95 thru ’01 APV - see GM (38035)
Luv Pick-up all 2WD & 4WD ’72 thru ’82
Malibu ’97 thru ’00 - see GM (38026)
24075 24080
CHRYSLER 25015
Chrysler Plymouth Chrysler Full-size
10310 25020
Cirrus, Dodge Stratus, Breeze ’95 thru ’00 Engine Overhaul Manual Front-Wheel Drive ’88 thru ’93
K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030) Chrysler LHS, Concorde, New Yorker, Dodge Intrepid, Eagle Vision, ’93 thru ’97 Chrysler LHS, Concorde, 300M, Dodge Intrepid, ’98 thru ’03 Chrysler & Plymouth Mid-size front wheel drive ’82 thru ’95
25025 *25026
25030
Rear-wheel Drive - see Dodge (30050) PT Cruiser all models ’01 thru ’03 Chrysler Sebring, Dodge Avenger ’95 thru ’02
*25035 *25040
DATSUN 28005 28007 28009 28012 28014
200SxX all models ’80 thru ’83 B-210 all models ’73 thru ’78 210 all models ’79 thru ’82
28016 28018 28020 28022 28025
30030 *30034 30035 30040 *30041 30045 30050 30055 30060 *30065
10320 36016 36020 36024 36028 36030 36032 *36034 36036 36040 36044 36048 36049 36050 *36051 36054 36058 *36059 *36060 36062 36066 36070 *36071 36074 *36075 36078 36082 36086 36090 *36094 *36097
Ford Automatic Transmission Overhaul Aerostar Mini-vans all models ’86 thru ’97 Contour & Mercury Mystique ’95 thru ’00 Courier Pick-up all models ’72 thru ’82 Crown Victoria & Mercury Grand Marquis ’88 thru ’00 Ford Engine Overhaul Manual Escort/Mercury Lynx all models ’81 thru ’90 Escort/Mercury Tracer ’91 thru ’00 Explorer & Mazda Navajo ’91 thru ’01 Fairmont & Mercury Zephyr ’78 thru ’83 Festiva & Aspire ’88 thru ’97 Fiesta all models ’77 thru ’80 Focus all models ’00 and ’01 Ford & Mercury Full-size ’75 thru ’87 Granada & Mercury Monarch ’75 thru ’80 Ford & Mercury Mid-size ’75 thru ’86 Mustang V8 all models ’64-1/2 thru ’73 Mustang Il 4 cyl, V6 & V8 models ’74 thru ’78 Mustang & Mercury Capri all models Mustang, ’79 thru ’93; Capri, ’79 thru ’86 Mustang all models ’94 thru ’03 Pick-ups & Bronco ’73 thru ’79 Pick-ups & Bronco ’80 thru ’96
F-150 & Expedition ’97 thru ’02, F-250 ’97 thru 99 & Lincoln Navigator ’98 thru ’02 Super Duty Pick-ups, Excursion 97 thru ’02 Pinto & Mercury Bobcat ’75 thru ’80 Probe all models ’89 thru ’92 Ranger/Bronco Il gasoline models ’83 thru ’92
Ranger 93 thru ’00 & Mazda Pick-ups ’94 thru ’00 Taurus & Mercury Sable ’86 thru ’95 Taurus & Mercury Sable ’96 thru ’01 Tempo & Mercury Topaz ’84 thru ’94 Thunderbird/Mercury Cougar ’83 thru 88 Thunderbird/Mercury Cougar ’89 and ’97 Vans all V8 Econoline models ’69 thru ’91 Vans full size ’92 thru ’01 Windstar Mini-van ’95 thru ’03
GENERAL MOTORS
280ZX Coupe & 2+2 ’79 thru ’83 300ZX - see NISSAN (72010) 310 all models ’78 thru ’82 510 & PL521 Pick-up ’68 thru ’73 510 all models ’78 thru ’81 620 Series Pick-up all models ’73 thru ’79 720 Series Pick-up - see NISSAN (72030) 810/Maxima ai! gasoline models, ’77 thru ’84
10360 38005 *38010
400 & 600 - see CHRYSLER (25030)
*38016
Aries & Plymouth Reliant ’81 thru ’89 Caravan & Plymouth Voyager ’84 thru ’95
Caravan & Plymouth Voyager ’96 thru ’02 Challenger/Plymouth Saporro ’78 thru ’83
38015
38020 38025
Colt & Plymouth Champ ’78 thru ’87 Dakota Pick-ups all models ’87 thru ’96
Durango ’98 & ’99, Dakota ’97 thru ’99 Dart, Demon, Plymouth Barracuda, Duster & Valiant 6 cyl models ’67 thru ’76 Daytona & Chrysler Laser ’84 thru ’89
Intrepid - see CHRYSLER (25025, 25026) Neon all models ’95 thru ’99 Omni & Plymouth Horizon ’78 thru ’90 Pick-ups all full-size models ’74 thru 93 Pick-ups all full-size models ’94 thru ’01 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups ’79 thru ’93 Dodge/Plymouth/Chrysier RWD ’71 thru ’89 Shadow & Plymouth Sundance ’87 thru ’94 Spirit & Plymouth Acclaim ’89 thru ’95 Vans - Dodge & Plymouth ’71 thru ’03
EAGLE Talon - see MITSUBISHI (68030, 68031) Vision - see CHRYSLER (25025)
FIAT 34010 34025
10355 36004 36006 36008 *36012
240Z, 260Z & 280Z Coupe ’70 thru ’78
DODGE 30008 30010 *30011 30012 30016 30020 *30021 30025
FORD
*38026
38030 *38031 38032 38035 *38036
GM Automatic Transmission Overhaul Buick Century, Chevrolet Celebrity, Oldsmobile Cutlass Ciera & Pontiac 6000 all models ’82 thru ’96 Buick Regal, Chevrolet Lumina, Oldsmobile Cutlass Supreme & Pontiac Grand Prix (FWD) ’88 thru ’02 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza & Pontiac J-2000 & Sunbird ’82 thru ’94 Chevrolet Cavalier & Pontiac Sunfire ’95 thru ’01 Buick Skylark, Chevrolet Citation, Olds Omega, Pontiac Phoenix ’80 thru ’85 Buick Skylark & Somerset, Oldsmobile Achieva & Calais and Pontiac Grand Am all models ’85 thru ’98 Chevrolet Malibu, Olds Alero & Cutlass, Pontiac Grand Am ’97 thru ’00 Cadillac Eldorado ’71 thru ’85, Seville ’80 thru ’85, Oldsmobile Toronado '71 thru ’85, Buick Riviera ’79 thru ’85 Cadillac Eldorado & Seville ’86 thru ’91, DeVille ’86 thru ’93, Fleetwood & Olds Toronado ’86 thru 92, Buick Riviera ’86 thru ’93 Cadillac DeVille ’94 thru ’02 & Seville - ’92 thru ’02 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models ’90 thru ’96 Chevrolet Venture, Olds Silhouette, Pontiac Trans Sport & Montana ’97 thru ’01 General Motors Full-size Rear-wheel Drive - see BUICK (19025)
GEO Metro - see CHEVROLET Sprint (24075) Prizm - ’85 thru ’92 see CHEVY (24060), ’93 thru 02 see TOYOTA Corolla (92036)
124 Sport Coupe & Spider ’68 thru ’78 X1/9 all models ’74 thru ’80
(Continued on other side)
years - consult your an asterisk (*) indicate model coverage a s of this printing. These titles will be periodically updated to include later model * Listings shown with Haynes dealer for more information.
Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514
(805) 498-6703
‘
Haynes Automotive
Manuals (continued)
NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information. 40030
Storm all models '90 thru '93 Tracker - see SUZUKI Samurai (90010)
MITSUBISHI 68020
Cordia, Tredia, Galant, Precis &
Mirage ’83 thru ’93
GMC Vans & Pick-ups - see CHEVROLET
68030 *68031 68040
Eclipse, Eagle Talon & Ply. Laser '90 thru 94 Eclipse 95 thru 01, Eagle Talon ‘95 thru 98 Pick-up ’83 thru '96 & Montero ’83 thru ’93
HONDA 42010 42011 42012 42013 *42014 42020 42021 42022 42023 42024 *42025
42040
Accord CVCC all models ’76 thru ’83 Accord ali models ’84 thru ’89 Accord all models ’90 thru ’93 Accord all models ’94 thru ’97 Accord all models ’98 and '99 Civic 1200 all models ’73 thru ’79 Civic 1300 & 1500 CVCC ’80 thru 83 Civic 1500 CVCC all models ’75 thru ’79 Civic all models '84 thru '91 Civic & del Sol 92 thru 95 Civic ’96 thru 00, CR-V ’97 thru ’00,
Acura Integra ’94 thru ’00 Prelude CVCC all models ’79 thru ’89
HYUNDAI *43010 43015
NISSAN 72010 72015 72020 *72021 72030 *72031 72040
Quest - see MERCURY Villager (64200) 72050 72051 72060
47020
Sentra all models ’82 thru ’94 Sentra & 200SX all models '95 thru ’99 Stanza all models ’82 thru ’90
OLDSMOBILE
Elantra all models ’96 thru ’01 Excel & Accent all models ’86 thru ’98
73015
Hombre - see CHEVROLET S-10 (24071) Rodeo ’91 thru ’02; Amigo ’89 thru ’94 and ’98 thru ’02; Honda Passport ’95 thru ’02 Trooper & Pick-up ’81 thru ’93
JAGUAR 49010 XJ6 all 6 cyl models ’68 thru ’86 49011 XJ6 ail models ’88 thru ’94 49015 XJ12 & XJS all 12 cyl models ’72 thru ’85
Cutlass V6 & V8 gas models ’74 thru ’88 For other OLDSMOBILE titles, see BUICK, CHEVROLET or GENERAL MOTORS listing.
ISUZU *47017
300ZX all models including Turbo '84 thru ’89 Altima all models ’93 thru ’01 Maxima all models ’85 thru ’92 Maxima all models ’93 thru ’01 Pick-ups ’80 thru '97 Pathfinder '87 thru '95 Frontier Pick-up '98 thru '01, Xterra ’00 & 01, Pathfinder ’96 thru ’01 Pulsar all models ’83 thru ’86
PLYMOUTH For PLYMOUTH titles, see DODGE listing.
PONTIAC 79008 79018 79019 79040
50020 *50025 50029 *50030
LEXUS
Cherokee, Comanche & Wagoneer Limited all models ’84 thru ’00 CJ all models ’49 thru ’86 Grand Cherokee all models '93 thru ’00 Grand Wagoneer & Pick-up '72 thru ’91 Grand Wagoneer ’84 thru '91, Cherokee & Wagoneer ’72 thru ’83, Pick-up ’72 thru ’88 Wrangler all models '87 thru ’00
ES 300 - see TOYOTA Camry (92007)
*61016 61020 61030 61035 61036 61040 61041 61042
Navigator - see FORD Pick-up (36059) Rear-Wheel Drive all models '70 thru '01
GLC Hatchback (rear-wheel drive) '77 thru 83 GLC (front-wheel drive) '81 thru '85 323 & Protogé '90 thru ’00
MX-5 Miata ’90 thru '97 MPV all models '89 thru '94 Navajo - see Ford Explorer (36024) Pick-ups '72 thru '93 Pick-ups '94 thru '00 - see Ford Ranger (36071) RX-7 all models '79 thru '85
RX-7 all models '86 thru '91 626 (rear-wheel drive) all models ’79 thru ’82 626/MX-6 (front-wheel drive) ’83 thru ’91 62693 thru '01, MX-6/Ford Probe '93 thru ’97
123 Series Diesel '76 thru ’85 190 Series four-cyl gas models, '84 thru ’88 230/250/280 6 cyl sohc models 68 thru '72
63025
280 123 Series gasoline models '77 thru '81
63030
350 & 450 all models '71 thru ’80
MERCURY 64200
Villager & Nissan Quest '93 thru '01 All other titles, see FORD Listing.
MG 66010 66015
911 914 924 944
except Turbo & Carrera 4 65 thru ’89 all 4 cyl models ’69 thru '76 all models including Turbo ’76 thru ’82 all models including Turbo ’83 thru ’89
RENAULT SAAB 900 all models including Turbo ’79 thru ’88
SATURN *87010
Saturn all models '91 thru ’02
SUBARU
MERCEDES-BENZ 63012 63015 63020
80020 80025 80030 80035
*84010
MAZDA 61010 61011 61015
PORSCHE
Alliance & Encore - see AMC (14020)
LINCOLN *59010
models '84 thru ’88 V8 models except Turbo ’70 thru ’81 all models '82 thru '92 Rear-wheel Drive ’70 thru ’87
For other PONTIAC titles, see BUICK, CHEVROLET or GENERAL MOTORS listing.
JEEP 50010
Fiero all Firebird Firebird Mid-size
MGB Roadster & GT Coupe ’62 thru '80 MG Midget, Austin Healey Sprite '58 thru '80
89002 89003
1100, 1300, 1400 & 1600 ’71 thru ’79 1600 & 1800 2WD & 4WD '80 thru ’94
SUZUKI 90010
Samurai/Sidekick & Geo Tracker ’86 thru ’01
TOYOTA 92005 92006 *92007 92015 92020 92025 92030 92032 92035 92036 92040 92045 92050 92055 92056 92065 92070 92075 "92076 *92078
Camry all models ’83 thru ’91 Camry all models ’92 thru 96 Camry, Avalon, Solara, Lexus ES 300 ’97 thru ’01 Celica Rear Wheel Drive ’71 thru ’85 Celica Front Wheel Drive ’86 thru 99 Celica Supra all models ’79 thru ’92 Corolla all models ’75 thru ’79 Corolla all rear wheel drive models ’80 thru ’87 Corolla all front wheel drive models ’84 thru ’92 Corolla & Geo Prizm ’93 thru ’02 Corolla Tercel all models ’80 thru ’82 Corona all models ’74 thru ’82 Cressida all models '78 thru ’82 Land Cruiser FJ40, 43, 45, 55 ’68 thru ’82 Land Cruiser FJ60, 62, 80, FZJ80 ’80 thru 96 MR2 all models ’85 thru ’87 Pick-up all models ’69 thru ’78 Pick-up all models ’79 thru ’95 Tacoma '95 thru '00, 4Runner ’96 thru ’00, & T100 93 thru 98 Tundra ’00 thru ’02 & Sequoia '01 thru ’02
* Listings shown with an asterisk (*) indicate model coverage as of this printing. These titles will be periodically updated to include later model years - consult your Haynes dealer for more information.
92080 *92082 92085
Previa all models '91 thru '95 RAV4 all models '96 thru '02 Tercel all models ’87 thru ’94
TRIUMPH 94007 94010
Spitfire all models ’62 thru ’81 TR7 all models '75 thru ’81
VW 96008 *96009 96016
Beetle & Karmann Ghia '54 thru '79 New Beetle ’98 thru '00 Rabbit, Jetta, Scirocco & Pick-up gas models 74 thru '91 & Convertible ’80 thru ’92
96017
Golf, GTI & Jetta '93 thru '98 & Cabrio '95 thru '98 Golf, GTI, Jetta & Cabrio ’99 thru 02 Rabbit, Jetta & Pick-up diesel 77 thru ’84 Passat ’98 thru ’01, Audi A4 '96 thru 01 Transporter 1600 ali models '68 thru ’79 Transporter 1700, 1800 & 2000 ’72 thru ’79
*96018 96020 96023 96030 96035 96040 96045
Type 3 1500 & 1600 all models ’63 thru ’73 Vanagon all air-cooled models ’80 thru ’83
VOLVO 97010
120, 130 Series & 1800 Sports '61 thru ’73
97015 97020 97040 97050
140 240 740 850
Series Series & 760 Series
TECHBOOK 10205 10210 10215
all models all models Series all all models
’66 thru ’74 ’76 thru 93 models '82 thru ’88 ’93 thru 97
MANUALS
Automotive Computer Codes Automotive Emissions Control Manual Fuel Injection Manual, 1978 thru 1985
10220
Fuel Injection Manual, 1986 thru 1999
10225 10230 10240 10305 10310 10320 10330 10340
Holley Carburetor Manual Rochester Carburetor Manual Weber/Zenith/Stromberg/SU Carburetors Chevrolet Engine Overhaul Manual Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repair Manual Small Engine Repair Manual, 5 HP & Less
10341
Small Engine Repair Manual, 5.5 - 20 HP
10345 10355 10360 10405 10410 10411 10415 10420 10425 10430 10435 10440 10445 10450
Suspension, Steering & Driveline Manual Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Body Repair & Painting Automotive Brake Manual Automotive Anti-lock Brake (ABS) Systems Automotive Detaiing Manual Automotive Eelectrical Manual Automotive Heating & Air Conditioning Automotive Reference Manual & Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual ATV Basics
SPANISH MANUALS 98903 98905
Reparacion de Carroceria & Pintura Cédigos Automotrices de la Computadora
98910
Frenos Automotriz
98915 99040
Inyeccién de Combustible 1986 al 1999 Chevrolet & GMC Camionetas ’67 al '87 Incluye Suburban, Blazer & Jimmy ’67 al ’91 Chevrolet & GMC Camionetas ¢88 al ’98 Incluye Suburban ’92 al ’98, Blazer & Jimmy ’92 al ’94, Tahoe y Yukon ’95 al 98
99041 99042
99055 99075 99077 99083 99088 99091 99095 99100 99110 99118 99125
Chevrolet & GMC Camionetas Cerradas ’68 al 95 Dodge Caravan & Plymouth Voyager '84 al 95 Ford Camionetas y Bronco ’80 al 94 Ford Camionetas Cerradas ’69 al '91 Ford Modelos de Tamano Grande ’75 al ’87 Ford Modelos de Tamafio Mediano ’75 al '86
Ford Taurus & Mercury Sable ’86 al '95 GM Modelos de Tamafio Grande '70 al '90 GM Modelos de Tamafio Mediano '70 al '88 Nissan Camioneta '80 al '96, Pathfinder '87 al '95 Nissan Sentra '82 al 94 Toyota Camionetas y 4Runner '79 al '95
Over 100 Haynes motorcycle manuals
also available
Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514 « (805) 498-6703
8-03
Common
spark plug conditions NORMAL Symptoms: Brown to grayish-tan color and slight electrode wear. Correct heat range for engine and operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range.
TOO HOT
WORN Symptoms: Rounded electrodes with a small amount of deposits on
tne firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Recommendation: Plugs have been left in the engine too long. Replace with new plugs of the same heat range. Follow the recommended maintenance schedule.
CARBON Symptoms:
sooty
deposits
indicate a rich mixture or weak ignition. Causes misfiring, hard starting and hesitation. Recommendation: Make sure the plug has the correct heat range. Check for a clogged air filter or problem in the fuel system or engine
management
advanced
ignition timing, lean fuel
mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling.
PREIGNITION
DEPOSITS Dry
Symptoms: Blistered, white insulator, eroded electrode and absence of deposits. Results in shortened plug life. Recommendation: Check for the correct plug heat range, over-
system.
Also
Symptoms: Insulators are
Melted electrodes. white, but may be
dirty due to misfiring or flying debris in the combustion chamber. Can lead to engine damage. Recommendation: Check for the correct plug heat range, overadvanced ignition timing, lean fuel
mixture, insufficient engine cooling and lack of lubrication.
check for ignition system problems.
ASH DEPOSITS
HIGH SPEED GLAZING
Symptonis: Light brown deposits encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfiring and hesitation during acceleration. Recommendation: |f excessive
Symptoms: Insulator has yellowish, glazed appearance. Indicates that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating.
deposits
time
accumulate
or low
mileage,
over
a short
install
new
valve guide seals to prevent seepage of oil into the combustion
chambers. Also try changing gasoline brands.
OIL DEPOSITS Symptoms: Oily coating caused by poor oil control. Oil is leaking past worn valve guides or piston rings into the combustion chamber. Causes hard starting, misfiring and hesitation. Recommendation: Correct the mechanical condition with necessary repairs and install new plugs.
Causes misfiring at high speeds. Recommendation: _ |nstall new plugs. Consider using a colder plug if driving habits warrant.
DETONATION Symptoms: Insulators may be cracked or chipped. Improper gap setting techniques can also result in a fractured insulator tip. Can lead to piston damage. Recommendation: Make sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine.
MECHANICAL GAP BRIDGING Symptoms: Combustion deposits lodge between the electrodes. Heavy deposits accumulate and bridge the electrode gap. The plug ceases to fire, resulting in a dead cylinder, Recommendation: Locate the faulty plug and remove the deposits from between the electrodes.
DAMAGE
Symptoms: May be caused by a foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could result in piston damage. Recommendation: Repair the mechanical damage. Remove the foreign object from the engine and/or plug.
install
the
correct
reach
X
Routine maintenance
.™ Tune-up procedures Engine repair
F
OfoTe) Tare M-(aremal=r-ilale| PNimexeyareliiceyaliare Fuel and exhaust Emissions control *
Ignition ‘Brakes
Suspension and steering Electrical systems A iTalate mettle le Unt
Chapter 2 PartB
Engine
Tal