Haynes Ford Full-Size Vans 1992 thru 2012 Automotive Repair Manual 1620920778, 9781620920770

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Full-Size Vans 1992 thru 2012 -E-150 thru E-350 11 Gasoline engine models

Haynes Repair Manual Based on a complete teardown and rebuild

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Includes essential information for today’s more complex vehicles

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Ford Vans Automotive

Repair

Manual by Ralph Rendina, Robert Maddox

and John H Haynes Member of the Guild of Motoring Writers

Models covered:

E-150, E-250 and E-350 Econoline Vans with 4.2L V6,

4.9L inline six-cylinder, 5.0L, 5.8L and 7.5L OHV V8, 4.6L, 5.4L OHC V8 and 6.8L OHC V10 gasoline engines

1992 through 2012 Does not include diesel engine information, Compressed Natural Gas (CNG) information, or commercial-chassis vehicles

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AUTOMOTIVE PARTSve &

AG ESP ORIS MEMBER Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park :

California 91320 USA? Oe t

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Acknowledgements The technical writer who contributed to this project is Ed Scott.

© Haynes North America, Inc. 1995, 2001, 2006, 2011, 2013 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-13: 978-1-62092-077-0 ISBN-10: 1-62092-077-8 Library of Congress Control Number: 2013945383 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. “Ford” and the Ford logo are registered trademarks of Ford Motor Company. Ford Motor Company is not a sponsor or affiliate of Haynes Publishing Group or Haynes North America, Inc. and is not a contributor to the content of this manual. 13-336

0-3

Contents Introductory pages About this manual Introduction Vehicle identification numbers Booster battery (jump) starting Buying parts Maintenance techniques, tools and working facilities

Jacking and towing Automotive chemicals and lubricants Conversion factors Fraction/decimal/millimeter equivalents Safety first! Troubleshooting

0-5 0-5 0-6 0-7 0-8 0-8

0-14 0-15 0-16 0-17 0-18 0-19

Chapter 1 Tune-up and routine maintenance

Chapter 2

1-1

PartA

4.9L inline six-cylinder engine

Chapter 2

2A-1

Part B

4.2L V6 engine

Chapter 2

2B-1

PartC

5.0L, 5.8L and 7.5L OHV engines

Chapter 2

2C-1

Part D

4.6L, 5.4L and 6.8L V8 and V10 OHC engines

Chapter 2

2D-1

PartE

General engine overhaul procedures

2E-1

Chapter 3 Cooling, heating and air conditioning systems

3-1

Chapter 4 Fuel and exhaust systems

4-1

Chapter 5 Engine electrical systems

5-1

Chapter 6 Emissions and engine control systems

6-1

Chapter 7 Automatic transmission

7-1

Chapter 8 Driveline

8-1

Chapter 9 Brakes

9-1

Chapter 10 Suspension and steering systems

‘

10-1

Chapter 11 Body

11-1

Chapter 12 Chassis electrical system

12-1

Wiring diagrams

12-14

Index

IND-1

0-4

Haynes mechan

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author and photographer with E-250 Van

0-5

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead

costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

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

that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the 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 The models covered by this manual are conventional front-engine, rear-wheel drive vehicles. They are available in various Gross Vehicle Weight Rating classifications; ranging from the 1/2-ton E-150 model to the 3/4-ton

E-250 and 1-ton E-350 models. Engine options include the 4.2L (256 cu. in.) V6 engine, the 4.9L (300 cu. in.) inline sixcylinder engine, the 4.6L (281 cu. in.), the 5.0L (302 cu. in.), the 5.4L (329 cu. in.), the 5.8L (351 cu. in.), the 7.5L (460 cu. in.) V8 engines and the 6.8L (415 cu. in.) V10 engines. The fuel system on all engines is a computer controlled multi-port fuel-injected system.

Power from the engine is transferred through an automatic transmission to the differential mounted in the solid rear axle assembly by a tubular driveshaft incorporating universal joints. Axles inside the assembly carry power from the differential to the rear wheels. Transmission types include a heavy-duty 3-speed model and several different 4-speed models, with fourth gear being an overdrive ratio. Some 4-speed automatics utilize computer controlled electronic shifting capabilities. Some 2004 and later models with 6.8L V10 engines have an optional TorqShift 5-speed automatic overdrive transmission.

Suspension is independent twin l-beam in the front, with coil springs and radius arms used to locate the knuckle assembly at each wheel. The rear suspension features semielliptical leaf springs. All models use hydraulic shock absorbers at each corner. Power steering is standard on all models. The brakes are disc at the front and drum at the rear. Some late models are equipped with rear disc brakes. All models use hydraulic brakes assisted by a vacuum booster. Some models are equipped with an Anti-lock Braking System (ABS).

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

Vehicle Identification

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.

VIN engine and model year codes Two particular important pieces of infor-

Number (VIN) This very important identification number is stamped on a plate attached to the dashboard inside the windshield on the driver’s side of the vehicle (see illustration). The VIN

mation found in the VIN are the engine code and the model year code. Counting from the left, the engine code letter designation is the 8th digit and the model year code designation is the 10th digit.

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

4.2L V6 4.9L inline 6

4.6L (Romeo) V8 4.6L (Windsor) V8

5.0L 5.8L 5.4L 7.5L 6.8L

V8 V8 V8 V8 V10

The Vehicle Identification Number (VIN) is visible through the driver’s side windshield

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The engine identification label is affixed to the valve cover

The differential identification tag is bolted to the differential cover

Vehicle identification numbers On the models covered by this manual the model year codes are: CORR cect 2012 Bincatinnnte cunts 2011 LaNnaxee rari 2010 QO acsstacstner tees 2009 B tata 2008 (Ote as. mash Stee 2007 Gi. Sees 2006 Dees ax eects 2005 teak) eee 2004 Re eee 2003 = 208 SP eS. 2002 A ietiwaessutecieenceke 2001 VicssneneeeAteess 2000 D Ge eee Te 1999 Wiscebetes.cscceeeree 1998 Mec idectantes cesteens 1997 ES ea eee 1996 SD creer eS: 1995 FR sentences seokknt 1994 PD reeweregeesapecrreee 1993 Nieveaite eeu: 1992

The VECI label is located near the radiator support

Engine identification numbers

Differential identification

Labels containing the engine code, engine number and build date can be found on the valve cover (see illustration). The engine number is also stamped onto a machined pad on the engine block.

numbers

Vehicle Certification Label The Vehicle Certification Label is attached to the driver’s side door pillar (see illustration). Information on this label includes the name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and other vehicle specific information.

The differential ID number is stamped on a tag which is bolted to the differential cover (see illustration).

Vehicle Emissions Control Transmission erUTCalon

Information (VECI) label

numbers

This label is found in the engine compartment (see illustration). See Chapter 6 for more information on this label.

The automatic transmission ID number is affixed to a label on the right side of the case.

Booster battery (jump) starting Observe the following precautions when using a booster battery to start a vehicle:

Booster battery

Dead battery

a) Before connecting the booster battery, make sure the ignition switch is in the Off position.

b) Turn off the lights, heater and other electrical loads. c) Your eyes should be shielded. Safety goggles are a good idea. d) Make sure the booster battery is the same voltage as the dead one in the vehicle.

e) The two vehicles MUST NOT TOUCH each other. f) Make sure the transmission is in Neutral (manual transaxle) or Park (automatic transaxle). g) If the booster battery is not a maintenance-free type, remove the vent caps and lay a cloth over the vent holes. Connect the red jumper cable to the positive (+) terminals of each bat-

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tery.

Connect one end of the black cable to the negative (-) terminal of the booster battery. The other end of this cable should be connected to a good ground on the engine block (see illustration). Make sure the cable will not come into contact with the fan, drivebelts or other moving parts of the engine. Start the engine using the booster battery, then, with the engine running at idle speed, disconnect the jumper cables in the reverse order of connection.

—

00-3 HAYNES

Make the booster battery cable connections in the numerical order shown (note that the negative cable of the booster battery is NOT attached to the negative terminal of the dead battery)

0-8

Buying parts 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

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

unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: |f the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques

ous tasks properly, which will ensure that the repair job is thorough and complete.

There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Appli-

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

cation of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the vari-

of them use a locking device of some type, either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasteners 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.

Grade 1 or 2

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

Grade 5

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 this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic.

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

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Metric stud strength markings 00-1 HAYNES

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 standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged.

Maintenance techniques, tools and working facilities eee ee eres Metric thread sizes

0-9 an

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

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 met-

5 to 8 12to 18 22 to 33

7 to 10 17 to 24 30 to 44

25 to 35

34 to 47

ric code to denote It should be especially Grades tinguishing marks

6 to 9

9 to 12

12to 18 14 to 20 22 to 32

17 to 24 19 to 27 30 to 43

27 to 38 40 to 55

37 to 51 55 to 74

40 to 60

55 to 81

55 to 80

75 to 108

Ft-lbs 6 to 9 14 to 21 28 to 40 50 to 71 80 to 140

ric bolts), while smaller studs carry a geomet-

grade. noted that many fasteners, 0 through 2, have no dison them. When such is the case, the only way to determine whether it is standard or metric is to measure the thread pitch or compare it to a known fastener of the same size. Standard fasteners are often referred to as SAE, as opposed to metric. However, it should be noted that SAE technically refers to a non-metric fine thread fastener only. Coarse thread non-metric fasteners are referred to as USS sizes. Since fasteners of the same size (both standard and metric) may have different strength ratings, be sure to reinstall any bolts, studs or nuts removed from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a strength rating equal to or greater than the original.

Tightening sequences and procedures

00-2 HAYNES

Standard (SAE and USS) bolt dimensions/ grade marks Grade marks (bolt strength) Length (in inches) 4~-QThread pitch (number of threads per inch) D Nominal diameter (in inches) All bolts, whether standard or metric, are

sized according to diameter, thread pitch and length. For example, a standard 1/2 - 13 x 1 bolt is 1/2 inch in diameter, has 13 threads per inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm in diameter, has a thread pitch of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining

the bolt heads. To begin with, the distance across the flats on a standard bolt head is measured in inches, while the same dimension on a metric bolt is sized in millimeters (the same is true for nuts). As a result, a stan-

Metric bolt dimensions/grade marks P_ L T D

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

dard 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

Most threaded fasteners should be tightened to a specific torque value (torque is the twisting force applied to a threaded component such as a nut or bolt). Overtightening the fastener can weaken it and cause it to break, while undertightening can cause it to eventually come loose. Bolts, screws and studs, depending on the material they are made of and their thread diameters, have specific torque values, many of which are noted in the Specifications at the beginning of each Chapter. Be sure to follow the torque recommendations closely. For fasteners not assigned a specific torque, a general torque value chart is presented here as a guide. These torque values are for dry (unlubricated) fasteners

threaded into steel or cast iron (not aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be applied to it. The figures listed here are approximate for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners

laid out in a pattern, such as

cylinder head bolts, oi! pan bolts, differential cover bolts, etc., must be loosened or tightened in sequence to avoid warping the component. This sequence will normally be shown in the appropriate Chapter. If a specific pattern is not given, the following procedures can be used to prevent warping. Initially, the bolts or nuts should be assembled finger-tight only. Next, they should be tightened one full turn each, in a crisscross or diagonal pattern. After each one has been tightened one full turn, return to the first

Maintenance techniques, tools and working facilities

0-10

Dial indicator set

Micrometer set

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

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

bolts, etc.). A pan of this type is especially helpful when working on assemblies with very small parts, such as the carburetor, alternator, valve train or interior dash and trim pieces. The cavities can be marked with paint or tape to identify the contents. Whenever wiring looms, harnesses or connectors are separated, it is a good idea to identify the two halves with numbered pieces of masking tape so they can be easily reconnected.

Gasket sealing surfaces Throughout

any vehicle, gaskets are

used to seal the mating surfaces between two

parts and keep lubricants, fluids, vacuum or pressure contained in an assembly. Many times these gaskets are coated with a liquid or paste-type

gasket sealing

compound before assembly. Age, heat and pressure can sometimes cause the two parts to stick together so tightly that they are very difficult to separate. Often, the assembly can be loosened by striking it with a soft-face hammer near the mating surfaces. A regular hammer can be used if a block of wood is placed between the hammer and the part. Do not hammer on cast parts or parts that could be easily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed. Avoid using a screwdriver or bar to pry apart an assembly, as they can easily mar the gasket sealing surfaces of the parts, which must remain smooth. If prying is absolutely necessary, use an old broom handle, but keep in mind that extra clean up will be necessary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated with a special chemical to soften it so it can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is recommended because it is usually softer than the surfaces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire brush, but regardless of the method used, the mating surfaces must be left clean and smooth. If for some reason the gasket surface is gouged, then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components. For most applications, a non-drying (or semi-drying) gasket sealer should be used.

Hose removal tips Warning: /f the vehicle is equipped with air conditioning, do not disconnect any of the A/C hoses without first having the system depressurized by a dealer service department or a service station. Hose removal precautions closely parallel gasket removal precautions. Avoid scratching or gouging the surface that the hose mates against or the connection may

leak. This is especially true for radiator hoses. Because of various chemical reactions, the rubber in hoses can bond itself to the metal spigot that the hose fits over. To remove a hose, first loosen the hose clamps that secure it to the spigot. Then, with slip-joint pliers, grab the hose at the clamp and rotate it around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone or other lubricants will ease removal if they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inside of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced with a new one anyway), the rubber can be slit with a knife and the hose peeled from the spigot. If this must be done, be careful that the metal connection is not damaged. If a hose clamp is broken or damaged, do not reuse it. Wire-type clamps usually weaken with age, so it is a good idea to replace them with screw-type clamps whenever a hose is removed.

Tools A selection of good tools is a basic requirement for anyone who plans to maintain and repair his or her own vehicle. For the owner who has few tools, the initial investment might seem high, but when compared to the spiraling costs of professional auto maintenance and repair, it is a wise one. To help the owner decide which tools are needed to perform the tasks detailed in this manual, the following tool lists are offered: Maintenance and minor repair, Repair/overhaul and Special. The newcomer to practical mechanics should start off with the maintenance and minor repair tool kit, which is adequate for the simpler jobs performed on a vehicle. Then, as confidence and experience grow, the owner can tackle more difficult tasks, buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and overhaul tool set. Over a period of time, the experienced do-it-yourselfer will assemble a tool set complete enough for most repair and

Maintenance techniques, tools and working facilities

Compression gauge with spark plug hole adapter

Damper/steering wheel puller

Hydraulic lifter removal tool

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

|

0-11

General purpose puller

Ring removal/installation tool

Maintenance techniques, tools and working facilities

Cylinder hone

Brake hold-down spring tool

Torque angle gauge

Clutch plate alignment tool

Tap and die set

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

Note: /f basic tune-ups are going to be part of routine maintenance, it will be necessary to purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely necessary for tuning most vehicles properly.

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

Combination wrench set (1/4-inch to 1 inch or 6 mm to 19 mm) Adjustable wrench, 8 inch Spark plug wrench with rubber insert Spark plug gap adjusting tool Feeler gauge set Brake bleeder wrench Standard screwdriver (5/16-inch x 6 inch) Phillips screwdriver (No. 2 x 6 inch) Combination pliers - 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush Battery post and cable cleaning tool Oil filter wrench

Funnel (medium size) Safety goggles Jackstands (2) Drain pan

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

Socket set(s) Reversible ratchet Extension - 10 inch Universal joint Torque wrench (same size drive as sockets) Ball peen hammer - 8 ounce Soft-face hammer (plastic/rubber) Standard screwdriver (1/4-inch x 6 inch) Standard screwdriver (stubby 5/16-inch) Phillips screwdriver (No. 3 x 8 inch)

Phillips screwdriver (stubby - No. 2) Pliers - vise grip Pliers - lineman’s Pliers - needle nose Pliers - snap-ring (internal and external) Cold chisel - 1/2-inch

Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch) Steel rule/straightedge - 12 inch Allen wrench set (1/8 to 3/8-inch or 4mm to 10 mm) A selection of files Wire brush (large) Jackstands (second set) Jack (scissor or hydraulic type) Note: Another too! which is often useful is an electric drill with a chuck capacity of 3/8-inch and a set of good quality drill bits.

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

0-13

Maintenance techniques, tools and working facilities a...

to dealer service departments. Occasionally, references to the manufacturer’s special tools are included in the text of this manual. Generally, an alternative method of doing the job without the special tool is offered. However, sometimes there is no alternative to their use. Where this is the case, and the tool cannot be purchased or borrowed, the work should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor Piston ring groove cleaning tool Piston ring compressor Piston ring installation tool Cylinder compression gauge Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge Micrometers and/or dial calipers Hydraulic lifter removal tool Balljoint separator Universal-type puller Impact screwdriver Dial indicator set Stroboscopic timing light (inductive pick-up) Hand operated vacuum/pressure pump Tachometer/dwell meter Universal electrical multimeter Cable hoist Brake spring removal and installation tools Floor jack

Buying tools For the do-it-yourselfer who is just starting to get involved in vehicle maintenance and repair, there are a number of options available when purchasing tools. If maintenance and minor repair is the extent of the work to be done, the purchase of individual tools is satisfactory. If, on the other hand, extensive work is planned, it would be a good idea to purchase a modest tool set from one of the large retail chain stores. A set can usually be bought at a substantial savings over the individual tool prices, and they often come with a tool box. As additional tools are needed, add-on sets, individual tools and a larger tool box can be purchased to expand the tool selection. Building a tool set gradually allows the cost of the tools to be spread over a longer period of time and gives the mechanic the freedom to choose only those tools that will actually be used. Tool stores will often be the only source of some of the special tools that are needed, but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers and sockets, because they won't last very long. The expense involved in replac-

ing cheap.tools will eventually be greater than the initial cost of quality tools.

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

from other tools. When tools are used with care and stored properly, they will last a very long time. Even with the best of care, though, tools will wear out if used frequently. When a tool is damaged or worn out, replace it. Subsequent jobs will be safer and more enjoyable if you do.

How to repair damaged threads Sometimes, the internal threads of a nut or bolt hole can become stripped, usually from

overtightening. Stripping threads is an all-toocommon occurrence, especially when working with aluminum parts, because aluminum is so soft that it easily strips out. Usually, external or internal threads are only partially stripped. After they've been cleaned up with a tap or die, they’ll still work. Sometimes, however, threads are badly damaged. When this happens, you’ve got three choices: 1) Drill and tap the hole to the next suitable oversize and install a larger diameter bolt, screw or stud. 2) Drill and tap the hole to accept a threaded plug, then drill and tap the plug to the original screw size. You can also buy a plug already threaded to the original size. Then you simply drill a hole to the specified size, then run the threaded plug into the hole with a bolt and jam nut. Once the plug is fully seated, remove the jam nut and bolt. 3) The third method uses a patented thread repair kit like Heli-Coil or Slimsert. These easy-to-use kits are designed to repair damaged threads in straight-through

holes and blind holes. Both are available as kits which can handle a variety of sizes and thread patterns. Drill the hole, then tap it with the special included tap. Install the Heli-Coil and the hole is back to its original diameter and thread pitch. Regardless of which method you use, be sure to proceed calmly and carefully. A little impatience or carelessness during one of these relatively simple procedures can ruin your whole day’s work and cost you a bundle if you wreck an expensive part.

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

maintenance

is to be carried

out,

some sort of suitable work area is essential. It is understood, and appreciated, that many home mechanics do not have a good workshop or garage available, and end up removing an engine or doing major repairs outside. It is recommended, however, that the overhaul or repair be completed under the cover of a roof. A clean, flat workbench or table of comfortable working height is an absolute necessity. The workbench should be equipped with a vise that has a jaw opening of at least four inches. As mentioned previously, some clean, dry storage space is also required for tools, as well as the lubricants, fluids, cleaning solvents, etc. which soon become necessary. Sometimes waste oil and fluids, drained from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, pour the used fluids into large containers, seal them with caps and take them to an authorized disposal site or recycling center. Plastic jugs, such as old antifreeze containers, are ideal

for this purpose. Always keep a supply of old newspapers and clean rags available. Old towels are excellent for mopping up spills. Many mechanics use rolls of paper towels for most work because they are readily available and disposable. To help keep the area under the vehicle clean, a large cardboard box can be cut open and flattened to protect the garage or shop floor. Whenever working over a painted sur-

face, such as when leaning over a fender to service something under the hood, always cover it with an old blanket or bedspread to

protect the finish. Vinyl covered pads, made especially for this purpose, are available at auto parts stores.

0-14

Jacking and towing Jacking Warning: The jack supplied with the vehicle should only be used for changing a tire or placing jackstands under the frame. Never work under the vehicle or start the engine while this jack is being used as the only means of support. The vehicle should be located on level ground. Place the shift lever in Park. Block the wheel diagonally opposite the wheel being changed. Set the parking brake. Remove the spare tire and jack from stowage. Remove the wheel cover (if equipped) with the tapered end of the lug nut wrench by inserting and twisting the handle and then prying against the back of the wheel cover. Loosen, but do not remove, the lug nuts (one-half turn is sufficient). Place the jack under the axle nearest the wheel being changed. There is a right and left jacking point on each axle (see illustration). _ Turn the jack handle clockwise until the tire clears the ground. Remove the lug nuts and pull the wheel off. Replace it with the

spare.

Install the lug nuts with the beveled edges facing in. Tighten them snugly. Don’t attempt to tighten them completely until the vehicle is lowered or it could slip off the jack. Lower the vehicle. Remove the jack and tighten the lug nuts in a criss-cross pattern (see illustration). Install the wheel cover and be sure it’s snapped into place all the way around. Stow the tire, jack and wrench. Unblock the wheels.

Vehicles

equipped

with an automatic

transmission can be towed from the front only with all four wheels on the ground, provided that speeds don’t exceed 35 mph and the distance is not over 50 miles. Before towing, check the transmission fluid level (see Chapter 1). If the level is below the HOT line on the dipstick, add fluid or use a towing dolly. Release the parking brake, put the transmission in Neutral and place the ignition key in

the OFF position. There’s no distance limitation when towing with either the rear wheels

Towing As a general rule, the vehicle should be towed with the rear wheels off the ground. If they can't be raised, either place them on a dolly or disconnect the driveshaft from the differential. When a vehicle is towed with the rear wheels raised, the steering wheel must be clamped in the straight ahead position with a special device designed for use during towing The ignition key must be in the OFF position, since the steering lock mechanism isn’t strong enough to hold the front wheels straight while towing.

off the ground or the driveshaft disconnected, but don’t exceed 50 mph. Equipment specifically designed for towing should be used. It should be attached to the main structural members of the vehicle, not the bumpers or brackets. Safety is a major consideration when towing and all applicable state and local laws must be obeyed. A safety chain system must be used at all times. Remember that power

steering and power brakes will not work with the engine off.

zi

Front jacking locations - 2WD models

Rear jacking location - all models

0-15

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

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum, varnish and carbon. Most carburetor cleaners leave a dry-type lubricant film which will not harden or gum up. Because of this film it is not recommended for use on electrical components. Brake system cleaner is used to remove brake dust, grease and brake fluid from the brake system, where clean surfaces are absolutely necessary. It leaves no residue and often eliminates brake squeal caused by contaminants. Electrical cleaner removes oxidation, corrosion and carbon deposits from electrical

contacts, restoring full current flow. It can also be used to clean spark plugs, carburetor jets, voltage regulators and other parts where an oil-free surface is desired. Demoisturants remove water and moisture from electrical components such as alter-

nators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive and non-corrosive. Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and, depending on the type, are rinsed off either with water or solvent.

Lubricants Motor oil is the lubricant formulated for use in engines. It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) from 0 to 50. The recommended weight of the oil depends on the season, temperature and the demands on the engine. Light oil is used in cold climates and under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights

from OW-20 to 20W-50. Gear oil is designed to be used in differentials, manual transmissions and other areas where high-temperature lubrication is required. Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered, such as for wheel bearings, balljoints, tie-rod ends and universal joints. High-temperature wheel bearing grease is designed to withstand the extreme

temperatures encountered by wheel bearings in disc brake equipped vehicles. It usually contains molybdenum disulfide (moly), which is a dry-type lubricant. White grease is a heavy grease for metal-to-metal applications where water is a problem. White grease stays soft under both low and high temperatures (usually from -100 to +190-degrees F), and will not wash off or dilute in the presence of water. Assembly lube is a special extreme pressure lubricant, usually containing moly, used to lubricate high-load parts (such as

main and rod bearings and cam lobes) for initial start-up of a new engine. The assembly lube lubricates the parts without being squeezed out or washed away until the engine oiling system begins to function. Silicone lubricants are used to protect rubber, plastic, vinyl and nylon parts. Graphite lubricants are used where oils cannot be used due to contamination problems, such as in locks. The dry graphite will lubricate metal parts while remaining uncontaminated by dirt, water, oil or acids. It is elec-

trically conductive and will not foul electrical contacts in locks such as the ignition switch. Moly penetrants loosen and lubricate frozen, rusted and corroded fasteners and prevent future rusting or freezing. Heat-sink grease is a special electrically non-conductive grease that is used for mounting electronic ignition modules where it

is essential that heat is transferred away from the module.

Sealants RTV sealant is one of the most widely used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills surface irregularities, remains flexible, doesn't shrink, is relatively easy to remove, and is used as a supplementary sealer with almost all low and medium temperature gaskets. Anaerobic sealant is much like RTV in that it can be used either to seal gaskets or to form gaskets by itself. It remains flexible, is solvent resistant and fills surface imperfections. The difference between an anaerobic sealant and an RTV-type sealant is in the curing. RTV cures when exposed to air, while an anaerobic sealant cures only in the absence of air. This means that an anaerobic sealant cures only after the assembly of parts, sealing them together. Thread and pipe sealant is used for sealing hydraulic and pneumatic fittings and vacuum lines. It is usually made from a Teflon compound, and comes in a spray, a paint-on liquid and as a wrap-around tape.

Chemicals Anti-seize compound prevents seizing, galling, cold welding, rust and corrosion

in fasteners. High-temperature ant-seize, usually made with copper and graphite lubricants, is used for exhaust system and exhaust manifold bolts. Anaerobic locking compounds are used to keep fasteners from vibrating or working loose and cure only after installation, in the absence of air. Medium strength locking compound is used for small nuts, bolts and screws that may be removed later. Highstrength locking compound is for large nuts, bolts and studs which aren’t removed on a regular basis. Oil additives range from viscosity index improvers to chemical treatments that claim to reduce internal engine friction. It should be noted that most oil manufacturers caution against using additives with their oils. Gas additives perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that buiid up on carburetor, fuel injection and intake parts. They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers. Some additives contain upper cylinder lubricants for valves and piston rings, and others contain chemicals to remove condensation from the gas tank.

Miscellaneous Brake fluid is specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake systems. Care must be taken so this fluid does not come in contact with painted surfaces or plastics. An opened container should always be resealed to prevent contamination by water or dirt. Weatherstrip adhesive is used to bond weatherstripping around doors, windows and trunk lids. It is sometimes used to attach trim pieces. Undercoating is a petroleum-based, tar-like substance that is designed to protect metal surfaces on the underside of the vehicle from corrosion. It also acts as a sound-deadening agent by insulating the bottom of the vehicle. Waxes and polishes are used to help protect painted and plated surfaces from the weather. Different types of paint may require the use of different types of wax and polish. Some polishes utilize a chemical or abrasive cleaner to help remove the top layer of oxidized (dull) paint on older vehicles. In recent years many non-wax polishes that contain a wide variety of chemicals such as polymers and silicones have been introduced. These non-wax polishes are usually easier to apply and last longer than conventional waxes and polishes.

0-16

Conversion Length (distance)

factors X X X

Inches (in) Feet (ft) Miles

Volume (capacity)

25.4 0.305 1.609

=Inches (in) Feet (ft)

X ne X

0.0394 AER

= Cubic centimeters (cc; cm’)

x

01061

=Cubic inches (cu in; in*)

x x X X

1.76 0.88 0.833 1.057.

= Imperial pints (Imp pt) = Imperial quarts (Imp qt =Imperial quarts (Imp qt) =US quarts (US qt)

=Millimeters (mm) = Meters (m) = Kilometers (km)

.

0.621

=Miles

is

ne

Cubic inches a in; in’)

X 16.387

Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt)

X X X X

0.568 1.137 1.201 0.946

=Liters (I) = Liters (I) =US quarts (US qt) = Liters (I)

Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

X X X

4.546 1.201 3.785

= Liters (I) =US gallons (US gal) = Liters (I)

Xx X X

0.22 0.833 0.264

= Imperial gallons (Imp gal) =Imperial gallons (Imp gal) =US gallons (US gal)

X X

28.35 0.454

=Grams (g) =Kilograms (kg)

X X

0.035 2.205

=Ounces (oz) = Pounds (Ib)

X X X

0.278 4.448 0.1.

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

Xx X x

3.6 0.225 9.81

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

X

0.070

=Kilograms-force per square

X

14.223

= Pounds-force per square inch

X

0.068

=Atmospheres

X

14.696

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

Force Ounces-force (ozf; 02) Pounds-force (Ibf; !b) Newtons (N)

:

Pressure Pounds-force per square inch Pounds-force per square inch

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

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

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

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

(atm)

=Pounds-force

per square inch

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

_

Pounds-force per square inch

X

0.069

= Bars

Xx

14.5

= Pounds-force

per square inch

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

(psi; Ibf/in?; Ib/in?) Pounds-force per square inch

X

6.895

= Kilopascals (kPa)

X

0.145

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

X

0.01

=Kilograms-force per square

Xx

98.1

= Pounds-force per square inch

(psi; Ibf/in?: |b/in?) = Kilopascals (kPa)

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

Torque (moment of force) Pounds-force inches (Ibf in; Ib in) Pounds-force inches

X

0.868

xX 0.113

=Kilograms-force centimeter (kgf cm; kg cm) =Newton meters (Nm)

Xx

8.85

X

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

Xx

12

X

1.152

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

(Ibf in; Ib in)

(Ibf in; Ib in) Pounds-force inches

(Ibf in; Ib in) Pounds-force feet (Ibf ft; Ib ft) Pounds-force feet (Ibf ft; Ib ft) Newton meters (Nm)

X

0.083

0.138

=Kilograms-force meters

= Pounds-force

inches

X

7.233

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

(kgf m; kg m) X X

1.356 0.102

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

X X

0.738 9.804

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

X X

3.377 25.4

= Kilopascals (kPa) = Millimeters mercury (mm Hg)

X X

0.2961 0.0394

= Inches mercury =Inches mercury

X 745.7

=Watts (W)

X

0.0013

X

1.609

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

0.621

= Miles per hour (miles/hr; mph)

X X

0.354 0.425

= Kilometers per liter (km/\) = Kilometers per liter (km/I)

2,825 2,352

=Miles per gallon, Imperial (mpg) =Miles per gallon, US (mpg)

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

Power

Horsepower (hp)

=Horsepower (hp)

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

Fuel consumption* Mee per oy Imperial (mpg) iles per gallon, US (mpg)

X X

Temperature Degrees Fahrenheit

=

(°C x 1.8) + 32

Degrees Celsius (Degrees Centigrade; °C)

*/t is common practice to convert from miles per gallon (mpg) to liters/100 kilometers (I/100km),

where mpg (Imperial) x 1/100 km = 282 and mpg (US) x 1/100 km = 235

= (°F - 32) x 0.56

0-17 DECIMALS to MILLIMETERS Decimal

Decimal

0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286 0.2540 0.5080 0.7620 1.0160 1.2700 1.5240 1.7780 2.0320 2.2860 2.5400 2.7940 3.0480 3.3020 3.5560 3.8100 4.0640 4.3180 4.5720 4.8260 5.0800 5.3340 5.5880 5.8420 6.0960 6.3500 6.6040 6.8580 7.1120 7.3660

7.6200 7.8740 8.1280 8.3820 8.6360 8.8900 9.1440 9.3980 9.6520 9.9060 10.1600 10.4140 10.6680 10.9220 11.1760 11.4300 11.6840 11.9380 12.1920 12.4460

15.2400 15.4940 15.7480 16.0020 16.2560 16.5100 16.7640 17.0180 17.2720 17.5260

17.7800 18.0340 18.2880 18.5420 18.7960 19.0500 19.3040 19.5580 19.8120 20.0660

20.3200 20.5740 21.8280 21.0820 21.3360 21.5900 21.8440 22.0980 22.3520 22.6060

22.8600 23.1140 23.3680 23.6220 23.8760 24.1300 24.3840 24.6380 24.8920 25.1460 25.4000

FRACTIONS to DECIMALS to MILLIMETERS Fraction

Decimal

mm

Fraction

Decimal

mm

1/64 1/32 3/64

0.0156 0.0312 0.0469

0.3969 0.7938 1.1906

33/64 17/32 35/64

0.5156 0.5312 0.5469

13.0969 13.4938 13.8906

1/16

0.0625

1.5875

9/16

0.5625

14.2875

5/64 8/32 7/64

0.0781 0.0938 0.1094

1.9844 2.3812 2.7781

37/64 19/32 39/64

0.5781 0.5938 0.6094

14.6844 15.0812 15.4781

1/8

0.1250

3.1750

5/8

0.6250

15.8750

0.1406 0.1562 0.1719

3.5719 3.9688 4.3656

41/64 21/32 43/64

0.6406 0.6562 0.6719

16.2719 16.6688 17.0656

0.1875

4.7625

11/16

0.6875

17.4625

0.2031 0.2188 0.2344

5.1594 5.5562 5.9531

45/64 23/32 47/64

0.7031 0.7188 0.7344

17.8594 18.2562 18.6531

0.2500

6.3500

3/4

0.7500

19.0500

0.2656 0.2812 0.2969

6.7469 7.1438 7.5406

49/64 25/32 51/64

0.7656 0.7812 0.7969

19.4469 19.8438 20.2406

OB 125

7.9375

13/16

0.8125

20.6375

0.3281 0.3438 0.3594

8.3344 8.7312 9.1281

53/64 2132 55/64

0.8281 0.8438 0.8594

21.0344 21.4312 21.8281

0.3750

9.5250

7/8

0.8750

22.2250

0.3906 0.4062 0.4219

9.9219 10.3188 10.7156

57/64 29/32 59/64

0.8906 0.9062 0.9219

22.6219 23.0188 23.4156

0.4375

LL)

15/16

0.9375

23.8125

0.4531 0.4688 0.4844

11.5094 11.9062 12.3031

0.9531 0.9688 0.9844

24.2094 24.6062 25.0031

0.5000

12.7000

1.0000

25.4000

0-18

Safety first! Regardless of how enthusiastic you may be about getting on with the job at hand, take the time to ensure that your safety is not jeopardized. A moment's lack of attention can result in an accident, as can failure to observe certain simple safety precautions. The possibility of an accident will always exist, and the following points should not be considered a comprehensive list of all dangers. Rather, they are intended to make you aware of the risks and to encourage a safety conscious approach to all work you carry out on your vehicle.

Essential DOs and DON’Ts DON’T rely on a jack when working under the vehicle. Always use approved jackstands to support the weight of the vehicle and place them under the recommended points.

lift or support

DON’T attempt to loosen extremely tight fasteners (i.e. wheel lug nuts) while the vehicle is on a jack - it may fall. DON’T start the engine without first making sure that the transmission is in Neutral (or Park where applicable) and the parking brake is set. DON’T remove the radiator cap from a hot cooling system - let it cool or cover it with a cloth and release the pressure gradually. DON’T attempt to drain the engine oil until you are sure it has cooled to the point that it will not burn you. DON’T touch any part of the engine or exhaust system until it has cooled sufficiently to avoid burns. DON’T siphon toxic liquids such as gasoline, antifreeze and brake fluid by mouth, or allow them to remain on your skin. DON’T inhale brake lining dust - it is potentially hazardous (see Asbestos below). DON’T allow spilled oil or grease to remain on the floor - wipe it up before someone slips on it. DON’T use loose fitting wrenches or other tools which may slip and cause injury. DON’T push on wrenches when loosening or tightening nuts or bolts. Always try to pull the

wrench toward you. If the situation calls for pushing the wrench away, push with an open hand to avoid scraped knuckles if the wrench should slip. DON’T attempt to lift a heavy component alone - get someone to help you. DON’T rush or take unsafe shortcuts to finish a job. DON’T allow children or animals in or around the vehicle while you are working on it. DO wear eye protection when using power tools such as a drill, sander, bench grinder,

etc. and when working under a vehicle. DO keep loose clothing and long hair well out of the way of moving parts. DO make sure that any hoist used has a safe working load rating adequate for the job. DO get someone to check on you periodically when working alone on a vehicle.

DO carry out work in a logical sequence and make sure that everything is correctly assembled and tightened. DO keep chemicals and fluids tightly capped and out of the reach of children and pets. DO remember that your vehicle’s safety affects that of yourself and others. If in doubt on any point, get professional advice.

Steering, suspension and brakes These systems are essential to driving safety, so make sure you have a qualified shop or individual check your work. Also, compressed suspension springs can cause injury if released suddenly - be sure to use a spring compressor.

Airbags Airbags are explosive devices that can CAUSE injury if they deploy while you're working on the vehicle. Follow the manufacturer's instructions to disable the airbag whenever you're working in the vicinity of airbag components.

Asbestos Certain friction, insulating, sealing, and other products - such as brake linings, brake bands, clutch linings, torque converters, gaskets, etc. - may contain asbestos or other hazardous friction material. Extreme care must be taken to avoid inhalation of dust from such products, since it is hazardous to health. If in doubt, assume that they do contain asbestos.

Fire Remember at all times that gasoline is highly flammable. Never smoke or have any kind of open flame around when working on a vehicle. But the risk does not end there. A spark caused by an electrical short circuit, by two metal surfaces contacting each other, or even by static electricity built up in your body under certain conditions, can ignite gasoline vapors, which in a confined space are highly explosive. Do not, under any circumstances, use gasoline for cleaning parts. Use an approved safety solvent. Always disconnect the battery ground (-) cable at the battery before working on any part of the fuel system or electrical system. Never risk spilling fuel on a hot engine or exhaust component. It is strongly recommended that a fire extinguisher suitable for use on fuel and electrical fires be kept handy in the garage or workshop at all times. Never try to extinguish a fuel or electrical fire with water.

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

When using cleaning fluids and solvents, read the instructions on the container carefully. Never use materials from unmarked containers. Never run the engine in an enclosed space, such as a garage. Exhaust fumes contain carbon monoxide, which is extremely poisonous. If you need to run the engine, always do so in the open air, or at least have the rear of the vehicle outside the work area.

The battery Never create a spark or allow a bare light bulb near a battery. They normally give off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery ground (-) cable at the battery before working on the fuel or electrical systems. If possible, loosen the filler caps or cover when charging the battery from an external source (this does not apply to sealed or maintenance-free batteries). Do not charge at an excessive rate or the battery may burst. Take care when adding water to a non maintenance-free battery and when carrying a battery. The electrolyte, even when diluted, is very corrosive and should not be allowed to contact clothing or skin. Always wear eye protection when cleaning the battery to prevent the caustic deposits

from entering your eyes.

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

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

Hydrofluoric acid This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses, etc. are exposed to temperatures above 750-degrees F (400-degrees C). The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.

0-19

Troubleshooting Contents Symptom

Section

Engine

Symptom

Section

Driveshaft

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Knock or clunk when transmission is under initial load (just after transmission is put into gear) .............c:c0ceee E@AkSratsrOMmuUOnCnVOSM attr ce se nee ss ae ticnenete tte nent eee Metallic grating sound consistent with vehicle speed...................SChaPING NOISSteaccs carson cetera ene ec ee WAlolte Toller rieccrecr pre meet eee te eae eee ee ee eee

ERS MNO tO Start WHOM NOL oo ra seaacncacervert-sos-2-iensleresacntdbeeaae EngingvacCkSiDOWGI oe Naren ee eter Nee rs a tee Engine lopes while idling or idles erratically ...............::cc:cccccesseeeees Enginemisses al idle Speed eee eset oot coat cscsiocds cs occaccseesSinipvtcenves Engine misses throughout driving speed range .............:.sccssceeeee Engine rotates DUE Wil MOUSUAN src.:cteecceseregevsececatnsncc ovacsssovseasueoeks [EROeeS 2 ig heats es aii ae Raa 1 at i Re

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rf x Rear axle and differential Knocking sound when starting or shifting gears.............:cceeeeeee Noise - same when in drive as when vehicle is coasting............... NGISGSWHENTELIFIING s22-ccelerccceec cece see eee cect seee See seed Soccer meee OIE AKS tees cesar eiccne.scehecsises {eusendttese seeder ech terse etanty eee ee a WIDGALOM ett esc sateee yar ctecweeheee iter reec ree, cee ace ena aes MT oe

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7

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12-35

12-36

Chapter 12

Chassis electrical system

Notes

IND-1

index

A

Automotive chemicals and lubricants, 0-15

About this manual, 0-5 Accelerator cable, removal, installation

and adjustment, 4-9 Accelerator Pedal Position (APP) sensor, 6-24 Acknowledgements, 0-2

Air bypass valve check, 6-29 Air cleaner housing, removal and installation, 4-9

Air conditioning accumulator, removal and installation, 3-13 compressor, removal and installation, 3-13 condenser, removal and installation, 3-13 evaporator orifice, removal and installation, 3-14 pressure cycling switch replacement, 3-14 system, check and maintenance, 3-10 Air diverter valve check, 6-29 Air filter, replacement, 1-22

Air pump and control valves, 6-30 Air supply pump, check, 6-29 Airbag, general information, 12-13 Alternator components, replacement, 5-12 Alternator, removal and installation, 5-11 Antifreeze, general information, 3-2 Anti-lock brake system, general information, 9-3 Automatic transmission, 7-1

band adjustment (C6 only), 7-4 diagnosis, general, 7-2 extension housing oil seal, replacement, 7-6 fluid check/change, 1-12 general information, 7-1 kickdown cable (C6 only), removal, installation and adjustment, 7-3 mounts, check and replacement, 7-5 neutral start switch (C6 only), adjustment, 7-4 removal and installation, 7-6 shift interlock system (1996 and later), description, check and actuator replacement, 7-5 shift cable/linkage lubrication, 1-19 shift linkage and cable, inspection, removal, installation and adjustment, 7-2 Throttle valve (TV) cable (AOD only), removal, installation and adjustment, 7-3 transmission control switch (E40OD, 4R100 and 4R70W), description, check and component replacement, 7-3

Transmission range (TR) sensor (1996 and later), description, adjustment and replacement, 7-4 vacuum modulator (C6 only), check and replacement, 7-4

Axle pivot bracket (right-side only), removal and installation, 10-7 Axle pivot bushing, removal and installation, 10-7

B Balljoints, removal and installation, 10-5 Battery cables, check and replacement, 5-3 check and replacement, 5-2 check, maintenance and charging, 1-16 emergency jump starting, 0-7 Body, 11-1 cowl panel and vent seal, removal and installation, 11-11 door hinge, removal and installation, 11-7 inner and outer handle and latch assembly, removal and installation, 11-8 lock cylinder, removal and installation, 11-9 trim panel, removal and installation, 11-9 dual cargo side doors, removal, installation and alignment, 11-6 dual rear doors, removal, installation and alignment, 11-7 engine cover, removal and installation, 11-6 front bumper and cover, removal and installation, 11-12 front door window glass, replacement and adjustment, 11-10 regulator, replacement, 11-10 front door, removal, installation and alignment, 11-6 front fender and apron, removal and installation, 11-11

general information, 11-1 hinged door latch striker, removal, installation and adjustment, 11-8 hinged glass, replacement, 11-11 hinges and locks, maintenance, 11-5 hood latch control cable, removal and installation, 11-5

hood, removal, installation and adjustment, 11-5 maintenance, 11-1 radiator grille, removal and installation, 11-11 rear bumper, removal and installation, 11-12 repair major damage, 11-5 minor damage, 11-4 seat belt check, 11-12 seats, removal and installation, 11-12

Index IND-2 ng Se Oe ee ad sliding side door, removal, installation and

alignment, 11-6 upholstery and carpets, maintenance, 11-1 vinyl trim, maintenance, 11-1 windshield and fixed glass, replacement, 11-11 Booster battery (jump) starting, 0-7 Brake light switch, replacement, 12-12 Brake On/Off (BOO) switch, 6-21 Brakes, 9-1 Anti-lock brake system, general information, 9-3 caliper, removal, overhaul and installation, 9-6 disc, inspection, removal and installation, 9-7 general information, 9-2

hoses and lines, inspection and replacement, 9-15 hydraulic system, bleeding, 9-16 master cylinder, removal, overhaul and installation, 9-13 pads, replacement, 9-4 pedal, removal and installation, 9-16 power brake booster, removal and installation, 9-15 rear brake shoes, replacement and adjustment E-150 models, 9-8

E-250 and E-350 models, 9-11 system check, 1-26 wheel cylinder, removal, overhaul and installation, 9-13 Bulb, replacement, 12-9

Buying parts, 0-8 Bypass and diverter control circuit check, 6-29 Bypass valve vacuum check, 6-29

Coolant temperature sending unit, check and replacement, 3-7 Cooling fan and clutch, check, removal and installation, 3-4 Cooling system check, 1-24 servicing (draining, flushing and refilling), 1-30 Cooling, heating and air conditioning systems, 3-1 air conditioning accumulator, removal and installation, 3-12 compressor, removal and installation, 3-13 condenser, removal and installation, 3-13 evaporator orifice, removal and installation, 3-13 pressure cycling switch replacement, 3-14 system, check and maintenance, 3-10 antifreeze, general information, 3-2 coolant temperature sending unit, check and replacement, 3-8 cooling fan and clutch, check, removal and installation, 3-4 general information, 3-2 heater and air conditioning blower motor and circuit, check, 3-8 blower motor and resistor, removal and installation, 3-9 control assembly, removal and installation, 3-10 heater core, removal and installation, 3-9

oil cooler (7.5L engine), removal and installation, 3-14 radiator, removal and installation, 3-5

C Camshaft and bearings (OHV engines), inspection, 2E-20 Camshaft lobe lift, check

4.9L inline six-cylinder engines, 2A-6 4.2L V6 engines, 2B-14 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-6 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-12

Camshaft position sensor, 6-22 Camshaft(s), removal, inspection and installation 4.9L inline six-cylinder engines, 2A-5 4.2L V6 engines, 2B-14 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-5 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-11 Capacities, lubricants and fluids, 1-3

Catalytic converter, 6-31 Charging system check, 5-10 general information and precautions, 5-10

Chassis electrical system, 12-1 Chassis lubrication, 1-19 Circuit breakers, general information and check, 12-4 Coil spring, removal and installation, 10-5 Combined air bypass and diverter valve, 6-29 Conversion factors, 0-16

thermostat, check and replacement, 3-3 water pump check, 3-5 removal and installation, 3-6 Cowl panel and vent seal, removal and installation, 11-11 Crankcase ventilation filter, replacement, 1-22

Crankshaft inspection, 2E-23 installation and main bearing oil clearance check, 2E-27 removal, 2E-19 Crankshaft oil seals, replacement

4.9L inline six-cylinder engines, 2A-9 4.2L V6 engines, 2B-17 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-9 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-20 Crankshaft position sensor (CKP), 6-21 Crankshaft pulley, removal and installation 4.9L inline six-cylinder engines, 2A-4 4.2L V6 engines, 2B-17 5.0L, 5.7L and 7.5L OHV V8 engines, 2A-4 4.6L, 5.4L, 6.8L V8 dnd V10 OHC engines, 2D-5 Cylinder compression check, 2E-13 Cylinder head cleaning and inspection, 2E-17 disassembly, 2E-16 reassembly, 2E-26

IND-3

Index

Cylinder head(s), removal and installation 4.9L inline six-cylinder engines, 2A-8 4.2L V6 engines, 2B-9, 2B-10 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-7 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-17 Cylinder Head Temperature (CHT) sensor, 6-23 Cylinder honing, 2E-27

D Differential lubricant change, 1-21 level check, 1-20 Differential Pressure Feedback (DPFE) sensor, 6-27 Distributor cap and rotor check and replacement, 1-19 Distributor, removal and installation, 5-8 Diverter valve vacuum check, 6-29 Door hinge, removal and installation, 11-7 inner and outer handle and latch assembly, removal and installation, 11-8 lock cylinder, removal and installation, 11-9 trim panel, removal and installation, 11-9 Drag link, removal and installation, 10-10 Drivebelt check, adjustment and replacement, 1-15 Drivebelt tensioner, replacement, 1-16 Driveline, 8-1 Driveplate, removal and installation 4.9L inline six-cylinder engines, 2A-10 4.2L V6 engines, 2B-19 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-11 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-20 Driveshaft carrier bearing, check and replacement, 8-7 Driveshaft(s) balancing, 8-6 general information, 8-6 removal and installation, 8-6 Dual cargo side doors, removal, installation and alignment, 11-6 Dual rear doors, removal, installation and alignment, 11-7

E EGR control system, 6-26 EGR valve position sensor, 6-26 Electrical troubleshooting, 12-1

Electronic Engine Control (EEC), system and trouble codes, 6-1 Emissions and engine control systems, 6-1 Engine coolant temperature sensor, 6-16 Engine cover, removal and installation, 11-6

Engine electrical systems, 5-1 alternator components, replacement, 5-12

alternator, removal and installation, 5-11 battery cables, check and replacement, 5-3 check and replacement, 5-2 emergency jump starting, 0-7 charging system check, 5-10 general information and precautions, 5-10 distributor, removal and installation, 5-8

ignition coil, check and replacement, 5-6 ignition module and stator assembly (TFI-IV ignition system), check and replacement, 5-9 ignition system check, 5-4

El Ignition system, 5-5 El ignition with Coil Over Plug (COP) system, 5-5 general information, 5-3

TFI-IV ignition system, 5-4 ignition timing, check, 5-8 starter motor and circuit, in-vehicle check, 5-13

removal and installation, 5-14 starter solenoid, replacement, 5-14 starting system, general information and precautions, 5-13 Engine oil and filter change, 1-10 Engine Oil Temperature (EOT) sensor, 6-24 Engines 4.9L inline six-cylinder engines, 2A-1 camshaft lobe lift, check, 2A-6 crankshaft oil seals, replacement, 2A-9

cylinder head, removal and installation, 2A-8 driveplate, removal, inspection and installation, 2A-10 engine mounts, check and replacement, 2A-10 lifters and camshaft, removal and installation, 2A-5

manifolds, removal and installation, 2A-7 oil pan, removal and installation, 2A-9 oil pump, removal and installation, 2A-9 repair operations possible with the engine in the vehicle, 2A-2 rocker arms and pushrods, removal and installation, 2A-3 timing cover and gears, removal and installation, 2A-4 Top Dead Center (TDC) for number 1 piston, locating, 2A-2 valve cover and pushrod cover, removal and installation, 2A-3 valve springs, retainers and seals, replacement, 2A-6 4.2L V6 engines, 2B-1 camshaft, balance shaft and bearings, removal, inspection and installation, 2B-14 crankshaft oil seals, replacement, 2B-17 cylinder heads, removal and installation, 2B-9, 2B-10 driveplate, removal and installation, 2B-19 engine mounts, check and replacement, 2B-19 exhaust manifolds, removal and installation, 2B-8

IND-4 MN

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intake manifold (upper and lower), removal and installation, 2B-5 oil pan, removal and installation, 2B-15 oil pump, removal and installation, 2B-16 repair operations possible with the engine in the vehicle, 2B-2 rocker arms and pushrods, removal, inspection and installation, 2B-3 timing chain and sprockets, inspection, removal and installation, 2B-12 Top Dead Center (TDC) for number one piston, locating, 2B-3 valve covers, removal and installation, 2B-3 valve lifters, removal, inspection and installation, 2B-13 valve springs, retainers and seals, replacement, 2B-4 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-1 camshaft lobe lift measurement, 2C-6 crankshaft oil seals, replacement, 2C-9 cylinder heads, removal and installation, 2C-7 driveplate, removal, inspection and installation, 2C-11 exhaust manifold, removal and installation, 2C-7 intake manifold (upper and lower), removal and installation, 2C-6 lifters and camshaft, removal and installation, 2C-5

mounts, removal and installation, 2C-11 oil pan, removal and installation, 2C-8

oil pump, removal and installation, 2C-19 repair operations possible with the engine in the vehicle, 2C-3 rocker arms and pushrods, removal and installation, 2C-4 timing cover and chain, removal and installation, 2C-4

Top Dead Center (TDC) for number 1 piston, locating, 2C-3 valve covers, removal and installation, 2C-3 valve springs, retainers and seals, replacement, 2C-6 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-1 camshaft(s), removal, inspection and installation, 2D-11 crankshaft oil seals, replacement, 2D-20 crankshaft pulley, removal and installation, 2D-5 cylinder heads, removal and installation, 2D-17 driveplate, removal and installation, 2D-20 exhaust manifolds, removal and installation, 2D-16 intake manifold, removal and installation, 2D-15 mounts, check and replacement, 2D-22 oil pan, removal and installation, 2D-18

oil pump, removal and installation, 2D-19 repair operations possible with the engine in the vehicle, 2D-3

index rocker arms and valve lash adjusters, removal, inspection and installation, 2D-10 timing chain cover, removal and installation, 2D-5 timing chains, tensioners and sprockets, removal, inspection and installation, 2D-6 Top Dead Center (TDC) for number one piston, locating, 2D-3 valve covers, removal and installation, 2D-4

valve springs, retainers and seals, removal and installation, 2D-13 General engine overhaul procedures, 2E-1 camshaft and bearings (OHV engines), inspection, 2E-20 crankshaft inspection, 2E-23 installation and main bearing oil clearance check, 2E-27 removal, 2E-19

cylinder compression check, 2E-13 cylinder head cleaning and inspection, 2E-17 disassembly, 2E-16 reassembly, 2E-26 cylinder honing, 2E-27 engine block cleaning, 2E-21 inspection, 2E-22 general information, engine overhaul, 2E-12 initial start-up and break-in after overhaul, 2E-34 main and connecting rod bearings, inspection, 2E-24 oil pressure check, 2E-12

oil pump, inspection, 2E-25 piston rings, installation, 2E-30 piston/connecting rod assembly inspection, 2E-22 installation and rod bearing oil clearance check, 2E-31 removal, 2E-18 timing chain/sprockets or gears, wear checks, 2E-17 vacuum gauge diagnostic checks, 2E-13 valve adjustment, 2E-33 valve lifters and pushrods, inspection, 2E-17 valves, servicing, 2E-26

Evaporative Emissions Control System (EECS), 6-28 Exhaust Gas Recirculation (EGR) system, 6-26 Exhaust manifolds, removal and installation 4.9L inline six-cylinder engines, 2A-7

4.2L V6 engines, 2B-8 5.0L, 5.7L and 7.5L ‘OHV V8 engines, 2C-7 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-16 Exhaust system check, 1-25 servicing, general information, 4-13

IND-5

Index

=

G

Filter, replacement air and crankcase ventilation, 1-22 engine oil, 1-10

General engine overhaul procedures, ZE-1 camshaft and bearings (OHV engines), inspection, 2E-20 crankshaft inspection, 2E-23 installation and main bearing oil clearance check, 2E-27 removal, 2E-19 cylinder compression check, 2E-13 cylinder head cleaning and inspection, 2E-17 disassembly, 2E-16 reassembly, 2E-26 cylinder honing, 2E-27 engine block

fuel, 1-24

Fluid level checks automatic transmission, 1-12 brake fluid, 1-8 differential, 1-20 engine coolant, 1-7 engine oil, 1-7 power steering, 1-11

windshield washer fluid, 1-8 Front axle arm, removal and installation, 10-7 Front bumper and cover, removal and installation, 11-12 Front door window glass, replacement and adjustment, 11-10 regulator, replacement, 11-10 Front door, removal, installation and alignment, 11-6 Front fender and apron, removal and installation, 11-11 Front shock absorbers, inspection, removal and installation, 10-4 Front stabilizer bar, removal and installation, 10-7

Front wheel bearing check, repack and adjustment, 1-27 Front wheel spindle, removal and installation, 10-5 Fuel and exhaust systems, 4-1

accelerator cable, removal, installation and adjustment, 4-9 air cleaner housing, removal and installation, 4-9

exhaust system servicing, general information, 4-13 filter replacement, 1-24 fuel injection system check, 4-10 fuel injection system general information, 4-10 fuel level sending unit, check and replacement, 4-8 fuel lines and fittings, general information, 4-5 fuel pressure regulator, removal and installation, 4-11 fuel pressure relief procedure, 4-3 fuel pump, removal and installation, 4-7 fuel pump/fuel pressure, check, 4-3 fuel rail and injectors, removal and installation, 4-12

fuel tank, cleaning and repair, 4-7 fuel tank, removal and installation, 4-7 general information, 4-2 Intake Air Systems, 4-13 system check, 1-24 throttle body, removal and installation, 4-11 Fuel injection system check, 4-10 general information, 4-10

Fuel Pump Driver Module (FPDM), 6-25 Fuel Rail Pressure (FRP)/Fuel Rail Pressure Temperature (FRPT) sensor, 6-25 Fuel Tank Pressure (FTP) sensor, 6-24 Fuses and fusible links, general information, 12-2

cleaning, 2E-21 inspection, 2E-22

engine overhaul disassembly sequence, 2E-16 reassembly sequence, 2E-26 engine rebuilding alternatives, 2E-14 engine removal, methods and precautions, 2E-14 engine, removal and installation, 2E-15

general information, engine overhaul, 2E-12 initial start-up and break-in after overhaul, 2E-34 main and connecting rod bearings, inspection, 2E-24

oil pressure check, 2E-12 oil pump, inspection, 2E-25 piston rings, installation, 2E-30 piston/connecting rod assembly inspection, 2E-22 installation and rod bearing oil clearance check, 2E-31 removal, 2E-18 timing chain/sprockets or gears, wear checks, 2E-17 vacuum gauge diagnostic checks, 2E-13 valve adjustment, 2E-33 valve lifters and pushrods, inspection, 2E-17 valves, servicing, 2E-26

H Headlight bulb, replacement, 12-7 Headlight switch, check and replacement, 12-7

Headlights, adjusting, 12-8 Heater and air conditioning blower motor and circuit, check, 3-7 Heater and air conditioning blower motor and resistor, removal and installation, 3-8 Heater and air conditioning control assembly, removal and installation, 3-10 Heater core, removal and installation, 3-9

Hinged door latch striker, removal, installation and adjustment, 11-8 Hinged glass, replacement, 11-11

IND-6

Index Mounts, engine, check and replacement

Hinges and locks, maintenance, 11-5 Hood latch control cable, removal and installation, 11-5 Hood, removal, installation and adjustment, 11-5

Idle Air Control (IAC) valve, check, removal and adjustment, 6-25 Ignition coil, check and replacement, 5-6

Ignition module and stator assembly (TFI-IV ignition system), check and replacement, 5-9 Ignition switch and key lock cylinder, check and replacement, 12-5 Ignition system check, 5-4 general information, 5-3 Ignition timing, check, 5-8 Information sensors, 6-16 Initial start-up and break-in after overhaul, 2E-34 Instrument cluster, removal and installation, 12-11 Intake Air Systems, 4-13 Intake Air Temperature (IAT) sensor, 6-20 Intake manifold, removal and installation

4.9L inline six-cylinder engines, 2A-7

4.9L inline six-cylinder engines, 2A-10 4.2L V6 engines, 2B-19 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-11 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-22 Multifunction switch, check and replacement, 12-5

O Oil and filter change, 1-10

Oil cooler (7.5L engine), removal and installation, 3-14 Oil pan, removal and installation 4.9L inline six-cylinder engines, 2A-9 4.2L V6 engines, 2B-15 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-8 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-18 Oil pressure check, 2E-12

Oil pump, inspection, 2E-25 Oil pump, removal and installation 4.9L inline six-cylinder engines, 2A-9

4.2L V6 engines, 2B-16 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-9 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-19 Owner safety checks, 1-10 Oxygen sensor, 6-17

4.2L V6 engines, 2B-5 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-6 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-15 Introduction, 0-5

J Jacking and towing, 0-14

K Knock sensor, 6-23

1-1

Main and connecting rod bearings, inspection, 2E-24 Maintenance schedule, 1-5

Maintenance techniques, tools and working facilities, 0-8

Managed Thermactor Air (MTA) (EEC controlled), 6-28 Manifold Absolute Pressure (MAP) sensor, 6-17 Mass Airflow Sensor (MAF), 6-19 Master cylinder, removal, overhaul and installation, 9-13

Piston rings, installation, 2E-30 Piston/connecting rod assembly inspection, 2E-22 installation and rod bearing oil clearance check, 2E-31 removal, 2E-18 Positive Crankcase Ventilation (PCV) system general information 6-30 heated PCV valve replacement, 6-31 valve check and replacement, 1-23 Power brake booster, removal and installation, 9-15 Power mirrors, removal and installation, 12-13

L Lubricants and fluids, recommended,

>)

Power steering fluid level check, 1-11 pressure switch, 6-21 pump, removal and installation, 10-12 system bleeding, 10-12 Power window system, description and check, 12-12 Powertrain Control Module (PCM), 6-16 Pump and control valve checks, 6-29 Purge control valve, 6-28

Pushrod cover (4.9L inline six-cylinder engines), 2A-3

R Radiator grille, removal and installation, 11-11 Radiator, removal and installation, 3-5

IND-7

Index i

Radio antenna, removal and installation, 12-11 Radio, removal and installation, 12-11 Radius arm insulators, replacement, 10-7 Radius arm, removal and installation, 10-6 Rear axle assembly, removal and installation, 8-5

Rear axle, general information, 8-2 Rear axleshaft (full-floating type), removal and installation, 8-4 Rear axleshaft (semi-floating type), removal and installation, 8-3

Rear axleshaft oil seal and bearing (semi-floating type), replacement, 8-2 Rear brake shoes, replacement and adjustment E-150 models, 9-8 E-250 and E-350 models, 9-11 Rear bumper, removal and installation, 11-12 Rear differential pinion bearing seal, replacement, 8-5

Rear leaf spring, removal and installation, 10-8 Rear shock absorbers, inspection, removal and

installation, 10-8 Rear wheel hub bearings and grease seal (full-floating type), removal, inspection and installation, 8-2 Recommended lubricants and fluids, 1-1

Relays, general information and testing, 12-4 Repair operations possible with the engine in the vehicle 4.9L inline six-cylinder engines, 2A-2 4.2L V6 engines, 2B-2 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-3 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-3 Reverse flow check valve, check, 6-30 Rocker arms and pushrods, removal and installation 4.9L inline six-cylinder engines, 2A-3 4.2L V6 engines, 2B-3 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-4 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-10

S Safety checks, 1-10 Safety first!, 0-18 Seat belt check, 11-12 Seats, removal and installation, 11-12 Scheduled maintenance, 1-5

Sliding side door, removal, installation and alignment, 11-6 Solenoid valve checks (TAD/TAB, AIRD/AIRB), 6-30 Spark plugs replacement, 1-17 type and gap, 1-3 wires, check and replacement, 1-19 Speakers, removal and installation, 12-11 Starter motor and circuit, in-vehicle check, 5-13 removal and installation, 5-14

sss

Starter solenoid, replacement, 5-14

Starting system, general information and precautions, 5-13

Steering and suspension check, 1-26 Steering system drag link, removal and installation, 10-10 general information, 10-8 power steering pump, removal and installation, 10-12 system bleeding, 10-12 steering connecting link, removal and installation, 10-10

steering gear, removal and installation, 10-11 steering wheel and clockspring, removal and installation, 10-8 tie-rod ends, removal and installation, 10-11 wheel alignment, general information, 10-12 wheels and tires, general information, 10-13 Suspension system axle pivot bracket (right-side only), removal and installation, 10-7 axle pivot bushing, removal and installation, 10-7 balljoints, removal and installation, 10-5 coil spring, removal and installation, 10-5 front axle arm, removal and installation, 10-7 front shock absorbers, inspection, removal and installation, 10-4 front stabilizer bar, removal and installation, 10-7 front wheel spindle, removal and installation, 10-5 radius arm insulators, replacement, 10-7 radius arm, removal and installation, 10-6 rear leaf spring, removal and installation, 10-8 rear shock absorbers, inspection, removal and installation, 10-8

+ Timing chain/sprockets or gears, wear checks, 2E-17 Thermactor Air By-Pass (TAB/AIRB) or Thermactor Air Diverter (TAD/AIRD) solenoid replacement, 6-30 Thermactor system noise test, 6-30 Thermactor systems, operations and checks, 6-28 Thermostat, check and replacement, 3-3 Throttle body, removal and installation, 4-11 Throttle Position Sensor (TPS), 6-18 Tie-rod ends, removal and installation, 10-11 Timing chain and sprockets, inspection, removal and installation, 4.2L V6 engines, 2B-12 Timing chain cover, removal and installation, 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-5 Timing chains, tensioners and sprockets, removal,

inspection and installation, 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-6 Timing cover and chain, removal and installation, 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-4 Timing cover and gears, removal and installation,

4.9L inline six-cylinder engines, 2A-4

IND-8 Tire and tire pressure checks, 1-8 Tire rotation, 1-13 Tools, 0-10

Top Dead Center (TDC) for number 1 piston, locating 4.9L inline six-cylinder engines, 2A-2 4.2L V6 engines, 2B-3 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-3 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-3 Transmission, automatic, 7-1 band adjustment (C6 only), 7-4 diagnosis, general, 7-2 extension housing oil seal, replacement, 7-6 fluid change, 1-12 level check, 1-12

general information, 7-1 kickdown cable (C6 only), removal, installation and adjustment, 7-3 mounts, check and replacement, 7-5 neutral start switch (C6 only), adjustment, 7-4

Index

V Vacuum gauge diagnostic checks, 2E-13 Valve adjustment, 2E-33 Valve covers, removal and installation 4.9L inline six-cylinder engines, 2A-3 4.2L V6 engines, 2B-3 5.0L, 5.7L and 7.5L OHV V8 engines, 2C-3 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-4 Valve lifters and pushrods, inspection, 2E-17 Valves, servicing, 2E-26 Valve springs, retainers and seals, replacement 4.9L inline six-cylinder engines, 2A-6 4.2L V6 engines, 2B-4

5.0L, 5.7L and 7.5L OHV V8 engines, 2C-6 4.6L, 5.4L, 6.8L V8 and V10 OHC engines, 2D-13 Vapor management valve (VMV), 6-28 Vehicle identification numbers, 0-6 Vehicle Speed Sensor (VSS), 6-20

Vinyl trim, maintenance, 11-1

—

removal and installation, 7-6

shift interlock system (1996 and later), description, check and actuator replacement, 7-5 shift linkage and cable, inspection, removal, installation and adjustment, 7-2 Throttle valve (TV) cable (AOD only), removal, installation and adjustment, 7-3 transmission control switch (E4OD, 4R100 and 4R70W), description, check and component replacement, 7-4 Transmission range (TR) sensor (1996 and later), description, adjustment and replacement, 6-20, 7-4 vacuum modulator (C6 only), check and replacement, 7-4 Troubleshooting, 0-19

Tune-up general information, 1-6 Turn signal/hazard flasher relay, replacement, 12-5

U Underhood hose check and replacement, 1-14

Universal joints, replacement, 8-6 Upholstery and carpets, maintenance, 11-1

W Water pump check, 3-5 removal and installation, 3-6 Wheel alignment, general information, 10-13 bearing (front), check, repack and adjustment, 1-29 cylinder, removal, overhaul and installation, 9-13 Wheels and tires, general information, 10-13

Windshield and fixed glass, replacement, 11-11 washer reservoir and pump assembly, removal and installation, 12-6 wiper arm, removal and installation, 12-6 wiper blade check and replacement, 1-29 wiper control module, removal and installation, 12-6 wiper motor, removal and installation, 12-6 Wiring diagrams, general information, 12-13 Working facilities, 0-13

Haynes Automotive

Manuals

GF

NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.

ACURA 12020 12021

12050 AMC 14020 14025

AUDI 15020 15025 15026

Integra ’86 thru ’89 & Legend ’86 thru ’90 Integra ’90 thru ’93 & Legend ’91 thru ’95 Integra '94 thru ’00 - see HONDA Civic (42025) MDX ’01 thru ’07 - see HONDA Pilot (42037) Acura TL all models ’99 thru ’08 Jeep CJ - see JEEP (50020) Mid-size models ’70 thru ’83 (Renault) Alliance & Encore ’83 thru ’87

24066 24067 24070 24071 24072 24075 24080 24081

10310 25015 25020

AUSTIN-HEALEY 25025

Sprite - see MG Midget (66015)

19010 19020

19025

25026

3/5 Series ’82 thru '92 3-Series incl. Z3 models '92 thru '98 3-Series incl. Z4 models ’99 thru ’05 3-Series ‘06 thru ‘10

25027 25030

320i all 4 cyl models '75 thru ’83 1500 thru 2002 except Turbo ’59 thru ’77 Buick Century 97 thru ’05 Century (front-wheel drive) - see GM (38005) Buick, Oldsmobile & Pontiac Full-size (Front-wheel drive) 85 thru ’05 Buick Electra, LeSabre and Park Avenue; Oldsmobile Delta 88 Royale, Ninety Eight

and Regency; Pontiac Bonneville Buick, Oldsmobiie & Pontiac Full-size (Rear wheel drive) ’70 thru ’90 Buick Estate, Electra, LeSabre, Limited, Oldsmobile Custom Cruiser, Delta 88, Ninety-eight, Pontiac Bonneville, Catalina, Grandville, Parisienne 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 (38025)

CADILLAC 21015 21030

CTS & CTS-V ‘03 thru ‘12 Cadillac Rear Wheel Drive ’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 Engine Overhaul Manual Astro & GMC Safari Mini-vans ’85 thru ’05 Camaro V8 all models ’70 thru ’81 Camaro all models ’82 thru ’92 Camaro & Firebird ’93 thru ’02

Cavalier - see GENERAL MOTORS (38016) Celebrity - see GENERAL MOTORS (38005)

24020 24024

Chevelle, Malibu & El Camino ’69 thru ’87 Chevette & Pontiac T1000 ’76 thru ’87

Citation - see GENERAL MOTORS (38020)

24027 24032 24040 24041 24045 24046

24047 24048 24050 24055 24059 24060 24064 24065

Colorado & GMC Canyon ’04 thru ’10 Corsica/Beretta all models ’87 thru ’96 Corvette all V8 models ’68 thru ’82 Corvette all models ’84 thru ’96 Full-size Sedans Caprice, Impala, Biscayne,

Bel Air Impala ’91 thru Impala Impala Lumina

& Wagons ’69 thru ’90 SS & Caprice and Buick Roadmaster ’96 ’00 thru ’05 - see LUMINA (24048) & Monte Carlo all models ’06 thru 11 '90 thru ’94 - see GM (38010) Lumina & Monte Carlo ’95 thru ’05 Lumina APV - see GM (38035) Luv Pick-up all 2WD & 4WD ’72 thru ’82 Malibu ’97 thru ’00 - see GM (38026) Monte Carlo all models ’70 thru ’88 Monte Carlo ’95 thru 01 - see LUMINA (24048) Nova all V8 models ’69 thru 79 Nova and Geo Prizm ’85 thru ’92 Pick-ups ’67 thru ’87 - Chevrolet & GMC Pick-ups ’88 thru ’98 - Chevrolet & GMC

neers

25035 25040

Blazer & Jimmy ’83 thru ’94, $S-10 & Sonoma Pick-ups ’94 thru ’04, including Blazer, Jimmy & Hombre Chevrolet TrailBlazer, GMC Envoy & Oldsmobile Bravada ’02 thru ’09 Sprint '85 thru ’88 & Geo Metro ’89 thru '01 Vans - Chevrolet & GMC ’68 thru ’96 Chevrolet Express & GMC Savana Full-size Vans ’96 thru ‘10

reer

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Chrysler Engine Overhaul Manual Chrysler Cirrus, Dodge Stratus, Plymouth Breeze ’95 thru ’00 Full-size 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 04 Chrysler 300, Dodge Charger & Magnum ’05 thru ’09 Chrysler & Plymouth Mid-size front wheel drive ’82 thru ’95 Rear-wheel Drive - see Dodge (30050) PT Cruiser all models ’01 thru ’10 Chrysler Sebring ’95 thru ‘06, Dodge Stratus ‘01 thru '06, Dodge Avenger ’95 thru ’00

DATSUN 28005 28007 28009 28012 28014 28018 28020 28022 28025

DODGE 30008 30010 30011 30012 30013 30016 30020 30021 30022 30023 30025 30030

CHEVROLET 10305 24010 24015 24016 24017

S-10 & S-15 Pick-ups ’82 thru ’93,

CHRYSLER

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

Audi A4 '96 thru ’01 - see VW Passat (96023) 15030. Audi A4 ‘02 thru ‘08

BMW 18020 18021 18022 18023 18025 18050 BUICK

Pick-ups ’99 thru ’06 - Chevrolet & GMC Chevrolet Silverado & GMC Sierra ‘07 thru ‘12

30034 30035 30036 30040 30041 30042 30045 30050 30055 30060 30065

200SX all models ’80 thru ’83 B-210 all models ’73 thru ’78 210 all models ’79 thru ’82 240Z, 260Z & 280Z Coupe ’70 thru ’’78 280ZX Coupe & 2+2 ’79 thru ’83 300ZX - see NISSAN (72010) 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 all gasoline models ’77 thru ’84

Challenger/Plymouth Saporro ’78 thru ’83 Caravan, Chrysler Voyager, Town & Country 03 thru ’07 Colt & Plymouth Champ ’78 thru ’87

Dakota Pick-ups all models ’87 thru ’96 Durango ’98 &’99, Dakota ’97 thru ’99 Durango ’00 thru ’03 Dakota ’00 thru ’04 Durango ’04 thru ’09, Dakota ’05 thru '11 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 Dodge and Plymouth Neon ’00 thru ’05 Pick-ups all full-size models ’74 thru ’93 Pick-ups all full-size models ’94 thru ’01

Pick-ups full-size models ’02 thru ’08 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups ’79 thru ’93 Dodge/Plymouth/Chrysler RWD ’71 thru ’89 Shadow & Plymouth Sundance ’87 thru '94 Spirit & Plymouth Acclaim ’89 thru '95 Vans - Dodge & Plymouth ’71 thru ’03 |

FIAT

36016 36020

36070 36071 36074 36075 36078 36082 36086 36090 36094 36097

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

ames ®

Escape & Mazda Tribute ’01 thru 11 Explorer & Mazda Navajo ’91 thru ’01 Explorer/Mercury Mountaineer ’02 thru 10 Fairmont & Mercury Zephyr ’78 thru ’83 Festiva & Aspire ’88 thru ’97 Fiesta all models ’77 thru ’80 Focus all models ’00 thru ’11 Ford & Mercury Full-size '75 thru ’87 Ford & Mercury Mid-size ’75 thru ’86 Fusion & Mercury Milan ‘06 thru ‘10 Mustang V8 all models ’64-1/2 thru ’73 Mustang II 4 cyl, V6 & V8 models ’74 thru ’78

Mustang & Mercury Capri ’79 thru ’93 Mustang all models ’94 thru ’04 Mustang ’05 thru 10 Pick-ups & Bronco ’73 thru ’79 Pick-ups & Bronco ’80 thru ’96 F-150 & Expedition ’97 thru ’09, F-250 ’97 thru ’99 & Lincoln Navigator ’98 thru ’09 Super Duty Pick-ups, Excursion ’99 thru 10 F-150 full-size '04 thru ’10 Pinto & Mercury Bobcat '75 thru ’80 Probe all models ’89 thru ’92 Probe ’93 thru ’97 - see MAZDA 626 (61042) Ranger/Bronco Il gasoline models ’83 thru '92 Ranger ’93 thru 10 & Mazda Pick-ups ’94 thru ’09 Taurus & Mercury Sable ’86 thru ’95 Taurus & Mercury Sable ’96 thru ’05 Tempo & Mercury Topaz ’84 thru ’94 Thunderbird/Mercury Cougar ’83 thru ’88 Thunderbird/Mercury Cougar ’89 thru ’97 Vans all V8 Econoline models ’69 thru ’91 Vans full size ’92 thru 10 Windstar Mini-van '95 thru ’07

GENERAL MOTORS 10360 38005 38010

38016

Caravan & Plymouth Voyager ’96 thru ’02

Talon - see MITSUBISHI (68030, 68031) Vision - see CHRYSLER (25025)

FORD 10320 10355 11500 36004 36006 36008 36012

36060 36061 36062 36066

38015 400 & 600 - see CHRYSLER (25030) Aries & Piymouth Reliant ’81 thru ’89 Caravan & Plymouth Voyager ’84 thru ’95

EAGLE

34010 34025

36022 36024 36025 36028 36030 36032 36034 36036 36044 36045 36048 36049 36050 36051 36052 36054 36058 36059

RN

38017 38020

38025 38026 38027 38030 38031 38032 38035 38036

38040

38070 GEO 40030

GMC

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 ’07 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza & Pontiac J-2000 & Sunbird 82 thru ’94 Chevrolet Cavalier & Pontiac Sunfire ’95 thru ’05 Chevrolet Cobalt & Pontiac G5 ’05 thru ‘11 Buick Skyiark, 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 ’03 Chevrolet Malibu ’04 thru 10 Cadillac Eldorado, Seville, Oldsmobile Toronado, Buick Riviera ’71 thru ’85 Cadillac Eldorado & Seville, DeVille, Fleetwood & Olds Toronado, Buick Riviera ’86 thru '93 Cadillac DeVille '94 thru '05 & Seville ’92 thru ’04 Cadillac DTS '06 thru "10 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport all models ’90 thru ’96 Chevrolet Venture, Olds Silhouette, Pontiac Trans Sport & Montana ’97 thru ’05 General Motors Full-size Rear-wheel Drive - see BUICK (19025) Chevrolet Equinox ‘05 thru ‘09 Pontiac Torrent ‘06 thru ‘09 Chevrolet HHR ‘06 thru ‘11

Metro - see CHEVROLET Sprint (24075) Prizm - ’85 thru ’92 see CHEVY (24060), 93 thru ’02 see TOYOTA Corolla (92036) Storm all models ’90 thru ’93 Tracker - see SUZUKI Samurai (90010) Vans & Pick-ups - see CHEVROLET

HONDA Ford Engine Overhaul Manual Ford Automatic Transmission Overhaul Mustang ’64-1/2 thru ’70 Restoration Guide 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 ’10 Escort/Mercury Lynx all models ’81 thru ’90 Escort/Mercury Tracer ’91 thru ’02

reer

42010 42011 42012 42013 42014 42015 42020 42021 42022

Accord CVCC all models ’76 thru ’83 Accord all models ’84 thru ’89 Accord all models ’90 thru ’93 Accord all models '94 thru ’97 Accord all models ’98 thru ’02 Accord '03 thru ’07 Civic 1200 all models ’73 thru '79 Civic 1300 & 1500 CVCC ’80 thru ’83 Civic 1500 CVCC all models '75 thru ’79

(Continued on other side)

eee

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514 ¢ (805) 498-6703 ¢ http://www.haynes.com

go

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ST ES

Haynes Automotive Manuals (continued) product information. NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest

®

TRIUMPH

NISSAN 42023 42024 42025

Civic all models ’84 thru '91 Civic & del Sol ’92 thru ’95 Civic ’96 thru ’00, CR-V ’97 thru ’01, Acura Integra '94 thru ’00

42026

Civic ’01 thru 10, CR-V ’02 thru ’09

42035

Odyssey all models ’99 thru ’10 Passport - see ISUZU Rodeo (47017)

42037 42040

Honda Pilot ’03 thru ’07, Acura MDX '01 thru '07 Prelude CVCC all models '79 thru ’89

HYUNDAI 43010 43015 43050 43055

Elantra all models ’96 thru 10 Excel & Accent all models ’86 thru ’09 Santa Fe all models ’01 thru ’06 Sonata all models ’99 thru ’08

INFINITI G35 ’03 thru 08 - see NISSAN 350Z (72011) ISUZU 47017 47020

Hombre - see CHEVROLET S-10 (24071) Rodeo, Amigo & Honda Passport ’89 thru ’02 Trooper & Pick-up ’81 thru '93

JAGUAR 49010 X4J6 all 6 cyl models ’68 thru ’86 49011 XJ6 all models ’88 thru ’94 49015 XJ12 & XUJS all 12 cyl models ’72 thru ’85 JEEP 50010

Cherokee, Comanche & Wagoneer Limited all models ’84 thru ’01

50020 50025 50026

CJ all models ’49 thru ’86 Grand Cherokee all models ’93 thru ’04 Grand Cherokee ’05 thru ’09

50029

Grand Wagoneer & Pick-up ’72 thru ’91 Grand Wagoneer ’84 thru ’91, Cherokee & Wagoneer ’72 thru ’83, Pick-up '72 thru ’88

50030

Wrangler all models ’87 thru ’11

50035

Liberty ’02 thru 07

KIA

72010 72011 72015 72016 72020 72021 72025 72030 72031 72032 72040

300ZX all models including Turbo ’84 thru ’89 350Z & Infiniti G35 all models '03 thru ’08 Altima all models ’93 thru ’06 Altima ‘07 thru ‘10 Maxima all models '85 thru 92 Maxima all models '93 thru ’04 Murano ‘03 thru ‘10 Pick-ups ’80 thru 97 Pathfinder ’87 thru ’95 Frontier Pick-up, Xterra, Pathfinder '96 thru ’04 Frontier & Xterra 05 thru ’11 Pulsar all models ’83 thru ’86 Quest - see MERCURY Villager (64200) Sentra all models '82 thru ’94 Sentra & 200SX all models '95 thru ’06 Stanza all models ’82 thru ’90 Titan pick-ups ‘04 thru ‘10 Armada ‘05 thru ‘10

72050 72051 72060 72070

OLDSMOBILE 73015

For PLYMOUTH titles, see DODGE listing. Fiero all models ’84 thru ’88 Firebird V8 models except Turbo ’70 thru ’81 Firebird all models ’82 thru ’92 Gé6 all models ‘05 thru ‘09 Mid-size Rear-wheel Drive ‘70 thru ’87 Vibe ’03 thru ’11 - see TOYOTA Matrix (92060) For other PONTIAC titles, see BUICK, CHEVROLET or GENERAL MOTORS listing.

PORSCHE 80020 80025 80030 80035

911 914 924 944

Optima ‘01 thru ‘10

Sephia '94 thru ’01, Spectra ’00 thru ’09, Sportage ’05 thru ’10

SAAB

ES 300/330 - see TOYOTA Camry (92007) (92008) RX 330 - see TOYOTA Highlander (92095)

SATURN

LEXUS

LINCOLN 59010

Navigator - see FORD Pick-up (36059) Rear-Wheel Drive all models ’70 thru ’10

MAZDA 61010 61011 61012 61015 61016 61020 61030

61035 61036 61040 61041 61042 61043

GLC Hatchback (rear-wheel drive) '77 thru ’83 GLC (front-wheel drive) ’81 thru ’85 Mazda3 ‘04 thru ‘11 323 & Protogé ’90 thru ’03 MX-5 Miata ’90 thru ’09 MPV all models ’89 thru ’98 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 92 626, MX-6/Ford Probe ’93 thru ’02 Mazda6 ‘03 thru ‘11

MERCEDES-BENZ 63012 63015 63020 63025 63030 63040

123 Series Diesel ’76 thru ’85 190 Series four-cyl gas models, ’84 thru ’88 230/250/280 6 cyl sohc models ’68 thru ’72 280 123 Series gasoline models ’77 thru ’81 350 & 450 all models ’71 thru ’80 C-Class: C230/C240/C280/C320/C350 ’01 thru ’07

MERCURY 64200

Villager & Nissan Quest ’93 thru 01 All other titles, see FORD Listing.

MG 66010 66015

MGB Roadster & GT Coupe ’62 thru ’80 MG Midget, Austin Healey Sprite ’58 thru ’80

MINI 67020 Mini ‘02 thru ‘11 MITSUBISHI 68020 68030 68031 68035 68040

Cordia, Tredia, Galant, Precis & Mirage ’83 thru ’93 Eclipse, Eagle Talon & Ply. Laser ’90 thru ’94 Eclipse ’95 thru ’05, Eagle Talon ’95 thru ’98 Galant ’94 thru 10 Pick-up ’83 thru ’96 & Montero ’83 thru ’93

except Turbo & Carrera 4 ’65 thru ’89 all 4 cyl models ’69 thru ’76 all models including Turbo ’76 thru ’82 ali models including Turbo ’83 thru ’89

RENAULT

54050

54070

Alliance & Encore - see AMC (14020)

84010 87010 87011 87020 87040

900 all models including Turbo ’79 thru ’88 Saturn Saturn Saturn Saturn

all S-series models ’91 thru ’02 lon ’03 thru ’07 all L-series models ’00 thru ’04 VUE ’02 thru ’07

SUBARU 89002 89003 89100 89101

1100, 1300, 1400 & 1600 ’71 thru ’79 1600 & 1800 2WD & 4WD ’80 thru ’94 Legacy all models ’90 thru ’99 Legacy & Forester '00 thru 06

SUZUKI 90010

Samurai/Sidekick & Geo Tracker ’86 thru '01

92009 92015 92020 92025 92030 92032 92035 92036 92037 92040 92045 92050 92055 92056 92060 92065

Camry all models ’83 thru ’91 Camry all models ’92 thru ’96 Camry, Avalon, Solara, Lexus ES 300 ’97 thru ’01 Toyota Camry, Avalon and Solara and Lexus ES 300/330 all models '02 thru ’06 Camry ‘07 thru ‘11 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 models ’03 thru 11 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 Matrix & Pontiac Vibe '03 thru ’11 MR2 all models ’85 thru ’87

92070

Pick-up all models ’69 thru '78

92075 92076 92077 92078 92079 92080 92081 92082 92085 92090 92095

Pick-up all models ’79 thru ’95 Tacoma, 4Runner, & T100 ’93 thru '04 Tacoma all models ’05 thru ’09

Tundra ’00 thru '06 & Sequoia ’01 thru ’07 4Runner all models ’03 thru ’09 Previa all models ’91 thru ’95 Prius all models '01 thru 08 RAV4 all models ’96 thru 10 Tercel all models ’87 thru ’94 Sienna all models ’98 thru ’09 Highlander & Lexus RX-330 ’99 thru '07

96020

Rabbit, Jetta & Pick-up diesel ’77 thru ’84

96023 96030

Passat ’98 thru ’05, Audi A4 ’96 thru ’01 Transporter 1600 all models '68 thru 79 Transporter 1700, 1800 & 2000 ’72 thru ’79 Type 3 1500 & 1600 all models ’63 thru ’73 Vanagon all air-cooled models ’80 thru '83

96035

96040 96045

120, 130 Series & 1800 Sports '61 thru ’73 140 Series all models ’66 thru ’74

240 Series all models ’76 thru '93 740 & 760 Series all models ’82 thru ’88 850 Series all models ’93 thru ’97

TECHBOOK 10205 10206 10210 10215 10220 10225 10230 10240 10305 10310 10320 10330 10333 10340 10341 10345 10355 10360 10405 10410 10411 10415 10420 10425 10430 10435 10440 10445 10450 10452 98903 98904 98905 98906 98910 98913 98915 99040 99041 99042

MANUALS

Automotive Computer Codes OBD-II & Electronic Engine Management Automotive Emissions Control Manual Fuel injection Manual '78 thru ’85 Fuel Injection Manual ’86 thru ’99 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 Engine Performance Manual Small Engine Repair Manual, 5 HP & Less Small Engine Repair Manual, 5.5 - 20 HP 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 Electrical Manual Automotive Heating & Air Conditioning Automotive Reference Manual & Dictionary Automotive Tools Manual Used Car Buying Guide Welding Manual ATV Basics Scooters 50cc to 250cc

SPANISH

TOYOTA 92005 92006 92007 92008

96017 96018 96019

Beetle & Karmann Ghia '54 thru ’79 New Beetle '98 thru ’11 Rabbit, Jetta, Scirocco & Pick-up gas models '75 thru ’92 & Convertible ’80 thru 92 Golf, GTI & Jetta ’93 thru ’98, Cabrio ’95 thru ’02 Golf, GTI, Jetta 99 thru ‘05 Jetta, Rabbit, GTI & Golf ‘05 thru ‘11

96008 96009 96016

97050

PONTIAC

79040

Vw

97010 97015 97020 97040

PLYMOUTH

79019 79025

Spitfire all models ’62 thru ’81 TR7 all models '75 thru ’81

VOLVO

Cutlass V6 & V8 gas models '74 thru 88 For other OLDSMOBILE tities, see BUICK,

CHEVROLET or GENERAL MOTORS listing.

79008 79018

94007 94010

MANUALS

Reparacién de Carroceria & Pintura Manual de Carburador Modelos Holley & Rochester Cédigos Automotrices de la Computadora OBD-II & Sistemas de Control Electrénico del Motor Frenos Automotriz Electricidad Automotriz Inyeccién de Combustible ’86 al '99 Chevrolet & GMC Camionetas ’67 al '’87 Chevrolet & GMC Camionetas '88 al '98 Chevrolet & GMC Camionetas

Cerradas '68 al 95

.

99043 99048 99055 99075

Chevrolet/GMC Camionetas ‘94 al ‘04 Chevrolet/GMC Camionetas ‘99 al ‘06 Dodge Caravan & Plymouth Voyager 84 al '95 Ford Camionetas y Bronco ’80 al ’94

99076

Ford F-150 ‘97 al ‘09

99077 99088 99089 99091 99095 99100 ‘99106

Ford Camionetas Cerradas ’69 al ’91 Ford Modelos de Tamafio Mediano '75 al ’86 Ford Camionetas Ranger ‘93 al ‘10 Ford Taurus & Mercury Sable ’86 al ’95 GM Modelos de Tamajfio Grande ’70 al ’90 GM Modelos de Tamajfio Mediano ’70 al ’88 Jeep Cherokee, Wagoneer & Comanche

99110 99118 99125

Nissan Camioneta '80 al '96, Pathfinder ’87 al 95 Nissan Sentra ’82 al '94 Toyota Camionetas y 4Runner ’79 al 95

*84 al 00

Over 100 Haynes motorcycle manuals also available

7-12

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320- 1514 ¢ (805) 498-6703 ¢ http://www.haynes.com

Common

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

TOO HOT

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

CARBON

tion. Causes misfiring, hard starting and hesitation. Recommendation: Make sure the plug

has

the correct

for a clogged

heat

range.

air filter or

problem in the fuel system or engine management system. Also check for ignition system problems.

ASH DEPOSITS Symptoms: Light brown deposits encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfiring and hesitation during acceleration. Recommendation: _ |f excessive deposits

accumulate

over

plug life. Recommendation: Check for the correct plug heat range, overadvanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling.

PREIGNITION

DEPOSITS

Symptoms: Dry sooty deposits indicate a rich mixture or weak igni-

Check

Symptoms: Blistered, white insulator, eroded electrode and absence of deposits. Results in shortened

a short

time or low mileage, install new valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gasoline brands.

OIL DEPOSITS 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.

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

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

HIGH SPEED GLAZING Symptoms: Insulator has yellowish, glazed appearance. Indicates that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating.

Causes misfiring at high speeds. Recommendation: Install new plugs. Consider using a colder plug if driving habits warrant.

DETONATION Symptoms: Insulators may be cracked or chipped. Improper gap setting techniques can also result in a fractured insulator tip. Can lead to piston damage. Recommendation: Make sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid

lugging the engine.

MECHANICAL DAMAGE

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

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

Symptoms: May be caused by a foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could

result in piston damage. Recommendation: Repair the mechanical damage. Remove the foreign object from the engine and/ or install the correct reach plug.

Inside this manual: & Routine maintenance m@ Tune-up procedures m Engine repair

m@ Cooling and heating @ Air conditioning m Fuel and exhaust m= Emissions control @ Ignition m Brakes m Suspension and steering m@ Electrical systems @ Wiring diagrams

Step-by-step procedures linked to hundreds of easy-to-follow photos and illustrations

¢ Complete troubleshooting section helps identify specific problems e Written from hands-on experience based on a vehicle teardown using commonly available tools

e Haynes tips give valuable short cuts to make the job easier and eliminate the need for special tools e Notes, Cautions and Warnings for the home mechanic e Color spark plug diagnosis

e Easy to use index

Models covered by this manual: All Ford E-150, E-250 and E-350 Econoline vans with 4.2L V6, 4.9L inline six-cylinder, 5.0L, 5.8L and 7.5L OHV V8, 4.6L, 5.4L OHC V8 and 6.8L OHC V10 gasoline engines 1992 through 2012 Does not include diesel engine information, Compressed Natural Gas (CNG) information, or commercial-chassis vehicles

ABCDEFGHIJKLM

2

Visit www.haynes.com for FREE videos, tips and details on our complete Haynes line

799-1917 ISBN-10: 1-62092-077-8 ISBN-13: 978-1-62092-077-0

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