Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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TIMING BELT Removal 1. Disconnect negative battery cable. Remove upper engine torque strut attaching bolts and remove engine torque strut. See Fig. 5 . Remove engine torque strut bracket from strut tower. On PT Cruiser (Turbo), discharge and evacuate A/C system. Disconnect A/C lines at junction block near upper timing belt cover. 2. On all models, remove upper timing belt cover bolts and remove cover. See Fig. 6 . Raise vehicle on hoist and remove right front wheel. Remove splash shield. See Fig. 7 . Remove accessory drive belts. Remove crankshaft damper. See Fig. 8 . Remove pencil strut. See Fig. 2 . Remove lower engine torque strut. See Fig. 5 . 3. Disconnect exhaust system front pipe from manifold. Disconnect A/C pressure switch at rear of compressor housing. Lower vehicle and support engine with a jack. If not done previously, discharge and evacuate A/C system. Disconnect A/C lines at junction block. Remove screw attaching ground strap to strut bracket. Remove torque strut bracket from strut tower. Remove upper radiator closure panel. Without disconnecting lines from power steering pump, remove pump and bracket and set pump aside. 4. With engine properly supported, remove right engine mount through-bolt. See Fig. 5 . Raise engine with jack until engine support bracket bolts are accessible, and remove engine support bracket. See Fig. 9 . Remove lower timing belt cover bolts and remove cover. See Fig. 6 . CAUTION: When aligning crankshaft and camshaft timing marks, always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed, or damage to valve components may occur. CAUTION: Crankshaft sprocket TDC mark is located on the trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause camshaft timing marks to be misaligned. 5. Before removal of timing belt, rotate crankshaft until TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). See Fig. 10 . 6. Loosen timing belt tensioner lock bolt, and insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley. See Fig. 11 . Rotate top plate clockwise until there is enough slack in timing belt to allow for removal. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. CAUTION: If timing belt was damaged due to incorrect rotating tracking (alignment), belt tensioner pulley and bracket must be replaced as an assembly.

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SUBJECT: Rattle/knocking Sound From The Front Suspension OVERVIEW: This bulletin involves replacing the front sway bar bushings at the frame. SYMPTOM/CONDITION: The vehicle may exhibit a rattle/knocking sound which may be heard at low speeds while driving over bumps and/or road surfaces with minor fluctuations. REPAIR PROCEDURE: 1. Replace both front sway bar bushings at the frame. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, 2 – Suspension, Front, Bushings, Removal and Installation.

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SYMPTOM/CONDITION: Some customers may experience transmission shift or performance concerns as follows: i. ii. iii. iv. v. During a rapid coast down while braking a bump may be felt just before a stop 3 – 2 kickdown bump or harshness 2 – 3 upshift bump or harshness 4 – 3 – 4 change mind shift bump Improved shift quality/driveability through all gear transactions NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 – Electrical > Electronic Control Modules – Service Information > Module – Powertrain Control > Standard Procedures > PCM/ECM Programming – Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the StarSCAN® Misc Function Menu. VLP Clear Counters must be completed on all models with a 62TE transmission. b. Clear any DTC’s that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the StarSCAN® Misc Function Menu. 2. Type the necessary information on the “Authorized Modification Label” and attach it near the VECI label.

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SYMPTOM/CONDITION: Front brake pads may exhibit excessive noise, squeal/shudder/vibration and/or lining life complaints. DIAGNOSIS: If the above condition is present, perform the repair procedure. REPAIR PROCEDURE: 1. Using the procedures outlined in TechCONNECT: Service Information tab /05 – Brakes, Base/Hydraulic Mechanical/PADS, Brake, Front/ Removal – remove the front pads. 2. Using the procedures outlined in TechCONNECT: Service Information tab /05 – Brakes, Base/Hydraulic Mechanical/ROTAR, Brake, Front/ Removal – remove and replace the front brake rotors (p/n 04721995aa). NOTE: Rotor replacement is recommended when switching to this type brake pad. Standard brake service procedures apply thereafter. 3. Install new pads (p/n 68053152aa).

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CHRYSLER ALTERNATOR See Figures 1, 2, 3, 4 and 5 Fig. 1: Alternator mounting-2.2L and 2.5L engines Fig. 2: Disconnecting alternator wiring-2.2L and 2.5L engines Fig. 3: Disconnecting alternator wiring Fig. 4: Removing the pivot bolt and nut Fig. 5: Removing the alternator from the vehicle Disconnect the negative battery cable. Label and disconnect the wiring (for easy installation). Remove the air conditioning compressor drive belt, if equipped. Loosen the alternator adjusting bracket bolt and adjusting bolt. Remove the alternator belt. 5. Remove the bracket and mounting bolts. 6. Remove the pivot bolt and nut. 7. Lift the alternator from the vehicle. When lifting the alternator out of the vehicle on some years with A/C, clearance may be restricted by the condenser cooling fan assembly or the A/C compressor and mounting bracket assembly, if so, removal of one of these items will be necessary. 8. Position the alternator against the engine. 9. Install the pivot bolt and nut. 10. Install the mounting bracket bolts, and adjusting bolt. 11. Install drive belts and adjust to specification. 12. Tighten all the mounting bolts and nuts. 13. Connect all alternator terminals. 14. Connect the negative battery cable. Disconnect the negative battery cable. Disconnect the wiring and label for easy installation. Remove the air conditioning compressor drive belt. Loosen the alternator adjusting bracket locknut and adjusting screw. Remove the alternator belt. 5. Remove the bracket locknut and mounting bolt. 6. Remove the pivot bolt and nut. 7. Remove the alternator from the engine. 8. Position the alternator against the engine. 9. Install pivot bolt and nut. 10. Set the mounting bracket in place and install the bracket mounting bolt and locknut. 11. Install the drive belts and adjust to specification. 12. Tighten all the mounting bolts and nuts. 13. Connect all alternator terminals. 14. Connect the negative battery cable.