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

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1. 2. 3. 4. Disconnect negative cable from battery. Remove timing belt. Remove timing belt rear cover. Remove oil pan. 5. Remove crankshaft sprocket using Special Tools 6793 and C-4685-C2 (Fig. 104). 6. Remove crankshaft key (Fig. 105). 7. Remove oil pick-up tube. 8. Remove oil pump (Fig. 106) and front crankshaft seal. DISASSEMBLY 1. To remove the relief valve, proceed as follows: a. Remove the threaded plug and gasket from the oil pump (Fig. 107). b. Remove spring and relief valve (Fig. 107). 2. Remove oil pump cover fasteners, and lift off cover (Fig. 108). 3. Remove pump rotors (Fig. 108). 4. Wash all parts in a suitable solvent and inspect carefully for damage or wear. CLEANING Clean all parts thoroughly. INSPECTION 1. Inspect the mating surface of the oil pump. Surface should be smooth (Fig. 109). Replace pump cover if scratched or grooved. 2. Lay a straightedge across the pump cover surface (Fig. 110). If a 0.025 mm (0.001 inch) feeler gauge can be inserted between cover and straight edge, cover should be replaced. 3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.40 mm (0.370 inch) or less (Fig. 111), or if the diameter is 79.95 mm (3.148 inch) or less, replace outer rotor. 4. If inner rotor measures 9.40 mm (0.370 inch) or less replace inner rotor (Fig. 112) . ASSEMBLY 1. Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. 2. Prime oil pump before installation by filling rotor cavity with engine oil. 3. Install cover and tighten fasteners to 12 Nm (105 inch lbs.) (Fig. 108). CAUTION: Oil pump pressure relief valve must be installed as shown in

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OVERVIEW: This bulletin involves rotating all engine exhaust valves, replacing the valve spring retainer locks with a new design to increase valve rotation at lower RPM, inspecting/replacing the MAP sensor (as necessary), and decarbonizing the combustion chamber. MODELS: 2004 – 2006 2005 – 2006 (CS) (LX) Pacifica Chrysler 300/Magnum/Charger SYMPTOM/CONDITION: The customer may experience occasional engine misfire (rough running engine) during certain vehicle operating conditions. In addition, MIL illumination may also have occurred due to Diagnostic Trouble Code (DTC) P0300 – Multiple Cylinder Misfire. Various single cylinder misfire DTC’s may also be present. If the frequency of misfire is high, the Powertrain Control Module (PCM) may place the engine in “Limp-In” mode. The misfire condition may be caused by one or more engine exhaust valves that are slow to close due to a build up of carbon on the valve stem. DIAGNOSIS: 1. This condition may occur when the engine is not allowed to run at engine RPM’s that are greater than 3,500 RPM. At 5,000 RPM or higher the engine exhaust valves will rotate if not impeded by high carbon deposits. Low engine RPM’s and high carbon deposits are associated with short trip driving where the engine is not allowed to fully warm to normal engine operating temperatures. Cold ambient temperatures will increase engine warm-up time and increase the likelihood of carbon deposit build-up on the stem of the engine exhaust valve. Fuel detergent quality may also contribute to the condition; the customer may want to try a different brand of fuel. 2. Verify that the engine misfire condition is not caused by faulty engine mechanical or electrical components. 3. If the engine mechanical and electrical systems are operating properly perform the Repair Procedure.

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NOTE: Before proceeding, review all Steering Column and Airbag Warnings and Cautions. 1. Remove battery ground cable terminal from battery negative post and isolate. 2. Under instrument panel, remove silencer panel below lower steering column cover. 3. Remove screws securing lower steering column cover/knee blocker, then remove it. 4. Disconnect parking brake release link at release handle. 5. Compress tabs on sides of data link diagnostic connector and remove it from knee blocker reinforcement plate. 6. Remove screws securing knee blocker reinforcement plate in place, then remove reinforcement plate. Remove screws securing instrument panel lower left reinforcement in place, then remove reinforcement. 8. Remove brake lamp switch. Discard the original switch; it must not be reused Remove screws fastening upper and lower steering column shrouds to steering column. 10. Remove the lower shroud with adjustable pedal switch; disconnect switch wiring connector along left side of column as shroud is removed. 11. Disconnect traction control off switch wiring connector; Remove upper shroud with traction control off switch. 12. Disconnect wiring harness connectors (as equipped) from clockspring, multi- function switch, halo lamp, SKIM module, ignition switch and BTSI solenoid. 13. Disconnect column wiring harness routing clip from column.

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HEATER CORE – LHD WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. DO NOT OPEN THE RADIATOR DRAIN COCK OR DISCONNECT COOLANT HOSES WHEN THE SYSTEM IS HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. REMOVAL 1. Disconnect the negative battery cable. 2. Drain the cooling system. Refer to: “Engine, Cooling and Exhaust : Cooling System : Service and Repair” See: Engine, Cooling and Exhaust\Cooling System\Service and Repair 3. Evacuate the refrigerant system. Refer to: “Heating and Air Conditioning : Service and Repair” See: Service and Repair 4. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Procedures, See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair\Instrument Panel Service Procedures\Instrument Panel Assembly Replacement 5. Remove the refrigerant lines from the evaporator connections. 6. Remove the heater core coolant supply hoses from the heater core. 7. Working from inside the engine compartment, remove the A/C-heater housing retaining fasteners from the bulk head. 8. Remove the A/C-heater housing drain tube. Remove the spring clip from the A/C-heater housing and body attachement point. 9. Remove the A/C-heater housing retainer bolts. 10. Disconnect the electrical connectors from the A/C-heater housing. 11. Remove the A/C-heater housing from the vehicle and place the assembly on a bench. 12. Dissemble the heater core. 13. Remove the heater core from the housing. INSTALLATION Install heater core into HVAC housing. Assemble the HVAC housing. Take the HVAC housing from the work bench and place into vehicle. Install HVAC housing to vehicle. Install underhood HVAC housing drain tube to housing and install spring retainer clip. 6. Install electrical connectors to HVAC housing. 7. Install heater supply hoses to heater core connections. 8. Install refrigerant lines to the evaporator. 1. 2. 3. 4. 5.

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REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Remove the HVAC unit housing from the vehicle. See: Housing Assembly HVAC\Service and Repair 2. Remove the heater core tubes from the heater core. 3. Remove and discard the foam seal from the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening on the dash panel side of the unit. 4. Remove the expansion valve from the evaporator inlet and outlet tube fittings. 5. Disconnect the HVAC wire harness connector for the blower motor from the motor connector receptacle on the bottom of the outboard end of the evaporator housing. 6. Disengage the HVAC wire harness from the routing clips molded into the outside of the HVAC housing components.Remove the three screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing. 8. Pull the top of the distribution housing away from the evaporator housing far enough to disengage the two hook formations on the bottom of the distribution housing from the two receptacles on the evaporator housing. 9. Remove the two screws that secure the upper intake air housing to the lower intake air housing. 10. Remove the three screws that secure the upper intake air housing to the top of the outboard end of the evaporator housing. Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening.