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

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REMOVAL: 1. 2. 3. 4. Remove distributor cap and rotor. Remove two module attaching screws, and lift module up. Disconnect leads from module. Observe color code on leads as these cannot be interchanged. Remove module. INSTALLATION: NOTE: Be sure there is a sufficient amount of silicone grease on the metal face of the module and on the distributor base (where the module seats), when reinstalling the module. The purpose of the silicone grease is to cool the module. 1. 2. 3. 4. 5. Install module. Connect leads to module. Install module attaching screws. Install pick up coil. Install cap and rotor.

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1. 2. Disconnect battery ground cable. On models with mechanical speedometers, reach up under instrument panel and disconnect speedometer cable by pulling cable while pressing tang on rear of speedometer head. On models with mechanical clocks, remove clock set stem and knob. On all models, remove screws attaching instrument cluster bezel to instrument panel, then the bezel. Remove two lower cluster attaching screws, Fig. 15. Pulling top of cluster away from instrument panel, lift out bottom of cluster. Disconnect instrument panel harness connector from printed circuit and remove cluster. Disconnect headlamp and wiper/washer switches. Remove lower extension assembly, engine cover, air cleaner cover and element, Fig. 16. Remove radio control knobs and retaining nuts, Fig. 17. Remove radio rear mounting bracket, then push radio forward in vehicle and lower assembly. Disconnect antenna and electrical connectors, then remove radio. Remove steering column brace bolts and lower column. Remove heater and A/C control attaching screws, then disconnect A/C, temperature and defroster cables. Mark cables for assembly reference. Remove instrument panel attaching bolts and nuts, then disconnect any remaining electrical connectors and remove panel, Fig. 18. Reverse procedure to install. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

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SPECIAL TOOL REQUIRED (or equivalent) ^ J-33039-A, Cam drive belt tension adjustment wrench. NOTE: O.E. manuals do NOT provide images of the timing marks, however, the alignment marks are located on the camshaft and crankshaft gears and the rear timing belt cover. REMOVE OR DISCONNECT 1. Battery ground cable, then partially drain cooling system. 1991 Pontiac J2000/Sunbird L4-121 2.0L 2. 3. 5. 6. 7. 8. 9. Coolant recovery reservoir. Serpentine, A/C and/or P/S drive belts (if equipped). Crankshaft pulley. Timing belt cover attaching bolts and the cover. Align marks on timing gears with the marks on the rear timing cover. Loosen water pump bolts, then using J-33039-A on the water pump eccentric, release the belt tension. Timing belt. INSTALL OR CONNECT 1. Turn crankshaft and camshaft gears clockwise to align timing marks on timing belt rear cover. 2. Timing belt, making sure that the portion between the crankshaft and camshaft gears is in tension. 3. Using J-33039-A rotate water pump eccentric clockwise until tensioner contacts high torque stop, then tighten water pump bolts slightly. 4. Rotate the engine by the crankshaft gear bolt 720° clockwise to seat timing belt on sprockets. 5. With engine at room temperature, rotate water pump eccentric with J-33039-A counterclockwise until hole in tensioner arm is inline with hole in base. 6. Tighten water pump attaching bolts to 25 Nm (18 ft lbs) and ensure tensioner holes remain aligned. 7. Timing belt cover and tighten bolts and nuts to 9 Nm (80 in lbs). 8. Crankshaft pulley, apply Loctite(R) 242 to bolt threads and tighten to 21 Nm (15 ft lbs). 10. Serpentine, A/C and/or P/S drive belts (if equipped). 11. Coolant recovery reservoir and fill cooling system. 12. Battery ground cable.

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On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow “Diagnosis” as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer “snapped” into its retainer, refer to “Temperature Control Cable Repair” in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: Condition: Cause: Correction For Number: 1. “Spring back” off full “hot” temperature control position (or not attaining full “cold” temperature door position). 2. “Spring back” off full “cold” temperature control position (or not attaining full “hot” temperature door position). The temperature control cable “clip” needs adjustment. Refer to the illustration for correct gripping of the “clip” during adjustment. 1. Grip “clip” at module end of cable while pulling temperature control lever to “hot” position.

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Remove or Disconnect (Figures 5 through 10 and Figure 20) 1. Battery ground cable. 2. Coolant recovery tank. 3. Heater core hoses (140 and 141) (figures 6, 7, 8 and 20). ^ Place a clean pan under the vehicle to catch any coolant spillage. ^ Plug the hoses. ^ Allow coolant in the core to drain into the pan. 4. Heater distributor duct (134) (figure 9). ^ Remove the screws that hold the distributor duct to the distributor case and the distributor duct to the engine cover. 5. Engine housing cover. Refer to Access Cover, Engine. See: Body and Frame 6. Instrument panel. See: Instrument Panel, Gauges and Warning Indicators 7. Lower the steering column. Refer to Steering Column. See: Steering and Suspension/Steering ^ Raise and support the right side of the instrument panel. 8. Defroster duct (130) to distributor case (124) attaching screws. 9. Distributor to heater case screws. 10. Temperature door cable (145) (figure 10). ^ Fold the cable back for access. 11. Heater case (124) and core (122). ^ Three nuts at the engine compartment side of the distributor case and one screw on the passenger side. ^ Tilt the case assembly rearward at the top while lifting up until the core tubes clear the dash openings. 12. Core retaining straps (123). 13. Core (122). Install or Connect (Figures 5 through 10 and Figure 20) 1. Core (122) to the heater case (124). ^ Apply a bead of permagum sealer between the core and the case. 2. Core retaining straps (123). 3. Heater case (124) to the vehcle. ^ Apply a bead of permagum sealer between the heater case and the opening in the vehicle. ^ Tilt the case until the core tubes clear the cowl opening. 4. 5. 6. 7. 8. 9. Temperature cable (145) to the heater case (124). Distributor duct (134) to the heater case (124). Defroster duct (130) to the heater case (124). Instrument panel. Steering column. Engine housing cover.