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

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1. NOTE: When the battery has been disconnected or reconnected, volatile memory information will be lost. The affected systems will have to be programmed by the technician or customer. These systems include: radio station presets, clock settings, seat memory, mirror memory, window memory and customer input keyless, window memory and customer input keyless entry codes. Disconnect the battery ground cable. For additional information, refer to Section 14-01. 2. Drain the cooling system. For additional information, refer to section 03-03. 3. Remove the engine cover (covering the throttle body). 4. Disconnect the crankcase ventilation tube and the idle air control valve inlet tube from the air cleaner outlet tube. Remove the air cleaner outlet tube. 5. WARNING: THE FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES REMAIN PRESSURIZED FOR LONG PERIODS AFTER ENGINE SHUT DOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE, TO PREVENT POSSIBLE INJURY. Connect the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (T80L-9974-B) to the fuel pressure relief valve on the fuel supply manifold. Open the manual valve on the gauge to relieve the fuel system pressure. Once the pressure is relieved, close the valve and remove the gauge. 6. Remove the locking clip from the pressure and return fuel line spring lock couplings. Using the spring lock coupling disconnect tools (D87L-9280-A for 3/8-inch line, D87L-9280-B for 1/2-inch line) on the couplings. Push the tool into the cage opening to release the female fitting from the garter spring. Remove the tool and pull the male coupling and fitting apart. Install protective caps over the lines and the fuel rail. 7. Disconnect the upper radiator hose from the water outlet connection and position it out of the way. 8. Disconnect the accelerator cable and the speed control actuator cable from the throttle body and the locator. Remove the screws retaining the cables to the accelerator cable bracket and position the cables out of the way. 9. Disconnect the wiring connectors from the throttle position sensor (TP), idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Disconnect the wiring connectors from the LH fuel injectors and the two wiring locators from the fuel rail. Position the harness out of the way. 10. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the LH spark plugs and position them out of the way. Refer to Section 03-07. 11. Remove the bolts retaining the spark plug wiring harness bracket to the intake manifold and the generator. Disconnect the ignition wires from the locators and remove the bracket. 12. Remove the serpentine drive belt from the generator pulley. Refer to Section 03-05. 13. Remove the generator retaining bolts and position it out of the way. 14. Remove the PCV valve and tube. 15. Disconnect the wiring connectors from the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Disconnect the RH fuel injector connectors and harness locators from the fuel rail. Position the harness out of the way. 16. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the RH spark plugs and position them out of the way. For additional information, refer to Section 03-07. 17. Disconnect the vacuum line from the fuel vapor storage canister purge valve. Disconnect the heater hose from the rear of the intake manifold. 18. Disconnect the main vacuum hose from the rear of the intake manifold. Disconnect the hose from the fuel vapor storage canister purge valve. 19. Disconnect the EGR tube nut from the EGR valve. 20. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve and gasket. 21. Remvoe the water outlet connection housing. 22. Remove the intake manifold. Remove and discard the intake manifold gaskets.

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Installation All engines 1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. NOTE: 2.0L engine shown, 2.3L is similar. Inspect and install new intake manifold gaskets if necessary. 2. Install the EGR tube. 3. Position the intake manifold and connect the PCV hose. 4. Connect the KS electrical connector. 2.3L engines 5. NOTE: Be sure to install the bolts in the previously marked locations. NOTE: To ease installation of the intake manifold, lower center mounting bolt, use a 6-inch long, 5/16-inch diameter hose. Install the intake manifold and the seven mounting bolts. 6. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolts. 7. Connect the swirl valve electrical connectors and pin-type retainers. 2.0L engines 8. NOTE: Be sure to install the bolts in the previously marked locations. Install the intake manifold and the seven mounting bolts. 9. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolt. 10. Connect the swirl control valve electrical connector. 11. If equipped, connect the AIR vacuum supply hose. All engines 12. Install the lower intake bolt. 13. Connect the MAP sensor electrical connector. 14. Connect the IMRC actuator electrical connector. 15. Attach the wiring harness pin-type retainer. 16. Connect the fuel rail pressure and temperature sensor vacuum hose. 17. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting. 18. Connect the evaporative emissions hose. 19. Connect the IAC valve electrical connector and wiring harness pin-type retainer.

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1. Relieve the fuel pressure. Refer to Section 10-01 for the procedure. 2. Disconnect the battery ground cable (14301). 3. Drain the cooling system. Refer to Section 03-03 for the procedure. 4. Remove the engine air cleaner intake tube (9A624) and engine intake air resonator (9F763). Refer to Section 03-12 for the removal procedure. 5. Disconnect the two throttle position (TP) sensor electrical connectors. 6. Slide the TP sensor electrical wiring out of the bracket. 7. Remove the coolant hose from the throttle body (9E926). 8. Disconnect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector. 9. Remove the evaporative emission (EVAP) canister vacuum hose. 10. Disconnect the EVAP canister-to-throttle body hose from the throttle body. 11. Remove the fuel pressure regulator-to-upper intake manifold vacuum hose from the upper intake manifold (9424). 12. Disconnect the No. 1, 3, and 5 cylinder distributor to spark plug wires (12286) from the spark plugs (12405), then remove the spark plug wire boots from in between the upper intake manifold runners. 13. Remove the two spark plug wire bracket bolts and spark plug wire brackets from the upper intake manifold. 14. Remove the distributor dust cover. 15. NOTE: The distributor cap screws are not removable from the distributor cap (12106). Loosen the three distributor cap screws. 16. Remove the distributor cap from the distributor (12127). Position the distributor cap and distributor to spark plug wires aside to gain access to the main engine wiring harness. 17. Disconnect the rear heater valve vacuum hose from the right side of the upper intake manifold, if equipped.

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NOTE: The 3.0L throttle body (9E926) and upper intake manifold are combined in one piece. 1. Perform Pre-Service procedures as described in this section. 2. Disconnect electrical connectors to the intake air temperature sensor (IAT sensor) (12A697) and mass air flow sensor (MAF sensor) (12B579). 3. Disconnect air crankcase ventilation hose (6853) from nipple on valve cover (6582). 4. Loosen clamps and remove air cleaner outlet tube (9B659). 5. Using trim removing tool, remove pushpins and accelerator control splash shield (9E766). 6. Disconnect accelerator cable (9A758) from throttle body. Remove three screws and accelerator cable bracket (9723) and position assembled accelerator cable and accelerator cable bracket out of the way. 7. Tag and disconnect connectors of emission control vacuum harness and remove. 4 9J459 5 9A474 8. Disconnect PCV hose from throttle body. PCV Hose EGR Vacuum Regulator Solenoid Intake Manifold Vacuum Outlet Fitting and Cap 9. Disconnect spark plug wires from ignition coil (12029) and position out of the way. 10. Disconnect electrical connections from ignition coil, EGR vacuum regulator solenoid (9J459), EGR transducer (9J433), idle air control valve (IAC valve) (9F715), and throttle position sensor (TP sensor) (9B989). 11. Remove two nuts and ignition coil mounting bracket (12N004). 12. Remove two nuts and ignition coil with assembled bracket, EGR vacuum regulator solenoid and radio ignition interference capacitor (18801).

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1. Remove the air cleaner outlet tube. 1. Remove the crankcase ventilation tube. 2. Loosen the clamps. 3. Remove the air cleaner outlet tube. 2. Remove the three nuts and the engine appearance cover. 3. Disconnect the cables. 1. Disconnect the throttle cable. 2. If equipped, disconnect the speed control cable. 3. Remove the throttle cable bracket bolts. 4. Disconnect the throttle position (TP) sensor and idle air control (IAC) electrical connectors. 5. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and EGR tube nut. 6. Disconnect the EGR vacuum regulator solenoid electrical connector and vacuum hose. 7. Disconnect the three vacuum hoses on the back of the intake manifold. 1. Disconnect the chassis vacuum hose. 2. Disconnect the engine vacuum hose. 3. Disconnect the positive crankcase ventilation (PCV) hose. 8. Disconnect the vapor management valve (VMV) vacuum hose. 9. Disconnect the two electrical connectors attached to the left side of the upper intake manifold.