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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1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in this section. 2. Disconnect the fuel line spring lock couplings. For additional information, refer to Section 310-00. 3. Disconnect the fuel pressure sensor. 1. Disconnect the fuel pressure sensor electrical connector. 2. Disconnect the fuel pressure vacuum line. 4. Disconnect the fuel injector electrical connectors and position the wiring harness to one side. 5. CAUTION: Do not loosen or bend the intake manifold runner control (IMRC) cable bracket. The bracket alignment is critical and damage to the IMRC actuator may occur. Disconnect the IMRC actuator cable from the stud and bracket. 6. NOTE: Remove the bolts in the indicated sequence. Remove the lower intake manifold and discard the gaskets. Installation 1. NOTE: Use new lower intake manifold gaskets. NOTE: Tighten the bolts in the indicated sequence. Install the lower intake manifold. Install the gaskets with the locating holes facing downwards. Position the gaskets in the position holes.

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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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All vehicles 1. Drain the cooling system. For additional information, refer to DRAINING . 2. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 3. Remove the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 4. Remove the 4 transaxle roll restrictor cross brace bolts.5. Remove the bolt and the transaxle roll restrictor cross brace. 6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer. 7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold. 8. Detach the fuel tube retainer from the upper intake manifold. 9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube. 10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer. 11. Disconnect the EGR system module tube from the EGR system module. Early build 12. Disconnect and plug the throttle body and PCV coolant hoses. Late build 13. Disconnect and plug the 2 PCV coolant hoses. All vehicles 14. Disconnect the throttle body electrical connector. 15. If equipped, remove and discard the 4 upper-to-lower intake manifold screws. 16. Remove the 8 bolts and the upper intake manifold. Remove and discard the gaskets. Installation All vehicles NOTE: Clean and inspect all sealing surfaces. Install new gaskets. 1. Position the upper intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 N.m (89 lb-in). 2. Connect the throttle body electrical connector. Late build 3. Connect the 2 PCV coolant hoses. Early build 4. Connect the throttle body and PCV coolant hoses. All vehicle 5. Connect the EGR system module tube to the EGR system module. Tighten to 40 N.m (30 lb-ft). 6. Attach the vacuum tube to the upper intake manifold vacuum tube retainer. 7. Connect the EGR system module electrical connector and vacuum tube. 8. Attach the fuel tube retainer to the upper intake manifold. 9. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold. 10. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer. 11. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads. 12. Position the transaxle roll restrictor cross brace and install the 4 new bolts. Tighten to 55 N.m (41 lb-ft). 13. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads. 14. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt. Tighten to 48 N.m (35 lb-ft). 15. Install the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 16. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 17. Fill and bleed the cooling system.

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REMOVAL: 1. Disconnect battery negative cable and drain cooling system. 2. Disconnect necessary electrical connections, control cables, linkages, vacuum hoses, ventilation hoses, and coolant hoses at throttle body and manifold. Do not disconnect fuel lines unless absolutely necessary. Special tools and procedures are required to re-install fuel lines. See “FUEL LINE REMOVAL AND INSTALLATION”. 3. Remove distributor cap and spark plug wires as an assembly. Place reference mark on distributor for rotor alignment during re- assembly. Remove retaining bolt and distributor. 4. Remove cover plates, retaining bolts, upper intake manifold and gasket. 5. Remove accessory brackets attached to lower manifold. Remove heater tube assembly from lower manifold. Remove retaining bolts, lower manifold, gaskets, and seals. BAFFLE INSTALLATION IMPORTANT: PCV valve baffle must be installed before manifold is bolted to engine! 1. Install PCV valve baffle on bottom of manifold using two-drive pins supplied. Hammer pin in the round hole first, then install other pin in the oval hole. INSTALLATION 1. Clean all gasket surfaces. Apply Edelbrock Gasgacinch sealant, #9300 to the cylinder head side of the gasket as well as head surfaces. Allow to air-dry. 2. Apply a 1/8” bead of O2 sensor safe RTV silicone sealer at the junction of the cylinder head and and engine block surface BEFORE gaskets are installed. Install intake manifold gaskets on head. 3. Eliminate the end seals. Use RTV silicone sealer instead (O2 Sensor Safe). Apply a bead of sealant approximately 1/4” high across the front and rear block end seal surfaces, overlapping the intake gasket at the four corners. This method eliminates end seal slippage and deterioration. 4. For ease of installation, we recommend using Edelbrock manifold bolt and washer kit #8524. It may be necessary to re-use the original stud bolt to hold heater tube bracket in hole #3 (See Figure 1). 5. Install lower intake manifold and retaining bolts. Tighten bolts to 15- 18 ft./lbs. in sequence (See Figure 1). 6. If fuel rail and injectors were disconnected, install components with new O-rings on fuel lines. Use only specified fuel resistant brown O-rings. Lightly coat O-rings with clean O-ring lube (brake lube) before installing. Clean fittings and replace garter spring, if necessary.