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

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Crankshaft front seal replacement is recommended whenever the engine front cover (6019) has been removed. 1. Disconnect battery ground cable (14301). Drain crankcase. 2. Drain cooling system. Refer to Section 03-03. 3. Remove drive belts (8620). Refer to Section 03-05. 4. Remove bolts attaching fan shroud (8146) to radiator (8005). 5. Remove fan blade (8600) from fan clutch (8A616) and remove fan shroud. 6. Remove fan clutch and water pump pulley (8509) from water pump (8501). 7. Disconnect upper radiator hose (8260) and lower radiator hose (8286) at engine (6007). Disconnect transmission oil cooler lines at radiator. 8. Remove upper radiator support bracket and remove radiator. 9. Remove generator pivot and attaching bolts. Remove generator (GEN) (10300) from generator mounting bracket (10153) and generator adjusting arm (10145). 10. Remove two bolts attaching generator adjusting arm to water pump and generator mounting bracket and remove generator adjusting arm. 11. Remove air pump pivot and attaching bolts. Remove secondary air injection pump (AIR pump) (9A486) from generator mounting bracket. 12. Remove four bolts attaching generator mounting bracket to cylinder head (6049), cylinder blocks (6010) and water pump, and remove generator mounting bracket. 13. Remove power steering pump pulley (3A733) from power steering pump (3A674). 14. Remove power steering lines from power steering pump. Remove four bolts attaching power steering pump to A/C compressor mounting bracket (2882) and remove power steering pump from A/C compressor mounting bracket. 15. Remove four bolts attaching A/C compressor (19703) to A/C compressor mounting bracket. Remove four bolts and one nut attaching A/C compressor mounting bracket to cylinder head and water pump. Remove A/C compressor mounting bracket from engine. 16. Remove the crankshaft pulley (6312) from the crankshaft vibration damper (6316). 17. Remove bolt and washer attaching crankshaft vibration damper. Remove crankshaft vibration damper using Crankshaft Damper Remover T58P-6316-D or Rotunda Gear and Pulley Puller 014-00293 or equivalent. Remove Woodruff key and crankshaft damper spacer from crankshaft (6303).

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Customer Concern: Tests/Procedures: Potential Causes: Diagnostic Codes: The service engine soon light is on with trouble code P1416 present. 1. Use a scanner and command the air pump on with the engine running at idle. Check if the O2 sensors go lean. 2. If the O2 sensor does not go lean on one bank, see if the check valve at the exhaust manifold is stuck closed, not allowing air into the manifold. Defective Check Valve P1416 Confirmed Fix Summary Confirmed Fix 18 – Air Injection Reaction (AIR) Check Valve 1 – Air Injection Reaction (AIR) Check Valve, Air Injection Reaction (AIR) Pump

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1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain coolant from radiator and cylinder block. Drain engine oil. Disconnect all necessary coolant hoses, electrical connectors, vacuum hoses, fuel lines and control cables. 2. Remove front exhaust tube. Remove intake manifold collector supports, and intake manifold. Remove exhaust manifold with catalytic converter. Remove air injection valve pipe. Remove intake air duct. Remove radiator fan and shroud. Remove injectors and fuel rail as an assembly. Remove distributor cap and spark plugs. 3. Set cylinder No. 1 at TDC of compression stroke, ensuring marks on crankshaft pulley and front cover align, and distributor rotor points to spark plug wire No. 1 on cap. Remove cylinder head cover. Remove distributor. NOTE: It is not necessary to install a stopper to prevent inner or outer timing chains from disengaging sprockets. 4. Prevent camshafts from turning, and remove camshaft sprocket bolts. Remove camshaft sprocket. See Fig. 13 . Mark and remove camshaft bearing caps in reverse order of installation. See Fig. 16 . Remove camshafts. 5. Loosen cylinder head bolts in 2 or 3 steps, in reverse order of tightening sequence. See Fig. 11 . Remove camshaft sprocket cover. Remove outer (upper) chain tensioner and guide. Remove outer timing chain. Remove idler sprocket bolt. Remove cylinder head. 6. Remove oil pan and oil strainer. See OIL PAN. Remove accessory drive belts. Remove A/C compressor idler pulley (if equipped). Remove crankshaft pulley. Remove front cover. Remove chain tensioner, tensioner arm and chain guides. Remove inner (lower) timing chain and idler sprocket. Remove oil pump drive spacer and crankshaft sprocket. Inspection 1. Inspect chain roller links. Replace chain if roller links are cracked or worn. Inspect cylinder head and cylinder block mating surfaces for warpage. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD under ENGINE SPECIFICATIONS. 2. If machining reduces cylinder head height to less than specification, replace cylinder head. After machining, rotate camshaft by hand. Replace cylinder head if camshaft does not rotate freely. Installation

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1. Remove the air cleaner assembly. 2. Disconnect the engine wiring harness electrical connector from the secondary air injection (AIR) pump electrical connector. 3. Squeeze the tangs together on the AIR pump inlet hose clamp at the pump until they lock, and reposition the clamp. 4. Remove the AIR pump inlet hose from the AIR pump. 5. Squeeze the tangs together on the AIR pump outlet hose clamp (3) at the pump until they lock, and reposition the clamp. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Squeeze the tangs together on the AIR pump outlet hose clamp (3) at the pump until they lock, and reposition the clamp. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 1. Install the AIR pump. 2. Raise and suitably support the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the AIR pump nuts (2). Tighten the nuts to 9 N.m (80 lb in). 4. Install the AIR pump electrical connector clip (1) to the bracket. 5. Lower the vehicle. Install the AIR pump outlet hose to the AIR pump. 7. Position and release the AIR pump outlet hose clamp. 8. Install the AIR pump inlet hose to the AIR pump. 9. Position and release the AIR pump inlet hose clamp. Connect the engine wiring harness electrical connector to the AIR pump electrical connector. 11. Install the air cleaner assembly.

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1. Loosen the AIR exhaust pipe (2) hose pinch clamp. 2. Disconnect the AIR exhaust hose (1) from the AIR pump (3). 3. Disconnect the AIR pump electrical connector (1). 4. Remove the three nuts (5) securing AIR pump bracket to transmission mount. 5. Remove the AIR pump and bracket as an assembly (4).NOTE: Refer to Fastener Notice in Service Precautions. 1. Secure the AIR pump and bracket (4) to the transmission mount with the three nuts (5). Tighten Tighten the three nuts securing the AIR pump mounting bracket to 50 N.m (37 lb ft). 2. Connect the AIR pump electrical connector (1).