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

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All vehicles 1. Remove the transmission. For additional information, refer to Section 307-01 for automatic transmissions or Section 308-03 for manual transmissions. Vehicles with manual transmission 2. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. All vehicles IN-VEHICLE REPAIR (Continued) 3. Remove the 10 bolts and flexplate or flywheel. • Discard the bolts. 4. NOTICE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin. Remove the flywheel front adapter. 5. NOTICE: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear. NOTICE: Drill only deep enough to penetrate the seal. Engine damage will occur if the seal is drilled too deep. NOTE: On original service seals, if equipped, the wear ring will be removed separately. Using a center punch, mark a location for 2 holes 180 degrees apart, 9.53 mm (0.375 in) from the outer diameter of the crankshaft flange. Using a drill bit of the appropriate size for the Slide Hammer being used, drill a hole on each side of the crankshaft rear seal as shown. Drill the holes to a depth of 8.76 mm (0.344 in) to capture the metal case of the crankshaft rear seal as well as the wear ring. 6. Using the 2 drilled holes, the Slide Hammer and a commercially available body dent puller attachment, walk the seal out of the rear cover by alternating from side to side to remove the crankshaft rear seal. • Discard the crankshaft rear seal. Vehicles with an original service seal 7. NOTE: Original equipment seals will not have a wear ring. If a service part has previously been installed, it will have a wear ring. If the service part was a redesigned seal, the wear ring will have been removed with the seal in the previous step. If the service part was an original service seal, the wear ring will remain in the engine after the seal has been removed. If the wear ring remained in the engine after removing the seal, use the Crankshaft Rear Wear Ring Remover to remove and discard the crankshaft rear seal wear ring. All vehicles 8. Clean and inspect the crankshaft sealing surface. Installation Vehicles with an original service seal 1. NOTICE: The crankshaft rear seal and wear ring are a one-piece design and need to be installed as an assembly. Do not separate the wear ring from the crankshaft rear seal or damage to the seal may occur. NOTE: An original service seal will have a wear ring without a flange and pre-applied threadlock. NOTE: Apply a bead of threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.

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During low speed turns/maneuvering, vehicle drivetrain feels as if it is binding or tires are scrubbing on pavement. Customer may also state that the ESP light in instrument cluster is ON or Flickering. Other customer described concerns may include, but are not limited to: • Tension in drivetrain • Vibration and load sensitive knocking from the drivetrain • Cracking noise upon acceleration from stop, while cornering or driving slowly • Shudder when cornering • Rubbing or slipping when cornering • Electronic faults in 22-Four wheel drive electronics: DTC’s 02033, 02039, 02042 or 02409 stored. The clutch disc of the differential has a remaining locking effect because of the differential control module software. This is perceived as tension in the drivetrain. Tip: The above symptoms can occur when driving with summer tires at temperatures below 7°C (45°F). In this temperature range the summer tires lose their elasticity. When fully turning the steering wheel the tire cannot correctly roll out and begins to bounce (slip – stick effect). This effect leads to the assumption of tension in the drivetrain, but the tension is in the tire wear pattern.

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Vehicles equipped with a manual transmission 1. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur resulting in complete clutch release. NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel. Remove the bolts, the clutch pressure plate, and the clutch disc. All vehicles 2. Remove the flywheel or flexplate. 3. Remove the engine-to-transmission spacer plate. 4. Mount the engine to a suitable engine stand and remove the lifting equipment and Lifting Eyes. 5. CAUTION: Do not pull on the spark plug wires. Twist the boot while pulling upwards. Disconnect the spark plug wires. 6. Disconnect the ignition coil electrical connector. 7. Remove the bolts and the ignition coil assembly. 8. Remove the bolts and the generator mounting bracket. 9. Remove the four bolts and the coolant pump pulley. 10. Remove the bolts and the crankshaft pulley. 11. Remove the crankshaft damper bolt.

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Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Disconnect the LH and RH battery ground cables. For additional information, refer to Section 414-01. Vehicles with manual transmission 3. NOTE: On vehicles equipped with manual transmissions, the transmission must be removed before the engine can be removed. Remove the transmission. For additional information, refer to Section 308-03. 4. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. All vehicles 5. Remove the cooling fan stator. For additional information, refer to Section 303-03. 6. Remove the air cleaner assembly. For additional information, refer to Section 303-12. 7. Remove the charge air cooler. For additional information, refer to Section 303-12. Vehicles with A/C 8. Remove the A/C condenser assembly. For additional information, refer to Section 412-03. All vehicles 9. Remove the radiator grille opening panel reinforcement. For additional information, refer to Section 501-02. 10. Remove the front bumper. REMOVAL (Continued) 11. Loosen the clamps and disconnect the power steering cooler hoses. • Plug or cap the openings as needed. 12. Disconnect the power steering tubes from the retaining clip and position aside. 13. Remove the bolts and power steering cooler.

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REMOVE TRANSAXLE FROM ENGINE 2. REMOVE CLUTCH COVER AND DISC a. Align the matchmark on the clutch cover with the one on the flywheel. b. Loosen each set bolt one turn at a time until spring tension is released. c. Remove the set bolts, and pull off the clutch cover with the clutch disc. NOTICE: Do not drop the clutch disc. 3. REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing with the fork together and then separate them. 4. REMOVE RELEASE FORK SUPPORT AND BOOT INSPECTION 1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using vernier calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 inch) If necessary, replace the clutch disc. 2. INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout. Maximum runout: 0.8 mm (0.031 inch) If necessary, replace the clutch disc runout. 3. INSPECT FLYWHEEL RUNOUT Using a dial indicator, check the flywheel runout. Maximum runout: 0.1 mm (0.004 inch) If necessary, replace the flywheel. Torque: 1st: 49 Nm ( 00 kgf-cm, 36 ft. lbs.) 2nd: Turn 90° 4. INSPECT DIAPHRAGM SPRING FOR WEAR Using vernier calipers, measure the diaphragm spring for depth and width of wear. Maximum: A (Depth): 0.5 mm (0.020 inch) B (Width): 6.0 mm (0.236 inch) If necessary, replace the clutch cover. 5. INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the release bearing. INSTALLATION 1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL