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

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TIMING BELT Removal 1. Disconnect negative battery cable. Remove upper engine torque strut attaching bolts and remove engine torque strut. See Fig. 5 . Remove engine torque strut bracket from strut tower. On PT Cruiser (Turbo), discharge and evacuate A/C system. Disconnect A/C lines at junction block near upper timing belt cover. 2. On all models, remove upper timing belt cover bolts and remove cover. See Fig. 6 . Raise vehicle on hoist and remove right front wheel. Remove splash shield. See Fig. 7 . Remove accessory drive belts. Remove crankshaft damper. See Fig. 8 . Remove pencil strut. See Fig. 2 . Remove lower engine torque strut. See Fig. 5 . 3. Disconnect exhaust system front pipe from manifold. Disconnect A/C pressure switch at rear of compressor housing. Lower vehicle and support engine with a jack. If not done previously, discharge and evacuate A/C system. Disconnect A/C lines at junction block. Remove screw attaching ground strap to strut bracket. Remove torque strut bracket from strut tower. Remove upper radiator closure panel. Without disconnecting lines from power steering pump, remove pump and bracket and set pump aside. 4. With engine properly supported, remove right engine mount through-bolt. See Fig. 5 . Raise engine with jack until engine support bracket bolts are accessible, and remove engine support bracket. See Fig. 9 . Remove lower timing belt cover bolts and remove cover. See Fig. 6 . CAUTION: When aligning crankshaft and camshaft timing marks, always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed, or damage to valve components may occur. CAUTION: Crankshaft sprocket TDC mark is located on the trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause camshaft timing marks to be misaligned. 5. Before removal of timing belt, rotate crankshaft until TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). See Fig. 10 . 6. Loosen timing belt tensioner lock bolt, and insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley. See Fig. 11 . Rotate top plate clockwise until there is enough slack in timing belt to allow for removal. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. CAUTION: If timing belt was damaged due to incorrect rotating tracking (alignment), belt tensioner pulley and bracket must be replaced as an assembly.

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WARNING: THE ELECTRIC COOLING FAN MAY COME ON AT ANY TIME WHEN THE IGNITION SWITCH IS IN THE ON POSITION. If the coolant has not been changed in the last 36 months, or 48,000 km (30,000 miles), or if the inspection reveals hoses, gaskets, or other components requiring service or replacement, the coolant must be drained and discharged, or saved for reuse, depending on its condition. For a vehicle with a rear heater, set the rear blower switch to 4 and the rear temperature control knob to the full WARM position. 1. For vehicles equipped with manual A/C-heater, turn the ignition switch to the ON position and set the front temperature control panel selectors in the following positions: The front blower switch to 4. The front temperature control knob to the full WARM position. The rear control switch to the 4 position. The mode selector switches to any mode except OFF. 2. For vehicles equipped with electronic automatic temperature control (EATC), turn the ignition switch to the ON position and perform the following procedures: Turn the blower motor control to HI. Press the TEMP button to the maximum temperature setting. Turn the rear control switch to the 4 position. Turn the mode selector switches to any mode except OFF. 3. Turn the ignition switch (11572) OFF. 4. Remove the RH engine and transmission splash shield (6776). 5. NOTE: Do not use a galvanized drain pan if the coolant is going to be reused. Position a drain pan under the radiator (8005). 6. Open the radiator draincock (8115) at the bottom of the radiator inlet tank (8079). 7. CAUTION: Do not allow coolant to contact the drive belts (8620) or they will be damaged. Remove the radiator cap (8100) from the filler neck. If the system is hot and pressurized, carefully release the pressure before fully opening the radiator cap. 8. Use an Allen wrench to loosen the radiator air relief plug three turns. Do not remove the radiator air relief plug.

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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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Drive Belt, Serpentine NOTE: Minor cracks in the V-grooved portion of the serpentine drive belt are considered normal and acceptable. If the drive belt (8620) has chunks missing from the ribs, the drive belt should be replaced. NOTE: When installing drive belts on pulley, make sure that all V-grooves make proper contact with pulleys. Conditions requiring drive belt replacement are excessive wear, rib chunkout, severe glazing, frayed cords, etc. Replace any drive belt that exhibits any of these conditions. Removal 1. WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE THAT TOOL DOES NOT SLIP. Using a 15 mm socket or wrench on bolt, attach drive belt tensioner pulley. Rotate drive belt tensioner (6B209) clockwise to remove drive belt from pulleys. Pulley Routing, Accessory Drive Belt — 3.8L Engine Installation 1. Install drive belt over all pulleys (except drive belt tensioner). 2. Rotate drive belt tensioner as described under Removal to install drive belt over drive belt tensioner pulley. Make sure that all V-grooves make proper contact with pulleys.

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To ensure maximum drive belt life and proper component operation, replacement drive belts (8620) must be the same type and size as the original drive belts . When installing a new drive belt , ensure that it is properly seated on the pulleys. NOTE: Mark the direction of rotation on the drive belt with a marking pen to ensure correct installation if the drive belt is to be reused. Failure to do so may result in drive belt noise. Drive Belt, A/C Compressor Removal 1. Loosen the A/C compressor drive belt idler pulley tensioner bolt. 2. Loosen the A/C compressor drive belt idler pulley adjustment bolt. 3. Remove the A/C compressor drive belt from the A/C compressor clutch pulley (2E884) , A/C compressor drive belt idler pulley and the crankshaft pulley (6312) . Installation 1. Inspect the pulleys for warping or abnormal wear. Replace any damaged pulley. To replace the A/C compressor clutch pulley , refer to Section 12-03B. To replace crankshaft pulley , refer to Section 03-01. 2. Install the A/C compressor drive belt on the A/C compressor clutch pulley , A/C compressor drive belt idler pulley, and crankshaft pulley . 3. Adjust the A/C compressor drive belt tension. Refer to the procedure in this section. 4. Tighten the A/C compressor drive belt idler pulley tensioner bolt securely. Drive Belt, Generator Removal 1. Raise and support the vehicle. 2. Remove the RH engine and transmission splash shield (6775) . 3. Loosen the inner and outer generator-to-generator regulator mounting bracket bolts. 4. Loosen the generator locking bolt.