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

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FLARE INSTALLATION PROCEDURES Step 2: Preparing the Work Area A) Support and remove wheel using jack and jack stands. B) Remove wheel, factory flare, and any wheel well trim within 4” of the rim. Step 3: Fitting Flare to Body Side Molding (Front and Rear) On vehicles with hard rubber body side moldings, it will be necessary to cut either the flares or the moldings. Note: Cutting moldings usually produces better results. Option 1: Cutting Side Molding A) Place flare into wheel well opening and mark a line where flare intersects molding. B) Protect vehicle surface with masking tape and cut molding on marked line. C) Sand molding end with fine grit sandpaper to smooth finish. Option 2: Cutting Flare A) Place flare against molding at point of intersection and trace molding contour on flare. B) Cut flare on marked line. Step 4: Edge Trim Installation (See Illustration #1) A) Remove factory installed edge trim when necessary. B) Peel two to three inches of red vinyl backing away from edge trim tape and affix to flare at one end. (With Adhesive Strip to the inside of flare, See illustration #1) C) Press edge trim into place along edge of flare in one- foot increments, pulling red vinyl backing free as you continue to work your way around the flare. Step 5: Flare Installation (Front) (See Illustration #2) A) Clip and/or tape flare in place on fender and verify correct fit. The inner flare edge should be in contact with the wheel well roll-under flange, and the outer flare edge should conform to vehicle fender contours. See Illustration #2. B) Once flare is positioned properly in wheel well rim, drill and secure flare to fender at location #1 (See Illustration #2) using the kit supplied 9/64” drill bit and a small rivet. Secure flare rear “flat” to fender roll- under with two small rivets in the same manner. Remaining rivets are installed at the locations illustrated.

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EVAPORATOR REMOVAL AND INSTALLATION REMOVAL SERVICE POINT SUCTION PIPE OR HOSE, DISCHARGE PIPE DISCONNECTION CAUTION: Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapor easily, possibly damaging the condenser and deteriorating performance. Plug the disconnected hose and the evaporator nipple to prevent foreign material from getting into them. INSTALLATION SERVICE POINT >A< EVAPORATOR INSTALLATION When replacing the evaporator, refill it with the specified amount of compressor oil and install it (to the vehicle).

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LUBRICATION SERVICE INTERVALS Transaxle/Transmission Check fluid level every 12 months or 15,000 miles. Change fluid and filter every 30,000 miles. If vehicle is operated under severe conditions, change fluid more often. If severe darkening of fluid and strong odor are noted, bands should also be adjusted. Transfer Case On 4WD and AWD models, change transfer case fluid every 30, 000 miles. CHECKING FLUID LEVEL RECOMMENDED FLUID Transaxle/Transmission Use Chrysler Plus/Mitsubishi Plus ATF, Dexron or Dexron-II ATF. FLUID CAPACITIES DRAINING & REFILLING ADJUSTMENTS KICKDOWN BAND TRANSMISSION THROTTLE CONTROL SHIFT LINKAGE SHIFT LEVER SLEEVE

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Valve timing procedures Valve timing procedures Ensure crankshaft at TDC on No.1 cylinder. Ensure crankshaft pulley timing mark aligned with 0° timing mark on chain cover [1]. Ensure notch on camshaft points upwards [2]. If notch not visible, turn crankshaft one more turn. Install timing gears as follows: Ensure crankshaft gear and intermediate shaft gear timing marks aligned [3]. Install LH balancer shaft [4]. Ensure timing marks on intermediate shaft gears and LH balancer shaft gear aligned [5] & [6]. Ensure RH balancer shaft gear and oil pump gear timing marks aligned [7]. Install oil pump housing complete with RH balancer shaft. Ensure timing marks on oil pump gear and crankshaft gear aligned [8]. Install injection pump as follows [9] : Ensure notch on injection pump gear aligned with mark ‘T’ on flange [10]. During installation of injection pump: Notch on gear moves in direction of arrow. Install timing chain as follows:

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Installation (2001-02 Montero) 1. Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the auto-tensioner body, place flat washer around plug so it will not contact vise jaw. CAUTION: Never compress the auto-tensioner too fast, or the push rod will be damaged. 2. Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. WARNING: Right bank camshaft can easily turn from applied spring pressure. Be careful not to pinch fingers when installing timing belt. 3. Ensure all timing marks are still aligned. See Fig. 11 . Install timing belt on crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump pulley, right bank camshaft sprocket, and tensioner