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

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Removal 1. Disconnect positive and negative battery cables from battery terminals. Remove the retaining bolt from battery cable support-to-frame bracket at left front of engine. Secure cables to engine . 2. Loosen radiator drain cock and drain coolant from radiator . Refer to Section 03-03. 3. Disconnect PCV closure hose at engine air cleaner outlet tube (9B659) . Release clips retaining air cleaner tap. Loosen air cleaner outlet duct clamp at throttle body (9E926) and remove air cleaner top and air cleaner outlet tube together. 4. Remove vacuum supply hoses from: a. Power brake booster (2005). b. Cruise control at check valve near throttle linkage (if equipped). c. Manifold absolute pressure sensor (MAP sensor) (9F479). d. Heater and air conditioner supply hose at A/C vacuum check valve (19A563) near A/C vacuum reservoir tank and bracket (19A566) . 5. Secure vacuum hoses to engine. 6. Remove upper radiator hose (8260) and lower radiator hose (8286) . 7. Disconnect power steering pressure switch (PSP switch) (3N824) . 8. Remove power steering pressure hose (3A719) from clips in fan shroud (8146) . 9. Remove two screws holding fan shroud to radiator and pull fan shroud out of lower clips. Rest fan shroud on radiator fan. 10. Disconnect automatic transmission cooler lines, if so equipped, from radiator . 11. Remove two radiator upper retaining bolts and lift radiator from core support. 12. Remove fan shroud from engine compartment. 13. Disconnect fuel charge wiring connectors at top center of dash panel. 14. Loosen clamps and disconnect heater supply hose at hot water heater elbow connection (18599) in lower intake manifold. Disconnect heater return hose at water pump. 15. Loosen retaining bolt and disconnect steering column at intermediate shaft. 16. Determine which type of air conditioning refrigerant is used in the vehicle. Follow the procedure for that specific refrigerant as outlined in Section 12-00 to drain air conditioning system and recycle refrigerant. NOTE: All openings in the air conditioning system must be capped to keep dirt, foreign material, and excess moisture out of the system. 17. Disconnect air conditioner liquid line at condenser and suction line from accumulator. 18. Disconnect canister purge hose at fuel vapor canister (9D653) under engine air cleaner base and secure to engine . 19. Release fuel system pressure as outlined in Section 03-04A. 20. Remove oil level indicator (7A020) . 21. Place a piece of 4×4 wooden block or other suitable material between the rear of the engine cradle and the forward surface of the oil pan sump to keep the engine from tilting rearward and damaging components when removing the transmission. 22. Remove transmission as outlined in Section 07-01 for automatic transmission and Section 07-03 for manual transmission. 23. Loosen and remove exhaust manifold stud nuts. Remove bolts retaining three-way catalytic converter (5E212) to muffler (5230) . Disconnect and remove muffler and three-way catalytic converter . Refer to Section 09-00 for specific removal and installation procedures. 24. Remove wheel hub bolt nuts (1012) and remove both front wheel (1007) and tire assemblies. 25. Remove dash panel ground cables (14303) . One is located on cylinder head just behind power steering pump (3A674) . The other is located just above where exhaust manifold (9430) and three-way catalytic converter connect. 26. Remove nuts and disconnect front stabilizer bar (5482) from front suspension lower arms (3079) . Discard nuts. 27. Remove front disc brake calipers (2B120) as outlined in Section 06-03 and secure to front suspension upper arms (3083) 28. Disconnect fuel lines along left frame rail near engine mounts as outlined in Section 03-04A. 29. Position a jack under front suspension lower arm and raise arm until tension is applied to front coil spring (5310) . Remove bolt and nut retaining spindle to front suspension upper arm ball joint. Slowly lower jack under front suspension lower arm to disconnect spindle from ball joint. 30. Position Drive Train Removal Lift 109-00002 or equivalent under crossmember and engine . 31. Lower vehicle until crossmember rests on removal lift. Place wood blocks under front crossmember and rear of cylinder block to keep engine and crossmember assembly level. Install safety chains around crossmember and lift. 32. Remove three nuts from bolts that retain engine crossmember assembly to frame on each side of vehicle.

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CONDITION & POSSIBLE CAUSE CORRECTION Hard Starting Binding carburetor linkage Eliminate binding Binding choke linkage Eliminate binding Binding choke piston Eliminate binding Restricted choke vacuum Check vacuum lines for blockage Worn or dirty needle valve and seat Clean carburetor, see ENGINE PERFORMANCE Float sticking Readjust or replace float see the ENGINE PERFORMANCE section Incorrect choke adjustment Reset choke adjustment see ENGINE PERFORMANCE Defective coil Replace coil Improper spark plug gap Regap spark plugs Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE Detonation Over-advanced ignition timing Reset ignition timing see ENGINE PERFORMANCE Defective spark plugs Replace spark plugs Fuel lines clogged Clean fuel lines EGR system malfunction Check and repair EGR system PCV system malfunction Repair PCV system Vacuum leaks Check and repair vacuum system Loose fan belts Tighten or replace fan belts, see ENGINE PERFORMANCE Restricted airflow Remove restriction Vacuum advance malfunction Check distributor operation Dieseling Binding carburetor linkage Eliminate binding Binding throttle linkage Eliminate blinding Binding choke linkage or fast idle cam Eliminate binding Defective idle solenoid Replace idle solenoid see ENGINE PERFORMANCE Improper base idle speed Reset idle speed, see see ENGINE PERFORMANCE Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE Incorrect idle mixture setting Reset idle mixture, see ENGINE PERFORMANCE Faulty Acceleration Incorrect ignition timing Reset ignition timing see ENGINE PERFORMANCE Engine cold and choke too lean Adjust choke and allow engine to warm-up Defective spark plugs Replace spark plugs Defective coil Replace coil

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Linkage Measurement CAUTION: Before attempting to test the Throttle Position Sensor (TPS), verify the linkage adjustment dimension shown in the figure above. This dimension MUST be 126.5 mm (5.0 inches) BEFORE testing. For linkage adjustment procedures, refer to Throttle Linkage Adjustment. CAUTION: Before testing the TPS, verify that the engine is set at correct low idle speed. Refer to Idle Speed Adjustment. This can be found in the Fuel Delivery and Air Induction system adjustments section. 1. After confirming the correct linkage adjustment and idle speed, proceed to the following: Throttle Position Sensor Location 2. Attach a paper clip into the center terminal of the TPS electrical connector. Do not remove the connector from the TPS for this test. 3. Attach the positive lead of a voltmeter to this paper clip and the negative lead to a good ground. 4. Turn the ignition switch to the ON position. Do not start engine. 5. The voltage at the TPS center terminal should be 1.0 volt (+/- 0.2 volt) with linkage at idle position. The voltage at the wide open throttle position

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Parts List (1) Power Plate (2) Gaskets (1) Linkage Plate (4) 6mm x 50mm Bolts (4) 6mm Flat Washers (1) 6mm x 12mm Flat Head Screw (1) 6mm x 20mm Flat Head Screw (2) 6mm Nuts (1) 6mm x 40mm Bolt (1) 6mm Lock Washer (1) 5/8” Dia. X 7/8” W/ 1/4” Hole Throttle Linkage Spacer 1. DISCONNECT NEGATIVE (-) BATTERY CABLE. 2. Remove air intake assembly. 3. Remove (1) 6mm bolt from throttle linkage bracket and save. (Ref. D) 4. Remove (4) 6mm bolts from throttle body. (Ref. C) 5. Install the power plate using (2) gaskets. (Ref. A) A. Place one gasket between the throttle body and power plate. B. Place second gasket between the power plate and intake manifold. 6. Install (4) 6mm x 50mm bolts and (4) 6mm flat washers. Refer to (Ref. C) 7. Install throttle linkage bracket using (1) 6mm flat head screw and (1) 6mm flat head screw with (1) 6mm nut. 8. Attach throttle cable assembly fitting with saved 6mm bolt. Refer to Step 3 9. Install throttle linkage spacer using (1) 6mm x 40mm bolt, (1) 6mm nut, and (1) 6mm lock washer. (Ref. D) 10. Inspect & Test throttle linkage for full open & closed travel before driving. Some cruise or kickdown cables may require adjustment. Please refer to your vehicles service manual for proper adjustment. 11. Reinstall air cleaner assembly. Refer to Step 2 12. Reconnect battery cable. Enjoy!

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If vehicle is equipped with air bag, air bag must be deactivated before servicing cruise control components on or around steering column. See appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES & EQUIPMENT. NO CRUISE CONTROL WHEN SET BUTTON IS PRESSED & RELEASED Check for: blown fuse, no vacuum at servo and/or defective servo, disconnected speed control cable, brakelight switch out of adjustment, faulty electrical circuit, faulty Park/Neutral switch input to PCM, faulty PCM. CRUISE CONTROL ENGAGES WITHOUT ACTUATING CRUISE SET BUTTON Check for: defective servo, faulty electrical circuit or control switch. CRUISE CONTROL ENGAGES WHEN ENGINE IS STARTED Check for: defective servo, faulty electrical circuit. ERRATIC SPEED OR ENGINE SHUTS OFF Check for: poor engine performance (surge), defective vehicle speed sensor, vacuum leak, faulty servo, faulty
CRUISE CONTROL DISENGAGES ON ROUGH ROAD Check for: brakelight switch out of adjustment, faulty cruise control switch, faulty electrical circuit. ENGINE DOES NOT RETURN TO NORMAL IDLE Check for: kinked and/or damaged cruise control cable, faulty throttle linkage.