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

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A/C and heating system components, engine compartment CAUTION! Parts marked with an asterisk (*) can be serviced only after the A/C refrigerant system has been discharged by a certified technician using EPA-approved refrigerant recovery and recycling equipment safety measures, A/C refrigerant system (R-134a), safety measures . Dust and pollen filter Where applicable 2- . Plenum cover Removing/installing 3- – -”> Evaporator water drain valve Located behind bulkhead insulation Removing/installing 4- . Heater core connections and vacuum hose guide 5- . Fresh Air/Recirculating Flap Two-Way Valve N63 Valve open when voltage applied Vacuum hose layout 6- . Coolant Fan Control (FC) Control Module J293 With fuse Fuse Strip S88 (1993 m.y.) With fuses Coolant Fan Second and Third Speed Fuse S107 and Coolant Fan First Speed and A/C Clutch Fuse S108 (1994 m.y. micro ) Connector terminal identification: micro 09.93 Fig. 5 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 ( 09.93) 10.93 micro Fig. 6 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 (10.93 ) 7- . Vacuum reservoir Insert vacuum hose 30 mm (1.2 in.) into reservoir Removing/installing Fig. 2 Removing and installing evaporator water drain valve Vacuum hose layout Fig. 7 Removing and installing vacuum reservoir

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Removal 1. Disconnect the battery ground cable. 2. Remove the camshaft position sensor (CMP sensor) (6B288); refer to Camshaft Position (CMP) Sensor—4.2L in this section. 3. Remove the exhaust gas recirculation (EGR) valve vacuum hose. 4. Remove the EGR tube upper fitting. 5. Remove the EGR valve (EGR valve) (9D475) and adapter. 1. Remove the bolts. 2. Remove the nut. 3. Remove the EGR valve and adapter assembly. 6. Remove the camshaft synchronizer adjustment bolt. 7. Remove the camshaft synchronizer (12A362). The oil pump drive shaft may come out with the camshaft synchronizer. Installation CAUTION: The Syncro Positioning Tool must be obtained prior to installation of the replacement camshaft synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. 1. Install the Syncro Positioning Tool on the camshaft synchronizer. Rotate the Syncro Positioning Tool until it engages the notch in the camshaft synchronizer housing. 2. NOTE: Rotate crankshaft to #1 cylinder TDC on compression stroke. Install the camshaft synchronizer housing assembly as shown. 3. NOTE: During installation, the arrow on the synchronizer alignment tool will rotate clockwise as the gears engage. Install the camshaft synchronizer housing assembly so the arrow on the Syncro Positioning Tool is 54 degrees from the centerline of the engine.

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Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. All engines 1. Disconnect the battery ground cable (14301). For additional information, refer toSection 414-01. 2. Relieve the fuel pressure. For additional information, refer toSection 310-00A. 3. Partially drain the cooling system. For additional information, refer toSection 303-03A or Section 303-03B. 4. Remove the power steering reservoir bracket. 1. Remove the bolts. 2. Position the power steering reservoir bracket out of the way. 5. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 6. Disconnect the fuel pressure regulator valve vacuum hose. 7. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. Disconnect the fuel lines. For additional information, refer toSection 310-00A. 8. Disconnect the eight ignition coil electrical connectors. 9. Disconnect the eight fuel injector electrical connectors. 4.6L engines 10. Remove the nut and disconnect the brake booster vacuum hose and bracket 5.4L engines 11. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. All engines 12. Remove the positive crankcase ventilation (PCV) hose. 5.4L engines 13. Disconnect the water heater inlet tube hose. 1. Release and move the hose clamp. 2. Disconnect the water heater inlet tube hose and position aside.

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All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Partially drain the cooling system. For additional information, refer toSection 303-03. 3. Remove the power steering fluid reservoir bracket. 1. Remove the bolts. 2. Position the power steering fluid reservoir bracket out of the way. 4. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 5. Disconnect the fuel pressure regulator vacuum hose. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. 6. Disconnect the fuel lines. For additional information, refer to Section 310-00. 7. Disconnect the eight fuel injector electrical connectors. 8. Disconnect the eight ignition coil electrical connectors. 9. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. 10. Remove the positive crankcase ventilation (PCV) hose. For vehicles equipped with 4.6L engine 11. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) connector, then disconnect the upper and lower EGR valve tube fitting.

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Installation All engines 1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. NOTE: 2.0L engine shown, 2.3L is similar. Inspect and install new intake manifold gaskets if necessary. 2. Install the EGR tube. 3. Position the intake manifold and connect the PCV hose. 4. Connect the KS electrical connector. 2.3L engines 5. NOTE: Be sure to install the bolts in the previously marked locations. NOTE: To ease installation of the intake manifold, lower center mounting bolt, use a 6-inch long, 5/16-inch diameter hose. Install the intake manifold and the seven mounting bolts. 6. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolts. 7. Connect the swirl valve electrical connectors and pin-type retainers. 2.0L engines 8. NOTE: Be sure to install the bolts in the previously marked locations. Install the intake manifold and the seven mounting bolts. 9. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolt. 10. Connect the swirl control valve electrical connector. 11. If equipped, connect the AIR vacuum supply hose. All engines 12. Install the lower intake bolt. 13. Connect the MAP sensor electrical connector. 14. Connect the IMRC actuator electrical connector. 15. Attach the wiring harness pin-type retainer. 16. Connect the fuel rail pressure and temperature sensor vacuum hose. 17. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting. 18. Connect the evaporative emissions hose. 19. Connect the IAC valve electrical connector and wiring harness pin-type retainer.