SECTION 0

GENERAL INFORMATION

CONTENTS

;~;~~ :';;::':~'t:b;i~~ii~~':::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

SECTION OA

\

GENERAL INFORMATION

CONTENTS

SUBJECT

GFe~:n::JI: '~~~~~i!:.~~:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

\ Certlfl •• Uon Label .

; ~~~~~~~~:~~~:-~~:~:~

EUCtr .tatlc DI.ch.rg ..

Common Abbreviations _ .

/" RPO Listing (Regular Production Option) .

SERVICE PARTS IDENTIFICATION LABEL

The Truck Service Parts Identification Label is providqd on all models (figure 1), It is located on the inside of the glove box door (or on an inner body panel for Forward Control models). The Label lists the VIN (Vehicle Identification Number). wheelbase, paint infonnation and all Production options or Special Equipment on the vehicle when 'it was shipped from Ihe faclory. ALWAYS REFER TO THIS INFORMATION WHEN ORDERING PARTS.

\. Vehicle Idenlification Number (VIN)

2. Wheel Base

3. Model Designalion

4. RPO and/or SEO Oplions

5. Order Number

6. Exterior Color

7. Painl Technology LO

Figure 1 - Service Parts Identification Lal

OA·2 GENERAL INFORMATION

-,

\

VEHICLE IDENTIFICATION NUMBER

The VIN is the legal identi1ier 01 the vehicle. On all models except Forward COntrol, it is located on a plate which is attached to the left top of the instrument panel and can be seen through the windshield from the outside of the vehicle (figure 2). On Forward Control models, the plate is on the dash and toe panel. To find the manufacturer, model and chassis type, engine type, GVW range, model year, plant code, and sequential number, refer to figure 3.

F-00687

Figure 2 - VIN Location

CERTIFICATION LA~

The Certification Label shows the GVWR, i. and rear GAWAs, and the Payload Rating for (figure 4).

Gross Vehicle Weighl (GVW) is the weight of\

nally equipped vehicle and all items added to it a\

left the factory. This would include bodies, winche~

etc.; the driver and all occupants; and the load the' carrying. The GVW must nat exceed the GVWR., rOSC":1fi front and fear gross axle weights must not exce~1 ~thSCf

and rear GAWRs. .J" e ror

F-01407

Figure 4 - Certlllcat ~n Lobel

The Payload Ra1in~ sho~n o~ label is the maxi;;m allowable cargo load (tncl~dl.nQtne \'''eight of the driver and all occupants) that the vehiCfe can can ... based on all factory

4

4

G T

o

R

C"O'M .....

A' C~t'lrl>le! 6tJs'

a C~~~ro;>lellncomtilele C Chil~ro;>lel Tr..,~~

D OMC Incomplele

GMOrCan30.I Bus GMC BIIS

GMC MPV C-hewolel M"II OMCTruc:k

• Vim .... 11" 4t~ SUI

U".41'1I!1Ch'UiI"iy~ Ch.:!II!1I

Code Type

C ConvenliOl'lal Cab 4.2

A Conventional Cllb 4 ~ 2

D Milllai)' TfUC=k 4 ~ 4

K Con~entlona! Cab ... x 4

V Conyentlonill! Cab •• -4

G Van 4.2

P Forw,f(l cootror •• 2

S Sm Convent lonal Cab4 x 2 T Sm Conventional Cab4 ~ 4 M Sm 118n 4.11 2

Engl". TVI>' andM8~.e

COd. Product, TVIN' APO

C DOA au, V8DItl'$el lH6

e. C~·Norlh 2!>l l4 fBI LN8

11 CF'C 50l ve T61 LOl

J 0011 62l VB D'Q~OlI LL4

K CPC 51L vs rer LOs

,_. CPG S7l ve <I sal LT9

N CPC 1.<lLVaTBI L19

R CPC 2.6L ve lBI LL2

1 CF'e 46L te I SSL L2~

IN CPC l<lLva.SBL LE8

CPC 4JL V6 T81 L6~

OVWRl8RAKE SYSTEM

Cod. aVWA A.~ Bf.U Sv.l.m

e 3001·COOO HvdrauHe

C c(l)1.5OQ(I HydrauliC

5OOHlOOQ Hydrllullc

BOOHOOO Hydraulic

700t.8O()(J Hydraulic

8OOt.!IOOO Hvdra ... ne

!IOO'.IG,OOO Hy<lrsulrc

lo(),OOH4.00(l H)"drslJllc

14.00Hti.OOO Hyd{~ulic=

N

J

Jiltltsv,ltll.WI

S~ LOIl'$. MO PCll'tllac:,MI F'oriWilyne.IN pg"ljaoc.MI

O!ln ....... OI'l M,mlinaOt-l DetrQII. MI SCiI[bcrQugh.ON lord3town,OH S"revePOf1. LA

F·04181

Figure 3 - Vehlcl. Identification Number

COMMON ABBREVIAnONS

GENERAL INFORMA110N OA.19

MAINTENANCE AND LUBRICATIONDB-!

/

j

hn,,-AmI)OfllI'1

Mj-A>!ol e CyI, NC ~ 1vr:.-N<~09

.~:=,(A}JlI"IAJfJFua'l~E!.IID)

=',,~ - ~ 1'1iO<t<oo ~._ sy,_

_~.i.LCI.- =~no Un' AIb-~iJdO

---;r--==~~~~I.

_~ AR;- _.10 Ttmporoluro """,,,I mx; -AN8r It!p CO<cI ~

IWlQ - Bo,._ M>sol~

P ....... - Bal,-~Eil)'

Bal~"-,,,~Tllrfrlini!l Bbl ..... Barrat

- aHP -Bml!e Hor_ BP-I!o'<IIPr_

B'T'DC - ~m TOp Dead CftMBf

C§:~ QrJrN, - Ca~Com'e~8r Ci;: - CotoI;tlc ClJrMimIr

-Ootltc Cen~1'J'1atef

-~CID","

_ C,CC - Compuiar ComrnBnd GoniroI C-~-CQmP""~

Cet8lytlc: i20nlo'Eirlar C8-CiIt!,nsBlrOO~1

tear - Q;oIIng Clutch IQrllkJelllbll

- CCI' - eon.oW c..;",r Puryo

- '_ U. - Chock £ngln.

WS - Cl1iIl;ngln& .... irb{ea(J

C'afri --' Counter EJectllHilCiJ'IQ F"~ ClO-Cublr>lrdlll/:;pl"""'"",

CL-ClOOOOtoojJ ,

CLC¢- C_loop Caro,",'" co.l!"' cmll-Cloo<>O l.oopThfDl!~1lOdy

1")OOOon COI'\'i. - Coriv.er18r

-it,;,~~~~

CV - c-I,nl WIodIy

~~I, - CjIIMO!{OI

1lIlB-1:UJ Boil SO .. ~-Du:II·I!o<Ir."""'I~ DEH~D;JlialEl_fuoll~ DfI-DIgjOBJ,FUOIIOIO!)iIon OiIl-QI_

_lliol-IlI_1bI

...-:- EAC-E;li3C:IJiC~~VQ1ii6

- EAS - Beclric AIr &orII_KhI1'lQ VIIN~

- ECG- 8e::Irorril: GOfl'I'fQf! ~I

- ECM- EI_ COr<II'OI r.iooulll

- EC~ - Emi_ GmIId &t."'"

. ~CU, - ". ngl"'.· GlMl. rBliOii UfiU ~ !;v.,...raJWeE_c.::"tlOI

------------

Uill OF AI/'rollO'fIVE ABBREV1AIIONS

• WHICH NAY HE USED IN THIS MANIJAL

3 4

BEVIR ~~~~: E~lired VIIIV66 ~~ = :a:aE!ct!OO Rttadion ~fII'I1 I

EF£ - :5aIly Fuel EoJ.apciBiltiii PC'V - ~I~ Drijfi~ V9nUliltion

t:Pl - EiS!:tKinic FuellnJac&irJ F!ECV - FilJWsr ~ Coo1roI Vi!.I~1!l

EGr;t - &!taus.:! GB:Ii: Hecirnlls&m PIN - Pall, Nautrl!l

.eMF- ElEdromllliV8 rOl"CQ PRO'" - Programmable, :F-Is~di Onl~

!:r.tFl - EJ:ectroolc- Mtx:IiJIe Fie:tard Memory

ros - EKhauS" Oxygen. SeniSiCr PIS - Power 3teE!ril19

e$C-_Io~Q<>n",,1 !'S1-~""",,For~'1nri1

oST - 01"""",," Spoil< 'hilI", Pt, - PDt

~R - EJectron[cail'; 'Tmed ~ Pm - Pow2f TBksctr

E:d'I.-E:I!:I'fBUBl

fI,;\lSS- Pod,raJ ..... _

s.r.ty _or'" I'I,bI!.-~OO!_rro"",,) 'W!l - ~"'" wn ... _

~:tI$ ...... Four 'l(meel Orl'o'El

~O-~""I'DUty

Hel- H~ e,_ tgoOiion Hr..~Mefgl,lry

~v~'':- ~tt'~~!lr eon,'11OnDi'

l-lIi'ACM -- MMlOr..Vt:!iU·Alr

COr'ldIlt(W'I:lng;IMOCM:rr Hm - Hllri11iIrr-Wi'1I·u:odYlili

1.<£-f<!tAi.t:onlrol IC-iilOlJi'.i ... ·~ IO-Id~irJe~

- Imi1;1t O:liJ"I'lbl.,n.C·-lClif!'lOlI!d: CcrT'l~r IP~ in~ymE;l~ ~i

ISC - !<!Ie !!gooO Pon"ll

Itm - KIIQm~j~~

tIm,'h - Kllomeli3111 Par 'HIM

I(v -I(J"""". [ThoooondS <I >IlI"1 ""IL - KlhlmBl.MJt", Iowi <~.-KII"l""""

i.-_

boil - FoiJr 'Gyfi"ndBr !n·lJrw 'I;~El1 L.-5-SI,~erln4i>r!I~1 ~-lE!lt~t

Ul-UJlR ... _.v...-_010_

f-~' - M:l1lifold Ab@OlutEi ~re

. ~~ ,:,=u":~C::per31Ure Sensor

MPG - ~ Fer G.a'llDrr MPH-M~lP«l1O!Jr MT-M~'li1lnti'I'Il~iOn

Nom -Nowlon "'''' .. IToo..,1

1)100- eu;,;a;, Di''''"''

g~~~~~~Ciffl

0.- O<ygen

J

Ilt-1llJiIrt

IA - ReIil;3(anca

!R·'- A,dlal fwrlM NC~ RF-i1~Fronl

RPM - P.evoliJOOl1!1o Par MlnVlli> ~~- Right RBlir

RTV - Ftoom Tempoerll!LJril VUrcinl:JfIIIl

15_1

FI"IFI - RaaponSB v.tm.rm Rl't1iiU1F RWD - 1Wr~'" Orivo

SAE - s..",," 01 """""'''''' Engm!!. .. SI-~!ilemlrrternBtJlJnBl' Sol.-SidiBmld

T-'1brI:JochargllW

TAC - Th!3rm~ AI" {:;kiilll«

~--

~ T9I - l'IvCl;. Bcd,lnl_

..,0" TCC _ TrSf1!iITksilJn ~0i101 w.d'1

.... TGS -1ian~n C~f"OIitiC!l 'Siperli:· me - TO, Ciod c..\oI

TP~ - Tf ... LIO f'OOlliOn_

Tud:IO - TurtlOtl'lOl9Or

T\I'-ThiOIII.VtJve TVBV-I_rg,, __ ~ ...

NRS -Ji.lri_ , lIII010 SumlrmiOn l'VS- 'Thorm!iil Vaowm Swilet!

~·Joffil-~"'Ofii!l_

V-~'I

V--!l- ~ C:r-IiM8I" ,Engine - ~ec1 ina"\('

V -3 - EI;Ihl C)'inoo Eng ... - AA"'I'"

iI .....

Vac.-"kruum

VATS- ~ AI1!1-Th!3ft.5rJ!efr! VIN - Vehicle IdenIlIicalJorr NlJmboi' VI~ - 'lJ.ahre:!! III RecaYef

f- vas - ",_ Speed S!m!lllr VMV - 'lJBCUUm :Ma:lul:a.lat 'WIve

WI-_

Wifj-_11lase

w,!Q -Wllhaul

-I--WOl- 'I'Me Qp'¥'l Throtli8

);·VflIII't - 1i:ql;art9)Qn \I'aI¥a'

5 12 3 4 1

1. Air cleaner , /

2. Conlrol Unkag. 1'011115 3, Tie Rod End'.

4. wn ... , Boar~

5, Stoortng

5. MB.st.l!llr lnoor

1, Tr rf;s"," - Manllal

.... Automatic

Carburetor Urrkage - ve l'I,'ers~ Jai:r1l!S

lI'er 5h:ilf'l Slip Jo~n~

'Ii 1. FJ·ont dRear AJ.:kI

12,0"'111.1. I~, Sr.""

II

7

8

10 9

2

3

5. T..,.smi«ion Control Sllafi 6_ AEr C1e.a.her - Elom9n.t

7. T~I'SSlon - :M8nU(il1

- .... !oFlt.~.

e, R""r A)d. 8, 011 Filter

; O. Brake Master Gyllnd'.' 11, P.'IIl~ Br."" Un .....

lOOO23

1. Control Ann 8"""nll" and earl Joint.

2. 11o Rod End. ~. _oIl!8arIrlI!"

4. Siee'in!I Gear Clutch Cross'Sholt

I:IB·8 MAINTENANCE AND LUB"ICATION

s! ~ IJ .. .. ~ o ~ • . .. • • .. .. .. ..
0 D 0 n 0 " r, n n
~II! Q ole
13 ;1;11 00 () 0 "
;!;
.. lq'liq .. .. ..
1fi SI~
... li;i;~O o Q
.. W o
! =~D 0 o
::ill! .. .. .. ..
0 "
Q
, ~~c o C " o
..
.. ~- tlill u o o
iii II. v
;r_i/t: ~~ .. • • 01 .,
! .".
~l =~ (10 c 0-
S .!!&l ;ItS o () (:I
., , , .. .. .. .. .. .. .. ..
Ii; _N =:!III! c "
• v " " Q <J C;
to ;[j'~ ",:1 0" ,
:I J!1I
E d ~li on o (J ,
;., 1:" I ti ;:! • • • c
=ii ..
~ I~
.. bill! 0 0 0
~ .oii ~iI 0 0 0 " o
.. ",
! c • • .. ..
.. '" ;: c 1 7·14 GfNEIlAL INFORMATION

'G' SERIES

RPO: L03/LOS

ENGINE CODE: H/K

5.D/S.7l vs

o COMPUTER I;_QMMAND 0 ECM INFORMATION

CONTROL 5ENSOl\5

r .! EMISSION COMPONENTS (NOT £C.M CONTR.OillO)

'1 !Icrtmn.l, l:Qt1tmt Moduli- (E.CJid.) C2 .iJLDldll;.gitMHtX-wqMnGf

CJ ·~t~VK(I£HGmt~Q'ON"ligtJt C!Ii ~t,.. tflr~~ g'I;IlIJfldi

CA FIH~p ... nl!!!l

a ~t:lpumpttnOOfTnIlll«OI'

o ECM CONTROLLED COMPONENTS ~1.njl!qQll"

• h!I.inifuid Altsolvic Pntt~l.ir~f!'lll..AI'.l .. , r.-alli:U:WIIl!!nll'ill ... @ (JICV~

fxbilUaQ~J91!'1l Nl 'urol Mad~. (io1L afill:rl

C rhl~u~lfI!O!Utja;n (T.JIIL5..) tf!ll AiriPump

o Coor.t:n, r.mp,,"r,l1l.lfl! N1S ~IVil!l»I'Caniltll!!r V@'.hkl. 'Ptllld (\I.J.SJ

Ib:ttnII'Iic 'pa t" Cornr~ Ii: noeh: CE • .!l.c.~

jdJi!o .ir"(lCIntrof J fu.e4""",pn!laYJ

~ T~~!.Hon~ ..... nt!"C1uW1torrQJrctDr

" EIJlC'UOni( :!illliJrII t1m~OI !:HlfflMGrll..!i.T.1

fi.I R:.e.m6lol!i5l1ll[trllll'!~o.I!

ElcrnQJnic; .$c1i14-11; eontrol tnoduie (U.C.)

8 O.il PQ'II'-tt w.ottdI

9"am AiFCDfi1tr.M ~noid (~.i,.c.l

'2 E!!-hIlUIIG .. :rIl.ft""IoI'~tian 'II'.~'II.II'n-Sllil.f'IQ4d 1l1li T • .jI i'iDniu'QII clOW"~hlf' "I;o~ ~THIIiJI...UIQ O!'l.!f'

!,

figure ,-". (cmponenlLocaUons S.0l./5,1l(G Seri~s)

/

I

DRIVEABILITY SYMPl \--------~--------------~====~~

SECTION 2 DRIVEABILITY SYMPTOMS

CONTENTS

Before Starting •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

Poor Fuel Economy ~. *' a ~ *' .

ECM Intermittent Codes or Performance ~ ~ ..

Dieseling. Run-On •••••••••••••••••••••••• " •••••••••••••••••••••••••••••••••••

Backfire .

Rough, Unstable. or Incorrect Idle, Stalling ..

Above Normal Emissions (Odors) .

Hard Start " ;; .

Surges and / or Chuggle .

lack of Power. Sluggish. or Spongy ..

Detonation/Spark Knock .

Hesitation, Sag, Stumble t _ ..

Cuts Out. Misses .

BEFORE STARTING

Before using this section, you should have performed the SYSTEM CHECK in Section "3" Diagnosis.

Verify the customer complaint. and locate the correct SYMPTOM below. Check the items indicated under that symptom.

If the ENGINE CRANKS BUT WILL NOT RUN, see CHART A·3, in Section "3".

Refer to the related Chassis Service Manual for corrective action of dr iveahi l itv symptoms that are not fuel or emission related.

Careful Visual Check

Several of the following symptom procedures call for a careful visual (physical) check. This check shou ld include:

• Vacuum hoses for splits. kinks, U! connections. as shown on Vehicle Control Information label.

• Air !'e~ks at throttle body mounting: manifold. See Section" 4".

• Ignition wires for cracking, hardne routing, and carbon tracking.

• Wiring for proper connections, pill cuts.

The importance or this step c: stressed too strongly - it can lead to c a problem without further checks ano

valuable time.

The following symptoms cover severr To determine ira particular system or COl used. refer to the ECM wiring ding application.

POOR FUEL ECONOMY

Definition: Fuel economy. as measured hy an actual road lest, is noticeably lower than expected. Also, economy is noticeably lower than it was 0.0 this vehicle at one time, as previously shown by an actual road test.

•

CHECK:

Engine thermostat for faulty part (always open) Or for wrong heat range.

Fuel pressure. See CHART A·S in Section "3".

Ignition timing. See Vehicle Emi~siol Information 'label tor procedure.

TCC for proper operation. See Section"

·2 OR'VEABILITY SYMPTOMS

ECM INTERMITTENT CODES OR PERFORMANCE

Problem mayor may not turn "ON" the "Service Engine Soon" light, or store a code.

The ECM code charts, in Section "3" or Section 15", determine if there is a fault witha circuit, or, if ;';e is an intermittent problem. An intermitent leans that a code is stored in the ECM memory, but Ie e ircuit is 0 K. Refer to Section "3" for wiring agrams.

Most intermittent problems are caused by faulty electrical connections or wiring. Perfor-m careful check of the suspected circuits for:

Poor mating of the connect-Of halves, or terminals, not fully seated in the connector body (backed out),

Improperly formed or damaged terminals. All connector terminals, in a problem circuit, should be carefully reformed to increase contact tension.

Poor terminal to wire connect.ion. This requires removing the terminal from the connector body as outLined in Section "3".

If a visual (physical) check does not find the cause of the problem, the vehicle can be driven with a voltmeter connected to a suspected circuit. An abnormal voltage reading, when the probtem cccurs. indicates the problem may be in that ci reuit .

• Loss of code memory: To check, disconnect TJ and idle engine until "Service Engine Soon" lil comes "ON" Code 22 should be stored, and k. in memory when ignition is turned "OFFJ', for least 10 seconds. Ifnot. the ECM is faulty.

• CHECK:

Electrical system interference caused b~ defective relay. ECM driven solenoid, or swit. They can cause a sharp electrical suq Normally, the problem will occur when t faulty component is operated,

Improper installation of electrical options, su as lights, 2-way radios, etc.

EST wires should be kept away From spark 1'1 wires, distributor wires, distributor housing, cc and generator, Wire from CKT 453 to distrtbui should have a good contact to ground.

Ignition secondary shorted to ground.

CKT's 419 and 451 intermittently shorted ground.

ECM power grounds. See Section "I II ( location.

DIESELING, RUN-ON

Definition: Engine continues to run, after key is turned "OFF", but runs very roughly. If engine runs smoothly, check igniticrt switch and adjustment.

Check injector(s) for leaking. Apply 12 volts to fuel pump test terminal to turn "ON" fuel pump and prime fuel system. See CHART A·S in Section "3t1•

BACKFIRE

Visually check injector and TBI assembly fuel leakage. See Section "4".

Definition: Fuel ignites in intake manifold, or in exhaust system, making a loud popping noise.

CHECK:

gGR operation, for being open aU the time. See r;CRdiagnosis in Section "9".

Output voltage of ignition coil. See Section "6", For crossfire between spark plugs Idiatr ibutur cap, spark plug wires, and proper routing of plug wires).

For intermittent condition in primar}, ~gnition svstem.

Engine timing - See Vehicle Emissl0 Control Information label.

for faulty spark plug. and/or plug wire. , hoots.

For proper valve timing.

Perform a compression check ~ look for stickir or leuking valves,

DRIVEABILITY SYMPTOI

ROUGH. UNSTABLE. OR INCORRECT IDLE. STALLING

Definition: The engine runs unevenly at idle. If bad enough, the vehicle may shake. Also, the idle may vary in rpm (called "hunting"). Either condition may be severe enough to cause stalling. Engin-e idles at incorrect speed.

• Perform careful visual check as described at ~ Minimum idle air rate. See Section "4",

start of this section. ......... Check A.l,R. system. There should be n

• CHECK: to ports while in "Closed Loop". See Sect EGR valve: There should be no EGR at i, Section "'9".

Throttle linkage for sticking or binding. See Section "'4",

• Run acylinder compression check.

Ignition timing. See Vehicle Emission Control • Inspect oxygen sensor for silicon con tan

Information label. from fuel. or use of improper RTV seale

.__ - ECM ground circuits. See Section "I" for sensor will have a white, powdery coati

location. will result in a high but false signal volta

lAC system. See Code 35 in Section "3", exhaust indication). The ECM will ther

Diagnosis in Section "4". the amount of fuel delivered to the

..... - Generator output voltage. Repair if less than 9, causing a severe driveability problem.

or more than 16, volts. ~ Check for fuel in pressure regulator 11

PIN switch circuit. See diagnosis in Section "3'·, present, replace regulator assembly, See

or use "Scan" tool. "4".

PCV valve for proper operation, by placing • Check ignition system: wires, plugs, rotor

finger over inlet hole in valve end several times. _ Monitoring block learn will help idem

Valve s~ou~d s~ap back. If not, replace valve. cause of the problem. If the system is I

See Section 11 . __ ean (block learn greater than 138), ,

~ Evaporative emission control system, See "Diagnostic Aids" on facing page of COt

diagnosis in Section "5", Section "3". If the system is running ric

NC signal to ECM terminal "B8". "Scan" tool learn less than 118), refer to "Diagnost:

should indicate Ale is being requested whenever on facing page of Code 45 in Section «3".

NC is selected and the pressure cycling switch is • Stalling may be due to an incorrect idle I

closed. See diagnosis in Section "3". Refer to Code 35 in Section "a" or "Idl,

....... Controlled idle speed. See Section "4".

EXCESSIVE EXHAUST EMISSIONS OR ODORS'

Error" in Section "4" for diagnosis.

Definition: Vehicle fails an emission test. May also have excessive "rotten egg" sm (hydrogen sulfide). Excessive odor does not. necessarily indicate excessive emissions.

Perform "System Check" in Section "3".

• IF TEST SHOWS EXCESSIVE CO AND HC, (or also has excessive odors):

• Check items which cause engine to run RICH.

• Make sure engine is at normal operating temperature.

• (HECK:

Fuel pressure, See CHART A-S, in Section "3", Incorrect timing. See Vehicle Emission Control Information label on vehicle.

Canister for fuel loading. Sce Section '"5".

PCV valve for being plugged or stuck. or blocked pev hose. See Section "II"

Spark plugs, plug wires, and ignition components,

Check for lead contaminat.ion of cu tul vtic converter !look for removal of fuel filler neck

rcstr-ictor-I.

Check for improperly installed fuel ca Section "4",

• [f the system is running rich, (block le • than 118), refer to "Diagnostic Aids" 01 page of Code 45 in Section "3".

• [F TEST SHOWS EXCESSIVE NO,:

_ Check items which cause engine to run or to run too hot.

EGR vale for not opening. See "EGR Check" in Section "9",

Vacuum leaks.

Remove carbon with top engine cleaner. instructions on can,

Check ignition timing for e xces s iv advance, See Vehicle Emission ( Information label on vehicle.

If the system is running leu n, tb loct greater than 138)1 refer to "Dlugnost!c ! facing page of Code 44 in Section '"3".

)RIVEABILITY SYMPTOMS

HARD START

Definition: Engine cranks OK, but does not start f-or a I.ong time, Does eventually run, or may start but immediately dies.

HECK:

'or water contaminated fuel.

ue l pressure. See Section ~3", CHART A-6. PS for sticking or binding. See Section "4"_ GR operation. See Section "9".

uel pump relay 1ST & Ml - Connect test light uween pump test terminal and ground. Light iould be "ON", for 2 seconds, following ignition )N". See CHART A-5 in Section "3" .

n 7.4L, and some 5.7L engines, u fuel module rcuit will run the fuel pump for 20 seconds, Ilowing ignition "ONtt If this circuit is not nctioning, this may cause a hot, hard start ndition. See Section "3", CHART A-5A.

rr a faulty in-tank fuel pump, check valve, rich would allow the fuel in the lines to drain .ck to the tank after the engine is stopped. To eck for this condition:

Ignition "Or'F".

Disconnect fuel line at the filter. See Section., "4"_

Remove the tank filler cap. See Section "4". Connect a radiator test pump 'to the I ine and apply 103 kPa (15 psi) pressure. If the pressure will hold for 60 seconds. the check valve is OK.

•

Long cranking time but eventually runs, Refer Section "3", CHART A-3, Engine Cranks but VI Not Rtln.

Check ignition system for:

Proper output, wi th J -26792 (ST -125). Worn shaft.

Bare and shorted wires.

Pickup coil resistance and connections. Loose ignition coil ground.

Moisture in distributor cap.

Spark plugs, wet plugs, cracks, wer improper gap, burned electrodes. er bea deposits.

If engine starts, but then immediately stal open distributor bypass line. lf engine th starts, and runs OK, replace distributor pick coil.

Hard start, with engine at normal operati temperature. See Crank Signal Diagnosis, Section "3".

•

•

SURGES ANDIOR CHUGGLE

Definition: Engine power variation under steady throttle or cruise. Feels like t.he vehicle speeds up and slows down with no change in the acee lerator pedal.

a too [ is available which plugs in to the ALDL nnector, make sure reading of VSS matches ~~LcJe speedometer. See Code 24 in Section

lECK:

"intermittent EGR at idle. See Section '-9". nltion timing. See Vehicle Emissl()n Centre! formation label.

line fuel tilter for dirt or restriction. See -tART A-6 in Section "3".

,el pressure. See CHART A-6 in Section "3". merator output voltage, Repair, if less than 9 Its or more than 16 volts.

:CQpenuion_ See Section "10".

• Inspect Oxygen sensor for silicon ccntaminati. from fuel, or use of improper RTV sealant. TI sensor may have a while, powdery coating 31 result in a high. but false signal voltage (ri, exhaust indication). The ECM will then reduthe amount of fuel delivered to the engin causing a severe driveability problem.

• Remove spark plugs. Check for cracks, wea improper gap, burned electrodes. or headeposits. Also, check condition of distributi cap, rotor, and spark plug wires.

---_-_---

DRIVEABILITY SYMPTOI

LACK OF POWER, SLUGGISH, OR SPONGY

Definition: Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part way

mpare customer's vehicle to similar unit. .ke sure the customer's vehicle has an actual blern.

:nove air cleaner and check air filter for dirt, for being plugged, Replace as necessary. 'er to Section "12"

ECK:

ition timing. See Vehicle Emission Control rrrnatien label.

. restricted fuel filter, contaminated fuel Or 'roper fuel pressure. See CHART A-6 in tion "3".

M Grounds. Refer to Section "I".

R operation for being open or partly open all time. See Section "g".

ierator output voltage. Repair if less than 9 nore than 16 volts.

~ne valve timing and compression. [ine for propel" or worn camshaft.

• Check Exhaust system for restriction:

1. With engine at normal o pe temperature, connect a vacuum gag: convenient vacuum port on intake m

2. Disconnect EGR solenoid e leconnector or connect EGR valve dir vacuum source bypassing any swi t. -Solenoids.

3. Run engine at 1000 rpm and record, reading.

4. Increase rpm slowly to 2500 rpm . vacuum reading at steady 2500 rpm.

5. If vacuum at 2500 rpm decreases rna 3', from reading at 1000 rpm, the, system should be inspected for restric

6. Disconnect exhaust pipe from engi repeat steps 3 & 4. If vacuum still more than 3" with exhaust discern check valve timing.

DETONATION / SPARK KNOCK

Definition: A mild to severe ping, usually worse under acceleration.

The engine makes sharp metallic knocks that change with throttle opening.

:k for obvious over healing problems. >w coolant.

)Ose water pump belt.

estricted air !low to radiator, or restricted ater Ilow thru radiator.

:K:

soor fuel.quality, proper octane rating. :orrect PROM. (See Service Bulletinsl. RMAC for staying closed. Sec Section

.ion timing. See Vehicle Emission Control mation label,

system for low pressure. See CHART A-6 ction "3".

Check EGR system for not opening. See "g".

For proper transmission shift points. Check TCC operation. See Section "10". For incorrect basic engine parts such a heads, pistons, etc.

• Remove carbon with top engine cleaner.

Follow instructions on can.

• On vehicles with 7.4L or 5.7L (over 8500 engine and a dual catalytic converter s check [or an exhaust restriction in th converter area. See Figure 3-13.

DRIVEABILITY SYMPTOMS

HESITATION, SAG, STUMBLE

Definition: Momentary lack of response, as the accelerator is pushed down, can occur at all vehicle speeds. Usually, most severe, when first trying to make the vehicle move, as from II stop sign. May cause the engine to stall, if severe enough.

'erform careful visual (physical) check as escribed at start of Sed ion "2"

:HECK:

'uel pressure. See CHART A-6 in Section "3". ifater contaminated fueL

,nition timing. See Vehicle Emission Control aformacion label.

Fuel pump cycle system. See CHART I Section "3".

TPS for binding or sticking.

Generator output Voltage. Repair ifLess ths more than 16 volts.

For open HEI ground, CKT 453. See Sectio Canister purge system for proper operatic Section "5".

EGR valve operation. See Section "g".

CUTS OUT, MISSES

Definition: Steady pulsation Or jerking that follows engine speed, usually more pronounced as engine load increases. The exhaust has a steady spitting sound at idle or low speed.

ieck for missing cylinder by:

Disconnecting lAC motor. Start engin· e. Remove one spark plug wire at a time. using insulated pliers.

If there is an rpm drop on all cylinders (equal to within 50 rpm), go to "ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING" symptom Reconnect lAC motor.

If there is no rpm drop on one or more cylinders. or excessive variation in drop. check for spark on the suspected cylinderts) with J 26792 (ST·125l Spark Gap Tool or equi valent, [f no spark, see Ignition Section "6". If there is spark, remove spark plugts) in those cylinders and check for:

Cracks

Wear

Improper Gap Burned Electrodes Heavy Deposits

• CHECK:

Spark plug wires by connecting ohmmet ends of each wire in question. If meter over 30,000 ohms, replace wire(s).

Ignition coil and secondary voltage using lester J -26792 (ST -125), Or equi valent.

For restricted fuel filter. Also check fueL for water. See Section "4" for IDeation.

For low fuel pressure. See CHART A Section "3".

Check for proper valve timing.

• Perform compression cheek on quest ioi cylinder(s) found above. If compression is repair as necessary.

• Visually check distributor cap and rotc moisture. dust, cracks, burns, etc. Spray ca plug wires with fine water mist to chec shorts.

• Remove rocker covers. Check for bent pus, worn rocker arms, broken valve springs, camshaft lobes.

I

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u... ~_ <.1 "0< COMPUTE!,! COMMAND CONTROL (WITH ·SCAN") 3.,

The rQllawiog terminaia nre used:

A .. This terminal pr-ovide:& a. gl'oumi circuit to otner" terminals,

H - ThjS ter-f'!!n.;'i,1 is U1(l "diagnosuc terminal" for lhe ECM. 'When grounded to "A" ter-mlnal, the "SerVLcE!" Engine Soon" light wil. nash codes (key '-ON'" and engine "'OFF'1 e'ltering the diagnostiC! mode or na,!;Ihe.s- il field service mode (e~gi~c: funl1i!1g) to deteemlae Ll eyetem Ie in Ii "Closed" Ijl" -Q1Ktn Loop" operation.

C m' Tbis termiunk an some €!ir m;)I'\Q;gnmnnL !ily:&tem8~ [B wlred to the K",ound sid.e ar the I!I(tr~:rir ail' ~(]ntl'(ll vlltV't. IL Q-,Q,i\ bt!i ~ to d.i.agnose the air ma.no.r.cfrlent.3y.st.tm. Rerilr t.o Beetion "S"

E ~ This. terminal is the serial dat;l line On ull cngtn(!1; I!IXcepL 2.5L and is used by a "Sean" tool to rend various syste-m diili1 information.

F • Thi.s l'!1ll"'l1ing,1 Is I.Isc:d t.o dlegnese the TCe ~Y:9't.c-m .a.nd Is wlrau to the ground Bid-eofthe 'reC so.l~JuJld. lklre. to'sedi(]n ~la'·.

G· This tarmfnal is used t.o di3grtQse the rUG I pump ~~uit on pJI CK !lefi~:s. Oi'i. oUie.r engui-e:s the Cuel pump te"t lead IS In the engine compartment near the fuel pump rl!!lny. Refer t(J CHARt A·5 Of A.·5A.

lot ~ This ler'm,inaJ is- used 1.0 diDgnosc lhc brake system Dft OK, truc:Ii;.s. Refcr Lo "CK Li.ght Duty Service M;nutll· fQr oddi.Li:rmoJ information.

M. This oormlnul ilJ the sertal data line ror the 2.5L engines and is used by Q "Sco n ,. l6u I Lo re ed v ar-i .. U!. system dat41 i~formAt.iofi.

WIring Hamess and Connectors

1\ wiring harne-ss eteetetealty e(lnn(;t!U tha ECM to variol4Ssens.oJ',50lenQtd l1li1d. relays vt'thln the sy:ltt.!lrn, Many c;anne~lOrq; in .. 1'10 eng'ine cornpurt.rnenr uee e.n:'lfironmellt;1l1y protected becauae or Lhe aystems iDW 1I0ttal{-e:!J and eurcem lav-el!il.

Information S"nsors

In. ctdditlon to the [eM. the Compl,ltel" Comm3,f\d

Control system nas: the: (ollowin:g Il'iform. .. tiofl S~'H;SOf"5;

• Oxygen fienso"

• Cool unt Sf.! nJ;or

• Tltmllie pmiltion '!i@ruKlr

.. Manifold absolu_w p ... e!:!sl.!_l:'e s.:r.:'I\S~t"

.. V@·p~oi!le !!IJ!ltad ien:f.t)i'

• M~nj ((!old Le rn Illl:nli-ure:s.e ru;or

• Ki'ock ff.msor

l.In.d t.h4! following input5I'ignal!S:

.. Park/neutral ,-witch i!llgMI

• Cronk 8igmll

• DLs-ll"i1:mt.or reference 5trna1

• Power 5'll"lEring pressure.!low i tc.h signal

• AJC control9ignaJ

• Trnnllmi"siott gent posl UOH signal

• ECR vacuum signal

ELECTRONIC CONTROL MOOULE (Figure ].-] Qr 3-4)

Thl! Elec'l;ronic Col".! lro I Mod-ul-a (ECM~ hi located i the passenger ~mpartmBnt Ilna is the .;ontrg.! ~~~ 'Of th~ Comp~ltf CO.rn.maM Control s.ystem.

The ECM conatantlj- looks at the inrl)l'rno.tiO(J frol vo.rhlus sensora. and oontrol!! the !tI.-YilLetilSl lhat affi:j ve hiete perfuemaeee, The ECM performs th diagnc!Jtil! run~ti.oi\ (If lJji:: IYiil4lm. Jt. can rl!cogniz operatJofiJJ.1 pr(JbltmSi alert. ilie driver th,r.ough t.h ··Scrvi.-.:c Engin£ll Soon'" light. and atDre a code or code which id,en-clfy the pmblem .B.n!!'8SILO aid lhe te(!D('1i-ciu. In mo:.k.ing folrp~if'll. Si!~ dia~tl -IeetiefL formor informp.~Gn.

'('he ECM is designed 1.0 pl'fKlE.$6 the: varjeus Inpr informnLion (Flgun? 3-1) end then sends the" ri~I;!!5S8r tllElctdeal responses to eomeul fuel detlveey, !l.pal' timing and Qth@"remis.siGl1rantrot 5yS:lent!3.. T~~e il'l~ infDrmation hQ6 an int~rJ·l!.I;!!It.iQn ~o mort; th~n 01'1 cutput, theeereee, iflhe une lnput railed it ,ou.Jci..:ffOt more l..han CIne! :!!i)'Soom$ epemctcn.

"rna- ECM hna a "lesrnlngH abillty whieh allows i t.o make ~oM"1!i~Ha'n!I fGl'minor varl@tirll'n!!il [n th~ rU( s),:5tem to lrnpr-eve dr-iveabilH}'. U L~e brlllcr'y 1 dtsecnneeted to c:Ie{lr c.odes. or ror- re pnb-, lh '1e~.:t'ning" precess ho,s to begin ollov-un!lIDn.

3·4 COM~UTER COMMANo CONTf!OL(WITH "SCAN")

m",,,

m EOI H_RNIfiSS CI;tNNEcroA$ 'TO [CM

figUfl!!! 3-4 E1emonic: Contfol MQftwlliil! (V' & val

1\ i;;nillll@:G m_",y bD not.ed III lhe ve.htel e'e ~rrllrmnrn:lC!lJ Tu "tecsh" the- vehicle ... mnke sure the engine is ELt (Jpe:rnting temperature, and dd ... e. ot part throu.ta, whh mode-tate oe(:vhil:"dliOrt uud idle l;iJI\d,!ticp-Jt_j, vnLil normu.lpc_trqrf.fiil~1!!! returns.

NOTICE: The- EeM muat be. ma lme lned .at. 3. temperature below 185~"~ (8S"C) at aU Limes. Thit mOlit e.g~Qij6Ilfthc .... elticle is 11'1,.11" I,.hrolJ,gh II ptUnl. baking. precess. Tne ECM' wUI bee-orne Inopereulve ir !lei t ampur n.tu re :e~ned.5j 185*'F (fl ~"'Cl. Therefore, kL i!S ret! I) m m.encecj LtllH If;l'mMr-;J,ry \NiUlilllion be IJliiCCd ~f"-D".nd. t.1iE: ~CM dW"ing t.he lime the vehicle is in D pidnt oven or mhar high temperature, precesses.

There uee two t.y~ Qf ECM':j "":l~,J II:'! light duly lrueke,

A vehicle ftquipped w'LI'I () 4 cylinder engine hns un ~:CM [rerc-r-r.cQ lo M GMP4) wiLn I..wo )XLft51 fol" !1Vl'V"ice. r.. I!:tml.rolJeY" fan EC.M' wiLtm~tn ~e1t}·Ciin a-nd u M~mCal tMe,rn.ory and. Co.ilbrClt\t)1'I r,mitl.

hl1 vehide-s with oil Vo. 0'" VB eyllnder engine have '-;'1 eCM trcferred to [is GIllfCMl with three pnrts (0," «!rvi~e. A conlmllu {an ElCM without a PROM~. ii f)R.OM "",,1tl, !lpe(;m~ i~(og'''fn infQrmodi(ln ror Iln ~nll:in(l l.i,[ld II'lChiCiI~ find Ell Co.lPllk w;t.h !ipec:drh: ;ulibriltl.on informettDn_

'-'1ern-C;(l1 (L4] [Figure 3-3)

This l15&Elm~l)' carltnins both the functions Qt the IlROM and CuPok. Llke the PR:OM. 1l ~6tlt._'ljng the librllli€ln~ f'lp.e<led f()1'" tk s~iIle v(:r.ic:lc (\~ w~1I iiS th~ l'lt::k~liP fu~1 eonl.rl"!l cin::!.HLry rC(J,yiru4 inhc roiit. onhf! I':C~t h~n'U1t;d.nma~ecl nrrlluJ •• y

PROM [V6 & V8) (Figure 3-5)

·1 nformat.iDn ('H' speetfle (!-rlf{;np. and 'U'e:hi(:le ill programmed Y~(Pg ;ltl !n~cgrat,.td "ttcylL cAHc-d a PROM, (PN>gJ"ammobl. R.ad-Only Memory). In Lb. p~rl$ book. iL Is tlated as Rl:"alibruLof_ This allows one model or eontrotler to Be used rol" man)' different vebletea, Thl! PROM is IQI!altd, iMide th.i;l £CM ~l'!d has i.,nrormalitfn on lhe wthicle's weilJhlo, engifltl, tr~m,i:!tsiO-I\. ;.l.xle nllio. LInd several others, Whlh, eno gCM part number ean 00 ueud by many vahlele linl!'~, ill PROM isl,l'i[oI·}' i5.peoi::w.c and mumt be ueed for the riKht vehicle. Fer this. r-~IL">Onl it 1S VEf'y important fn check the latest ",;p;rts book and Ser-vlee Bulletin In{ormntion ree the COrrect part fhHl'ibcl' when (cpludl1g 0 PROM

CalPak (V6 & VB) IFigure 3-5)

A. CalP~k 15: used to unijW ruel deliver, if oll'ler porI!! or (he ECM or ••• m'4lod. If In. C.lI'~k i. mii5iiil,g. n.will rEHiiUll ill B nD:EW~oilndi'i.in ~oiindili6n.

IJJ • .,.,

m PAOiA IENGIIII~ tALIBRA'i"ORl

4,5 1211-8f

Figu,e3-5 PAOM ""dC.IP.kIV6&V8) FUEL CONTROL

F .... cl ~elIlI'tty i-s r:on!.rolled hy t!3e Comput.er C(lmtll.iiJld Control 8)"slc::m. T'he g(tl'lcr"(li descriptton Dr fuel eorueol t.;; in Seetlen "4" 'l'hllil lneludee the rue.1 injeetmr. preseure regulnter, idle air centrol \tUl .... e ur'ld lhill f:yel pym_p~I~tr,cal circ=uil

INPUT INFORMAnON Coolant Temp«,al .. ,e Sensor [Figure 3.-6)

The COO!tIIrH l.tf'f\Fie~1.llr~ ::'I.emHH" i!'l:rJ. ~hp.:"·mistar 'c. r~:!iI:liilOr whidl dw.rt~:!i Villuc based (If I lemf)en.ti.l,1ttl mount~ in the engine eoa\anl slrun..m, Low orzoolQ.nt ~mpef'_ilture produCoe$' 3 n,igh resisl4nC~ 1100,000 ~hms III 40"C/.",O*Fl whilr; hJgh l\!mperlllun: c.auSoes Jow re~[:J;IOJ'\C(l_17n ohms: ur. l30"cnSfi"F;

COMPUTER COMMAND CONTROL (WITH "SCAN") 3·

...

'I'he MAP sensor rl!<ilclini:: la the -opfM)SitA! (Jr what ., would measure on. a vacuum g-.ogc-. When m.e.f'lif('1 p'l'euunl' is bigh. vaeuum is low. Tnl!!! MAP ~e~Mi" .al$u used to meas:un banrnetriC! pr~!I~ .... rt and ~edain c:~ndiHQn:ll. whid\ atlows tht ~CM aUlomaU.;otly ruijl.lztfoi' rl.iffe.rent attitudes

The ECM t;Cl'Lds a 5 volt. reference 5ignal to LJ MAP sensor. As the manifold peessure changes, ~ el.eC:lri.eaJ rlHlBtMI~ af t,t.e- lII~s:ot ilfitl changes, l i'mmitDring the sensor o ... tp""t. voltage. the Be M kru» the mnnlfuld pressure. A. h.lgnE!'T pressuro. II;l vacuum ~hi:8h volla~:-~l requires mote fue-l. while lower pres!!l~. n_i8h~r vacuum ([ow Vl)jUlCa) requir !~s:!l.f.\).el.

'fhe ECM. uses th.e MAP scMOr to cont.rlli Iu dU:livcry and. ignition timitlg.

"'-1-15

[!J MANrFOI,O VA,UUM TUII [!] aeCTRKAl t:6N:Nt~OR

"'''7 'iS21i484.1! I

~~'~'~~.~--~~~~7=~------~ Fi9ur~ ].7 MAP Si! ~ !::Ot

'---

3·6 COMPUHR COMMAND CONTROL (WITH 'SCAN")

';;f~

. UL ... U.71..!.!!. l.!!.)

IT] "'"Orn.E ;iQDV IISSEMaLV

m THR.Om! posmON: .5ENS9ft, ~ NON-ADJUST.A.BL.f W THROnLf POSITION 5HNSOlii • NGN4I.OJUSTA_SL.£

~ THROTTLE pOsmON .s~~SOA • AD .. n,lSTA9U SCREW ASSEIMBL V

~ETAINER 153t:152.-6e

Figure 3 .. 9 'fhrotth!! Pos(ticn Sansur- V6IVSI

A third wirE! is co I':IrleCl~ ~o the Eel'll to mnuaura hI:! voltage from Lhe 'tPS~ A.1 thCl thrutllo vulva 8_rt!I~1I!l !3 ~ihnnR'ed (tioceleftL,j.Oir pe(hi.! rnnvedl, t.he outpld of t-hl!i rps ;tlISO .:,h,Ij..tigaii. At a dosed. ~roUle pQsitio:nl ttl.l;!' Iu.lpul, or 0-.1<' TPS.is low (llpprmti,mJllCly • .5 ".oILs' As he ~hrnttle valve epees, the output reereeses :so that. It. wide~pen throttle, lhe otapu1. voltage should 00 tppl'Oxim:1tely 5 vetes,

By mon:it4l'if'ig lhe "'II.ILput voltage fecm the TPS. n~ ECM min determine fuel delivery I:rj].':u~don tnr"OtUo 'a] VC! Bngle (d.n'll'e,r demnrrd L

h":::: 2;;::;:; T;:i<h <!::=!.t5Ii:.~":,~i:~

e~~'If!lre) mpupted 00 Ji-? 5[" 8nginlt in the! ~~Jf:-.-__

:J

-------

u ••

The; vehlele .sPl!'!!d Sensor- I VSSI IOCil;l.Cd b.ghind Ithe !i~@dom~l-ar or Dn. the tmnsmlseten on CK Dr ~ oS ri.l!oa t ~e,n.d!ll a pula in~ 'l,'ililage ::Lignn I tr:lo the ~c M, hic:~ ~he E eM ('o-n" erts ~ mi les per h(loY!", Th is cnenr mnlnly cururola the coerntlen or HUJ Tee YHLl!!m? shin light, end cruise control

Knock S.nsor

COMPUTER COMMAND CONTROL (WITH "SCAN") ,p

Power Steering Pressure Switch Signal

We.ik.,J in the engine: blOo..,I-., the knock sensor retards lgn.ll.inn Liml~g ,juril1!!: a !ip:trk kfi,Qock COrldltiofl to allow lhe BoeM to mai ncaie mextmum tlming advanee undl.'r mo5leond_jli~J\S.

ParkiN e y tra I Switch Sign. I

Tht! Park/Neutra.l (PIN) switch. located Qn the steering ~tumft. is used (lin B,n aowm~tj~ ~rftm;rni&.sion 'll'ehielQ to Indiea,ti:! t.O rue 8CM ~h~ii. lhc transmlestcn is in park or neutral, This iefurmation is used to «Inlnll lh{l operation of lhe transmiaalon converterclutcn and Idle air control.

C.rank Sign~1

The ECM uses; Lhi.$ signal to tell when the v ehlel~ l~~;n UJEI STAlt't.rNO 1'I'IM;!(lo.

Distn1>utor Reference Signal

The dhildbutor aenda ;f! :!:Iignai to the ECM Lo indlc:uUl both .en.~ne rpm u."d e.runkshnA porlsition. SeQ Section '"'6" rar furl,..her iftfOnno.tion.

'l'he CQrnpuLur Commend CDnLr()1 ~ysi.ctm hIllS a d.iagnostlc By-St!Jm bunt til'to the eCM to lndleate a failed clrculr. An amber n$er-vicu Engine Seen" light 00 thE Instrument panel will illummate if:,l problcl'lJ bali been r:tfHe<:1.<.."<I when the e8g:in.c nnd \'ctlicl~ JUG running. fhi:!!: Ilgh~ i~ ulso used fOr" a bulb 0.1'",1 systttm chock.

The Sy~tam Cheek is the 'l!!rtln.g point. rDT' the di;U!)li'}.!itic proe!!lture!! 9" lin e:ml.s.sio!15 tell f¥!ilu.'re. The oi.CLg~)I)~tic: e:hl:Lrts ELT,I!!! refuted to 1.J'i~ ECM and will det.ermin.<: if the ECM is wCtrking properly. This ~ec:tiol\ diagno:ses the; fuel .. y~\crn ccnsrelled by the geM and ha.s cnar1,s to dlrjgf1fulc u tin!uit whe-n ~he ECM hllS'di.5p'ilye1!i Jj .eL'Jdc

The :!iy9:LCm i"i:q"'I("(!'SEl:I'l A LOt.. r~!ld*oyt. .... S[QJl·, tocl, Ll,i.eft41mclc:!r, test lis,hl, Qhmmet.c·~. digital YDrt.mll!:tcr wit.h 10 megohm~ imp!:dOl..lli,;;c IJ-34D29J\). vOoi;:Uium guJl:o and jl..lmpoi1'f wjrt~ fo-r diagn'lJ'5lis, !{e-(Il'r to Sc:l:LLOfl "'13" tQ<l' .;la.alUOnru lnfGrmauon It,bo",.~ :sped;:.j Lools, If o;l "Sc-tlnl> t.ool is not o,\'aHablc., rerer 110 Sottiun '·15".

BUl6 CHECK

With It,e ignibon "ON"" ood en£'ino nol running.

Lhe I~ i't,Ip ,,11f)uM 1I1umjn:a~, wh[cll indkMI!<!!1 lhuL the ~:C~ hWi oompLf;!rJ!d 'thec:irtuilIO 'Lurn ·~O~'· tll~ IIMhL If the ... Stt"'II'i~ EAtine Soon" light i~ n()~ WO~·'. rc(cr1,0 CJlART A·t rordingnm;;il'l

When ~hl;' engln.: iii lilD.rted. lh~ lil!ht will turn '"orr,'" ff Lho li~hL r;[;mnifl!-i '·OK" rt'ror ~Il -...,.~tem dw(:k.

Th-e power steering pressure switeh Is used witt the k,. I ina.a r Emgine and i.~ ~~ated nu.ur jhe POW(,J s~cfi.nif g'Bllr. When I5ll!;!ierii\g l!! to LhCl extreme te-l"i o. righlo.lhe 5witch 131!1j)sed and lhb signal will i.ncre~ she idle air r- ate and retard the spark fer-a atable idlr.·,

AlC Control Signal

'fbi:s stgne.l lndlemee that. ~he NC eonercl swli.clt u turnud "'ONh and the eressure swl l.ch is" closed, ThE ECM uses this s·igJ"!;t1 to adju5l Lhl!" idle speed n.n.d ~" Z.SL a.nd 2.8L engii'i.i!s, vngRg1:!s the- Ale CQm"pre9~CI eluteh.

Transmission Gear Position Signal

A switch. la>~n~ed inS;id" t.he au.t e m a t lc t["lIll"L!:lm.iS:5ion. Opoetll when ~h~ Iranemlaeion !!IIblns to hlg h gear. This sigDBI tB used for delayed dlse(lg3gcITIcnt or lh@ tranamisaion el)l'l"'ertet c:lutc:h.. ~.rClr to S&tioo n .. lO'· ror ~puifi..t: 4pp IteaHon,

DIAGNOSIS

SYSTEM CHECK (Figure 3·'~)

Sl,,~ thi~ is the starting point for tbe dlo.gno5.ti.G Itl'"ocetiure!i Or' finding the 'plU.s .of f __ n emission§' le:!it fallure rdways b-egin h.cFf:t.

The :::!.Y:9~ell'l el'ltek is plJrfl:lrmE!d through the twefv4 V:rmifial a~fuhl)' liii.e d.iagno-st.ie link (Ai.DL' oonnooi.o[' IFigure 3-2) under the instrument ptlClcl in LhE! passenger- co mparrmem.

The Computel" ComfluH\d Control S.)'s~iI!'m Check is II P1"iKedUftt Lhfit. delonnlncs the (ollowing:

L Bulb Check - l>o eheek SES liRht c:iI'C~.iii~ und tOoL tbe ECM can -cam-pie·1.e the d I"c.ui L.

2. OinRno~tie Mode· this Ind lentua If the iiiugliOStiC c:odcs)'slAlm is worki,ng,

"5(:l1n"' DaliJ. . this detel'"mines it Lh-e iteM l!'l s:up;plin~ lnpuL~:nd ol.lt.pu.L \'"tsual doc!),

.1.. E.ngine Slllt1, • ~his mp ls done nne," It hilS heel"l (iOU!t'mll'1cd thDt thg ECM will di!iplay e~dftil u,nd datil._

Ol~er COOe::s . Procetd. Lo appli~ble ~h.ur1. ir.6 eode i!i di!iplayetl, Scanning 1 A~ d~ IIi fur typical vn.lue. mllY indicale 11 problem rlrp.:.J. if lht!1' M(! i.neil'r r1!cl, [f all !ly9t~m~ JPpe 1lJ' ti;l> ~ [undicnLng, r.eview' tne "Dri\·e'ilhild,\· Symptoms·' in Section "'2."

The !tv!l.l~m <:hecll: !';WI'U. wilh n hulh cohl'ck If

Llu:!r(!' i~ ~Ll "Ser''II"ke Eng; M SfH),n"' I i~1l L n·f[w [.1 C!!IIIHA·I

'1·8 COMPUTER COMMAND CONTROl (WITH 'SCAN"J

Field Se",](e MDde

!)iagnostic Mod~

f the di~lViq;lL~C termina.l "'B"', in ALDt. r:;oqm:do{', i:a. [Tounded wilh Lhe ignition nOr-.'" lind the engine : LOI'I:1C'd. Ihn system wtll e n te-r the diugnostie mode.

Wlth tflill key ~ON" :l)nd tho ~Jlgine "OFF·.!", jumper \L.DL I.enninsi9. -B.II to. "'A". The "ServLce Ene-inc joan" ~[Ght ahculd nash Cod.e 12. to indi~tc- thi.'lt lbu ~i8gn~tit.,j..: ~:r$1Jcm la working. COOl!! 12 o(gn~i~U of "one lceh'' tollQwl"d by D: pause and the:I'I"two flashes". Tbe 'ode will rnJM!Bt for 3. totn.1 or thi'"cn times and w~1I lmtlnua til' repent if thera Ilrii' lIU ether codes steeed. ~hl:s peceeduee !:an ~Iso be d01l1! with some "Scan" ools.

If Cod. 12 d_ not display, r.f.r to CHART 1\·2, \ n3~liingCad.B]"2 deee nQt me-~n!.\l'i bIlgin~ pr-oblem; ~ ~lmply means that the- d!3Iftlo~lk mode t& working. I.ny other stored CodlCS (Figure a-l6) wilt begin to t.sh .n.., COO. 12.

Rer-tlt to seeuee "1.5" r61" edditlonnl ii\(oriInitior.J hIl-ut. fiuliing !:od!!'l!i"

IGNITION "ClN~.1Ef,]6[NE nMIIf.e.. fSTH!; *!iilBIVlCfflllIGINiI!! SOON(5[5) lKiHT "ON- STiEADV?

.6-12-81 -1"il5-18-U

ltthediagnMt.ic terminal ~B- is g:rounded wiLh ttl!! englne< runnlng, tho system will enter the nt'ld service mod/!. In this mode. th~ "'S=r'll"~~ Engine SoonH lighLwoUl s.n-ow whether th.e svstem is in "Open" or "Cleeed Loop" and fuel Bytcm 15optratingnonnaUy.

R.efer to Sectio n "lv" for additional ioformntion Oil Ilald seevree rnMto.

·"ca~· Tool

A. "Sean" I.OQI is designed to lnterfaee wHn the Computer C.om r~Ul.r'ld Centre! s;'f.!item. It !luppli~!!I a visual rtUdjl"<g of most inputa l.Q the: E:CM and som.e Gulputls·, Revh:'w lhe ~o.ol inatr-ucrlnn manual to un-doCtlitdnd ltanperatlon and lim!Wl,;ion..l.

Con.necl a -S(:~n" toot to t.he ALDL and cipn!'Lteitirf" I iglne:r !!l)nnfC.t.af ur 12 volts and thlj!r~ should be Q. 'l/i$\-Iol lnstructlon d..iB'lJlayed, JIU,ere i!;i (I'D" di.spluy or 1.-001 n:tJ.G6 "ND DATA or NQ ALDL" wil.h 19niUon ··ON" ~ refer to CHART A~2..

With the tool ill the eode- position, lhe display w;:~doYi' will indi.~I!IJ~ a.fi,Y eDdil! stered in the ECM memory (Figt.lt~ 3·U31 ee:fe:rnng to the appliciilble code chart. the tool will ""Scan" I1n input. to determine II iii. specifil: eo:il'euit is open,tinS" pl"{lpetly. U them are ne. cedes, t~ !5yat..em etr,e(.k ts tumi'lfllt«i. A..ddlt.i.olial i.nri;H·mQI;!iQon on '·Soon·' lool& le ln Section "'13'".

Lf there ure additionsl driveabllity ~ymptom5i, rof'!!t"" to Section ·'2"'.

[I there 1I,re nddHion.g;[ eedes, r~rer ltr applicable. ~~e.hnrt"

Engine Does Not Sta rt

if the e.ngin.t t:m.nks but wtll not start, r-efer lo CHART A·3 f,/IIC'ougb A*6lo deLe:rndnl1 ifilien is a1uel or lin j l len preble m,

Code System IFigure 3·' til

1'he ECM IS 13'<iuipped with a i!il!!lf-dlapu):si!;il ayS'lem which dt'!.I!ds :liiystEm failure and aids th·e t..Ett::~ni(:.i4n in locating Lh!! elreult at.tault ~i:o ij eode.

'Th.e ECM is: 1"1611)1 ;It eompuU:lr. It. L.iii§i sensors t.q 1Qi11i,. Q.t If].;);ny tnglnc O"jNnI LIrlg o[!omUUcTl!i_ I t has 8 memory and jl. knQW5 whaL a iCertain !5-en:!lOr readin& should be under cert.ain cond.iti.on!j. Th:ese conditions lUI! de.sertbed on the [3CinFr page of cuc), cud:c- c:ha.rt. I r d semol'H" r~~~irr.!r j9 rmt wluu. t.h:a BCM lh.lnkili ·~t I&hiJuld ~. lhe ECM will turn on the "Service BnKine Soon" llgh.l on t.he instrument panel, arid. wiii ~t.ort a code In tone memory. 'The ~od.e telh whit:h. dr'CuU, tl\(l ttouhlc iii in. A cir~tiH eol'\:~i:~Ut Gf g ~~s.oi'" lIu~1i di:S. cootant t.empemli!f.g., U1e wiring illld oonnB>CwNi La i,·, und the geM.

COMpUTER: COMMANO CONTROL (WlTH WSCAW) 3-9

A.:n "lnll!o.rmUten't,JI ~od:e i!l One. whicn cl:o.e, ru~t reset ftl!:C'U. a.nd i& not :pr~r;nt. while you Me 'Working un the vehicle, The is onca CiluBed by a loose eonneetion, Th! rad.r.qr p;3ge of B eoda chart will contain diagnoS'til!: aids to nelp ~n dote~tin8' intermiUcnbi_

A "nili'd" code ~son-e ...,hi . .::his present when ll;i1u are working (In the voe-hic:liO nnd the condition s.tiH :EtXiBt!i while wo.rking on the vehicle, The enart with the 1itore:d rode "umbel' will lead yOIJ I.D Lhll!i eeuse or ti'tt problem.

Clearing Codes

Wh~ ll\c ECM .6I!ots n code, lbfl '"Ser'vicf! En:gineS60n" light wi,ll come "'ON" am! G code will be 5itol'cU in mea-nuy. Irthe problem is lntermlttent, the light will go out. nJ'ter 10 secood.:;; when uie f~l,Ill gous away. However, Lheeode wilJ lit.:a.yin the ECM memory ror~O g_torts or until the- b~t1;ery yolt.a.gli3 kl the ECM is renwYcr;I., Remlol'rinr hatLer,)' voUage tor 3 Il eeccnds .. >11 alear all ,rored cod es, Thu Eel>! II fu .. OM .100 bo used t;o ~Iear(odes on all vehleles except CK whkh hu arose link.

Codes. ihouJd be CIH,rcG. ~t.r- repair'S h& ve been ~mplfJ~. Aj,150, i!IOn,.~ cU.ugnos:t.ic eharta will leU ,yClU LCI clear UJe cOOe9 ~rQrt w.ing the (hart, Tilill allows the ECM to sel.. t..ht! code white gains till"O\Jgh Lb~ chart, whidl will h.&1,p t.o find lhe ea,W!e .()f the PMb[em mere qui.kly.

NOnCE, T. pte,,,"' ECM damage. the key mus' be -OFF- when diii<:O;'ii'iec:tillg or ~DJlecl:Lng pogW-O:'r LQ ECM ~ ra r e :-::D.mp~e battery <obi e, EeM pi",.i!. Ec~i fuse, jumper~bi05. etc.)

ELECTRONIC CONTROL MODULE

T-h(l did:gnmrla; or thttllCcLrDore eCHlll'ol mQcl ... t~ ~eCMl start:!il with lhfl! ~)'1it;(jm cht:!'Ck.. l'tte wdc 8)''Sl1Im IndieBLeB a r~Hurc or B S'peciJie dri!U~l uod d~DgnOSts: m.ny inaicatt: replncemlln~ of ~hc EeM. 1\ Cod~ 55 ind~,~w,:!l tflElt the ":CM hil& Called a.Dd must be rcplil.li:t:d.

Lr Lhl! ECM has I:mli!'n Feplnceci 0 1'1,0 \b~ oCfJlodHion WiIl.5I not COrTteU!Q, Lhe f~H1lwi ft~ !nf6nf.i.ti.tiq~ may be th:~t,iiJ.8C:

• An inrorrect ECM or PROM/Me rn·Cn! appH~tion mily cause a mnlfunetiot'l lind may 01' mo.y n,oL&eLa~ode.

• If lhi"!o c:onllt";;tln a.' ~ht ECM iEi lile pDlHilble pr"CIbl-em, th.t- wl'minal" may hElv~ to be rem-l)'II'oo rf1JID the C().l1oecLon; in order lfl ~rO(J(jdy (lhl!t1k them,

• Althol.lgh th~ PIl.OM/~em--C;l1 nitely railS, it gp(!tu.t.e-s as part. {If Uti; ECM. UI!i!reforf!. it couh:l be lhe ctlUSle 41rLI'l~ 1Jrublom.

• Alt.hough R rar-e cf,lna.itiQIl. Lhe reptaecmen EeM may be rau.lty.

• In the: ease er an lnlennit~~ problem. refer- t Sectioil "2" and make: a car-eful phyaica [n$pection otthe system Involved.

• It shorted 50hHI('dd, n~l ay roil 01" ha rness I'na (lillUSI8"ELn ECM ·l.Ofl.1.il nnd D 'fI!!ipIEIIQe~(l!n~·ECM r.. fBn when It It irliitalled. Ollie 0 :tJ;hQri. ~B1:iLe J34636, BT '£1405. or equlvulent B:5 8 rast accurate meane cr cbe-elt:ing for a short eireuit, Rufuf to EeM quod drIver (QDR~ eh~k WOi"l repla.cingBCM. {fi"iguce:3-18l

ECM Quad Oriver (QOR) Check

The ECM Wie'S an lruegmted dr~it. (Ie) caJl~ I qull.d driver (QDIt) in plo.cc or &cpante tra.n.si$Wr:

Wturn "'ON" or "OFF" different. i:-ir~uil.!i eontrol.le.d h. the ECId Each QDR ~H15 rour separate Oulpl,,'l!.:5 th,,· -ClUJ independently tum "ON or -OFP" fgul' dilTer£!n circuits.

ECM icnicl!' part number 1.22774'7. used with Vf &. V8 englaes, dQe3 nO\ have; rnulL pr-o reet.le n therafcre, a Ringle fault.}" ctruuit many time, cau!ie"s"31 fbut- QOR OI,HPlJU tu be inoparative or "ON" Q.II U~( time. A filiiM QDR usually :r'.E!:Sl;t.lt~ if'l el1.~er a. ~nurt.ec tl.r o-pcfiECM outpuL. Because gf lhe in" .... euscdcurrenr now. two QDn outputs nre used to delve the Tee soleneld.

Refer- 00 the ECM QDR eheek procedure (f'iSUft 3- l3), 'fbi., I!hock will not lest al] £eM rlll'!..::Lioi'l_iI buL it wi.!~ dO~l.:nn:l.M ira 1ipC!'lX:ti~C" circuit hil:5 ICIUU&CQ a .fijJel::i.fic QDR to r.iI in th.lleM.

A fuulty eireuit i!J the j~rgMteouse Dr a loiIeoc qOR, LheJ'oeo'(ore, the eheek pr()c;~_urB should be u:S~ if ttlere i9 an ind~c;;!,tIOfi of uil ECM f"eplaeemenL, espet:i.llly iI l.he rCmov&a [eM £!){_hlbita ehar@c-teri!Jtic5 or u <10 mllgod QDR .w:n a"

• "SES··lig.ht:"""'Il.hl'l.o~(ld(.'sst.orn<l,

• 'fi:l'Igtne will "M $l.U.i't filid/6f ECM ,*,,",U I1Dt flash Cod. 12.

• Flkke:ring. int-ermit.t.ent,ordim '·SeS··light..

• Output, Bu.ell 25: Tee (:ir(uit, is in()p~rJl.U\le Or "ON"atelltimC;lJi"

~'r'Lgifit m1.!f' r.at, :5u.rgEli or ~ta.l.l,a.

II "Scan."' ~ool m-errn_tk Dr inoperat.ive.

Tbt! eeAt psed wHh on L.4 cogine has Ie circuits thal af"! faull Jlf'otocll!if:l, Lhe['for-e, if n ~irl;"lJit h~j fAi!N, ~hto Ie mn)' n1JC be da.mli4fe:d jlnd will kC(3J1 thl!! ci.n;ulI. open untll the' lo,ult ii'l t.h(l cin:lltl hili.!i I:mert cJ)rrectll!d. When the- f.g,uh has bl!'en cnrr·E'~tE'a. .fE!in:!illlll ECM :lndche~k drmiL .R.eplllee EC~ rU11_v U t~e circult;'s .still inoperative

P·ROM

3-10 COMPUTER COMMAND CONTROL (WITH 'SCAN")

A PROM that has (all-ed 1)1' was lnstalfed Ilnpropedy wjll g@n!:!ro.ll'IsetaCOd[!'51

Mem·Cal

A. Meffl~CiliJ Hni~ has [aHed or wiAfi lrestufled i[flpw'j}tirly will set D Cod.e ~ I.

CalPak

A .no stnrt and run oonditjo~ wlll f'l!IsuiL If the CillPo_k i.:!il net. i~ta,nil<i ln th~ ECM A CElIPElik lhDt le rem" .... eo will set e Goda 52.,

FUEL CONTROL

Fucl delivery i~ controlled. by the Computer CQrnltIlIInd Ccm~rol &yshutl,

The .:;I[ar;i,Qsiii oi" Juel sunjru] !ilnrt.1i with '"'Etlgil'Lc!

Cl'"{lnk~ But WUl Net Run" CHART A.,'). Thfs c.h:c.rL will test the fUlid system and lfiherC' 18 n problem, will ledd you to I!hee.ktng t.hfl' luol pump relay eieeu il, d.i~gMih'l.g th!:: injC(wr cl["e:w.L n .. diagnosing the fu.el syst.t:nl.

fuel Injector

Tesl[,ng t.h.ci rl"ld injector elreuit ;s In CHART A-3 u.1.d ild:ditlona1 diagnosis in CHART A..ot.

A fuel injector wn,jch d,0E!:!l not open 1tUl.)' CUl!SC ,jI Il'll-:d.ru't. eonditiee. A.n inj~C.lOr wblch i_II sLlIek plirll;>, npen.could ~3ustll9!!iOrJln:l~UrClII.n.,ar;&lt.ting. 5<J long eran k ti m(.'~ WO\i ld be notic&d on some engines. A1Bo, die: ... :Hng could o.li:ur b(!C"8UliS S,Dm~ Cu.el CQuld bt:j()livl.lr't'd tot.he-engine after the key is turf'led ·OFF"

~r<lS$U'1! RegulatDr

Testing lhe pressure fegLI laL(]f d rc.ulL is! ill CIIAR'r A·3 .od A,4

Ir the pross:ure nguJntor in lht TEl supphe21 ~1"P'1~lJ'~ which i.s too low (~eJow 62 kPa. Of" 9 psi), POOt' :lIcrf!)rmllnc:e- could rCflult, If 0\11 pl"1!'2itmre is too high, ,.in pI eElJlant f:Xhflu::H odor miry rE!'Eiult

The dif,l,i[1'Ins~ of ldlt: aJr control C8.n be round in :ode .15 ctU,lrl for t.oL engine and ~ti{,Jn ~ ... " t('Jt' ;:jill Ilh(lrf.:mgim:!!I!;.

If LhoEl lAC ... c.I'I,I~ is dis~(infh!Jtll:!d or e[]nr.l~C'l~ci with .he lIuiliir:t~ rUllning, tbD idl(l rpm mtLy be wrong. Ln .hi~ ~;l:oK1, on. tn~iI16S with "'l"fH 2·2-0 unlts, the lAC tal..-.: mily he r~d by turnintl Ul@ il{nition switch ·O~" liInd "OfF" one Lime. Drl etlirinC!l u!:lii'l.( u TiU ioO I_mil. t.hi:! idle rpm is l'~set. u.i it ~fII·~ ;Ibn.v~ ~n mph 4~ kmlhrl.

'flu' tAe valve o.m~(.Ls ~rli)' the IdICll;;hBnll::t»f'ljiltu~5. (lrlhe engine. If it is Oopl..m full)" tee much al~ wilt be JlHowe,t!. il'l t.1lt: fn.u.ni..Cgld and idle speed will be high, H It. 18 stuck dosed, tOD little air will be al1t)w(.-d in lhu manifold. end Idle s;pe-e;d will be too low. If il.. i5 stuck part way open, thE: idJe n'l.u"y bf! rOlJgh" and wilt n ...... t. respond to ~t'l8',i:n'l} 1A)1J;d' ~~lD.l1gu'll!.

Fuel PYmp Circillt

Code f)4. lndteates 0 ratlore in lone fuel pump eireuh.

'two t.ypes of futl ptJ 1'n!;J rel.oYEi are WR!iI DO light. ill.lt~ [f''IJ~k;s. Tho S,'fnnd M serie!!; use nne type ued C, K, R, V, G -n.nd P 'Imr-il:!os use the ~the-r type. UQttw NLa~s I}[IV'J" tile earne function, but terminai.s ~r't'oQge'l\enL ts different, Both eetavs ho:ve tl tetm[tinl ro tclt rhe (ut:11 pump operauon. This Is: elth er a aoparata terminal Io.c:a.teti l'icar the I'clily er alon! tM BCM llSJ"nes!!I or at t(,·i'miill:i1J "G" in ~E!- AL.DL. ecnnectcr. By ;~Pfllyi.ng '!iolt.ago .u.l ~1tj_1i bermlnal, it tall be deteemlned U the rUC!l1 pump will operate. Thi'i terminal will also prime the fuel Hne to the TBI unit,

f{e(e-r to CliART 1\·5 !}or 1\~51\ for d[ag'ru:t.!>i'S offucl

~""'P '."'Y <iroulL,

An iooporati .... B fWElI pump woul-d cause it no siart coooitlon. Afusl pump whlch dces not pro v ide e'l'mugh pressure can result in poor PE!rfGrm;an~

An inopEiF,lllvc Iuel pump filIluy C;lUi i'CSull in Igiig ~t'!~ir'lg t~rncll. pllrllc;!.I.lnrUy Hthe engine 1$ eotd. "h~ ell ~rC::lSIUQ t;wit.ch wilt tum "ON" the f'llel pump, aa 'SO(].n us 0 Ll pressure reac aas about 28 kPn (-4 p!I'i I.

Fuel Module

Oil (J 7.4L cneiI1c Or u G Vun with '" S.'lL et\lfIfic and wi olh(!f 5.7L cnghl1lti over 8500 GVW, ~ [uel mothllfl will C)\'@rride- tht! ECM twa secon.d ttnllli.:r find li1_11! ru!!'1 pump will rLJn for ~wenty .!iel::onm. und ~b!!'n :::;h\.ll,. "0(-"[4"" if the 'Yc.h.i.:1c: ~ rlQ~ a-w.,te.d.. ThL:!i c:i.rc-u_it. t:OrrDcl$ u hot rC:Iiot.c._rt (vuiJ'O[" lot:kl during u ~tgh I.'I.mbicntcondition.

Fuel Module Chea

I. D~~oonnt'd ~hc fue! modulo. ICHAR'r 1\·5 OR A .. 5AI

2. Wllh [I Lest lig~t Ilnd ignitiun "ON", pube eonneet(lr terminal "0'; ~, gr'(ll,Ind. Cifcuit [s OK if light is ·'ON··. 1'here i, an open it the light is. "OFF",

3, P'robC! ~onncC't.ot LermmllJs '·C" I:,.(j ~Il" with l.e-sl li~ht. Circuit is OK i.f lil;f~1t is '·ONm There is an DP!!!" in~r~Lll'Ld c;_!I'~t!it irli~ht15 ··(J~f"

;'~ IgniHot\ ··O!"F", Probe Ci)ruH~i~el.Or ttrrTli.nols "A" 10 "0·' wil,.b te~t HghL. Ignitic)I'J "ON'·, ~e~L light. -&ho-uld illuminate ror two sCC'(I.nd:r. l'h~re Ui an UpCI"I in .... u!ot'irC'u,it irLnelighL is"OFp-'!'

5 Replillc(! ru~j mooule- if Lhere I!;, no tw~nLy :lIeccnd l'u('llmmj}Oj'Hl-r-dliril\

COMPUTER COMMAND CONTROL (WITH "SCAN") 3-11

Fuel Pump Circuit (Two Fuel Tanks)

A quick check can be made by prCS:lling Juel t.sJnk seleeter switch with the 4gniuQn "ON" and Hs,tflning rllt" t1'IfIovCmmt of the :le(ccwr vuln. NiJl.e lhat lhu B;(ilHtor switch is pat" of the Iuel pump reJ.IiIY circuit, lherefote. ~he val .... t w[LI only operate for' two secende or twenty i(eql.1ppcd with a rue! medulu.

f(efer ll)CHART A.~§A for l.l1c dln;gnosl;!i Dhh,., fuel pump. relay eirl::u:it.

IC the p..-ob1em is "Engine Crank, Blil, Wi 11 Not Run", this di.Ggu.osi); IS uaed because tl'lC(c is no fuel pump operuLhm nnd 'Will detel"'mluu Lr lhlll elect.rtfnl ~Y!!!ltel'n i:!! epereeleg.

The clrcled :number~ {l'O CHART A.-SA refer to inronnat.ion pravided bGlow:

L "fbi,. proecdw---p applies di'ee~ 'VollillC to run the furu pump,. l'OR'Rllftg the fuel Lank selectee :JwllCh willl~t tht J;}pefQ.HDn or eneh fUli:lJ l4udr pump.

Z_ [f neither pump would run. the ~Qnt;)ct;s inside Ute ,reluy Dr fuel tank $eleetor swit.ck may be! teeperaelve. Check lingle GOnnet-tor (figure 3-13) ton/white. wire to the Iuel pump relay on the {lOwl.Chcck the two termlaal tQI'o,ne<:tor (F~1{1.I1"'C 3>131 tan ned W:l1, wt!'e 1O the fuol p~{j)r:il,

3. TItIs :!i te p dH~oI:k_., v9lt.l1g0 r rem lhl!l bat~e-ry and Ihe ground (:ir'c;uit "0 Uw relay_

4_ This Lest dtUlrn)ine:s i.r there is voltage from the EC M lerminal "A L" on the ECM to. Let'lt1in;d "'01'1 (In the rel:nyeonnector,

It TIlJs eumpletea the fuel P~Il'li'l-toQla)l' clreuh but if Lbi'S wognMiB W;):I u~cd hecnuae the engine would not g~rl, tben diagnose the oil pressure swlteh,

Fuel Tank 511lectot Diagnosis (iwo Fuel Tank,,)

f'o. qulek eht:!c.k ~n be made by tll>hmlIlR' ffl" the sC'lect!H' valve ()parallOn when pr~!I~i~1f reet LJ.n.k ~lE!d,Of' ~wltch and the ignition "OW Cbe<:king5e'Jeelcr valvecircuil· ClfART A-5/\.:

i DisconnectfuC'1 ptlmpaDnfu~'!!LorjFi.guri!'3- IJI

2, Dlseennee .. Iuel WI"lK 5ele~tor vulve J~i!I t'iHttl.:t .!i:wll..c iii ~Onne:.t=t.O'r (P:igure ~ - I ~}

3. i\ppl;, lIZ; vl:tlLs LQ the r'Y~J JlUlYlP !.t:'st terminal at Lha fuel pump rtl~y

'" Connect ~ test Ught. het.WB-E!fI terminals "E" unt.! --'0" on lhc selector va.lve canneett}l' ;.1r)d ruv ..... e ~li;l..:\.ijr ~""'it.ch Irem lop to boLtom posll.Ol1_ t.lgltt .h.uld he"ON"lnbol.ll P<'.i~lo ns.

• If llgtu i!!I "OFF'" in both pesltlons, eheek ror i'lp€!n In that. cir-euit or faully Elwili!.h

• rf lij{ftt i~j'OFF" in one position, dte-Gk ffll" f)PCIl !11 tJull drcuitor ~ riJulty ~witfh.

OJ flnil TAN~ SElECTO~ $WfTCI-'I []] fOl,jEl. pLlM po GIjJ.f'INECTO~

A - T A.N 'WlFlf:i TO .. efT rus I. I'UMP

III - GPiAV WIRe: Ttl AIGHT I!'UEt PUMP m T ANM'MTr!; WI~ TO ''IJE'L PuMp' ~H.AV

m BLA-C:K GFtOIJNI)WIR~ TO fUEL TANt( SElECTOR SWfTCH

W FUSfiPANEl

[§] eU'S EiAA; GFlOUNIJ

Figu.re 3 • 13 Fu@1 Tank Sl!lector 5whch

• ({ light. is ~ON·r in botn positions. cheek Iual

gag{!cireuiL. -

5_ Oi~onn~t 12 volts. (:6fiMt\ fuel pump eonneetcr and che<:k r~(jl gi:lgo.

(hecking Fuel Gage (Two Fuel Tanks)

There Bhauld be 3 dil'n"refiL qwnllty of Cuol III the len and nlth .. l'utJ lo!fl.kih Refer to CHART A.-SA. for elect,r1(Al di"cl,ii.

L Disccmnl!l;lL fuel tank aetector- ~al "'Ill und meter switch eonnaetor. ~ .'~gu.re 3~14-1

2. Igrntien "'ON".

3. Jumper Lerming.l-s "A" and "B" on the ee leetor v~lva connector. Fuel g'3.ge should lndieute qunnt.iLyof!.he Fight fuel tank.

Jumper terrnina.ls "C" .... l1a "3" und LhD' g.B.I';'E! ::;hould i(!Jcli..;~f.e q ..... nW,y Qf lhe ll!n fuel tenk.

• rr .. here was ne lndlcation in either po-sition. check for on upen circuit Irum termin"t '"B" lu the Iuel gage. Make sure that. lhe two tertninai eennectcr , with one pink wire thut. i.1I located near the ,elector vo_lvl3 rFigure- j - 15l. L::l J:Oi"r:".e(Uy cnnnected.

• [r thur'e 'NOh 110 Indlcatian in nna po~~tion check: r()1' an DpI!rI dreu.it in thlJl pt)'titiof"l OJ'" ftlult:v 5mdin.~ unit.

• If there is 01 oI:h~ns:!e indit:utcd htH.wccn lIilnk'5.

Ulet'irclJitilt:OK.

~·12 CQMl'lITER COMMAND CONTROL(WrTH "SCAN-)

CD GROUND WIRE' - u:rr U"ffT m tA-'"

[!] LfFT RIEL PUMP ANO :Sf:fIIOI""G

u"rr

!II ~·O" "'"'' .~

~ UFT UNIT CONNEC10fl

,.IGHT ~MT CO:N"'~(;TOR GA.O~~Ci VvIHE - RIt::lHf UNrr IT] "IGHT JUEL:F1JMf! ANIJ

SENO,,"r,lG UNIT IT] RIGKT FUl!il TANK

Dill FV~l TANK SILECTOA YAl.11:

A.NO ,",e.TE~ SWITCH

OIl S£LEiCi"Qfl \l'AI.vE ANt) M~TE:~ swrrCH CONNEC10fl mJ LEfT NfL TAN.

f.igure 3· f4 Se~e(tor Va.lv@andMete'rSwitEil

Cannl!d:or

Ingition "-OFF", oonne-ct. rutl tank eeleetor valve und mater :swikh c:ota.tte(:'Or.

Perform fuel '1'9tem pr&lS.surn t~Elt tCHART A-lH [f ongine w(luld. not. run in one gor eit.her ~~I~t;to-!' :ilwU.¢hfXja.lti(J.ri6"_

OOLANT TEMPERATURE SENSOR

Cnd~ 14 er Cod~ 16 indieutee u ro.ilure ~,., L.ht oQl;y,nt tcm~f'at,urlB!lif.HlSQrdrt:"uiL.

.\otru;t "Scan" tiMlt~ di!!lpl:.J.t cnginol.l temperuturo In !grees eentigr8dc Aftttf' cng'inu iii started. lh~ mpe ratu I"C should rist steadily to about 9Q'liC then iLhHhj: when thermostat open~,

lAP SENSOR

Cooc.13 or Code 34 ;_ndic:;ule~.g faih.!,re- in t.1lt! MAP fl:fiUr etreult. Alsa I"efer to MAP output eheok u.gnQais on paRe 3·'73 til cbrtk: the MAP sensor if ere is no code.

XYGEN SENSOR

CDde 13 indif;uLE!:5 un open in the olCygeli sen6{jil" 't'l.lIt. Code 44 indj.eo.tH 11 shQrted c;xygeft Scfi$.ijr 'c.ull Coda 4-!l tn.diCllU;ltl3. high vQIL-u.ge In Lh~ lJl!;)'g~n nt:ior dn::uil. ira Code- i8 Stt.. the engine will i.llwayl';

UJ flEAR I.AMP CONNlicrOR - PU";C WH1_!.i FROM FUE!._ GA.Gl' TO FUeL TANK SELeCTOR vAlve AJ.lD """RS~TCil

~ U:OT FUE, ~U"P AND st~D'NG UNII' CONNetTO" U:F1' I'Im pUMP AND SEND'N; ""IT OONN,Cfi)R Un' G'ROUNO W1fi1f

[j]_ flIGHT fUEl PUMP AIIIO SfNOING U~1T C;;ONNiECTOR

[j] ~1(itIT GROUND WrAE

[1J FliGHT fUBl PUM~ AND SENDING uMi

Ffgu!el.1S Two Fu@ITankWiring

ron in the "Open l.Q.op" miJde. The: o~)'gtn :fjtn~f' voltage output COn be meusurud wit.h III dig-ito I vnltmeter ha.'1ing fit leaat a 1 C mag uhms Input j,mpedanC{!'_ Use of a :aUmiw-d ehep t.y~ YD~tmet~r will raauh ln cn inIlCI:UrBte'~dil1iJ.

Normal "Scee" v ol~ge 'l'wries between 100 t..,V to 999 mV L1 and LO Vt)iL) wh.ile te "ClnseG Lenp" Code '3 JIIeL;o;; if! one minute if voltage remains between .35 ned .S!l volt-s. but the: system will go "Open Loop" 1n !l:I:Wl< ~ I S seccade.

U~l ng the "Seen", ebeeevethe b I f)cic 1 tollrn values at dl{(er(H'It rpm and air now conditions. Tbe "$¢o,nn ulse di!lplay!i: lhr block cctls, se t.litl bloclt 1{!D.f'n valuea Co_" be checked in each of lhe cells to determine when Code 44 or Code 4-5 may have been ~L. Ir the eandlfion tor Code 411i eetats. the bll)(:W: teae rr v ulues wW be nruund 1:50. If .. he ccndltlnn for Code 45 ~xl;;.lsl the block l(luin ",~IIJ-1!:Ii w·.~1 be around Ii 5_

THROTILE POSITION SENSOR

Code 21 indiUltcs that there is: n shorted TPS cleeuit. Code 22 indlc:n~s thnt rbeee j:!]! ~Il opoen in tn~ TPSi zlecult, When n c~ is set, tho(! El:CM will L.LSC an IlrtitlciiJl value for' throtUo po1Jition and some cng.lmt pCTfor'ftUim:e will rcLurn,

A broken l'PS enn cause inle-rmill£!nl bursts Df fuel rt'om the injectof(sl and an u"."'I~a_blc Idle l')C(;'lu.sc Lh~ ECM thi nk~ We th .. o~Ue l:; In~r,,'ing,

COMPUTER COMMAND CONTROL (WITH ·SCAN'·) 3-13

A -&.11'1" teo! reads l~.lt"~Uh: posltlcn in yoUS, Sh(JlJld r",;)d QOOUl [53 votts (2.5LI. _46 ... olts (2.8L.), ,6'0 volts (4.3L & V8) ± 75 veus with ~n.r.altle dfii .. ·d and ignition "ON" Of a~ idle. Voltage should Increase Olf.11 steedy rule;;jtj lhroU,lc is moved I.nw_,td WOT.

"Scan" 1'PS whlle depre!J~ing uecc lerutor pedal wlit! engine stopped Jltlld 11,!rntLJon "ON"' Oi'!lplny .sh(lould v ury [rem betew 2.5 yoHIS ~~.fiDO m V) when thnJHle WELS doser:l, ~o y,yr;,.4.5 'l(oH~(450a mV) when thrDLtle is hetd iJt wId.e open IhrotUe pnsiti()~,

TPS Output

181 no {4 . .3L and VS Engine)

Thischet:"kshould be pl!rformiJd.'}~I.v WRen throtLle body ot TPS has be-en I'"eplt.~ 0'-, ofter the mintmu.m i.llrnow has been ;Q.djo,skd.

L CODnecl dlgil.ul ... ol tme te r- If-J4029.A, 01' equl v alent, from TPS. eonnecrer o!;(:r-min.ll.,1 -B" t~rk blue wtre] to ~ermifl8J -A" (b!ilck wire), Jumpers [or ~rmil'lQ.I ~,coe~! can be made using I.«oin.ls "1214836" aDd "12014831'\ A "Sean" tool ron he used to reed TPS output veltage,

2_ Wtth Igpilion "ON"", and e-ng'ine sWpp~d. TPS ... ol~g~ Shl',H.lId. be Ii!BS than 1 ,Il volt If RlDr-l!' th.r,tn 1.0 1o'!;IIL, check: Ttlil'lilflYm idl c speed berore replaelng TPS.

3, fiemnve vcltmetor endjumpees and eeeenneet TPS c:onneet.or to sensor.

TBI22012.8.L Engine)

Thi.!;: c.i'lecli: ehuutd 00 performed (l.ni~ whee 'lhroU.ls body -p:1fU t\ay(! heen replac-ed 111" Mler Lh(l ftli.nimiHD air now hils been edjueted,

l Conne-(~digit.at vaILme-lC'rJ-34029-A or equlvotent Fr(]m TPS ronnect.t)( l-<lrmLMIllI "13" Idnrk blue wfl'.cl to LerminJ~1 "1\" tb[n,ek ",.trek ~Iumpe:rs rOr oor-mf 1'1::111 tltCt!flS can be m[lde mlifi~ ~QrmhHI h. -1214836" .nd "120141>37" A "Scan" 1001 can be WiOO til reed TPS i,ullJul voltage.

2. With igniti(Ui "ON"'. cngtne 9ropped. TPS yoU,ago 5:~olird be between .42 and _54 voll,..g,

If;';ojj!t..ige is olltfltl';![iIlRe. rot.aki1'PSunHi (lAS ± ,00 vo[Jll.EiI attH,~t.u~ned

4_ !t aoo'l'e .... olt.u.£C limilnt.ion cannot tie oillatl)cd! "-(!pl.Qel!: TPS.

S, Rel:JlIJv@ vJ)ltmeu-r llnd jYrnl)~nl ttlCGfmed TPS C'onnec:tor to 9:ei"t~or, ., ......

T61700

This c!lec.k shoYId. hC' ~rf(!rm1Sd only when throttle l)gdy llwi.s have lxien n!pla~l'd or I.I.fter the minimuDl iljr flnw h~s tx.'tln odjU:!il@d_

Connect digital ","01 l.ni{l:ttI r J~4029~A i'r (!'(.juii.r!,tl-Cfil jeem 'l'PS Mfim,':t;1.or lermwol "(1" ~dar"k bh.lI: wlre tQ lcr-m!",fi~ "C" (black wire} Jum por-a Io termlna! ueeeaa can be mad u~ine ter mlna! "i2148jl3n and "12014837", A "Sean' toal ean ~ used Ul r~ad tM-I!! TPS OU.tpu.L rottalJl!

Wit-~ iRnjt+Oll "ON", engine stopped, ~hi]i Tf": ,!{DILa~c ~holiid Ire: j615:S ,har.'l L25 volts, [I n'iUTQ thzn 1,25 volts. TBphICI!TPS.

Rbmoye the veltmater .and jbrrtp(trs. reeonneet eh TP-S C'ann~tor to .. ~{! s-ei'i;SOr.

VE.HICb. ~PEED SENSOR

The ... ~hi~l(! speed SilnBftl" ~ir(:l"J:it diu.gl1osis Is b COOIl' 24 chart.

"Scan" re;l,d~ng ebcutd ul oael y mateh witl speednmerer ttudir1g. wlth drive whaala Lurnlll~.

MAT SENSOR

Code 23 lndieatee thnt t.hC-J't ls an open in the- MA1 circuit Crxi~ 25 indicat..es thul there is a short u grDUnd in the MATcin:uit.

A "Stan" to-ol reads te mper atur-e or the !)II I!l'.nt..tilrlng' Ul'C engine and i5bould rea4 .;10&6 tv ~f.i'I~.en ujr temperatur-e when engi.ne I, cold, Dild riSCltf n~ undarhood te mpararura LncreaSM.

EGRSYffiM

Cooe 32 lndicaree that there Is (L fniluj'(j iii I.h~ EGR l5yata m dnui"t_

IDLE SPEED

Codu35 1i(!U;; when there hi a problem with Idle ~ltr control on El 2..51.. engtne, R~fer y) dillg"091S in SecLLor "4'" rCir idla nir er,.nt.rol..;:r.eck rol)r othiJ-t' enginl'J"ti

.. S"s;lcm too lC'oo I ~llgh .u.h-/r",el ml-lol

Idle speed may he too high or toe low, ~nA"inE speed may ... ary up and down, diseortn~cting [1\( does nat help. M~y l!lct.Cl1'11e 44,

"~,{L,f''' ;,J,i1d1 .... r vuhrncrer wLIl rued en oxygen ~e:nMlr outpul. lees then aoo mV L3 'l'oll1'il.. Check for low ,re-guhJood fuel prctJSure'or w • .Ilcr' ii'I fuet 1\ lean e!tn:J.u!I'l wJl~ ati j)~:!fg~n !.c"~r QIJI.pUI fi:oced \ibQvc 800 [fly 1'.8 yolLI:i) will.be 11 contaminllted nnllOl', ul>ually 5iliGone .. This may abo sel a Code 45,

• SV8-t5!'m l{l{l ,..ieh [Low ~ir/ri.lell';)"lOI

ld.le speed l·GO low. "Scun" -Il6unts ·U5I:UE:!lIl~ (]bf~"'E! SO, Sy&Llt'm obvl!lJlu,&ly nen I1.nd me:,!" e-:'(hibit n~,-,c~ ~moke exhaust,

~Scart'· too! 3ndtor vollmeter will rend un nx~'gtm ~osor RiKI'IQI fl:!led aoove! 800 fl.IV i 8 yulu;)

RECTRONIC WAHl< TIMING

3·14 COMPUTER COMMAND CONTROL (WITH ·SCAN ")

PARK/NEUTRAL SWITCH

Wh,rm t.h~ syseem ;s mnning I'm lhl! iRnilion module. t..h.al IE. DO volta~ r;m lhe ~YP(!~~ lin 1 \.he ignition module- grounds the 'EST tignal. The ECM expects to see n(! \'olr.age on tM. EST line during tel:5- L:onditiot) lf it!W1)i. (I; IItlltrJ.ge. it ill.!]'!.!;; Code 42 and will f!ljjLgO [nt..o the 'EST mode.

when tbo rprn for EST iii reaehed {abDut 400 rpm), lind b;y-jm55 'f-Qlt.a.ge applied, the BST should tlO longer be pounded In the ignition. module so I.he EST voltage ~hDUld be ti3tyll'r(.

[f Lh~ bypM."ii llne is aperI Dr grounded, t.he jgnlt~9n mcdlJJe. will o_oi ~witc~ la. ,EST mode 80 th,<: EST eol L.[lG'E' wlll he low and Coae 42.will be St'"'

I f the EST line I~ grounded. the Ignltton module Nill switch to EST, but because the. Il~e IS grounded \hDl'tl will be no EST signal, A Code: 42 will be ~l.

Code 4'2; se~ il'the're is en epen Or' I:l !lhort to gro)J11d In the EST or by~:!jI c:il'c.ult.

ELECTRONIC SPARK CONTROL

Code 43 sets if there is ~n open or short to ground n thl} ESC cil'tuil,

If IJ"'~ ~,u:l.il-it::m:!i ror a. Coo~ 43 D.1'"('i prl!l!;(!ri~. the '5e,unu 'lNUI [I_I WD) a diep lay'" yes" _ 'l'here she [J Id ne t be • knoek nt idle unless en internal engine prcblern, ee a rystem prebtem e~i5ts,

,YSTEM OVER VOLTAGE

Cede 153 eete 01'1 i:It 2,,5L (::nginc: if therc l~ votLagc rr-e-:J,ler th.o.n 171 volts rOt LwO IltlCIIH"Ld" til ECM crminul "01"' 'T'hi,j; lndicnt!:!s lhaL lhe:r@ is a basic tenerater problem,

Oi(i!fm~Sii~ or Lhe parklrlfwlrtLl switch is on po!:!! 3~ 75 Qr LhUi sectien,

CRANK SIGNAL

TltoD erunk liilgmd dh,gI\b-!i ls proced are ie en pa,ge 3- 77 "f'thi:lio aeetion. IHner.e is no crank signal to the ECM. the engine may be hard to start,

POWER STEERING PRESSURE SWITCH

Till!' diagnosis or the power 'BteerLng preaeure awlteh is: oov@t'ed on pa~ 3-1DQtthE!!i&eetion.

Dl5ffl!!!UTOR REFERfNCf SIGNAL

The- dlatributoe reference signal is eovered in SeCdDO "6" oftne lRnilion !l.yslern and eteeteonle spark ~nntml.

AJC CLUTCH CONTROL

"'h@ dfagncsla of the A/C ell.Hoell ecetecl un 0. 2_5L engin-e ~ covered. on. 'P;l,~t ~-6t of t.l1t.s $~ti_,,!n nn.don 2,SL ""gin,< on pogo J"il5 .

AJC "ON" SIGNAL

The: di!lgnoj!::l~ Qf ~hCl Ale "ON" s.igna) QJ'! all 6ngii'lC~ tither thnn :2:.5L i3 coven .. rd Dn page ~6 oftbis aoetion,

EXHAUST SYSTEM

RefeT to Pigure 3~ i 7 for- dlugno:[!il (Iof ,_ re-Slric.~ exhaust system.

COMPUTER COMMAND CONTROL (WITH -SCAN-) 3,'!

CODE IDENTIFICATION

The "~r"'ic:e Engine ~I"!" Ugh" wBl only be "ON" if \.he maUum:tion exists under tho ecndltiona Hs,l1!!d aelow. rr the ma.llurL'Ction clears, the liRht will ~() nut. and the rode will be :!Jto:r'cd. in tha ECM. AIJ'/ ~D<i1l!S I :sw..oo will be ~i1!ged ifrm preblam r'~c-u.r~ w\~hifi50 cngineEl-t~}rL.<;.

COP£ AND CIRCUIT

Coo. 13 . 0, Sen"" Open Oxygen sc,!'IS(Jor Circ-uit

GodB 104 - CooJ8.ntSe~r High Tempe:ra~utC Indiattiart

Cooe [5· Cootant$en!lor Law 'Tampereture lndlcatiou

c.d.21·TPS SigtUll V.lto~. liig.

CodeZ2-TPS Signal VDh:u.~!re Lew

c.d.23.MA'I' Low Te.mperuture Inuh::il.li,oll

'Coo. 24· VSS ,Nq vehicle Speed lndic;l,tioCl

Co<loi5-MAT

H igh 'rernpc"O:llur~ Indll;OJ,tiol'l

C<>d. 32 . EGR

PROBABLE CAUSE CODE AND CIRCUIT

lndicilles that the Code 3.1 .1\.IAP Seruor

oxygen sensor elecuh or Low VnculJm

sensor was open (or one

minul.O whil(!iorrid~e.

Set:; if tho sensor or Codn 34· MAP SenB{lr"

algnul Ilne beeamea HiS'A V!l:~uy;f'!1

grounded tor' 3 seconds.

5cUi irthc sensor, connaettons, ~r wires 'I) pen faI' 3 seeonda,

T?S IIGIt.agc gt"e-atf!or lhun 2.5 VDlts: far 3 I!i~CI ms with legs ~ha.fI L~OORPM.

A ahA)rted ee ground at ~~n Slgniiil CLrl;:uit will :S-i:ll-cg.cJQ j n ,3 aeeende.

Sets if the sensor, !!onne(liOQ~, 9'" wires op-en ror 3 sesu Ildi-.

No vehlcle speed preat;:-M d url ng 11 ruad I(I"-Ld UIX:(: I.

Sti~ irl.ho!illritiOr or ~i~n.ulltn.c heeames grounded tor J $tJ'C:ond5.

Cod.3S·IAC Cod. {2· ~ST

Cod.4S·~SC

Code .4

Lean. Exbn.u~t. [ndiclllion

Cod. ~5

Rich Exhaust Indlcatiun

Coo. 61

Cod. 52

C<l<l.53

~u~u::::~~~~~~ Coda 54 _ PloLcl PUmp

OR. .[.,o.w v <Joll.:i.lg-t

SWLtch nolchl!J.t.td uf'l.t'r

tbe ECM hag

eemmanded EGR [or.ll

specified pedkoo of time. Cooe :is

f!:CR M)1(!~oUj(tN:ult

~I)e" r(lf' :l ~pe¢'i0.ed

pui(lfigrtinili'

PROBABLE CAUSE

MA P sensor output to high Joe D ~on~~ or an open ~i~;(ll eircuit.,

L,a.w af niJ out.put from BElllB:4J[ wHh engine runrung.

IACeri'or

EC M has .5el'-n un cpun Of g(lo\U]Qt-d EST or BY"!)IlMdn;uIL

Signal to (h. eCM has remalned lcw Icr ten long or tn(! sy~t(tm has [ailed 4. runctioraiU cheek.

&-bi lloxygen:EienEil;lr voltage, eerenlns below .2 vmlts {or -obttUl20 seeonda,

Sets if oJ(~gcn sensor ~.olb:JgE! ramnlrta.abnvn .7 ""olu fur about I minute.

Faulty MEM·CAL, PROM, or EeM.

FuelCALPAK mig.,!iling I)r rawly

SY5lU!"'ffi (l v!H'v,o I roge [hdiclilc::s 0. basic: glllng-rator problem,

SoLs when 'he rud p'urnp vliIIl ml!!;o Iii 1'11.5:9 lhen 2- vel ts when reference pulse:5! ilfe being reeeivee.

~."I'~ EC~t

FIgur!: l ~ 16 - ECM Code 'S ~'5tem

3·16 COMPUTI'R CO MMA,!II!) CONTROL (WITH MSCAN")

I.~. HA~N[$.s CiC~~[C1:Oii:

ISWA'I'.'F"~TY'ltlW~

EO!

CHART A-1

NO "SERVICE ENGINE' SOON'· LIGHT AU. ENGINES

rrC:lIit Oesuiplion:

Th~rt!:3houldoUlwilYli be IIIBte~d)' "Servtee EnginoSoon"' lIgh .. when the ignition is "ON'"' iii"ld .cagine 1ilAlppe-c;l. iit.tl:rry ign.iUon vc;ll!:.c.ge ts supplied La the rtghl bulb, The ECM will contrul tile U,gh~ end turn It "OW by "tIviding-o jfmlmd path thrmrgh CKT 419

~5t DeSC/ipt;ian~ N"umboc·rs t,E'lc-w rCr~r W drded rmberaen lh.¢dilignos.tic eh(trl.

rf the n!SC in holder 13 btGwn. refer to lacing p.8gl! or Code 54 (or eempieta eleeun.

L"~in:g a ltt.!ltiiglil CCllnll!(te<i W .12. 'l,l'olt51,1H'obe eaeb or Iha sySlf:n'i grou.nd. e[reuil:!:i to be sure Il rood grnlLlid fs prPSe!1L. &.."t ECM Iermlrml end view ill rr~At. vr t.his seoC\.ion (or ECM pin 1«:3tions or gruund drclJ i 1.810

Diagr'io5ticAids:

l.t the engine runs OK • ..::hjjck:

• Fnu,lty JigM by[b.

• CKT4l90pen..

• Gu.~c fWR! IlIA ..... n, Thhl: wilt result in nj). gltJp ttghrs. oil ot' ge:ncratGr lights, !ltiL." belL rumindee, e-te~

If Lnu i2nli::lne: <:rankti but w Ill not run J check:

• C-onUnl:l(loW!i bgt~ry~ru:se O,.fuslbleliok epee.

• eCM Ignltlnn ruse open.

• B;llLeIQ' CKT 3 .. 0 1.0 EeM open.

• Ignition CKT439 to ECM 01"'0, ill Poor «Iii neethm to EC M'

COMPUTERCOMMANDCONTflOl(WITH ~SCAN·J 3 17

• "'081: CaT -t 18. wnH n:S:T UGHT TOGAOUNO. IS nil S.E.S. UGloojf ·ONl'

• GA(iI;:FUSIi

- f,&U1TYIUl&

- OPO! ell 419

- CncI9S1f~nDTO

;';'QiTAi§J

• OP;fN tON. reeo TO aul..B.

CHART A-1

NO ·SERVICE ENGINE SOOWLIGHT ALL ENGINES

G) lOCAlE ANCoCOfUll:eCT 5HOR" '1'0 6ROUNO IN tXT TI:IAT H~C '" IlOWN'RJf.l~

• lGHIT10flil JlQW.

• CIS.cCNlIII[C'rlCM (ONN~CTO._$c.,

• 16N11lON "'0"-

II' JI-'ROB' cn lao ... ]'9 VdTH nST LKHIT TO GROUND. r:sHlIL~ftT ·O,N· ON elOTHCIn51

CI.IEARCOOH 11."10 CO:!>I~IR'" ~<LC5(O lOOP n OPUi.,II"nON ANCtNO '"'!iu::Vitl ~NGllilt $I:J.ON- UC;,H'_

3-1 If COMPUTER COI\l1MAND CONTROL (WITH "SCAN·)

L,,_ MA,iN!;$$ eONNf:l'f(!oJII 1S W,U. ('fROHT VIM}

li-l:H7

L_+«-+-_ o~ .. ~, '-------t~'il.&- ORIN461

CHART A-2

NO AlDl DATA OR WON'T FLASH COQ!; 12 uSERV1CE ENGINE SOON" LIGHT ON STEADY All ENGINES

Cirruit Description:

'1'hcr'e !JhOlJld alwayg be- a steady ""Se,rvic::.-e Engine $oQnti light when the Ignition i!i "ON" and engine stopped., Hiinery ignitlol'l V()tt.;].g~ i!l supphed to the Ii.Sh" bulb, "l'1e ECM will turn the light On by grounding CKT 419-, WIth the d.i.fl,goO'.a:H" re-r·mirn.t geeunded, the light 5ho"ld nash e. Cod.e- l2. followed lit any UQLJble- eoouts) ennred in memory.

fl ~tead}' Hgtrt S'Uggll!!ttail Eihort. ,o,iii:t"Qunc In lllc' ltght control CK'r4·l9 • or on open in dbgnl)l5t~1il CRT .j.,'i!.

Test Description: Numbers below refer to circled num~l"5 sm the dtRgnosti.c mnrt.

I rr there- is a problem witli. the £CM thiif.. eause-!'I a '"&.an" tool to not rend Serial data then the ECM should nolntl£h n Cod~ 12. If Code 12 does nash, hoe sure th.t the "Scun" lOOl i~ wgrking pt'"()perly on Yi'iQ4.hei" vehicle. If the "Sam" Lilli fu.n.ct[onlng ~riJpudy .Old CKT 461 le 'OK, t •• PIlOMfMorn"C.1 or ECM m8y bll LU Iaul t ror the NO ALDL symptom.

!fUm lighL goes. "OFF'! when tne ECM eonnecLot' 1:5 di:-;ct),me-cled, thon CKT 419 is not shorted Lo gnJl.lnd

.l ThIS step \IIHl cheek fer uri open diagnostle CKT ~51,

4. At. t.his; polru the "Scrvree "~na:inli!: SoIlI1" li!1;M. wiring is OtC The problem ill! ll. faulty EC'-1 (IT PftOMlMcm,C3I. If C()de 12- OOfl5 lWi nagh, tne ECM should bn ['~pln.Ce-d using tbe origin.al PROMfMem-C.I. Repl ac , Ih. PRUM/M.m-Cil.1 on1y aFt!:!' LrYLng un HeM, 11..:5 Il dele-ctive P1l0M/M~I'I'L.CuJ is! aft unt ike ly cause of the problem,

COMPUTER COMMAND CONTROL (WITH "SCAN") 3·

CHART A-2

NO ALDL DATA OR WON'T FLASH CODE 1:

"SERVICE ENGINE SOON" LIGHT ON STEAD ALL ENGINES

IGNITION "ON"', ENGINE "OFF", IS THE "'S.£. 5." LlGMT "0"'''1

GROUND OIAGNOSTIC TERM. OOESUGHT FLASH CODe 111

IGNITION "Off-, RECONNECT EeM.

IGNITION ·ON'. ENGINE STOPPED. DIAGNOSTIC TUMINAl NOT GROUNDED. BACK PROBE rCM, CI<T 451, WITH TEST LIGHT TO GROUND,

~- -----~---,

~ SEE (HART A·' :

....-----------~

IF PROBLEM WA.S NO ALDlOATA:

(HECK SERIAl OATA CKT461 FOR OPEN OR SHORTTO GNO.8ETW£EN rCMANDALDl CONNECTOR. IFOK, ITIS A FAULTY [(MOR PROM/MEM~CAL

ClEAfl(OOES ANOCONFIRM "Cl.OSED lOOP" OPERATION A.NO NO ~SERVICE ENGINE SOON~ LlG,HT.

7S361;:18 7-9-8(;

COMPUTER COMMAND CONTROL (WITH "SCAN") 3-2

IF c,;OO( 54 IS. STORED. US.f: THAT (HART fiRST

CHART A-3

NGTflE (RAN.KS-Btff-WILL NOT RU~ 2.SL ENGINE

/

\,

-22 COMPUTER COMMAND CONTROL (WITH "SCAN")

481 RfD

12V~ IGN

£(M1

439 PNKfBLK __ - TO ECM

2.8l(S. TSERIES)

4.3l & V-8(P. R & VSERIES)

, ..

.6. LTGRN ~14 ECg_M

467 LT8lU 016

1812211 UNIT

INJECfOAS -=-

4'.LTGRN~D14 ECg_M

467 LT BlU 016

TBIUOUNIT

INJECTORS -z-

~-'y·'"'"

481 REO

INI.I

12V~----~.---v

IGH 10AI7_SAM.VAN)

4.3L & v-a (c. K. G & M SERIES)

1S 3777 7-4)7-87

CHART A-3

ENGINE CRANKS BUT WILL NOT RUN ~~~~ ", •• d '1 .s:lL

.ircuit Description:

This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in he tank. This chart should be used on engines using the Model 220 throttle body.

'est Description: Numbers below refer to circled umbers on the diagnostic chart.

A "Service Engine Soon" light "ON" is a basic: test to determine if there is a 12 volt supply and ignition 12 volts to ECM. No ALDL may be due to an ReM problem and CHART A-2 will diagnose the ECM. [fTPSisover 2.5 volts the engine may he in the clear flood mode which will cause starting problems. If coolant sensor is below _30°C, the ECM will provide fuel for this extremely cold temperature which will severely flood the engine. Voltage at the spark plug is checked using Spark Tester tool STt25 (J267921 or equivalent. No spark indicates a basic ignition problem.

While cranking engine ther-e should De no fuel xpr ay with injectors disconnected.' Replace un injector if it sprays fuel or drips like u leaking water faucet.

4. Use an injector lest light lik-e BT8320. ( equi vale nt , to test each injector circui t. blinking light indicates the ECM is contrc lltn the injectors.

5. This test will determine if there is fuel pressure, the injectors and that the injectors are operating

Diagnostic Aids:

If no trouble is found in the fuel pump circuit I ignition system and the cause of a "Engine Cr-anl But Will Not Run" has not been found, che-ck for:

• Fouled spark plugs

• EGR valve stuck open

Low fuel pressure. S-ee CHART A-G,

• Water or foreign material in the fuel system.

• A grounded CKT 423 (EST) may cause a "~ Start" or u "Start then Stall" condition.

Busic engine prohle m.

COMPUTER COMMAND CONTROL (WITH ·SCAN'") 3-.

IfeODE 54 IS STORED. USE THAT CHART FIRST

CHART A-3

ENGINE CRANKS BUT WILL NOT RUI ~

3). IGN ·ON"w IF S.E_S.L!GHT IS OFF, SEE CHART Awl.

• INSTALL ·SCAN" rOOL ·IF "NO Al.O ..... see CHART A-2.

• (HECK THE FOllOWING;

.YPS -IF OV(R2S11 ATClOSED THROnLE, SEE CODE 21. • COOLANT-IF BELOW ·30'<. see coer 1 S,

• IGN. "OFF" FOR 105.€CO..wOS. IGN, gON". • ONE FUEL TANI(;

usnN FORPUMPTO RUN. DOES In

• TWO FUEl TANKS:

LISTEN FOA PUMP I .. tACH TANK USING SELeCTOR SWITCH. BOTH PUMPS MUST ~U~,

DO THEY BOTti ItUN?

c"ooJ '1 S. -, L

NO

r-- ------------------~,

: ~~~~~~~:~~PA~~~AY CIRCUIT :

l ._. J

NO

r-: -----------,

: SEE IGNITION SYSTEM :

I CHfCK IN SECTION (; i

t... ~..1

RECONNECT SPARK PLUG WIRE. OIS(ONNEcTINJEctOR CONNECTORS. CRANK ENGINoE.

IS THERE FUEL SPRAY FROM ONE OR 80TH INJECTORS?

r'- --------------,

: seE IHJECTO.ft<IRCVlT :

I OIAGNOSIS CHAAT A--4 I

~:=:::::=::::::::::::::::;=.._---.c ~

7SH7. 4·27·81

'UTER COMMAND CONTROL (WITH "SCAN")

482 WHT

.----------------- 468 U GRN ----I

481' REO

INJA 011 ECM1

........r;,__--- .... \. ~_.--- 439 PNKJ8LK --- TO,E(M IF UISIN:G

IGN lOA eCM 1 ,FUSE

EST

REFERE

424TAN/!ILK

9YPAS!

GIIOUN

453 BLKlRED

~

TO IGNITION COil

CHART A-4

ription:

L should ony be used if diagnosis in CHART A-3 indicated an injector circuit probl. ts fail to blink when tested, diagnose one injector circuit at-a time.

stion: Numbers below refer to circled 2. This step tests for 12 volts to the in]

Ie diagnostic chart. also determine if there is a short to v

",iii determine if the ignition module is ECM side of the circuit.

a reference pulse. if the wiring is at 3. This test checks Cor continuity to the I

the ECM is at fault. By touching and

a lest light, connected to 12 volts, to

a refernce pulse should be generated. If

st light blinks, the ECM and wiring are

COMPUTER COMMAND CONTROL (WITH HSCAN"

•• <0 ~ ••••••••

• FROM • : CHARTA-] : : INJECTOR TEST : : UGHTDOES :

CHART A~4 INJECTOR CIRCUIT DIAGN ~

5.7 L.

• MO""£NTARILY TOUCH HAIlNI:SS CONNECtOR tERMINAL CKT llQ W!TH TEST UGHT TO 12 VOL T5. NOTE INJECTOR TEST UGHT SHOULD -BUNK- EACH TIMIf' THE TEST LIGHT IS REMOVED FROM en 430 .

0: =~~,!'NNE~~~;EaOR

CONN£CTOR

• DISCONNECT c-o (32 PIN) ECMCONECTOR.

• lGNInON ·ON-.

• PROBE CONNECTOR TlRM. ·014" OM.· 011i· WITH A T~ST UGHT TO GROUND.

CLEAR CODES AND CONFIRM "CLOSED lOOP" OPl'RATION AND NO "SERViCE ENGINE SOON" LIGHT.

4 75

3-30 COMPUTER COMMAND CONTROL (WITH "SCAN")

4400RN ;}

rul~~,r~"·~'

~~~". ..' f 'l·l~HT 1

SWITCH ~

-l:J~E TA~HT

. 120 TAHIWHT

fUELPUM~. >- 490 RED 011920 PNKI8LK (el)

nSTTERM.

OR AlDl {(KG)

'USEUNK (~K)

BA.rr I2V

OR IECM B FUSE (R'lfGP)

7·,20-87

Fun MODULE

lOA

PNKlBUC 39 ~ IGN f2V BLK/WHT 450 iCM'lGN

ECM

CHART A-S

1r ON AU 7.4l. G VAN WITH 5.71_ ,IU'IIO AU OTHER s.n. (I'veR 8500GVWENGINES.

FUEL PUMP RELAY CIRCUIT DIAGNOSIS (ONE FUEL TANK)

~

Circuit Description: Loooo;) l..f 5.1 L

When the ignition switch is turned "ON", the Electronic Control Module (ECM) will turn "ON" the infuel pump. It will remain "ON" as long as the engine is cranking or running" and the ECM is recei distributor reference pulses, If there are no reference pulses, the ECM will shut "O~FH the fuel pump wiel ~~after ignition "'ON" or engine stops except when a fuel module is used.

The pumpwtJtt{eliverTueT1Othe TB[ unit where the system pressure is contretled to about 62 to 90 kPa 13 psi). Excess fuel is then returned to the fuel tank ...

A fuel module is used on all 7.4L~ G van with 5.7L. and all other 5.7L over 8500 GVW engines to corr hot restart tvapor lock) during a high ambient condition. It is designed to over-ride the ECM two 'Second p operation and will run the fu.el pump for twenty seconds at initial ignition "ON".

Test Description: Numbers below refer to circled Diagnostic Aids:

numbers on the diagnostic chart,

1. This procedure appl ies direct voltage to run the r uel pump. [f the pump runs, it may be a fuel pump relay circuit problem which the fo'llowing step will locate.

2. This step cheeks voltage from the battery and the ground circuit to the relay.

3. This test determines if there is voltage from the ECM, terminal AI. to terminal ""0" on the relay

connector.

4. This completes the fuel pump relay circuit but if this diagnosis was used because ehe engine would not :run then oil pressure switch should u lso be diagnosed.

• An 'inoperative fuel module may be the caur hot stall/no star-t condition. Check for pow, ground circuit to the fuel module and a ccr circuit to the pump from terminal .. A·~. If 01 the pump does not run foe the specified '20 SE at initial ignition "ON", replace the Fuel Mo~

COMpUnR COMMAND C;ONTROl(W1TH uSCAN'

CHART A-5

f!U ~t MOlH,'!'!,J! I~ I AU 7"AI..-G VAN 'IJI S,7L Alie A,LLQn s..nOVIi;F!85'DOG (·N:GINI'5..

,.

3-34 COMPUrERCOMMANOCONTROl{WITH "SCAN")

THROTTLE eODY PRESS.URE REGULATOR

MODEL 700TBI

FUEL .&;~;:~~;;;;?;:=5~~

TANK

CHART A-6

FUEL SYSTEM PRESSURE TEST

All ENGINES Good ij .s, , L

Circuit Description:

When the fuel pump is running. fuel is delivered to the injectorts) and then to the regulator where the system pressure is controlled to about 62 to 90 kPa (9 to 13 psi). Excess fuel is then returned to the fuel lank.

Test Description: Numbers below refer to circled pump test connector. pressure should be from 90 to

numbers on the diagnostic chart. 124 kPa (13 La 18 psi).

I. Pressure but less than 62 kPlI. (9 psi) falls into two 3. This test determines if the high fuel pressure is

areas: due to a restricted fuel return 'line or a throttle

• Regulated pressure but less than 62 kPa (9 psi) - body pressure regulator problem.

Amount of fuel to injector OK but pressure is too low. System will be- lean running and may set Code 44. Also, hard starting cold and poor overall performance.

Restricted flow causing pressure drop - Normally; a vehicle with a fuel pressure of less than 62 kPa 19 psi) at idle will not be driveable. However, if the pressure drop occurs only while dr-iving', the engine will normally surge then stop as pressure hegins to drop rapidly.

Restricting the fuet return line allows the fuel pu m p to develop its maximum pressure (dead head pressure}. When hutterv voltage is applied to the

Diagnostic Aids:

• If the vehicle is equipped with a fuel module, the module must be disconnected before performing the fuel system pressure test. Refer to Section "4"

• Fuel system is under pressure. To avoid fuel spillage, refer to procedures in Section "4" for testing or making repairs requir-ing disassembly of Iuellines or flttings

• On VB or VB engine, the rue I pressure drops to almost zero psi after pump shuts "off".

COMPUTER COM MAND CONTROL {WITH ~SCAN'

• l~mON -OfF"". I

" FUEL TAfiiIIK QU,l.HTTTV 0.[(,

• INSTALL PR.[~ SUR! CAGI!! AS DyTllN rn IN ncnoN 4.

• IGHnU'N .. O,..· .... OTt"'-EUIJ.R-i;wrrl-ltN2 SECClND5.

CHART A~6 FUEL SYSTEM PRESSURE AlLENGINES

I

NO PACBU!"MIOUND I

IlES5 TO"''''~ ~ •• ' ..... 1 I I

I AOQV' 'I''''' Ih.ij I I

IREPlAG FL11iR I ~NDR[CH[(J(.

AlaVI.!] .'.1 ttl p"il I

1

TW:;i'2Qo .1

~E:P'L ... tl FUlL

M.U'{,il, 'COVER

WH"ICH INfi..uD!!li I

Pfl'[SSURI!! IttGULA TOR.

TI!I1100

R~if'L"_CE ItRES5UIU

RUiU.A TOO U'V. l

• Dl5UJ.NNKJ lNJ:faOR ~ONNteT(J.R.

• DI§[O.NHi~ fUl!l. Rntll;Ut LIN li:fUJC.tHl.:i HOSI

• At rr-.[H ~, 6 ~,D. FUX ~ms ( TO lHROTIUi II at itD! Of Rl!TlJPrN uHl.. lN~ un TKE OTM[P!: UID rfl 1M A.'PPRO .... iE·O GASOUNi! CONT A1fiI!IElt

II ~on ~U[l.PAES$LJR~ WJTKIN:2. SECOND:!ii AFTI IGNJTn;uv. -ON- ....

OMPUTER COMMAND CONTROL (WITH "SCAN")

ECM

ENGINE GROUND

PPL412

O,5ENSOR SIGNAL

O,GROUND CIRCUIT

2·2 451

CODE 13

OXYGEN SENSOR OPEN CIRCUIT ALL ENGINES

)escription:

~CM supplies a voltage of about .45 volt between terminals "D7" and "D6".([[ measured w digital voltmeter, this may read as low as .32 volts.) The Oxygen sensor varies the voltage, bout I volt if the exhaust is rien. down through about .10 volt if exhaust is lean.

ensor is like an open circuit and produces no vcltage when it is below 3150 C (600·Fl. An opei cold sensor causes "Open Loop" operation.

tcriptioru Numbers below refer to circled in the diagnostic chart.

13 will set if:

ngine at normal operating temperature

t least 2 minutes engine 'lime after start. 'ygan sensor signal voltage steady between ; and ,.55 volts.

irottle position sensoraignal above 4%.

I conditions must be met for about 60 conds,

the conditions for a Code 13 exist. Item will not go "Closed Loop",

,,]I determine if the sensor is at fault ( . or ECM is the cause of Code 13.

r this test. use only a high impedence n meter, This test cheeks the conti. 112 and 413 because ifCKT 413 is r o[tage On CKT 412 will be over

I.

Diagnostic:Aids:

Normal "Scan" voltage varies between 999 mv (.1 and 1.0 volt, while in closed loop. sets in one minute if voltage remains hetwee .55 volts. but the system will go "Open Loop' 15 seconds. Refer to "ECM Intermittent Performance" in Section "2".

o INGIHI! AIMQ.JlMAl gpEJ"~11~~ ',~MPI:!'IlI:tlJ~1i lillj:glOVi: oo"C).

• AyMi EN~N~ ~ov~ 1200 ItF'M fOR T'W"O M!.Nuns. DOts ""((AN- tPf_!J!C.A, n "CLOUD LCl 0'''1

DlSOOf{l!lI!€f (J~, !Ii:l!:"!li~1iL

tIi lU:M'U!I ttill.Fq\llS$ CKT.an 'TO GIiI:'CUiNO,

! ill "'seA,." 5HQlJI.D ~:Jl5'LAY'Oj! VOt.l'A6i' DillOW J:

VOL T5 1_ ,,~) WITH EHGlNE RU N ~tIi~. OIlUIT1

S'ENSOA HARNIi S.!ij CONNf.oOIl i.;I!iiIN(l jI, "",M,. 11 $i-i:OYbO ,_~ .,3.,' vO.!. TS ~gQ ~ ~ :mY).

CODE 13 OXYGEN SENSOR OPEN CIR All ENGINES

tPOTER COMMAND CONTROL (WITH "SCAN")

COMPUTER COMiVlANO CONTROL (WITH ~SCAN'

ECM

..

5V

2.5l.A.3llYl&G\lAN - 45~ aLl(

ALL EXCEPT ABOVE -- 452: BLK

CODE 14

COOLANT TEMPERATURE SENSOR CIRCUIT (HIGH TEMPERATURE INDICATED)

ALL ENGINES

;cription:

ant temperature sensor is a thermistor that controls the signal voltage to the EeM. tage on CKT 410 to the sensor. When the engine is cold, the sensor (thermistor) resistar l ECM will see high signal voltage.

agine warms, the sensor resistance becomes less and the voltage drops. At normal enginE ,(85·C to 95·Cl,. the voltage will measure about 1.5 to 2.0 volts.

iption: Numbers below refer to circled the diagnostic chart.

will set if:

ra l voltage indicates a coolant rer atur e above 130'C (266'F) for 3 ids.

~ will determine if CKT 410 is shorted to ... hich will cauS€ the conditions for Code

DiagnostiC Aids:

f"OOU.:NT SENSOR

U,M,I!'f:AA tuitf: TO :U!i:I:STANCf! VA.IL'IJ I:S (APPRCo'{IM. Hi)

Check harness routing for a potent ground in CKT 410.

"Scan" tool displays engine temp. centigrade. After engine is started, the should rise steadily to about 9V'C then st. thermostat opens.

See "ECM Intermittent Codes or Perf Section "2"-

The "Temperature to Resistance Val the right may be used to test the eoolar various temperature levels to evaluate th (If a "slewed" (mis-scaled) sensor. A "sle could result in poor dr iveabiiity complaint

.. .'C OHM.s.
110 1(111 11~
lMi .. ~~jJ
,oa l. I.~M
,. , . 3 .... 1)[;1
•• 1.!iOC-
•• -1 1:J"sOa.
• ., . l5.gllg
-4ll -'"l 1.0Q,1CiQ CODe 14 COOLANTTEMPERATURE SENS CIRCUIT

(HIGH TllMPERATUR.E lNOI(A TEe ALL ENGINES

rnn~ UI15 INT~ ~fT~"T. 1~ NO .C~IJI:Q:N"'.l (J~{}[:5i, Wl;IUi .5TCR~O~ Rtf.ll!!lIt TCI -rHAGH05TlC "'"'S'" 'O~ f~o.sG i'.G_~_

I g~ tI, u ~HQ,R'T~Q 10 ~RCUNDI~ .

en 4 fO :H1Q~ TO $~N~O:l ~AOI.:JiNO OR,curf. o.

;~A.1;!6 rt 1!fM..

VlPUTER COMMAND CONTROL (WITH "SCAN'"

COMPUTER COMMAND CONTIWL.(WI.TH ~S(AN

fCM

CODE 15 COOLANTTEMPERAT SENSOR CIRCUIT {lOW TEMPERATU.RE INDle ALL ENGINES

sv

2.Sl" 4.3l M & G VAN - 452 BlK

. All EXCEPT ABOVE -- 452 BlK .

Dt:SOOMtECF' 'SE;NlSOIi:

i\,iMp,tii: .. !\kN~U TliaM!ttlAI.5 fOGiIli1HIliJ. "'KAN· !!iiH,Q'UlD OOPU. "I" ~ JtI"t; Oft MOKllc eessm

CODE 15

COOLANT TEMPERATURE SENSOR CIRCUIT (LOW TEMPERATURE INDICATED)

ALL ENGINES

.cr.iption:

lant temperature sensor is a thermistor that controls the signal voltage to the ECM. tage on CKT 410 to the sensor. When the engine is cold, the Sensor (thermistor) resistar e ECM will see high signal voltage.

ngine warms, the sensor resistance becomes less and the voltage drops. At normal engim ,(85°C to 95°C), the voltage will measure about 1.5 to 2.0 volts.

ipticn: Numbers below refer to circled the diagnostic chart.

will set if:

ial voltage indicates a coolant ierature less than -44·C (-4'1°Fl for 3 rds,

it simulates a Code 14_ If the ECM es the low signal voltage, (high tempo) and n" reads 130°C or above, the ECM and reOK.

wil l determine ifCKT 410 is open. There e 5 volts present at sensor connector if d with a OVOM.

Diagnostic Aids:

(AP'p.ft01[J~1!)
.. -c OHM5
~"'o '00 U!li
iilj '0 4$l1
lOll " I.!IO~
70 ,~ 3,400'
<10 ~ 7.500
20 ·7 13.500
-11i l5 .. 00Q
40 .40 'UC'.lCIIJ A "Scan' tool reads engine temperatur centigrade. After engine is started, the I should rise steadily to about 90"C then st, thermostat opens.

A faulty connection, Or an open in CK' will results in a Code 15.

See ··ECM Intermittent Codes on Perf Section "2".

The "Temperature To Resistance Val the right may be used to test the coolar various temperature levels to sval uate th of a "slewed" (rnis-sealed) sensor. A "sle could result in poor driveability complaint

CQMPUHfI COMMAN!) CONTflO~ (WITH "SCAN

COMPUTER COMMAND CONTROL (WITH "SCAN")

ECM
416GRY
4t7 nK Bl,U
452 BUt
2.SL
ECM
416GRY
411 OK BlU
452BLK
452 all{ TH:IlOnu: n..QSI;O_ : [JQ ~S' "5~_~;· 1!J15:P'LAY 'tP5 'OV,~ II; ~.5 yeil.. 15'1' !

CODE 21 THROTILE POSITION SENSOR (TPS)CII (SIGNAL VOLTAGE KIGH)

ALL ENGINES

:JTTLE !fION ISOR

0.

CODE 21

THROTTLE POSITION SENSOR (TPS) CIRCUIT (SIGNAL VOLTAGE HIGH)

ALL ENGINES

t Description:

e Throttle Position Sensor (TPS) provides a voltage signal that changes relative to the throttle blade Signal voltage will vary from about ,5 volts at idle to about 5 volts at wide open throttle,

,TPS signal is one of the most important inputs used by the ECM for fuel control and for most of the

mtrol outputs. .

rescription: Numbers below refer to circled r< on the diagnostic chart,

Ie 21, will set if:

Engine running

TPS signal voltage is greater than about 3,5 volts

All conditions met for 5 seconds, OR

TPS signal voltage over 4,5 volts with ignition "OW.

.h throttle closed, the TPS should read less n .70 volts. Ifit doesn't, check adjustment.

l.h the TPS sensor disconnected, the TPS lage should go low if the ECM and wiring is

,bing C KT 452 with a test light checks the 5 ts return CKT, because a faulty 5 volts return I <a US" a Code 21.

Diagnostic Aids:

A "Scan" tool reads throttle position ln Should read about .73 volts 12.5L), .45 volts (2.1 volts 14.3L & VBI ± .75 volts with throttle do, ignition on or at idle. Voltage should inc rea steady rate as throttle is moved toward WOT.

Also some "Scan" tools will read throttle ar = closed throttle 100% = WOT.

Refer to Section "2" for "ECM lntermitteni or Performance".

"Scan" TPS while depressing accelerator with engine stopped and ignition "ON" [ should vary from below 2.5 volts (2500 mv throttle was closed" to over 4.5 volts 14500 mv throttle is held at wide open throttle position.

,44 COMPUTER COM MAND CONTROl (WI1H "SCAN-)

ECM

2.Sl

iHAlCn'l..I; 'OSJTION Sl;II$O~

W(lT'rr" '7--kr------------ "'.0' I ", c ~~~hA~.,r,.~~.~-------------------------.110~~

~"'~u~J:'~j~--r C.lL'YI!lIitVMGIil' .&!Q!LJI:

,. L 2.!l $'1 Ii AlL{J ~-----------.au Ill.

IIW)

CODE 22

THROTTLE POSITION SENSOR (TPSj CIRCUIT (SIGNAL VOLTAGE LOW)

ALL ENGINES

<uit Deuription:

Tl\e ThrnU.te PO-SltiOft Seruor (TPS) provid@1!I a Yolt,ggf: slgrmJ thD.1. change$ re4auve to the thrni.Lle blade. rial voltBigewi!1 \'iff [rom alxlut..5 at idle loabo\tt 50 vatU; nt. wid~ open thrQttlt,

The TPS signol is one of the must impor~nt- inputs used by the [eM to.r fuol control and ror mOSl of the ~ cont.rol outp:uts"

:t Description: Num,Ocn below refer to elreled ibera Oil the dia;l:nonh: ciJarl.

COOII!! 22, will set if:

• £1'I:glne f\.i.nninl!:-

• "l"rs; signal vuttage i.9-1~;!'I!;I than about .2 volt {Dr

S,sKCr.ldlS.

Blmulatae emie Zt: thigh valtsgel If the i<;CM reCfllirfLi~e!l the high signal volt3gr !.he: E!CM and wiringlifii-OK.

fPS . ~,BL; R.r •• to "Adj"'Lable TPS QUIP"l Ch-eek;;; in th~ 5«llo!\. 'TPS· e~cepl2.8L: Repl3cc fPS.

fhUl sirnulntes B high 'Signa! vijltago to ~hec.k for lftijpcninCKT417,

Diagnostic Aids:

A '"Sca,,, II ton I read;!!! tnrDtL te paal t i 0 n in \0''0 It" Sn~uld r ••. d .b.u~ .73 ""Ii. 12.5[,1. ,.8 vol" (2,81..) .. 60 11011., (4.3L &. V.6'~ ± _01:1 vults wtth thl"(lCU'I!l closed and ~~nl tlcn en Or' at III le, Vol Lngo shGuJ d i nereaae at B sll!tl"dy eaee Q Lh eeu! c is !1tijov(Hi towb rd WO'T r

An "pt}_.!l or :shc,rt. to ground in CKT!!I; ..:116 or 417 w'ill result In 0. C-ode2:2_

Refer to Seetlon "Z" raT ·'~CM In~etmiU.e_nl Codes en' Performance",

~~n"' TPS wMle tJupl'l!$sing aec:eJeratllr pedal with engine :stopped und 19nition "ON"_ Diapli).}' shou.ld vary from below f.S volts ~2500 ill'll) when lhtotLle was etosed, to over 4.5 voltS: (4500 my) when throttle is hetd at wide opefllhroUlc po!1hion_

COMPUTER COMMAND CONTROL (WITlI "SCAN") 3·4'

CODE·22 THROTTLE POSITION SENSOR (TPSj CIRCUIT

(SIG~N. VOLTAG~ LOW) ALL ENGINES

T~01TlE a.mlD

DOII!s,rSCAH·IH!JiI.Jt'tTM ~VU!,OCi mv)Oill BELOw1

~'CNNi:CT't~ '5EN5CR.

.. JU,..IIEIII (:KJ5 4.UI .0411 TOGUIUIt,

·SoE.UI'" !iIoolOUlD OISPU. V lP~ O'IJ!II! U V (400)0 """III)..

1111110 A_oomCIIItALC.OD[!!i WUI! STORED. I!Uif:IR TO rOlA~N:O~T'U: .... ~. Oft IFAt.UtI~ ',I,oC:t.

,.OIllt;CICT417WlTtU n:S1U(i.HT COHH'IC"1"fD TO n VOLTS.

·KAH· TOOL SKmn.D I)I:iPlAV Tf'S eVER

en IHC'EN. opt

SHORTt.DTD Gl.OU~O_ o.

5t101lOTg TO ~~NlCR IiROVNO CIRCIJIT. OIl

[l'AULn' [CM CONNECTION,. CO<

FAULTY fOIl.

cn.UiCP[H. ""

'SHOIIT10'fO '6 .. 0UWO.

o.

fllUlT'r CONNIrnQIL o.

F .... ui.fYli(J.t,

' .. ~!i-a1 .'!.HII!S·i

:-46 CQMPIJTER COMMAND CONTROL (WITH "SCAN")

COMPUTER COM MAND CONTROL (WITH ·SCAN"

CODE 23

MANIFOLD AIR TEMPERATURE (MAT) SENSOR CIR (LOWTEMPERAiURE INDICATED)

2.Sl ENGINE

TOTP5 AJilO (OOLANT TEMPlRATURE Uii"SOR

5[N50'GA.OUNO

1·20-11 ,g3t591

CODE 23

MANIFOLD AIR TEMPERATURE (MJl:n SENSOR CIRCUIT (lOW TEMPERATURE I!I)OICATEDl

2.5L ENGINE

reuit O@5uiption:

The Milmuold Air Temperature (MATI Stl'iSor iJ: a LnGrmi.smr thaleontrols the 'Slgll.lll voltage to tbe ECM.

It ECM applies a. volt.oge (-4-0 volt.sl on CKT 472 to the sensor. When the air l~ told, the sensor (thermhttod smtan.ef' iii high. thererere the 6CM will!Se1! iii. hi,gh dgnsJ voltage, Iflhe ;Joir ~ warm, Uil: seILSO( rUfI.ts=t.una i~ N thereror~ the geM will OOC a low voltage.

rst Description: Number-s below rc:(er l.q c;rclC'd mbers em thl!" d.iagno!it.iA:! chan.

Code 211: wilt set ir all c(Jodi tiofl.s tI~ mftl!

• A slgD3i vC)l~iJe if'ldi<:atti2:i a manifold air tempeeetuee below -3{J°C (-2!~PI ({Jf 12 seeonds.

• Tim.c ~i(lI;ie 4l:ngineost.art is 1 minute (II" IQnj{pr

• Na VSS(vchide not moving] -

,\ Cod,c 23 will set, due to an I)~f! sensor, .... i-n. ur ~rm'iX:UJln. ThiSl [,est ..... m ai:t(l:Hllinc Ii the wir.ing and ECM.", OK.

ThIs wH[ dete:rmir~f: if tho !:iignlll CKT 472 or ltH'! 5V r-elln'1i CK.T 452 it; (l,pl!_n.

Diagnostic Aids:

A '·Seanr, t,gol ,'e;p:dij ~em1'ier!lturE!: o( tht! 3,1r en~ring lobe engine 3nd :3holJld re';}d ,;;lose ~ ambiellt air temperature when enfinc is cold. urtd rises us undernood temperature lneruases.

Cnrefully c:h~ek hoene-55 and. connections ror possible g-pe11 CKT-472 or 452,

ll:dc-ri.CI ~ctlon "2" for "'ECM lnt~rm,ittent Codes 0:)1:" P.erformo.nr:o,"

The "Tuasperuture to Resl$toMc vatue" !!"«:i'le nt Lh~ right may be used l{J tDst th~ MAT senser at veelous temperature levels kI evaluase the pos;lSibilily of a "slewed" (mia-scaiedl sensor, A "slewed" sensor l!olJ;ld rt~it. in poor drjveabi..lity eoraplatrue.

ntA.G'f,iO~n( .AID
M~T$I;Nu]R
UMJitRUURE"TO RE.:5I:ST&~CE VALUES
(AP"mUMra.TIr)
'F '~ OMM"S
lID log ."
160 7. 'sa
100 31 1.800
7. ~Q '.400
40 1.500
10 _7 1l,.50Q
0 ·18 15,000
-4, -<i4 IOUOO : COMPUTER COMMAND CONTROL (WITH ·SCAN")

•• V!HIClE SPEED SIGNAL

[eM

+------- ,137 BltN

12V

.P'/H'SWIT(H

r 4SO BlKmHT --. --. 434 ORNIBL~

---L ClOSEPIN

~ PAR~ OR NEUTRAL

12V

753 1·9·

CODE 24 VSS CIRCUIT FAULT All ENGINES

t Description:

,ECM applies and monitors 12 volts on, CRT 437, CKT 437 connects to the Vehicle Speed Sensor ilternataly grounds CKT 437 when drive wheels are turning. This pulsing action takes place aboui er mlle and the ECM will calculate vehicle speed based on the time between "pulses".

Scan" tool reading shoulde!oselY match with Speedometer reading with drive wheels turning.

les(f,iption: Numbers below refer to circled 's on the diagnostic chart.

e 24 will set if:

CKT 437 voltage is constant. Engine speed is more than 200 rpm

Vehicle speed signal (voltage on 'terminal "A9" is less than 10 mph06 k/rnh)

All conditions must be met for 10 seconds.

se conditions are met during a road load rleratlon.

i test monitors the ECM voltage on CKT 437. , the wheels turning, the pulsing action will It in a varying voltage. The variation will be ter at low wheel speeds to an average of 4-6

~

ltage of less than 1 volt at th~ector "1

oates that the CKT 437 wire is shorted to ~CK'nS-7 at the vehicle speed

Dr. If voltage now reads above 10 volts, the de speed sensor is faulty. If voltage remains than 10 volt, then CKT 437 wire is grounded.

,7 is not grounded, check for a faulty EC~ ector or ECM.

3. A steady 8-12 volts at the ECM con indicates CKT 437 is open or a faulty vehicl sensor.

4. This is normal voltage which indicates a I intermittent condition,

Diagnostic Aids:

L "Scan" reading should closely matd speedometer reading, with dr ive wheels tur

2. Check park/neutral switch diagnosis eI vehicle equipped with automatic transmissi

3. If park/neutral switch Is OK, refer to Intermittent Codes or Performance" in ~ '2".

COMPUTER COMMAND CON'TROL (WITH "SCAN") 3-4'

DISREGAAO(ODE 24 IF SET WHilE DRIIiE WHEELS ARE NOT TURNING.

• ASSUMES SPEEDOMEtER IS WORKING OK.

• CRUtSE CONTROL ·OFF-.

• RAIS~: DRIVE WHE£LS.

WITH fN:GINE 'DUNG IN GEAR; "SCAN" SHOULOOISPLAV MP:Ii ABQVE O .

CODE 24 VSS CIRCUIT FAULT ALL ENGINES

5 TQ 12 VOLTS. NOT VARYING

-CHEC,K COf4NECTIONS AT VS5.

- C:HECICFOROP(N CKTAl7.

- (HECK FOR 12V AND GND AT VSS.

• FAULTY V5S.

YES

(OD£ 241S INTERMITT'ENf, If NO AOOITIONALC'OOES WERE STORED. REFER TO OIAGNOSfl( AIDS ON fAClNGPAGE.

CLEAR CODES ANOCQNFIRM "'CLOSEo lOOp" OPERATION AND NO "SERVICE EN'GINE SOO~"lIGMT.

COMPUTER COMMAND CONTROL (WITH ·SCAN"} 3-5'

PUTER COMMAND CONTROL. (WITH "SCAN")

MANIFOLD AIR TEMPERATURE SENSOR

EeM

'----------- 472 TAN

MATSE

TOTPS AND COOLANT TEMPERATURE SENSOR

'----------- .... ~- 452 BlK

CODE 25

MANIFOLD AIR TEMPERATURE (MAT) SENSOR CIRCUIT (HIGH TEMPERATURE INDICATED)

2.SL ENGINE

ription:

rold Air Temperature (MAT) Sensor is a thermistor that controls the signal voltage lies a voltage (4-6 volts) on CKT 472 to the sensor. When the air is cold, the sensor ugh, therefore the ECM will see a high signal voltage. As the air warms, the sense and the voltage drops.

,tion: Numbers below refer to circled e diagnostic chart.

. 11 set if;

I voltage indicates a manifold air r a t u r e below 150°C (302°fl for 2 s.

ince engine start is I minute or longer. de speed is present.

Diagnostic Aids:

A "Scan" tool reads temperatur entering the engine and should read clo air temperature when engine is cold, underhood temperature increases.

Check harness routing for possible sl inCKT472.

Refer to Section "2" for "ECM Inter: or Performance."

The "Temperature to Resistance Vl the right may be used to test the M, various temperature levels to evaluate t of a "slewed" (mis-scaled) sensor. A "51 could result in poor driveability complair

InowoJij"(_ !!OISI"

CODE2S MANIFOLD AIR TEMPERATURE (MAT) SENSORCI~CUIT (HIGH TEMPERATURE INDICATED) ALL ENGINES

OIIA(jN05TJ( A~D
MATUtllS.O.
UMPffll.. T'lJIIII] TO RUtSl Melli VAl.UES.
~,I\P~gTlr.II.nl
-c OttMS
... , .. , ..
1"1 1. .,.
100 .. '.800
1. ,. ' ....
•• • 'i'.!000
•• ·f IljOQ
·18 ~5.o00
..., ... lOG,100 CU "''2 !!;I"I'OATI!O TO ~_OUMO. OR

Cr., "'2 fitOftnO TO Uf;liOR 41lCiliiD CiRCUIT .. O.

f.lUL.TYI!;CM,

~~-1·''1 .7$3,,0.4.1

3-52 COMPUTER COMMAND CONTROL (WITH ·SCAN·)

Numbers below refer to elrc

!.Imber,!; On di-ugnostic charL.

By groun . ng ure dirIgnostic !crmi fii,'ll' I thl!l IE G R sulenntd Ilh uJd IHl nnergi~ BIle[ iYllQ'" vacuum to be ",.,plied. 0 the ECR 'Valve and the veeuum ,hoyldlwld,

Wilen the dta nestle terminal 19. LlI"i.grounde!rl. lhe vueuum W ~b[:l OR "'8.~ve ghou!d bli:!:cd tiff ~hn;I'LJgh .II \lei'H. in lhu 50 old ilnd. UU, YU1Y~ should dose Tho g'ilge may Qr U)' nol. bleed off bur lhl~ de S

not Indicate n ptobtCl _ /

This tcSI. ",in deta.rrnib:~ir thIC_ I!II<:tncJ;l.l ~~rDI pnrl,.Cr thu :5ys;,tem lli,;\\ r;lbllNl~-,ootfiidQI'" nr;otoI.!'I~n(lid ttoat rlJ.ult,

Thts syS't.em uses u negative bn(kp"eJ!i~r'c ... a!ve which Shliuld hold Y9CUUm wilrh ~nginij ··OF'P.

R)SYSTEM

When engine\ i., started, e,;buust backpnlssum ahauld 1::1ItJSe: vUI;;uum to bleed. Dff D:nd valve aheuld {IJ~!y C-!Q_:S:e.,

Diagnostic Aid"

• Before i:'.cpUici ~~~IIXl.k. the teJii flee {I r IC'u:e:h EC M' !:;onLrQ lied rehty and sDleno ~9H, Rl!!fcr til) SCM QDR Check procedure, figure 3 .. 18. S~., ,SCM

wiring diagruifi ee l l Lc.r~O. of

$9letle~.d.[g) and rclo,yI:s.J hhled. Replace

Any eclenold where reslBro,I'.jC!!. measures- tess than 20 ohms.

3·54 COMPUTER COMMAND CONTROL (WITH ·,CAW)

-

ro~:':G:':.:.':v~' ==:::~;;j""""jL[:;===E= pOlI;jt~

_ MAfIIl"OLO

i---------- -----------'!AT"M

I !':GiR

I$OUiHGtO

: N.C,

J"MI

' .. 1 fU ..

.4:19 JIIN"KmLIl J

KM

, ,

, ,

i "I:NTfll,;nlll

11. ~ --= ~~"' .. _ ... __ ..... _. _ ..

CODE 32 EGR SYSTeM

2.Bl, 4.3L (ST), 7.4L & 5.7ll0VER 8500 GVW) Circuit Oescriptlo,,:

The ECM ()~~ a'SOIe-Mi.d tdI cont.rol Lhe exhaust Cas Re,;:il"(:lJ.lat..ion (EGR) valve. I Tbi, $Oien.otd is lorma.Uy elcsed, By providi~g a. ground path, the ECM energh:.e, lhc solenoid which then allow!J vacuum to puss

u the EO Fi. val ve, "

Th~ ~CM m(miturs EGR errl!e:ti'lle-:ru~~g: by dI(H!t1t:::rg'b.ing the EOR untri)! ~ien(lid UlCf{!by ltiibLlUing Qr! ~aeuum to tho EGR valve d.iap'tu-~p.. WIth (tio EGR valve elcsed, fuel tntf,-grntl)l" cuunts wH.l be greater- than .hey Weor'e d.uring; nOrmal ECR opcnti~n If the GMnge Ie not within. the ectibraied window. 8. Code 32. will be

leI.. i

Th. ECM will eh .. ki;XiRoi"'r.n~o",h.",

• Veh iel~ speed js o.bG .... e. ~O mph.

• E"glnti vnclitJm is between 403nd~' kP;}.

• NOCMtlgl! In throttle plsitioo while Le!J~ i8 being run

rest Descrifl,tiQn ~ NUMb!)[£. Mhi-"I ,roler to circled rumbers on Lht-dl'-l.gno::l&h:t:hurt.

With the lgnlelnn "ON ,- (logine !ilOpped. the sclunold -l!j,bDUld' not be en~rgiMd .. nd 'll"QCU1l111 liholJ.ld na,~ pBS:!iI to tnt EOR varve. Gnlunding the dillg~.g!!lolJc:\ermi;n"J wlll cn.c{'gtu- thco i!:til-Ienold unci allow 'ViI,c\llJm ~ pass to vaive,

Checks (or plugg~ EOR passages, If passages- are plu-gg-td. lhe engi,neo may have Hvt:te autonaLion on. ucco~ef'"lltion,

Thil!! EOR $Oll!'nDla will rtoL btl cnucglliC'd in Park or Neutral. This rest will defer m+ne If the PsrktNeutn1! $w'wh input is being reeel ... ed by the ECM

Diagn<lstic Aids:

• BeforE! r'eplaeioG ECM. use al'l ohmmel~[' and eheek thE' r~!i_,tiH~ (if eael;. geM ceotrnlled l'"e,l~y ."<1 ,.i.n.id •• 11. Ror.r To ECM QDR eh ee k prM!(':i.hJ.li); Flguee 3-lB.

See RCM widn~ dlagrnrn ror coil terminal identification of a.ol€MidCsl and ft!lay(sJ to he <h.<ked.

ReJ)I;J:1:e lJ,n)" :soltlrl~id where reeiesanee measures less lh.iln 20 ohms.

COMPUTER COMMAND CONTROL (WITH "SCAN") 3,55

CODE 32 EGRSYSTEM

2.8L, 4.3L(ST), 7.4L &5.7L (OVER 8500 GVW)

• ~J

I ',' '1', 7:5 ~a.Gi), 1-11-'ll;1

<:). ~fi:~'~~~~I~GI;~sQI,,~ .. ung,v""(ULf~lIO'!:E

.. ~H_~O: PO~TED V.AQ/UM iOUPIti 1"0 jQ1,tiNt;:UI;lI ( IF- If!;!, O'K.It~.JI!A.rl',

.. eM ~(.1t: 1IA(UUM H Olil!! IIIIHWIf'1II S-OUNOII] ~ND VAL 'lIE F=OR: 111'-; S'TJIJCT10M.

.. r.N~fp._U A HAN!) H~ LD \iAOJI,IM 'Fi)MII' WI,ll01 ~A~ I QN MAHIFOlP s!Ot Of: IE~R .sOL[HOIO .

.. KiNITIOf,t ~~111;~ IliNIjI~uiQ"'PEg 01.l,GN05 flCTERMlN _L GoPtO UHPIe'O_

.. AJlPi 'Y VACUUM.

.. CI'S,I!IUItVE EGRVALV~ ,

.. \l'Ab. ... II;$~(:jOi..bI'lll()VI. CQ~S rn

,A;!!(ONN ~CT j;GIt !l.OUHOID_ ((INIt'ECi VACIJUM~Eioi!: TO ",,,tUUM I-!OS~ AT [~It .... A.k.VIE. ENG-'IMIEAiPIIOI{PIIi.ti,;" gPLMTINIij l"~MI".

IH DR4'1iE' (AUTO"..,.,t'II: TIUH:5..) trom ,IIRA'::IiS ANO ACCII!U,RA'I'EMOM[NTAIlIt'f ljP TO AalQYT 111l00, ItPM_ O$URV€GAGt

5HQU!.O HAYE 'OYIER,3;IIACLl:U~ 110.11 lESS r",ANi' II,·

3-56 COMPUTER COMMAND CONTROL(WITH ·SCAN")

ECM'

~ MAP S~NSOR 6

It I '~lj -., s s 'Y

MANIFOLD ~~~~----- .$.U t.,l(;i!tN

~~~;~:: u .. ,.; --------- 4~:i P",I.

(VACUUMI, ,Vitt:NGI~!' 4.6!i1' !!l.lCJtlA:H --'1~;;-L_jL._...J

"~!.,M.AI,I.I;ii""oI!J,IfSiRV ~4~~ f":£Ii.

COOE33

MAP SENSOR CIRCUIT SIGNAL VOLTAGE HIGH (LOW VACUUM) AI.LENGINES

crrl'Llit Des(:riptiQn:

1he: Manifold Abu.utl} Fr(!ol!i:5,l,J.fe (MAP) S@IUiiDF respends to ch:o.~!!iI in ml!!_nifoid 'P1'1!!!MlluN ~'VIlCii.iUtll). Tbe ECM tt.l:!~i"~!i th.l:sinfo['mEHilJn I3.Sa. signl3.l VGIt:ase tne.t wHl 'I,IQ.ry r'Nlom a~'!.i..f; l to 1,;5 !'!ot'U! Il~ idle to 4-4Jl. Y~lts lit wkle DpE n Uu·oUle.

T@l,l: O@.!!icription: N'LIm,butl below Fcoflir to airulod fiilm~r!!. On th~ diflgna:;t_tC ~,h.tt['"l

I. Cgcl~ 3~ wi II 5e'1. w~~n:

i Si.1!:Il21 is too hlgh roOr a U,~ itreQ~'- t~~f!. 6 seeccda.

~ne muir;rn or 4 law UH:II,table ldlEt mny .sl!t c.ooil3.

... Engi.ne, Ru.n."ing:

Manifo ld pressure weai~1' than "15.3 It: Pa (NC 'OFF"") B1.2ki'.(AlC "ON"l

'Tllr(J.ltle al\lit'l~ T~s!S thiln 2'k';

CoildHlofi:!l iffi.i5 t rot' '2: ~~mdi_

2, Wit.h the MAP eeueor dleconneet the- ,r::CM~ ~h'luld see n le ...... voltage L-rth.e ECM and wlrinl{ 19 OK .

!ow .,;~ 1.5 'Ii

Diagnostic Aids:

.n e " AjtUI.I<1., •• Voltago" ... 1. allb. rlghlllla,y be 'II:IIc!:! 'w) t~t lic::MAP lHl.n5.ul'" iI!. II; IIp!!'Cmrt Bh.itud.e II!!:,,~I tu evaluate lhu po:8sibHity Dr B. tl.!iI~Wl;!!d" (mil;l .. :!ioCD.led~ 15eIlSDr. A "slewed" !1II!.n![(IIf eould M;~ult in poor dri:'ii~.a.bi li~y ~mp'l-3in~,

~:'n(i!le mi$i1reor,g, low'Urb.3l4bl~ ldlc mny iIOil·I.COOiEI J.J, DisCQ fI neet MA P sensor il.:nd :8"ySll0.rn. wl II go il1tAJ buckup mode. If tha mi:!d'i.rl!' 1)1" Edl!!' eendltdo a rematea, S'[!I! >< D ei veab i I it)' S!r'mptl)m..g"' In Se.etiorJ ~2.p-

Reref to "£'CM! IntG.f'm~l..t-e['Jt Cqdc:s or Peercr-manee" if' Se-t:U",," "2-.,"

COMPUTER (OMMANO CONTROL (WITH ·SCAN") J-~

,.. IF ':NG.NE~DL,( IS IOUGH, UN,$-T AI", ~ ~COR"'Ect.

CODia .noRI U!ING (HART. UE5YMPTOMSIH sr(TIONl.

.. I!NGltll! IDUNG •

.. ooeS"SCAJil-DtSM,A'.MMOlil.! VQl'RO*OV1:R'i'

CODe 33

MAP SENSOR CIRCUIT SIGNAL VOLTAGE ~IGI (LOW VACUUM) ALLENGINES

I<lNIllQN ·ON" ENGINE HoppeD VOLTAGES

IIOL,. AGE RANGE

ALnTUCE

Meters Feet

Below30S 305-1010 610-91. 914-121' 12'9-15~4 1524-1829 1129-2133 211]-2438 24311--2743 ~743-304a

a.lowl,GOO UHIO-Z.OOO 2.000-3.000 3,000--4,000 ',000-5,000 5.000-6.000 6,000-7,000 1.000-81000 i.0(JO..9.000 9.000-10.000

3.8-5.5\1 U-S.1V l.S-S.W 3.3-5.0V 3.2~4 .. 8V 3.0-4.6\1 2.9-4.SV 2.8-4.1V 2.6-4.2i1' 2.5--'1.011

LOWALTITVD~ " HIGH PRf55URE " HIGH VOLTAGE

3-58. COM~UTER COMMANCl CONTROL(WITH "SCAN")

~ MAP SIiNSOR I 6 ECM
It I .~
.n' Gl'f SVIUiI
M"-'NPfOt:D 412 lTl:iRN <,
Auown AUCX -&55 WI \
'flfSSUA!!
('ItAOJUM)
z..nU4fjjl'![
ULM,AUG'I,IAN .. R .... ---4.505PI''I,,
Jilin
1·lC~81 ~~lHn CODE 34

MAP SENSOR CIRCUIT SIGNAL VOLTAGE LOW [HIGH VACUUM!

ALL ENGINES

Circuit Clescription:

The M~n[fold Abs.Qlu~ Pr~~J,iJ'e (MAP~ SI:!1...~ rt3pOncii Ito ~hfl!'lgCi i~ m~l1.ifQJd p~~l,1re {veeuuml. !rhe E!:CM receives tJai!) infOf"ffl.4).lioft':;'s.Gslgflol v'I>lloUgt t.but will YIll'Y frotn about l (.0 l.S "'Oil,.5;it ;-dle to 4-4,5 volts 81;. wide epen throttle

If t.l1o MAP sensor fails lhe ECM win substitute a Jlxed MAP value and use the Th:rottle Posi.lion $ens.or C1'PS) torontTol Iue! di!'liy~l'Y_

Tes,(; Des(riptiQn~ NYJRbt:rS below rdljr W drdcd numlx:n on the diugnO:fit.ig chart.

l Cede 34 will set when;

• Whl!n engine ia leaa than 600 rpm.

• .Vi!u'I,ifalrl Ill"~~l,ire !"~ding ~'I1:Sj UiDn l:I. kPd, condittoTL"I.m.~tror 15~0I1.d.

tu:

• F.n:e:i I1I1l' t~ gruatar- then Ball rpm.

ThrotUIl' .a.ngJ~ c'i"i!r20%.

manifold 1i[,II!!!iSU~ !iIi!~ tll.an IS kPIl «!ruiiUrHl~ met Cor 1 second .•

2. This _tests ~I) 5CC if ... he .sensor ia 8~ [Dully fer the tow ... onage cr trthtn! is: III ECM Of IoVll'-ing problem.

3. Thls simulaees.a nigh 1ii.gn~1 volt,.g.ge to che(:~ of pn npen in CKT 432. Ifth' tOi' light I. bright d~rlnl thl~ Lest. CKT 432 Is probable shorted lo gr-ound lf "Scan' r-cadl over 4 VQHs at this lest CK1' 416 eun b.G checked by measul'ing the Yl'Jllage at ter-minal "'C·'. (should ~ 5 VQI~I

Diagnostic Aids:

An intermittent open in CKT:!; 416 willl'esutt ln CL Cod. 34.

Ref~r ~i) "ECM i !"ill!l'miUent Cod!li .,1' Perform Q n~" if! S;)dlon "'2n.

Th.o "'Althuaoil to Vc:dt.o..go" 3C1al.e at Ihe riS'ht mnv be used to ~:5t lhe MAP aenscr iH ;0 speCifiC' altttuae IEi'r,l'eJ U!I evaluate tile pcsgibiHty (If [L_ "slewed" (rULS· SJCalrKIl M:i1,.~r A "~lewp'~l1 ~n_'>01' could rosult In P(WJf drlv~obah'i OOrfjploints.

COMPUTfR COMMAN[) CONTROL (WITH "SCAN") 3-Sg

.. IGNJnOH'''O'fI~'C1A tOSi!CD.N.OS

'" UAII'rtNQlNE ANr;JolMM.i;OIAf{I.'" NOT[ MAP V""I"IEQ.,.·5"'N·

DC ~5. '"SCAN" Dt::Sl!IlJY IVIAP BliLOW.15 VOU51

CD 6 :E':~~~o,:~i. WI~~.

, PleBE TUMUilj!LL -'B" (C:l('fll~l WITH A UI.'iIfT TO 1.1 VOLTS.

• lGNmON "cr!l"'_

'"s.cA:H'" SHO'UlO IUAC (lV~" VOLTS.

OOI!$IT?

IGIIlInON ·ON- ENGINE SlOPP£D VOLTAG£Ji

A,"nTUDE VOLTAGE RANGE

Metll!!tI Feet

Il.elcw](]5 gelowl..ooo 3.8--5.SV

305- 610 l.ool>-Z.OOO !.ti--S.l\,

611)--914 2.ool>-l.Ooo l.""'-5.1V

9'4->219 l,OOIkJl.ooo 1.l~~.O'"

11H-UZ4 4,llOO-S.OOO 3·,2--4.8V

,524-1&29 5,Q00-6.000 3.1>--4.6'1

1 RH--l13l 6.000-1,000 2.9--4.5V

1Ill--2438 7.000-S.000 1.&· ..... 3'1

2.3~--274! B.000-9.oo0 1.~.lV

2743 .. 3048 9,000-10.000 2.>--4.0V

LOWAWTUOf. HIGHPRESS/iRE; HIGHVQHAGE

CODE 34

MAP SENSOR CIRCUIT SIGNAL VOLTAGE LOW {HIGH VACUUM} All ENGINES

C:ICTU'ZOJI'EH ••

CKT Ql :§:NOlfll:D TO iljlllOUNO

o.

tilT .. ]1 ~.Halln:D UI5INiOIi GROUNfi 0.

FAULty i'OJ!

QJ!Aft coces .... .MfJ CO"'~'IIIM -n.OSEO l.OOP- O,fJlAT10N AND NO -SE~VlC!: tMGrHtl SQOf,I-I.IG.HT,

3·62 COMPUTER COMMAND CONTROL (WITH "SCAN")

TAOt.L.EAg

'~QJWHT

@ Q 4:10 PfllM'HT

C I ~24 "",I,Ntm,1

o ' ~S3 IlI,.K,tII;~D

£CM

l_~~,4... __ 4lc PP~T -, :+-- 42JI TANJ!II"K ~T~-=~gA "1t:(~'T l~$t.M'V,l!,t!1

453 i_L.lG'1t:fD

All EXCEPT 2.5L SIT TRUCI(

CODE 42 ELECTRONIC SPA.RK TIMING (EST) ALL ENGINES

,j rcu ttDes CrilltiOii

ReFer- to pale 3-'9 rO'f EST Cl,l\d Cod@4.2.

I!$~ De,.sqiption: N"umoorB below re.fer to c:irc.ltd I,lffi_het$ en f.he diagnost.it: c-hart.

€-()de 42 means the ECM has 6e~[1 an open OF short to growl:tl in the ESf Or b1PfUis cireuita. 1'h,is ~t flJ~nf'fI\fi Code 42 ind that the (nulL 1;1lUr::Linr 4le c:odt:.L! present,

CheCk.::; rDr a nornlfl.1 BST 8l"O~I~d paUl tbrIJugh the Ignition madule. An EST CKT 423 shorted ~n Cr6urid will a.l:ial ,-pad lees than 6o{)O ot"lQ\~~ MW·'!fVII!r. this wm be- c~eclred (~~r,

I\:a. the test light voiw.ge lOu!:he:s CKT 424. t,b~ module ·should ~wi.\.Ch (Qu:iing Lhl!' uhmmerar to -overf':l.ng_e" if lhe mater is in the IOQ-200 ehms ~~Uilrl,

Sl;lvding the 1-0.-20,009 ehme pO&l\lon will Indicate above 5000 Dhms..,' Th@ important thing iB that the medule "'!ilwitJilied"",

4. Tko mo-<!uJo did MI,"'I!.<b "nd y,j •• lOp .be<1« [0"

• IlSTCK'I' 423 .ho.rtcd to ground.

• 8ypnlis CRT 424E ope n.

• Faulty ignlt1lon rt.ooul.e(:o.onection o~modl!le. is. CnnfirrM thlll ~ Code '2 i.$ 0 rQu! t.y r.-CM l1:ru~ net. an inl.OrmillCn\ In C K'I'. 423 or 424.

Oiaghostic Aid5:

T~e "Scan" ~l_doe$ no) hflvc ;JfiY ObmLY t.o help

di'gno,." c"d. 42"robl.", '

Rcfc-r to Seetlon "'2"' rcr ''HeM lntermltteni Code or Po rfc rrnunce. Ii

COMPUTER COMMAND CONTROL (WlT'fI ·SCAN") 3-6:

(ODE 42 ELECTRONICSPA.RK nMING (EST) ALL ENGINES

.. CUAIItCODf,1,

'II! IDlE ElftijNE K). 1 MINilJTf OK I,JNTiI!. ,CQp~ 4l SoU$.

Pi:lE,5 C-OO[ -42 SEn

... ~iiiTiO~ "Off-.

• Dl$(OQri!!itT t.c:M (0",,,,, Et"I"CAI!5 • ... KiH-li1C ..... ClfI ...

II' OIfMMIH[It Ul[CTCIR ~"'OIIH n.f .000 '1"0 ll)OlJ OKMSMNCi.ti •

• H:OIIII!!!:(tII! HAR~f.S$(:ONJtIli·aOIi: 00 IiJ 'MT" lUi 'Ot1~mll:ro~oU~~,

:iT~H(I'J"", jiljf~g\,;[Sj 1mH ~,o~_. ClC.e5:rT'J

o -;. VilTH e HMM:ETEfi STJLlCONNi!(:T(O TO E(MHARN.e $:ii Q;l' .. ~~ "iii~~IJHO .• ~.tijN PR(I~ ['liM HAifNi~SCJ(T.i~4 'lM.TH fH~ 'fEST LlGH10JH"IECT.e.O "1'0 "~ VOL 'tS. ~ A.5 'Tisii' :LIGI-IT (CNT ,l,CT5 O,T IiIIl,l. ~5~T~"'fli 'SHOULD -5Wn:04 ;F~tJ~ UNDER '500ro ClVE.~ 5,.C1O(i OHM!i.1

OOf:sm

:;H2~1117

~ 7!;; ~:'291"1

3-64 COMPUTfR COMMAND CONTROL (WITH 'SCAN")

ECM

tt.-jw~ t,'"-l

I!. • .", ..... o.."'...!1~o III'''' ELECTRONIC SPAR K CONTROL (ESC) CIRCUIT

(''''...L '-( "!y ALL ENG!NES ~

~rcu i1 ,Oemi pti Dn: ...._ 5_1.1.. ~,,,,It..

B1eC:.trm:ti:e sp3rk COf1.t.rol i~ w:clJmpl~he-d 'i'i'ith II module that Miflcis D. "{]It.n~:e signal 1Al UU! EC'M_ As t.h.e lQek 1ienBOr de~c:UI, ~ngil\E!' knock. the 'IIQIt..1Ge fr(',."1 thCi ESC mooula r;.o the ReM drDP-S. nnel ~ :6IigngJ!I, t.b,oI;! ~M to re;to)i'd tlm-1D~r The £CM will ~UlM lhe 't.imlng when k.n.ock ia detected and '"Pm le abo* ,aboQuL ~OO

11, ~ ..

C'Ode 43 means the ECM has beea tow vo-ltugc I:!L C.K.T 485 terminal "'A1'" for tongc~r lil.iU'i 5 ~rU:IS with thu ine r-unning or the :;jY5:te-m nu..::; fiUl'Ed Lhl! functional cheek,

rhi,S il;Y!t~ern pl::!rfCl r:rte; a Iunetfonal eheek eeee per ~tc.rt.~"'P 1O cbl'!ck lim ESC system. T" perfnrm tills te:st. t!,i!I'l EC)II 'IltfU udVi.!Jr1.i:I!:!I u.~ spark when .fool~nl Ji ;O.~,,-~ 9~"C ;Iud a~ a Ml!lh load oonditi!Jn (neal' W_'O.T_~. "l'he f.CM ~~1f~ "Cn'Cil!UlJi,8 i!iiinill al"B1" tg ~"1;~ l(,~ k~otk Is dntcctl!d 'ThE!' ru.n:di.on.aJ eheek i:!i per£lll'm.eQ onee per ~t....r:t.r!.l.P IIln~nr"km:Jck_ iii detected when C(Io(Ill3.li'It iJ btl~rj]w '91ii"C (l'!h.1+F1, the, ~t OM passed -~:nrl tb:e' (unetion~j cht.'!C.'kwlli not.b(! run. H"thl!' rUrt~t!onfi.1 t~~k Inljs.Lhe ",S8nLee ~nGitlc Sonrl.'" li;A:htwlll i"(frl!ij,in..,~ l."UI ill"W-on

110 turned "orvn ,iJr unut n knoc:k. si!J.rtal il> dflOOCl.eQ ~ - -

. 1..-1.. l~' ""-'10

Test De~Q'ip-ti.·9n~ N IJm~C'l1i below II"ili:f.er- to cirdcd. l"Iumhcn err th'll dj..lgrn:mti:c eherr,

I Ir tho IWmiiliurlB far- II Cxle 43 fit.(l present, she "Scan" .... W1llL"':t!y:s di5FiOlY -y~~"_ Tb~~ !l.no'!.l.!4 ~I; I)~ {L ~~k lit Idle unless an in ternu.J tin~,1~m; Fr.illim. or a IiiIYlile m prl[illle.m. ell: i.sll.

2.. ']"~ test wi II d·e-term inc' if ~ha :system le rlnfcL:ianinll at Lhi, linm. USY.D.ll)' EI kl"l.a.c:k ~~ilJl1.o.l dJl r.e A:el'um .. t.e~, by LoFip:ing on the f"lFrht r.:-~hay:a.~ ~t!jfLlld Ir nc knock :sdlfl;).~ is gnnerutcd. try

Ul:ppi ne; on block (lQPie.1O tht' urea or tim sensor. Beoauae Cooe 01,'13 sets when U1~ signal vol!.ngo! on KT 4:S~ remal.t.L1! I.,w, this teae should ~~ tbe ~~I on CKT 485 to go hi~h. :rOo 12 '0)'" .igl1"' d be see 11 bY' Lhe eCM as n eo knock" if' tr.c

M and wiriAJ.1,ttrt OK .

.... Il[~ test will det,c:r'min~ Lr ~he k'nb!~ ~1!I~ignD.l l&

l'.(!lf'ig det~~d. un CKT 4lHl or rJ. ,~~):.~ module i~

uLri"lyli. Ji'",

:1. Ir CKT 496 is routed to elose ~D eeeendary i:gn[tion; wi~!I.. u"e E5C m,wull:I rnuy see lh~ ililt:rrerf!'n~' as a knock slgt"lul.

6. 'I'his cheeks the !;mLJnd dl1::ui~ ro the moolJle. A.n: open ground. will <I!:!LlS~ the voltage on CKT 4B5· to be lJbout n \'0111:3 wh1eh would cause t.bE;!! CodE! 43 I\l!',elioill.ill test te fail.

7. Cu!'Ln!!ding CKT 4SS with.u 't,esl; ligh~ tQ 12 \,()Its should gencrute a kn'IJek. stGTIBL 'This will deteemlne it the BSe m-oduje' ~~ QPer:1t.\ng mrrert,ry.

DiagnQ~tic. Aids:

Coal! .Ij.:i ,1:11.11 IJ.e caused b)' ;[I ra.v1l;y (Qfl'le~!101'l Dt LhE!" knock !ie:!"ISQI' iH. l'hi€ ESC ~nDd'bl.le 0("- UiL 'lh~ ECM Alae iI!'I'~e,k CK1' 45 !'or '¢.::;i!b~CJ [Ipl!'n 01" ahn r- t loa g~t..L,ld.

Hi;l:j"'f W Sec·ti{!n ""l'" for '"ECM I ntermutent CQdea

Cit" Perfo r- monee" .

COMPUTE" COPoilMAND CONTROL (WITH ·SCAW) 3-6!

CODE 43 ELECTRONIC SPARK CONTROL

(ESC) CIRCUIT 6>~.O

ALLENGINES~ '1 "'\ ~S.-'L;

• 1I;~1Ni,IIlUNG..

• "'-O~NTARq"l' TQlXH 10100:

S~fIIS(l1l HA.'!iIN~'S5 \C('f .tIg6j WITH • fUTU<itU1C 'IV.

• fJlCHrwrTH! ruTUGiHT mNT ... cts CIKT 0491, A. :ii:NOoC:t: ~h~~'AL SHOYLP!fI! (l~"f!R.\ TEll.

• l!!iA KNOCI SIoGNA.L{NDlCATnJ

WITH ~SCAIi-l

l-'l-8J "l':!iH!lHi.i

11'1 ~N IIlOtlllll!lU ItHOO: fA!M I [" ~ [.un, R""A~ I~ UR;'M iNCt"'!!! PAOlll!t.t. If: OK, CHI;'CIC. FOil ROUilllCG Of WIRE FROM KNOCK 5t:N50R:m f5CMOOULffOR;lflCI(rHGUII' f.A1cn: ~"O'II; i'GNALS fROM,a~ iA,'UAC;~NT MRE. R(RIJVTf AS HECU.SA~Y. If I\OuTfH<ii i!.lO~i\ta. UPlAe1ItNOU :S:fl601l

Hii COMPUTER COMMAND CONTROL (WITH ·SCAN")

. ~-~. --.---------- ........

. . - , A __ o_' T~N"U

'_ co ••• , (0, )SO" so ,

, [NGINE

IIUtAUU GfliOOHD

, ....

ECM

~GROUtlO ORCUrT

CODE 44

LEAN EXHAUSTINDICATW ALL ENGINES

,ire"i' Oe.cription:

The ECM t-uppli4!1Ii a voltage Df .about..45 vclU bcl;wc:e-n t;e.r'mjna.hl "06" il.I\a -00·', Ilf me.a!l:ured. with G. 10 ler bltm digita.l vDllmetD:r, thia m..t.y Mj.4 n! 16w lIS .32. volts.) The q.)tyge.n ~d.~r varies she voUAge wiUd.n a iiigfl oCaooul 1 volt ittho ~~h@.l.!]:t if! rich. down through aOOut.JO vol~s (fe,:ho:~st i,s; ICaiI.

The sensor j,5 like on open ci.n::uit. end produces no Yoh.age w'hcl1I it iSi below liIl:Kmt 31.5aC UlOO'"E'). An open. !l1SOr elreult er cold senaer eauaee "Open Loop" operaU.,n_

est Description: Numb. ... below refor to cln,lod umbera o [I th1! diagno!iltiC: (!harl.

COOl! « i~ set when Hie o1C.fgcn senIor 'Signal ,0U.'lle 0" C KT 412:

• ReJ.Yiillfllo below.2 volta rDl'20 seeeede.

t! And l:hc.system iso~r-adng in nClosed Loop".

U~i_n:lil: the "-ScanilOl ebeerve the block learn v uhma dl rrcl"en ~ rpm lind alr now co.,d:iUa [15, The "Seu n" So du.plnYI> the bloek eells, so the bl~.k learn vaJu:e.:!i il'II be ~h~~ i'PI t.oeli or t.lle c-ells to d~t-e.l"mi!"le when .e C94:Ie 44 mey have been set. If the ro"diLl(Jrlii (or lde. 44 ~xb;.t:5. the block learn v{(lUe8 will be around .0

O~ygen Sen!'l9f Wjrg. ~n~gr piRl~i1 m4Y be m I!l.p!}sitionlld. and cant.aIQtinl[ lhc cKha.1.I1lr1.. m.e.nif-old.

Cn'!lCK rOf intll;!l.rmlLtcnl ground in '!Mire beLwel!n cunnectee :Jrnd senser,

• FUl!'l Conta,minatior'l. W,tl!ir, e".r'iI!'I1 if1 am ... lI amO[J,nts, neur lf1e i"-lank ruel pump inl<:t. Cllri be dtHvcted 1;.0 Uj.c if\ie~torii_ Thtt wowr causes fi IfJ.Un t-rthu Ulit a.od C'OD ~!3~ a COOe 44.

.. ruel Preaeure. System will be lean it pressure is too 'ow, It may be ne(f!!isary to mBflHol"' fuel pressure while d .. b .. ing the veh[cle ot varicy_s fflad il~1 an/or loud!!! Il! ':---ann .. fi, Sii-e- Fut!1 Symm liiiagnoa.1&,

• A[R System_ Bs sure alf is flOL being direeted to the e:dtIlU9't. JKU'1QI: ..... bi.l'e 'in '·C losed l,.Q.o.p" If l~e ~Io.d.: IOcOrii 'i,lti.luc god down whllllJ ~ucl"t[fig alr hose to I (>ft. I::ilde or ex nllu5t pc rte, rllfer to Section 8. rr the above ere OK. it 198 faulty-oxygen sensor.

• CKT 413- If CKT ~IJ is o-pen. t.he yolt,·4ge at termlnJ)I-D7" will htO\l'ftrOM volt..

• S'in'!'iH Ha,fllh.!, Ee naor- pigtail m-ay be mlapue.ihlnned and c:!onta(iting the exhaust manitold.

• lftt.11 chC'c.k OK. theoryStn t;UW3:t1r iill. (null,>",

COMPUTiR COMMAND CONTROL (WHH"SCAN") 3-67

eODE44 LEAN~XHAusr INDICATED ALL ENGINES

.. o.l!i(;ONH e.cr 01 5oE'N~OR.

!I MfH uu"rJ4:1! jDUNii -.s(AN~ $HOU.~ c,5puy ...

U!H!!)!!!: !r;l;.TW'E ~N .,):5 '!lOt rs ANO.55- VOlTS D5(f oj'II..,,,,,,,g.j9mv),

~um

t-tJCE.u f.i IIIfR:RMITTENT.

IF IoJOJlDDmCN"'loC,1:l0'!,5 W'!~! iTCIltI!D,.ft~'II!:IRTCI -tl'l.~.GNO!!lTJ(.

! ~\Ig,-s-_cu~n·AC_~G:PA_G.i.

~'~N!1 ·'i!5~'t9"-if

,.68 COMPUTER COMMAND' CONTROL (WITH ·SCAN")

rN(jIp.u G,"OUNO

IIU,. VW""IU~ t:NGIIN'f ~~"'C TO is'"O AT 1100· IIfj;lM,

• C-OE,S ·SON' IND~Tir Oz u:NSO_A .... iJLr~GE fIX(DIUlUlW .its r.lOlT_5 !~$oQm .... ~t

eCM

11)1~A1,;ltlND (lAO,IiT

~.~(II.~1 ltiOJ;Q11!

CQDE45

RICH EXHAUST INDICATEO All ENGINES

f(,yit O!i'Hrip~io.,:

The ECM :$ullpi it:::i ,g, YO~t.ugilli 'l}f abOl.l!t.45 yoJ~ tU::~vi~en lef'l'llin~l9< "D6'" and "'D7H• or mt-u.su.-H. with ~ l!) ag-ohm digil.O.l voltmetec, thiri ffiiljl" n:.nd as Igw cs .32 v c-it,s.l' 'The O;ty':I«!n S-etl!ICJr vaeiea the vclsage 'I,·d,O:!.in .. 11&:"E!'OC about I wlL ifth.e exhaust Ia rteh, down through ub:oU.l .to vtJ~tt! trcJi:haus:t ls leae,

The :;::e~f.J,~ is: like lin Qpe-R ~irellitand JlNi~u~c!!i no !{ollagl;l> whun it IS below o.bod~ 315 "'C (EiOltP'). AD open riser '10 ~~W L Df IiIDld 5eI'\:3I) r'C;;! !.I;:lIe:S "Open ~~., operation.

!-st 'DE!!icription~ NwiLbe:n; below n:!fl!![' 1:.0 <:-In!h:d Irn.bo~r!il DIl t.he diagnostic chart.

Code 45 j~ set when the ox;ygen SaDS'lF atgna I vcltage er CKT,,:I,12:

• Remu.iru ube v .t: ,7 volt.fi filr 50 seeoeds, D.1'I.d in "CID ee d Leep"

• r;ng-ine time aitet"stnrt is I minute or more,

• "hr~l.tie ~nl{ie greater t.haIl2%. tabout J: wll!i ubcve idle 'lif.lllugc)

3gno>li( Aids.:

US[1'j~ the "Sean", observe U!C blo<k i~;[I!"n, IJnIUE!!I dirfQl"'(]nl rpm .lI.nd air flow oomlitlorui The ··&:1n" Ki displays the block cells. eo the nlock learn ~.uI,iJM n he checked In eueh of ih,e celis to determine when u Code 45 miloY Iti1 "(I Me [,)!ll.UL Lf th.o (orKittion:5I L(l r de .;.5 u ~r;.Ls_. t.:h~ block leurn vul uN; will b;c o.tt)IIU'!~ ~.

PUll! I Pres.o;uN:. S,)"'$te-m will 1Jfl' rich ;rprll!siSiul'e .s WQ high. Th(: F;CM. ,eiiI~ com~en'Sat~ ,ru eorne incrC'<.IJPI!'. Hewuvcr. ir lt g~'t!j too higb, u Cooe 45 m.l:,l:y be set,

See F'uoet $y:!l;lem d.iDgft(l~i:!)lCh(;trt. _LtukjE'lillnjw;t!Jr.

Cfw.ek for lucl ;;;(;1 11 tnmi nated oil,

• HE[ Shieldil'll~q_ An epen ground CKT 453 tlgniUui."l sY::ll.em r!:{~ren~ !ow) ITI.ii.~ t'M'"1.11l11" eMi, ur In.dllCti:d cl.oC'¢U'i~l "I1.Gi~e", ThiEl ECM It)l}ks ilL thia "noise" BE rtfm'tncc pulses. ThE! Il.dditlanCiI pulses reau [t in 0 nighl!'i' lhW1. ;(l(tua.l e IlginB speed 'SigrJaLThJ; €oeM ~he!'1 dallvars tee -much fUe'I, CGlJsil1.g systttT!; I,.Q I![Q rich~ EngLn-e tachomcttr will .111SC1I!1Q(lW r.lgi1er lhal\ aetual engine ;spcl!rl whl~n can help in.di_sgMiing-lhiS p,t"rJlbllE!m.

• !(~.~ls_U!_:r_?ul'!I!e. Check ror r'I.Jt~ saturation. if full sf Ieel, ch.e&;:k .;-;g.niJ;lt.er 'c:clli.trol und h_o.!!e~. Se-e E .... a~n:rLi ... t BmiS5i~~ CQ-nt r- ol in Se-ct.iJilti 5~

• ;\1: A P &IU;O[_ An out"pyt that ea usee the :BeM to aenaar a higJle~ than notllllli m,[lnifpld preaaur-e [Itlw 'i,I~CY'!.lm~ oi;ar.i eeuae t:ba system. to go eteh. DiS!::'!.HliiCIliiUfig tb~ MA,? ~n.oor- will allc~ t."'e ECM to i!iet a th:lJd .... lIIh.!.e r..,r the MAP senses, Substitutes. differ,!)ot "MAr s~n!i:(H· Ii the e lch (i)l"i,d i Ll [Jon i" £"OM whil e the seli.Sat" Is diS«!onnEctA;!d.

.. ?rr;;S;$lJfC R.,g!.!lftto~, Ch.eoek rof le.ii.k.lng Ifue[ preeeure r~g;ul a tj)t di.o.p:hr .. gm by eheeklng £Or presence 'Dr liquid fua,1 in '~M: vacuum Ilne to the f-egl,:llil~r.

.. CIi.~oCk fot' ItAkin'! r~1'i1:1 pr~:Si!iurlB ;,o:g'l.ltou~t' diaphragm .by {;n1!:1;;kl:l'!.g vueuum lLIi'i!' tiJ regulatorfor iUol!l.

• I;f§, An lnteemtttent TPS oulpu~ ""ilj eauae the:ly~te'" L) ~(I rfeh, due 1..1111! fa.lse Lf'die(!t;Q.!'t or the q!l'l~i nc W:<;~ [~J",yJL ~R·

COMPUTER COM MAND CONTROL (WITH ~SCANn 3"69

CODE 45

RICH EXHAUST INDICATED ALL ENGINES

r:.... • RUNW"~IENGINE 11S'e,.ou·~~"rUOliR"M_

\.!..J .. ~1:.5 "5C&1.Ni' TDDLClSPt.A1 CJS.c.HSQII, AXUI ,A'Ovti,1~ vgl.T:i (150111'11)1

• OISCONJltECT 0., 501150" AND JUMP(~ tlANlU5 CKT 412 TO GROUND,

• ·:KAH" .sHOULD D1SPU.V OllL(LCW .:!, VGLf! ~J$O mY',

r;JOE.$l'n

1·:1;",1'-8"1' ~'-S 3''iI~''~

1-70 COMPUTER COMMANO toNTRQL(WITH "SCAN")

ECM

jNTANK ~--------------~

IUUHEAOCON.1iIIiCLOR ;5c au;

..... ...

iiAn ".

FUlL PUMP TESTTlflaot,QB ALDt.1(;KGJ

CODE 54 FUEL PUMP CIRCUIT (lOW VOLTAGE)

Circuit Description

1'lie-"'UllUSO( Lbe fuel pump CKT 120 is monitored by the ~CM nt. t~rmi~:al '-8i"' {l.l'td it; used 00 compensate fuel dtliver-y ba'5e-d on sySlem vettage. Thi!l..5ig[l.~j i:t atso used lob stoTe a. cOOt if the ruol pump r(lI{lY la d,o(f.~ctive ur Iuel pump voltage iii 1'112" while Ule E!'nginc L" running. There :r;houtd bl;looou.ll2 vulte 01'1 OKT 120 ror a.tleust 2"l!condsaflcr!.he i,l{TIition Hi; turfleei, or Ilny ~lme referunce p .... Iaes are being received ily the ECM.

Cc)dO 54 wilt :;et if the voltagn Ilt terminal "(}2." is lea;,; ~hi!fl 2 volts fot" 1.5 secl)(1ds atnce the lust referenc't' pulse wu$ eeeeived. 'This (Ode is designod La detect Q [nulty retuy, eausing o;!l;~ef!.ded crunk: uma.und the eode will h<;Jp the di!.'i.g(l~!llsor an cnlfi.flt l.hnl "Crank!!. But Wl11 Not Ram. Of

If a (aul" is detected du.ring io~,r~-up, \h~ "Servsee El\gine Soon" iight wlll slay "'ON" until til· 'a:niuon !~

erc1c<li "OIi'F",

Diagnostic ,ll.i,k

• ~e~ECM l!ltcnniLL~ntCcd(:SQr j.crfl'}rmuncEI" in Section ""'2"

1-H1 7S],S .... ·,r:

COMPUTER COM MAND CONTROL (WITH "SCAN") 1-71

CODE 54

FU EL I'll Mp CIRCUIT (LOW VOLTAGE)

-'SJl9.:11 ~.~~-.11'1

3-n COMPUTER COMMANO CONTROL !WrTH ·SCAN-)

CODE 51 CODe 52 CODE 53 CODE 55

CODE 51 FAUL TV MEM.CAL (2.5L ENGIN E) OR

PROM PROBLEM (EXCEPT 2.Sl ENGINE)

CODE 52

FUEL (ALPAK MISSING (EXCEPT 2.SL ENGIN E)

, (toIe'G fOH~$S~G CAI.J"AIil ANOrMA! .... U P1N A.RI; R,lU r tH:S.[R'TI:O I:N THf.! I soo::n· ·tf c It. 'UPi..A~r EO. ..

CODE 53

SySTEM OVER VOLiAGE (2.5L ENGINE)

I 1Hj!!iCI[]DI:INDO'ff5rtlBIU:ts.J,6ASICGntH.R.a.roItFtOn~M. I,

.(O~II!! '!;, W'lLl~(r~\r.oLT'AC!; 1111 ~!:M UItM.IMAL II 1 ~ .cJII! .... Uft nu.p,j t,. _, 'rICt T!i FOil J 5~CON:[}S..

t!'(KI;II;I: iI'Ng i\._tll~1R I;~A~NG'n:snM. :

CODe 55

ALL ENGINES EXCEPT 2.Sl ENGINE

7!:Ui&JI 'J,~::!,,~,

COMPU'fER COMMAND CONTROL [WITH "SCAN"J 3·7:

RESTRICTED EXHAUST SYSTEM CHECK ALL ENGINES

Proper diUrlG.::ifiS rill'" 8 resteicted cxl'U\ust eyatem lis essentrnl beroro uny components are replared, EiLtl~f" of the rollowingproeerlur@!l mn)' bo used rOr"rli.Bg[l(lgi~, dl!lKnding uponengilleQr V»I u.Std.:

CHECK AT A. I. R. PIPE:

OR CHECK AT 02 SENSOR:

I, Rerncvo the rubber host Ol lbe eahaust, Illanif'old A_Ut pipe- check vulva. Re-.m.j)v~ eheck valve,

2. Col'lf\ec:t a futll pump pressure fr-Iuge te iJ t!O~ and nippl~ from a Propan-e Enrichment Oe\' iee U269 U r Iaee ill USlt4.\tlllii'lJ_

3, 1ru;e:rt the !I.ip-ple i,l'110 the exheuet malli.f~Jd A.'-R. pi!",.

I. Care.fu[l)' remove 02 !?t~f',

2.. (n~tall Borroughs E:lthaust a.)gkp("~S$urll Te!lter (BT 8616 or BT 8603) or equivalent in plaee orol ,'ren~u("litllll' £UusLmtmnl.

3. After eOI11Flet.ing tost d:e5-~l'ibeil below. be SUm tQ coat. Lhread.s flr 02 ,,"~I'" -w'iLh 3.t'!tl· aelae compound ?IN ,lj61369~ ()r ~Qi'll'dl!JM pl'"ier te re-trL!'ttaILnUOfl.

DIAGNOSIS:

Wit.h the engine idlinl( at normal opernl1J'tg temperature, observe the exbaust. system b~ek.pf'e5S'ur£! rnu.di.ng 00 the gauge, RtH.lding};hould. not exeeed I t psi {8_b k.Pg.)_

2, Acc-eierMe engine to 2QOO r-pm und ob5enega'llRe. Reading ~hoo.ld n(lt(iKcced 3 p5'i f2tl.7 kPill.

3~ Irt.be backpressure. et elther r-pm, eseeeds ~p:;ciIiCi.ltion. n ruarrieted exhauet syatem is. lndleated,

4. InNpocL the enrire exnausr aystem for u cchapsed pipe. heat diateess. or possible intel"nat MUmer Jailuee.

5. lf Iher-e are neubvfcus 1"'(l.uI!:OM ror the!" excessive b:l;ckpl"~I:l:!l:U,r~,1;1 r~li'lcted ¢iitalyUt CO.i'lvct'ttf sl'iould l:1e ~Ll!:ipeC'l~d and re~I:),e-erj lJSl11jif current reeommended p.t"~~'-!rlP.\'!,

3.74 COMPUTER COMMAND CONTROL (WITH "SCAN")

~ MAP SENSOR. I A eCM
1.1 .~
"'6 GillY 5V.Ef

MANifOlD 4.n LTGftN
.ABSOLUTE. A.lLC .. 4$'!: PPt.
foii!S$ijU
(VACUUM) l,5J..Efl~~i
A4911U1:1C:11U1
.IIJLM , .... UCVIJi & 11;'" ---A'5!ilP"-
-:::- 15]61}7
7·30·87 5-17-17 MAP OUTPUT CHECK ALL ENGINES

Ci leu i t Descrip tio n:

The M.an.ifold Absolute PHli!i.Eiilire rMA.p) 5e1l&IH' DU!!11'E1-Ul'I!1E1- manllold.praaeurelvacuuml o.nd sendlS that signal la the SCM, TlIe MAP ~en!llll" i!!li m.alnly uBed rCl!' rue. erdeularlon, when the ECI'.( ls running it! lh~ throttle body ~a<kiJP mod~, The Mf'.P 5eMO!" Is !llM! LM!:f}Q togo d1li::wrmil'le the h:(l.!"om.etri..;! gr~~!illI"E! and tc help enlCI.iI.o.t.e rl,lel delivlIr)"

Test De-scription: Nu.Mb~rs be:low ~fef' to -ei~ltd number-s on Lhe- diagnoai-1f:.I:ha.rt.

I. Checks MAP sensor DUttlUi. voltaga to the ECM.

This 't'ol1.3,ge. without engine running, represents U bOl"omete-1' reading to the eCM.

2_ Applying 34 kPo. (lor' hgJ vacuum to the MAP ~c:.tmQr~"'j)uld ~l,l.Se the volbl.8e to be l.2 volt!l Iss Lb.an Lhe v ohage tit Step L Upon applying vQC\ly,m Lo LhE! Stll:1SOJ', lht chel'l'f! in voltage 1inould be lnsaentaneous. i\. slow 1o'1)!t.ag:e change indicats~ iI f;.uJlys.enslI!".

:), Check vacuum heee to eenacr" fl)r leaking .rH' rcst.ri(:tion. Be sure no other vacr .. rum devices Me connected to rhe MAP- bose.

COMPUTER COMMAND C;ONTRal (WITH "SCAN") 3·75

I(:Nmo,. ~OK·, [N~~ $TQ!"lf"flll,

·SCAN'" roOl5HOULOI"OIO.lE ~ 1J00T,A.G1! INITHIH TloIE \IIALU U ~HlIwN ~N 'HIE CH_li.IIT II !lOW.

MAP OUTPUT CHECK ALL ENGINES

~ .. Il'J$(OHHI!CT YACl.IUM H Q5fl .. T MAlI

\,!.I 5i.MSO ........ O~ur::i HOSE

C::ONIflIIIEO '" HAND VAOJUM PUMP TO MAfoSINSOil

• S1'U1ENalNf

• "w.L.Y JAt'lI.(1a-)N'If'A(UIJMANtJ Non VQlTAGE CHANGf. (VOl. TAm SHOULD II' 1.l. •. U VOUSt.E55 TH,I,N 5n't .•

r- -- --- -- -AlTIru-OE- ----- .. --- voiTAGiAA'N-ii-

:, MlE!!tl!fli Feet

,.row lOS 8-"0 .. 1 ,000 ,3.8···5. S\I

305-610 1.000··l,IlOO 3.6·-5.3\1

6tG-914 2.000··3.000 1.5·-5.'"

914--1219 UIO0-4.000 ].]-5.0\1

121\1-1524 4.000-5:000 3.2-4.8\1

'524--1829 5,000-6,000 3.0--4.6V

182g...2133 6,000-7.000 2.9 ....... 5\1

2133-Z08 7,000-8.000 2.8-4.3\1

24311-2743 a.oW-9.0QO 2.6-4.2\1

2143··]00 9.000-16.000 2-5--4.0\1

l~9~~t_r~~~!_~~II!~~~~SS_~~~_'_~~~~_~~~~~~~_

o.t: •• (OOlS ANO COH~RM "CLOSED 1..0011" OPt." n.ON AND 111.0 ~s:nVICE E'NG1H,f; 500U'" liGHT.

s·;n·11 "75J111ii-l:--6-!,tI!

3·76 COMPUTER COMMANO CONTROL (WITH ·SCAN")

uv

PARKINEUTRAL SWITCH DIAGNOSIS ALLENGINE!i

EXCEPT up" SERIES

(AUTO TRANSMISSION ONLY)

Circuit Description: "'D~~ '1 So' '-=-

The P3r-klNcu.lro,1 Swif..fh t_:-g"Ql':tI!i ltc c:i!]:sm to FOund. it! pw-k or-neutral and open in drhe t1IDgC1i.

The ECM :!i,up'plies ipHion Yl}ltugs, through ;p c,urtcnt. UmltiJlg .t'e1!Ilstor, ~ CK'T 454 nnd ~Cllsfl u elosed Iwir..eh, whenthe voltage 'on CK'T" 434drope. to 1E:s:3 tluLn one volt..

The ECM U!loe:9 the PIN signnl as one o(the inpUt! locllnt.rol:

Idle Air C9~tNl VSS Oi.~ .. tl<. EOR

Te.st Description! NiJiii.be.TIi below refer lo ,c;i r-c: led ocmbeee en UtI!! d,i;g.gn'l)st.ic: chnrt,

1 Checks. for l). closed switch to grollnd in park position. Diffcrtlnf. m{lkes of ~Sean" tools will read PIN di£Tt:r'cnLly. Refer to opc:nllon. manual for LYl'le (ir dl.~lliy used fqr ~ :Ii~inc tool.

Chl;~,k:s. for DI1 open :sw~t&h in drive fir re v erse runge.

Be sure '"5<Q",'" l mtieatea d.ri v e • even wn He wiggling snifter to ~~~t for An intef"mittenl or miMdjw;ted 5witc;.h. in driYo I1iinge.

Oiagnostic Aids;

If CK'1' 434 lndicat.&s PIN (grounded_), white In drive rllt1gG_ t.ht!: EGR. would be i~pe!".s.tive. resulting in po1!slble:aeiDnotion.

rfCRT 434 always indkalCS,dfivc(()pc-nl. w. drop in. the idle mEtyex:i:s~ when lhll!J,gI.!'D.r~I(I'ctor ls moved into dr.iver;J.nge.

COMPUTER COMMAND CONTRO~ (WITH ·SCAN") 3-7~

PARK/NEUTRAL SWITCH DIAGNOSIS ALLENGINE5

EXCEPT .pH SERIJ:S

(AUTO TRANSMISSION ONL YI

5.-,2t-l' *7$~1;;1-G{

3-78 COMPUTER COMMANOCONTROL(WITH ·SCAN-)

ECM

N.,O.

'GHmoN__/,.-_,--------- ...

'li'MICH t.IIAH, fRA"S,

CiUr(H START !!iWlTOi

CRANK SIGNAL DIAGNOSIS ALL ENGINES

:ircl.iit Description:

Crank signaJ 18 a J2 V(]~tfi lilg;nal to the ECM during crnnking to allow oC-fidc:hmt!'l" and eaeeel dia~ostic:3 mtf l enginil!!' ie fu:rinin,gor 1.2. volta Ianu lonj;l(!i(" 1)1] ejreult.

rest O@5-criptien: Num~r, be.low fete!" tn ~iR.led 2. CbefkstDdet.l!rnlin..e1f50u:r~eofG.lloen flJS.eO!' ruse

lumben; gR the, d.io.gDOsti.; (:no.rl.. link, WS:...<i a fau.Uy $CM_

Check.; ror normal krank£ng) vel tag" to Iurmlnul

"ClI·· or ECM. T ... lig"' should hi! ··ON" d"rln~

~r3nkinB" and then. ,go "OFF''' when engine. is

""LollIr.

COMPUi£R COM MAND CONTROL (WITH ·SCAN") 3-79

CRANK SIGNAL DIAGNOSIS Alb ENGINES

• P'JIICU il!CM C.QHNII!!(TOK (J('f!Wi mTtJ T£5i' LIGHT TOG1i(ii • .rHig,

QA"!I!I;iiNG!NIIi,

" nSTLro:HTSHOUlOIUUMINAT£.OO£.$I11

\

3-90 COMPUTER COMMAND CONTROL (WITH "SCAN)

M;(QM~aSOR Q.i.JT(H

AlC "ON" SIGNAL DIAGNOSIS 4.3l AND VB ENGINE

Circuit And Test Description:

TUrTlJnR on the air corulitilJfi.ng ,s\iPlJllel CKT .5~ b;iL(:e-~y v oltl.t~,oE! to lh~ NC tomp.ressor dutch and to terminal ·58" of the BCM ecnneeto r- t.o i ncreeeo l.d 10- Air tale o.ng mllintAin Idle-speed.

The ECM does !'lot centrol the Ale eempeesser 4;:.lutl:h. t.hefe-rore. if Ale does D{lt runctlon. refer' to the AJC ~iftlnn or t.he service mtlnUQI fo:r dingnMlS of the system.

Ir NC is operating pro~fll una ldlc lIpee6 diP'" too tow when th! NC COf'llpreS£;Q1" tueas "ON" or niirut too hil"h when the NC ecmpreeecr t,\lrn:s "OFF,"' cncc-k f.gr ;!II Q~n CKT e-9 ~ the ECM. If e::ir~u.il!l are OK. it [s ~l. ruuHy t:cM (i>nrl,ecl.ol'" ler-m.il'laJ "88"(11" E:CM.._

COMPUTER COMMAND CONTROL (WITH ·SCAN~) ~-9

I ECM QDR CHECK PROCEDURE V6 OR VB ENGINE

US( TtfISCH(CK 'RO(~OOfU! ONt..l AlinA OTHEfI, OI&GNOSTIC OIA.IlUiHTHI! S.UtVIC't- MAN\,IA.I" "AY~ DUf.MINtO THA,TTHEj;jE WAS ~N f;CMfA,ILUltf.

• RrMOvf THE ECM FIiiOM f}<l~ VIi:Hta.E.

" toEnl"Y THE SEj;lV1(E ~ln,lMIlU OF THf EC]'UIlpt rse VeHIUE.

" 11$ Tli.E, I'M ifP.VlII;;E ...... I\T N1JM8~ 12217411

• ... ~n~ TO lISTIIHLOW Of T}!E ICM TERM""AlS W..rn:H ARt QOII OUTPUT1.

• USINGTHt J:OOJC CHM !iCAlEOH DYM", MtASi;ii:£ RUISTANC( II~!N. TU! II!CM Q.$I AND I!}"C:M fQi! f[RMINAlU!iT~D. B.l.ACK (NI;G.) U:A.01"O o.SE J'ND IUO(ros..JLEADTO ~(MTnIMI.NAL

• AU. nFl_)4~AL5IJ5.ntll5.aQ\I\'D HA\I'~ P.:ESISU,NCi OF 51i .. OKM;5 OJ;!: NlOK~,

" I;I!(}TtlflYl

1

TH[ !tItIO« ll.!5T !-lAoS DnUMIN (0 THAT A OOR IJ4 TN ~ ~CM HAS I!lUiN !;tI!lM~GIi~ IT IjM-o:tr IMPORTjVIT TO lO(ATiE "'''0 .IIEPA.'1l; n-I'E CROJ" OR CClf,IIIIIO"" ENT nfl,'f O-U'SED THE DAMAGi. 'fA[iUll;f TO DO so WILt :AUUL.l IN ... HOTH.fl II FA,ILUIUi 0 .. IHIi NEWl 'f "-r~AC;:EO E~, ANi'f J[ IUdIN.ltL VII1'fM L!~~ f'HAN ~Ol Q+lMi fI:~~I$TAN:a. f5 CONN!.C.TI[O TOADI;FECTPlI (lOft THi! II!CM r~AMENAL WrTHTHI; 1.000SirRIlis,liTANC;:E WAS CONNECTED 10 'rH~VEHInI; CIRtur'" MOST UICI;l.V TO K"Vl CAUS{O TH[ QORF,AllUliI.E,

• OISCON!lrltCT THE (OMIi'CINE NT IN TH.A T"EHlO..t (i"(VI1' ANI) ~~.;(i "OR A !:KORT TO 'JOt TIlt?L il iHE OFl,CUIT 1'S.p,jIO'TSHOIli~010 VCI,TA6E,FlfPlAtE fHI;' '"MPONIiNr IN" TI-I" T (1~'UIT II.NC TH f UfiI,

E(M" .2.2.7'147

,<10
Qo~ OUTPUT QRCUI'T
PWNaUI. HRMINAi.
A2 A1( RELA '( (2.IU
~ NorU5ED
0' NOTUUD
'" Il.-,C 50llNOIO
.. fGP!. Oil!: fVRV S OI.ENOJO
A< SHUGHT
~ TCC SOlEN010. DOWnSt11fT
.7 IIE'LA't OR SHlf1 UGHi , •. !".GI .••. ~CM'SFAUlT'PROnCnO, _ I

CORIlfCTfAUI.Tl' OI(O.IIT, REIN:51'.,1U.L [CM ~(H«:KClR(UJT, RE~CtECMON"-'t

IF CIRaJIT15 STU I:NCPEIlIrTIVIE:.

FI-gure3 .. 18 ECM QD~ChE!(:.k prO(C!lau.,e(V6orV8]

• ICl'l'·"CN·.llil(ifltl1;:NOl RUHNII4G..

,. U'51E: A fUSW AMMJ;"lI!;A tAp." BU Of MEASU-RING, "1 U .... ST 2 ~MP5 (.'-344129-" Qr!'. fQlJW"',"~N'i'l.

II f:ONN[CT OHELUD OF IHI: AMMHflll: TO CMA!iSt!r~OUN[)_

CONHleT THII!! fi:EMAJNIHG LEA.D TO 1:",1+ ~IIi'~In.E:

OR.con wlilOt WA!'i U~fO ABOVE.

• MEASUIU_ 5UST,p,II"rIEO (.URREN.' HOW 'THROUGH ,,,CH QliO.nT'Ofi I ",IHli,jTrSUlH(i'N MO!;T o.S,[S. 'OlE TCC 50l(r4011J CANNOT BE 1;:A$ft.. y TtmDfO~ CUfl:RENl DIilAW~

• HOf! AM'EM-Gil.

I

]IF NO cmcurr!-lM MOlil'( nU,N O,7j "M"S CURRENT L~ 1------- 0 •• "'_

,....._-----, ';::~===~

• CHlCKfORASHOIHTO I. !\E:~glil;!IIl V()lTA.¢~INU!:fS:SN~

CURRENT bMW CiR.!:lllt .

• If NO st+OKf f(j

voir A.6E:, ~~PU.tE, IU;UTIiC SOL.OHJIO Olt fU~""''I{,

If! ~ ClJtOJITIS) ~IAS.MO"1i THA.N O.7!!i A'fI[P§ CUIUI.[NT

[JJiIAW.

• USE DVM J-34029-A OR EQUI\lALEN,

'·10.8'1 i!lSm413!i-61

3-92 COMPUTER COMMAND CONTROL (WITH 'SCAN")

WIRE HARNE5S

ON-VEHICLE SERVICE

The F.CM hD_rn~5S !I!!1~trie:llll' C!)nl1ot"Cls t.h~ ECr>,t to the V;)I"O-U5 solenoids, ,-wlh:he'~, and sensors in ve.hi"lc ~nginc and pas.,engt:rf;;offillilrtment

Wire harnesses should be replaced wiuh proper pur-l, number h-O.ttLC!1i5~5, When atgnnl wiri':!iI are eplieud, into u ha r ness, US:!I!!. wir~ wi'Ll;. h lg h tem~:rrHYn~ in45ulDtion Ilnly,

Wah the low eureeor ~rU:I voltage lavale (l)Ll:nd ;., '1.1-18" ayatam. it l!ll imp!JrtDnt thllL the best 'P'OH:s.ibi~ bond [It::LIt w ire RplieC:iI be mode by sa'de:l"illR' th-o .II;pllclll;S, d5 shDwn in Ftgut-e3-19.

Molded on eon.J1el;::lG!,,~ r equl ru complete tt:'plill4;;cment. or the conne<:wl'", This meum B?licing a new connector Q.Rsembly i [Ito the' haeaees.

RerC!r IJ;l- r'igtJrtl;1i 3-:2._2. ~hrolLR:h J~~3. f(lf wiring di;p~tT.!~

&rplill"~m""l1t ceoneetces und LGrmlnnl:lir are Hated til Group ~.965. orthe :SWlndard PIlrt5 Catalog

CONNECTORS AND T£RMINAL5

Use eare. whtn probing .n connecter Dr r~pla,",ii'lg Lermin31Jj in litem. It is. pesaibte to Shott mnwG1!"n QPposila. li:!rminnJa. If ~4 t't.g,ppenz, LIJi L.ha wrong

cermlne l pair. it te possible to d3mu.g~ cer tal n camponenss. Alway, U5e iumpnr wires between connectors, fot' circuil eheeking. NEVER probe r.hrcmgn lhe WMlhcr~Pac-k !1f-8.1; US4! t.tIi4!p.Qmete.r s.d.~ ptet' J 35.812, {ir aqw"sie nt, which prDvides 3." "([1)1 hook ij iJ of thn Lach. lead. 'Til!! eennectcr test o.di:i pta r kLt. J3S6t6. {)~ rl!ql1l!ll'sl.ent. conW.in_!; an fI;:!i!!50.rt.rmmt of noxibll!! eoneeeteea, used tu prllrM tElr'minah: during dlagneets. FU!'JE! ~f'i\(i"c:r fin;J test tool OT 8618. or e.qui-.;altnt.. is u-~ed (tOIl"" removing a rU!>e end to adapt ruse hclder, wiLh a meter, for dlagneeia.

Wh€!n diagnoslng, open circuits are often difficult t.o locals by sight, because oxidolioi\, CIt'" tatmlna.1 misnl.igr.menl are h:,dctc~ by the C:Qimll!ctilr8. Mer-ely wiggli,nB ,(l c:Qbilrtt::l.uF 0n. u !K!OSOf', or in the wi.ring h;;urn:c-,~, 1'1'U11 l:urretL the npen elreuie ecndlnen. 'This shouidalwnys be coru,idE!r-oo, when al'! opel"!. eieeuit, Dr rall!!:!lamnsor i~indi4!~ted. In.Lel"mlLU!·n~ Ff(i'blems lfiiiy< etec. be caym by l);kl.d.i1+td Qr lseee eonnectlcne.

BerorCl making 8 connecter repair; be c:e.rtaln of the ~yP<l' of connector. Wl!"sther·Pn.ck and Compact Three l;:onneetofiil1ook ,similar, but are serviced dffTetct\Uy.

}W';UD LEADS

lWIST~DJsHIELl)H) t:AijLE

A~

f OUTEJII JACKET MYb .. R L ~f,MO\lE OtfTiEA JAe~tT,

2. UNWIIl,AP At"U"'INU~{MVu!'R TAlItl. I:Hl NO ....

REMOVE: MYL,AA.

1. LOCATI! DAMAGEO'l'l'IR18:,

2. Ht!MOV,E; ,INSU-LjIITION A.S RE:OuuH=p.

c:

a, lJl+C~IST CONCUCTOFIS. nAlJI' INSU1.ATlON;'f; NECESSAJW.

SJil.lce: • SOLDl!;i!I

E3 ~

3. SPLICE TwO WlflE-STOGI!THefiI USING SII'uce eLI PS .... NO ~aSIN eoA ~ iOl.pE~,

4. &pUCE WIRES USING S:P~I(:E CI.-IPSAtoiO ROSIN eOAE SO 1..0£A. WRAP EACH :!;PUC!; TO INSU LAn.

~. WRAP"""TI<I:IM"tLAA AND gfVI11II {UNINSUU.T£Dllltlfl;~.

1\ Ui

FLgurB 3-19 • WlriE! H.ar.nE!+!i"5. R,ep.ai~

4. QOve-ft SPL..ICIi WITH 'TAPE: TO JM!lUI,..ATIi f1!RO"'_' O'THERWlfii~.

S. FII!!1W~ST AS nNOAI:: ANO TAPE WI'fk E.L.eCTRIG,o\b TAP-IE ANO HOI.O 1111 PLACEi.

Micro-Pack

COMPUTER COMMAND CON1"ROL(WI1H • SCAN") 1-9,

~(er ee Plgure .1·2,0 nad repelr procsdura-jor .repl..C!eerntlilil Dra Mi.er.u"P.s.f:k terminal.

Metri-Pack

Some eennee lOr:!- use ter-m lnu Is (lull ed Mol!! lr i- P~k 5cf-lo9. '150. (PLgul'1! 3-211. Ths!3l!1_ may l.1~ed I)t tt,le ~oo~l1t:&J:!ru;or,i1..E3 wel! B.p. "f1J3. I 'bU"~~,

They are al~o ';eI,l~e<i "P!.I!Il·'I'u'LStl(i't" termlnale, brx:al..!.!ie. tc i.n.staH il icrrn.iiULl OC'l t1 wlre, !.he w ire ia f"ir-st fnserted thrl:JUgh tile seal (5, and conneetee (4), The termil'lA..I isr thl!r! ~.-rimJled !jj!"l ~.h_e wire l).nd ~hie le-rmi~~ 'F!i,lll~ b~k i nw ~tte- OOiffUXW( !;.Q se-ll~ it In plnce.

[IJ "" .... [IJ TER~IN.l.;

m LOCIlIN6 T~I\!(i

ill TOOL .J3309sl9T8z34-A

l'~ J!!l4!-ili

T(l remove a termlanl:

1, S'id-e the seal back on the wire,

2, [I1SE!'r't ~QQI (J) BT-B51B, er- JJ5689,. ( equlY:o!eflf:,:3.' :!j:hr;ioW., In inseet ~A'· ~UI,d "B," nlleUH the tbfffl I'i'iQ I tOGk~ng tr:r.b (2).

3. PUI9 h -lli'! wlre Dnd terminel (;I ut Uu:uugh U ecnneeter-.

1 r ~·!L"'CIin!f the termlual, reshape Ole ·ICI(lking lang (n

Weather-Pack

A W-eathe.r-f'i'.I!l!k eneneetor ean be idl!lItiried by rubber· seal, l,H the I!'l;!:ar [!If the eonnacton. Th 1!i:ii'ii'!ce~I;', whj~n is I..iS(:cI in t.h1.: ~tlR:i"J!: C(irnpartmE.rI P['liJIte'l:U .ji;guin~t mo1.I;t,;!.I,re and·dirt.. whidli C<I'I.Ild ";:!I"~!i\i o.l:idiJLlon Dild dcpo;l:iiM 011 rhu jerminule, Thpretecttnn is lmportaut. beeauae or the V-I!["), 10 vol~lile Dnd (UI'!"ent levels round in the eleermn '¥$\<m,

Rupak.of Q. Weiill.hcj·~k ttrmln;p,1 L3 :ihQwli. i Fi,!:Un! 3-Z2. U"" _I J2S7~2, or BT8234-"" to '""'0' LtI.1E! ptn and slea .... e tarmlnals.

if r-e-mn"Ya.J is attempted wHh. an. ordi.'!'UI..f"), pic!

Un:re ls n gm chg,n" ,~~ t.hi' ~rmi:n.at wilJ ~~Ii or d~.f.~[m[]d:.. U!:l[lko mt!d~,rd bl;}de t.~ ili!:rmi.ruJ.I:

L.l:1e:5'l!! termlnaja cu.nfiQ:t bc sttalgl"ll.aned. once they a. bent.

M.ai{e ('!;l.r~i.n th.p.t thl! ~ntl"'iCto["s om pr-Orp.t:t'J s~tG-d ,!1;(trj all .or the eeefing j-inge iii pleee. wh_!!! c~nm:~t:th'lg lcuda, The· hinge type nap provides backup, ur secendarv ll)cklng feature (Dr th eonn~tor·_ T1l(!), El1"-IJ w;t.<d t.o itJ'lpr(l,,~ the COo[\n~t' reiiabi I i ~y by r:eta Lfl.in:g tli-lll 'lUffil:ru:i;!g ~ Lf U\.e S'fJ'l(t l~:rmii'i~t IQI;k tanga ere noL lXl'ii~iDIlN 1J:ro~:dy,

w'Ctalh6r~r~ck ecnneedcne eannat b-t! to'PI.(lI;;C! with l'itnmiurd .vonn.C'ctj-o-i"'Is. In!ltruC'tiom; aru provldi ~ i lh W (!ulner-Piiek·o; nnecror and tet-mir • .a: ~ pa~ku.ge!!l

Mnltr .. i"AO!: S.~H[t!:;

'. ~ f~MA4: TE~Mr.NA.L

~, r..t;x;11NijofANG-

r-e--~-·~~·--""---i

I I

I fI1 I

I ~\.o,. . I

I .. I

I . -.'.-, I

I ,.___ L:J I

l ..1

r, TOOL J35M!J O~ IT -su .• "'. (OHN·EClQR ICD.,

s. selllL

:"94 COMPUTER COMMAND CONTROL (Wilt! ·SCAN")

ompact Three

Thu C., tn Fuel. Three (:(!oi1f1o~W!"", wh ieh looks slmlla r .r.j We,ut.f1er-PDick wi'l.ne.ewi", ~ 1'l'!5~ ~e:i,lI~ .lind ~5 uaed her-a reaiatance to the ~li.vit{ll1mtrlt is no!:. required. ala LYPB etcenneetcr. mliat likely,,:"; lJ::;;r:d al ihe :...i.r ;1"-1'01 wlsIHJ.lfj. US8' the atandurd metucd, 'IIIh-Cfl ,Pt!ii'fr1.R";.i terminal, D~ nat. !.lEi) thlJ W,MLn-c-r&PII.cit. flr.rll'!;At too' J~67~2 • nr 13.'1'823"'-1\.., us lhi!'~~ will rfl1!.1R;t ~ht: lC"·tt.!it".l4J!'I,

LEClRONICCONTROL MODULE

Hirr:il~c:cm.tnt .g( thfj Rtec1.n:lnj~ CtH1tnj~ !\1~idi.llf! :C~II tm'J.s·l:JU or a service euntrnlfer-, wltheut !:I. It~)M/C:LLlplL;k. OF MEl'm-C~1

I{ lh-c: dia..gno!iiti~ peoceoures rbqurred lhe I'~CM tu t ·r'!.;II;jI~~\.¢¢4, Vie eCM, PROM r CIl.lIJDk. und M.£!m·CI1I IQuid be tl1e<:"=C'd for ~hC' C"(H'I"(ft;;1. F);:;'I"L number. Ii thf.!oy ~; rameve til.:!! PROM and CiLlpuk. er _\'Jem,e n l, ana ~[~II l~C!m in the 8e"f'YLce- eorurullar, T'hC' service 'll~rH[[()r will nOt@ilhiLi'!.ll P~O~'IICuIIJ~br:. or i'ohm- 11.

m Important

WhC!rJ replaolng c. productlen ECM wtth,(l service ccnreotter, rrunsfar- the bfQ:gdccs~ C!:ode 3fUJ ilri)i.:!.kl.t:H<tii ~CM ]ls.:rt number lCII ll'l~ C~f'.Itroll(:lt" ~Il!.b~ l, 110 not reco ed inform Ill!o n em t he C!.~c()SS

'NOTIC.E: 'T~E! igniti(l,[l must bo(: "'OFf'\" whe n dt~nnectinB" Of'" :r!!~.,rm(t.ctitig tr.c !':CM (;g~iiector. 00 pre-vent. internal dllm~l:l!.!' .t,(j. ,h. SCM,

ECM (DnnectorTerm,nal Volt~gl;'

RO'fl:'r to FigtJi'c :J;.JJ LtI.nH.lg'n :1-35, ror .... g~~g~ charta to Rid in. di .. gi't~i!i"

ECM R~pla~"ment - with Mem-(.i (2_SL) figure,. 3-36, 3-37 and 3-44

8 Rem.owe or Dh·(onnect

I Nogadvo baHt!')' cable.

Conueetoes fro ill E eM. f];C~ 'mounUng hllrnwtli'c.

E:CM frqm·p,.5Blmger Gomj;ru.fL:m~nt Be M u iceess ((11'111;::' tFig,JI13: 3-~]. Morn-Cul removal ~Fi.gurl! -3...1S!,

II] Important

- ~"j')I~~oS!me:nt. ECM L!i SUtJIlTic-d without n Mem-Co.l.

ISO ~r~ ~b(jLlld he used when nHTI.-Qving Lt, rrnm the dllftlC'~.i",,(l [3;CM, because tt will bu r'~,I,I~:eJ i.n the n8'wECM,

USLIl~ two ring~r':5. ~hl):" born reU!i.rring .clip·~ h3~" uwuy fl'fIOl lhe.Mc-m.-Cal. A~ lh'iij wrn~ rime, gru:iip it i,'i,t ooLIl (;rrd~ ;;~r.Jd IHi H, !.Ill cn.r:"' !:If "lit" ~ol:ket_ Do nO'!,. remove the eover or the Mem-Cal. UiC or unapproved :'ti.:!om-C;JI r~mt1o;o.n1 m-r.:d'i.Q;t$ may cause diU"IIfi.w to the Mcrn...t.:',ol o-r OI'1lC!':tt.

~ Insp@ct (Figure 3.39)

For a ltgnmoru rrolcnC::I oi the ;\ieil\,C;.I1 ~nd ~.:l~rLJII'y :s~t...illUiido .. Du n_Ql upan the MfJm-C.ul

COMPUTER COMMAND CON'fROL{WIfH ·SCAN") 3-95

0f--------

.uDlCONNfCT'" ~[!] W"" ... 4"

1' ...... 1IT-.5O

TAHl'WHT G1NIE GNU·!:: % Ii,AqWHT

M_O. ~

~~~~.------r"'---;.'---b::--_'co.o.", HI': ;-KIILIC419 cs

MAN, T~"S. 1A

{LUlOI HART

SWITCH

1"~-_--_-"'~--1.~3f-----.:.$T-·-.r-5--0--"'E:__.--O--'D_:-=;;:_ PPl_n DJ

OX'l'GIEH5EN~ SlGltA.l

MAT

,~

,,'1.1 Uj,i!!, o--1r-------------

figun~ 3~l;3 .. E.CM Wlri"l"It;7 Oi.a9'ram ... 2_Sl (i of 3)

ECM

3-96 COMPUTER COMMAN 0 CONTROL (WITH "S{AN")

C1flJUIUTOIt [' .!~l sr nuc.)

",,",'16- "". ..5V JtlflRt:MI;£
OIUlU"17 on 1"PS~~"_Al
'IIILK":i~ ~ll ".'TU"~



ct. eooU"IT
'rf:L41Q TUOIUtA JURI
SIGNAL
~
MA.HlfQLD AiR
rAH~n: m HMP[~"'fu!!;t
'!i.e,""!. J1 PIN: 1;-0
CON_NE-crO~
I!GR!50UHOIO
E'~~ ----c;:.'}- .,~ '" EGj;jC:ONTAOL
A< IGNmOJil
IJIIn:(lO.JIiI PNKtI!IU.ji
•• " ~)--})-1TTT\-<t----<-E-----, r .IU •• , Llt6 lM,!fC'TOIIg;RlV.E:II Ll&Ll1rwHT "1 '5 loA, '01" -.- ttl

II.~ l.TBLUlDI,.C Ul 0" lACCOll·A-lQ

Vl;.lV L T Ci:ANJ'Nt1T 4&) [It lAC-COIL -.·111

LT i:iI!NJlI..It.u. Cl iAC CO!L ~." LO

H~~L t~E(T SWJT(H

&L.tiffll!lltll!i,i, ., ItEf{lIlli.Ng,LA;lW
rA,,{I!ILK 421 0' l!Iy.p~$5
p.p!,[w:lfT "l!l D. F!ifllilU"C~ H~H
WHTgl DO in L- BLIIJRI:D4!iJ

It[I"IIUHC1lOW

UV )OA.

".

'~II fUUPUMPII:ELAT DIlIV"F(t~\l1

FUEL PUMP SHi~AI.

3:2 P'lN(·g CQNNf.O'OR

COMPUTER COMMAND CONTROL (WITH "SCAN") 3·97

,,< lWl'!'(H ".0, '--_....L:..l

ALU/CflN .. g~ _ ell

(CM

to.!(

"N"3--r.:~_f'" ;--...-)-----------, Pfl:flSURE CYCLiNG '$WI"Ct(

OKGRNlWliT45i1 oQl AlC'5l6NAl

3:i G.Cf 201.

Pfltc;..'BlK --.rv-1GH

BLU oIIsa ., we fl.(l,A't' CONTROL

II PINi:·O (ONt.I[CTOR

F'igu'1!!3-25 ~ ECMWlril"lg llia-g:ral'ft42_5.l(lot31

1$H61 5-.iI7·tI1

3·98 COMPUTER COMMAND CONTROL {WITH 'SCAN")

M.O

5Efl:IALOAU ClAGt>lOSnc: lEST

O)c'I'GEN '5tNSOI\ GROUND

I~~t---~~------- PPl4.U OJ ClltYGfNSEfII'50R

•• 5lG,.,.L.

r ..

CgOl..ANT HMPEAATUR~ 11:1'15011

.o!.!1;; •••• J --r,:-f'~t----------, 4I'IlfSS-uitE CYCLING ~WJf4:H

TAN/eLI[ ",1 ., fCC CONnOl 1M •
A.t.JJl ,
r;.ONN,
TA.Hil.Ll.oti& ~HlfTI.IGI-f1
MANUAL fR~'ts. 11W'r)
5J1lflLAMP
,..,.Mi.,j*I, TIitAH:5MIS;SION [ .elm DIO G~'OlJNC
au 1'51 os aROUND
",. 'I(~,.m;~ illpi~-,l.-I
UHQ'i' Sf'f'[-CI CO ..... ICTOJI
s[N~Oft
PIN I ~O'''''L'''' PARI(
!lIMn .. ",0 NHJTAAl
~WlTi:H I Nt)
11>111 '"

.eM

Pfll"S5 0" 51N50R GROUND
L,TG~Nlj.l CU M.II!4I'5KiHAl
CR.Y"1' <" .5V~E"
1l1lj1ll"i,Ul1 <13 TIlSS1GNJI.L
i8U(.I;52 D. S.(~!j;oft,OltaUN.O
'1'[1.""0 CI. COOUNrT!MP
SIG:HIIL.
()1((;,AH59 AJ( SiGNAl
:11 F'EN'C·C
-CONNECTOR
~1I;n.a,y
(ONnOl Figur. )·26 • eCM wi<ing illagr.m· 2.8L(1 013)

'Ut67 ... H S-2'~n

]·100 COMPUTER COMMAND CONTROL (WITH "SCAN·)

COMPUTER COMMAND (ONTROl (WITH 'SCAN") 3·101

[CM

;itNCCK
" ~ET"'1lO
SIGNlI.lfE:St} j ... prflC.O
cnNNf:~(I~
~. UVlGH ,4.11'r<:.c CONTROL

!INliHUAL TIIIAHS .. S,J.iIFTLAMP

EACSOLlNOiD

.IiCDONI( S'.UUt CC)I'fT'UJl ""aDUL~

PAine lHUTnAl SWITCH CAlf)

E ... ,

I ••

• --- ('R't 41S ..... A. IiGA:

!~!l:OU:N<HO ~ONrROL

.
PPl-4U - '" OXl'Gi!:.N 'UN.S:Oil
~1~"1't.b
~'PUiI II.:B
t'\~-413' '" 0" 'f(iiU. S(NSOi'l (O"'"Ii~gii;
6~OUN-P
p", US 01 MAPGlilOUf"40
,.utI, V8,R.VMGP)
<>u~
CC~ ,
",r"'RNILJ~ en ~~f!:;JGN~L
~k.,.§tii (I' • S;y .Pie.FfRfN(E
OK'IIUl4n ell TP$.~KP:HAL
!M..1<:oiI5l . ., UttSOIil. GIII:OU!IIC
(~..!i.. "VI JrItMG~J
WUS1: 0> StNSOII GlOUwO
(.4.31. Cit .. van
YlL.41a. - ... tOCLAHT1'flIII'IP_
51Gl11Al
OI(G~"T59 ,. A.l(SIGNAL
),Z ;jI'f4\I(-U
CC"hINt'CTOIl ~+-I---

rt'S

(OOLA"," '1I:MII'UiATUJi\f SEI.ISCI:

AJ<.

~3 ............ .__U6i!N6iIi -fh+---- .....

1I1tE5_~ilU CVCL.JN!iill'_"'+ __ _'

5wrrc~ _J

$IRlA,,-OAr ... DUIof;iftomC TISf

S:'W'STEMGND

SlSTlMGNO

CFuu .. :: $IGNAL

[CM

3~1 02 COMPUTER COMMAND CONTROL (WITH "SCAN")

BAn

BUUWHT

A .~ <

"

.A.bl1,III.lAHg ~OM[!.n

FUEL ~UMP ~ElAY O"CUIT leI( RV G PI

ECM

8Z fun PUMP SlGNA_L.

1l jI[HC~D c<l""'(TO~

75J1IiI9 1-7-1117

Flgu;1!!30 - ECMWldng Dlagrilm-4_3L& V8 (2. df 4)

COMPlITfR COMMAND CONTROL (WITH "SCAN") 3-1

BRAK1i SWITCH

PQWN5HJPT COflllT~Ol ~lI!!lAY

DOWNSHIFT SQUNOiO

-rnM ~QO 'tRANSMISSION (C_lLK)

OOW'tll:§lllfT CONTROL RHAY

14""PIH 'oj CONNECf(

MJIIHI,JAI.
TjI,iNfIU,AS' _ J,' TRANS ..
f:":tFtu,MII---'"
~Jt:r'1

A'. v.!tuClE
1!~"jj.7 SPUb
Sl_fI~OR:
]:! .PINC41
CQNl"ttCiOIt
= PIN I ~~O.Niii.'" P'-'I'2J1lgt,llA:...A.I.
SWITCH sic S\MT'H~Af'I"~
'!::1.uG
(llllltll:x(1!;POJP) S})jo8?
Figure 3~l'l .. e:CM Wiri"g Dlil'gram - 04.3!. &'V8 ~J: ofill~ ].1IJ4 COMPUTER COMMANDCON,ROL (WITH 'SCAN-)

ECM

COMPiJfER COMMAND CONTROL (WITH ·SCAN") 3·1(J!

~1.l.pRQN1(; SPoI.lUC CGHnOl MODIJU

tUJtii IlIRIt OR I!-J.I1II[D - ro (NG[H Ii. GJilD. IINOCK

"57 'tE ..... UC Oill"fLl1tIiOO~ ~lI( -----111 It(TARO S~CN.UU;!iC) (r){apr~)

TBI FUEl INJECTION eCM CONNECTOR IDENTIFICATION
Thi$ EQIJIl,Poltage-chart is foi" u!j:~ ':Ii"th. -dIgital vQ'ftma.ter to furt.her aid In dfagnD'i:t~ Thlt vohaqE5
you gi!t may ...,-ry due to low atttl:l'y marge or othe r reas:ons. but th@)' 5hould b.e. very dose.
. IJ:lE FQUO~I!!G CONl:llnQNS MuST 8§ Met BEFORE TEmN .. ,
.. ~nglne ilto~'rating temperalYre • e:ngfhll!! id!irIg I" cJol.d loop~for "engln~ R",n- '!;;QIY:rnnJ
.OI:aQnwtfc teim,irujll Cltgrounoed 'ALDLt:aall"lol,instlltl!!!t:i
\lOlT .... GE \lOlTAG.
~~ . ~~:, CIRCUIT PIN ~~RJR · ·~~t m~~. i PIN ORCulT ·~EJ· FR~~
. to run"" .... ,'-", • <~NI .".N ., 'A.TI.U_\iQt.fS I> ,.
I" !~~ ... ~'~HTt'tI41 u_ T:~~ OF I~"f_ -",- '"",POM. "GOM '0 C!
W ' .. d ,""g. ('0 ~f.. OR I!~~ .. , """,nw •
EJ~
',. ,. ......... ILl "" .. HOTlJSlD
"lIJtv~ '"fi!lNf <$_ ,R.NI I~ ~ I.;;;'. esr n:
• ,. SOON- CO.1lIiOL "'"' " IUJ!U! Na_ftl •
_u_ ,. ;~:" .. .""""n
onl ""0 AT "' N.OTU$ED
Lu_ J..J ... " n • .u 0,. 1e,~~OO .. ... <"-N .. I •
I. . Int." ".u _u_ :fil ... IItOTlJSl:O
L,,_ m I :::g" ;'i1~N"j ... 0 •• l4'W A-II ~f "" ~.~~~~ I.
CONNIiCTOIt
... n 111_ NOW"D
• , mCiROUNn ,-11 ILl(
• • :5YSnM~ROU~Q A12 ;~ '" NOT lJ5'rD
_''''''''.0 '"' ~ ~DI .vm .. ".ouw" ·
HOT""o ,., li I:~ "" 'v .... , •• .-
NOT I, ... er IAC·.·LO n ";'l':'" I,,, NO' """
,n, I,,, ... ·.·HI n -r;:!i" • IWHT o • ,,"nul." • ...
NOT .... , ., .. los l.~r • ~~ D' mo.,." , .. "
I
I.". .... '''·.o"LO lcs ~1~~ur " ITA. DG .R.' I. f e, •
-
I NO""'" 'n ~~~l ~ I ... ", ."'.''''''''.AC · 1.<'1
I, .. , IL' I PI""'''" -"'- ~ ...
le, 0 <"'O.<!r.N" " ."""'"
t'j' ... 1.1 ~~~,~ .. , co, ."
tz, ....... • M"""NA <I "~'N gp "" Nny, <0.
, u~ Ll 1 .... ...,,, •. CI> .... " .n "n~uS'D
5 n, ... - <'-' n< .... n" .nTHu.
__. .~.~~~~c .. CI< GOY ):1 1I1~(:-O m. NOT "un
(ONN!CT-OIA
... CIs n .. .n,,","
11 ,. 'Arn •• " vn,' ". " .. >W m. 1111100.14 U "
, \,I'iII~11I!;f rrom SG W b;arn!!fy 'I,Iort.llg. !:Ilig4n;d'ri9 o)fi .pCl~I'ICJrl l;i'l ,Qm,~ ..... h .. ~t. ENGINE ..L&_
J V"rlIQ1iWI~IIiII2'I'!'If)tMi!ihJrt!'.
j 'I"I~I'1IJ', V~HICLE SrI l'RUCJ( M V!l~
, 1 ~V f!".l 'l'Wa'D("nd~
5 Me'4\Ufedba~{If'rrn.n~iCI] .. n:dJl.ll(l 01\1) 7Sn~
5-1&-8J
- '"JECTOII:

Oll'VlR INJECTOR Dklv'::", (S.7l P~

~I~~R

rfUECTOII; ~lVfR(s...7LP!

(~

.~~~ \!!MLJ th

~rTt::...----------- INtIT"Z3 lEU'

IE'Fu;£",a; ily-P"U

PIUIIIIARYCOIL

U li'1iN(.i:J. CONN_lEcTOR

REf. lOW

FigUfl!: J2 .. eCM Wiring Di8Qfam· tI.3L i!r \f8 (40' 4l

Figure FJ! r ~C.fii Canfle-ctarTerminal End V~f'W" 2..5L

]·106 COIV!PUHR COMMAND CONTROL (WITH "SCAN")

TBI FUEL INJECTION ECM CONNECTOR IDENTIFICATION
This _ECM ,,,,oltag.e (hart is fQf Y:loa wlth e digiliill veheneree ie further iilfd: In,dillgncsi5~ The'l,lClj1'.3ges
~Ol,.i get may uaf1J dut: to lo-w battery d\argoe. Or other reasons. but they '!inould be very doS. ...
THE FQbL0W1N6 C:ONOIi'iON5 M~5T BE M~ Bg[O.' TESTlN§,
• Engine it o:peratin'Q_ 'Mmperatu(e ._Engineidli"9In closed loop(-fOr"gn9in~Rvn" "alumn)
• Test terminal nut glol,inded • ALCL teol 001 inttlH!IId ,
VOLTAGE VOLTAGE
~~~ i~~· n .... IIIT .... ~';R~D 'CK~,t I~J~~A '" t',."UIT ralJ· rRNU~
. · I."" .'M. 0"41 I •• ,~~, O,RN 11 IIAn.U.VOlTS ., I •
I", In !!!-a.Ul'CH ,oJ 3:;'0' I~~ ., CD
-
, _n"" .. I~ ~ I~ ., .... ,,'"W •
I · ". ',n, A. ... .. HOT USiE Gl
·SEA;VI!f;;1 f:N(iINf 'A", .N :~;,I"~N{r,Hl
• " §O(]Jlf~ COK'JItOl. .. WUT WUT A' '. 1.0
I" .. ..... <C' I •• :;:':' I •• .M" .. o
• · I ~~~,\:'9.:!:"'f'" IT~~ "" Ill? U(SiGNAI,. , 5
... ,., "."LnOT •• 8::' In. ". o. Af(SIGJr,I,o,l. I !H1Z ®
I_or. _ •• ~~TI ~ NO'rUS([)
I", '" I ~!!~"1iC"" .. , ... 24 pitH A-iiI O,il; ... tIi .,n ~~f:_!~~L I. ei)
(OHN!:CTQR
• 0 MAP'GRDUJIO ., .... ~. "n'''''"
, • SY$i1i1M GROUND A,lt ~~T . ..
. -" .. " 'I; ~ . .>1 '!.:Y~M'AQ\jHD • 0
• . ~'~n. ,.; ..~
- .,K "' J'Io'RUU!.N , ,
t."" k,.", ,Ar .... , I", "\f:'" P. .OT~~'C
INn, I"'~I I '0"0' .. LT.\'~,"f F • Iw"~ , n. "n.~."'" I. '.IL
I ""T' I .... , l.ar-"A-KI I" :..~U/ A ~~ II::$T!I~A$5
W T OS • 4.7.5
INDt 1".-, ....... A~ I (l I ,. L~.~ , TAoN r .'0".'" •
"" •
I _no"" n - I@
I .... '" 0i''5.[N50R 51-C,UL •
'on, .... no n. .M"""
.•... "" ... ' <II ' .... IW"T no "M,,"n
Ifl' ... " I ~!,.':~,~!. ". .. , ~ nu .~,O«~
... ... _."ro" crt LTGIi. 0, .ant""
t . ~\,m~2. m ~":rUJ '~'I.~ 0" NOTt.IUO
<D I .. v m ..... _. 1m .. ,,' In "",,, .. n
,~,~~Lc, I <>. I" •• TGAN n. w" r-r n •• " I ••
I ""TO"',- (ONNf!CTOK
I .. , 01' ~OTU5EO
I .. · 1 ......... """, i en n DCU o •• lHJfcrru. A " 10
, 'II.Jne .. ~ro'" 60 to "oInll':r- ~Clll.ll'911:! S M~.n'llorC(j bll't""''iII"ntE-itnll'llll~ en IU1.:1 0 .. I:_ CtSi\,l') ENGINE 2.BL LL2
Il PlJ'ltn<,,"~ .oj';, po"tttJ'1I ~IIII! ''"'II!' W",,qo~1 s I.;! .... '~g*.r VEHICLE ~
, 'J'&fI~W.t'" ,,,mpr'.'l\l,'i!' , o v ...... Itn fIy( -cn-
i lI",f'~~ lttlg91i'-~~ , 11 II ..... ~.11.c...--( -o;rl~
. 1 zv i ,!\r rwo W(ofl.d~ G IJ Vwll~ncl'}J,;
7.1~1
·IiUI;i}.5~ FrgurE! ::I. 3Q - (OJ! (onnector Termmal EP'ld vrew- 2,,8L

COMPUTER COMMA"![) CONTflOL (WITH ·SCAN") 3·'09

2, 1\«Cl'Sa-roVlJf IOn .E:CM,

3, F.-CM inpll5senger(Q-mpat~Jn'H\t. oL, COtU<lt!C'tar:s to ECrvt

Functional Check

I Turn ignlricn "ON" 2, Ente{ dlagnosties

A. Cede 12 sh.ould rlush four i.in~~ tlf no ulher !!:90~ are pNrrcn~l. Thi.~ intii(.Ows the MemCo!.I' tl'i [narnlled properl~. und the EeM i!l Iunetlonlng.

B. 1r t-rouble Cod~ 51 eeeurs, or if the ~~rvl~G I!:Y1Ril'le mil.'"' ligflt la on conlitantly wUh .rIO C"Od.M. Ute, Mem-Clli i.!l not. Fully ~tl1tlEd or iii dcrcc::~,i .... 8".

• lfnot runy 1Je":1ted. press tinnly on the ends artM.-E- M~i!i.~C;1I,

.. Ir l~ is ilI!W:S~T)' t!l eerneve the Mtm·Cal. follow the previnua remc .... ul h'l::!ltru(]tions..

ECM Repia(ement- Wit" PROM 80 CALPAK {V6&V81

Figures 3-36 and 3·37; 3·40 through 3-4'1

B Remove odlis(onne-ct

L Negative battery roble Of" [eM B Iuse 2. Connec.to'rS rrom Lbo€! ECM.

J, ~C;U'L Refer lo FiGure 3<3.9 (or:l>tf"Yie;in!: L-hc ECM

E3 lnstall orConn@<t

1. SCM. Inta vei:dll!hl'.

Z_ Connector to t.he ECM,

3. Ne:~l.i ... c bnUQry enhle (Ir ECM B f~e.

.ct PoQffgrmSYlitemCheck..

Figurer 3:-40 ~ EJe"tr-oni( C'onlrol Module (CKI

OJ ~C"M HQUstNC m RETAINER

QJ HI!CT~ONIC CONTFUlL I't,'jPOUU; [!] BRACKET

III .<AT FIlS<R

~igurf! 3--4'1' - Ell!d1tJnic Centrel ModulI! (G)

PROM

R.;:rt-t to fig'.u"c 3-43. (or remcval and ins:tall.at.ion or. PROM,

CALPAK

R,eft .. te Figu.n:r 3-43. for removal and lnata llutdon Qf. C,\ t.fIlK.

IT] ECM HQ"l"~1 N(j leE fil NU GLOVE BOXl [TI ELECTRONIC C.Ol'tfRQl MODULE W AUA..!N[A

Figure ],.41. • Bectmnic Control Mod •• ale {A'll)

3-110 COMPUTER COMMAND CONTROl!WITH ·SCAN")

COMI'IJTEIl COMM .... ND CONTROL (WITH "SCAN"} 3-'11

2. fliftngn PROM l.II·r~ 1M md-.1"I'-tvPtl PROM nllXl"ollr fiKI' Nwn. E~. aM omd 'Dr 1M !IROMl:;lrrilr wn:1'I UIiI I'!oolc of'ftd eIi'- 'lhIi t.ocIol, PHil, elil!'11 1::M Wil11ui ... , iliM u:f u... 1D!:IIl IIfId I'DCIiI '1M II!I"IQ~td .-rNJ elf thl! .-ROM ,1:.11- rill up 1:1 !.If 1;1, pc albl., E~ iN CIII'PQ ... 11 iIInd 00' v... f'R OM ~lIr iIn thIi .. m. 'mlnnrr ;lind mck Ihl' .nd up II:Ij t,1r III l~urDIr. ~Ptn ..nIl ~12" Ymll 'C'lw pnOM t:IInl.r and IPFIIQM ~."._ 'PI tlw :PFlOIIj lQ~P!;. TIM .. FlOM iCl.nl.1f wlt'b .-ROM ~ ft ~Id: Ufl. t1'H 0' '!hi "ROM 1Odt .... ,D:Il.rv_

.,R .......... C:'O'i.P .... K ilt ...,jl.,.i,o _i _i_, Gr,u:p 'IfMI iCALI'AI< arT,. gf IIbii Mrn:!'W !I!I!'Id!~ !>ply. G.n\t" n::d:: thi UJt.,. fturij ii'Id m ~ 'li!fj,ili ilPPrr~~ .. firm ~ MFa.

:5. h'II~~ - rwfl1'W:Mil ·md ,Gf .... CAL!PAI( lCIH"i' jfJd ~LJU", .... Bkk. Do nat. r.:mon CAi.PAI( twm ~ ~l"'!'ltr Uo mnfll'lTl CAL.PAK ~II, ,~tdl ,In c.~..L~"< rr.r. ... r.ta! II:! .. !III ~ !In C!Wtii'f HId ""'Q),

H;tliIIIiI!

(' k.·

;If( / ~~~ ...... "" ••

.

c;.AL" _ •

Ifl. H iii' ~~ OI}i'iI;iQllu iii btlrlj IrqQUKI •• ~ t~ .l"iIie. 1'I_1Il~ IOn tM mntrGllitr M m.1(1 ,WH! ;~' ~ tl'il' ...-nt' 1h'tNI h'i"fltNIId SCM. RIII"VIII. IICI:iIU,c.:IIW!r.

7. I:ftftJI1 ,nOM end CA_tl"P.;1C nrl,llldi" 11i1.-nilCllrROM or ,CA1PAK ~~Ir.g htmjiftf, mlli:t' II.JflI' they h.w,tM -...m~ .-rt ns.mbtr ... '!he ~"nOM o:r CAL!p~IC.

rn iMpl!!~ :(kkrl'll!! 1".,.lllf!IP PAOMl

liON T,"E T!A~ 'ROM '5 'INSTAbl.!f1) UAC[CWARCS .. ~o THE! '!(lNITION fWlTCHTURNED ON. THE ,nOM :!StlESTP,OYl!).

[fJ,II'I;Pl:li"tmtt

Stn.il! ~cf't, of ,~iIf mul!t III .'~~ ""It" .... H n:nch In III)dk n. Pt~ -o_n Pili.OM or CA.LfA_1I<; 'c:arrillr lln~ H n. Ii Clinn1v ..-.t.d in thI 'mdli't. Do JIO~ prlli:II, an 'ROM .. CALP"'~,""";hI _ .

II. JiilliiU 'EOJI ~ ~f.

"'- r~11111 'EC'M[n p.t_f~,er ~~ IlIf'IG pII!I"'fonnl "D'I~G"'OSTI-C CiRCUIT DIECK ..... to' ,t'I)l"I'ilm"ll pm~r indalil't.klo,

Figl,.lr.:: ]·.l . Ser'lo'icing :ECM- [x(.ept2..5L

E3~"~~1_;I:;I ,. £.CY~~_r

m =::;~IIW~~'''-~ ,

:l.1I!IIE_"'Q!o~

rn ~.~~~~W)_H.

5£~~~Ta;:~

~II!"'_KJ(.

,,~,'

-.,:/'\. .... . _r

.....,. / ~ .'

r. .':t-:'-.""'.

:-..._ i:'-

., ... ,~_. ... - " :' -'!"!pIlI"

IEI-.,_·' .

~M':..-=:t~~~~:.&_

E1~iIr!ll~'~""

I ,.... ~I.WI~ CQ~,'IQI ~ t~ ftooI jt!l!

. Crw~.=!r~=:E~~1NM

1~ .. ~

E3Ini1Ii11R~,(fi;nrrJ,,,,,&'l(.f~il' 1 ~BlCl.t.blotoiC!Ioi-CA!"~Iur,

[!J ......

l)'PiI[oIi~l!j;II.~OtlI'NM~LIl'II(;,I;a~

?-L:~~.~~~:!~t~

~,'~5HlFIiiI_~

m_..,;

f'!rM''I!!!r~'!I!III~tlilt'J'lli,l;~

:EUI ~.." 1M M!;WGU. !11itI!l1 IlII Illgii1i1i! wMiolM ~~Nr"III1hil'IIII~MQ.l ~l

H~:~~i~mrlm~Nii!~!M_.

I !

t#fj!~· ..... ;-';;t:~jj ·· ... :tffi,,_~

E3_III!1r;ir~~'f.I t,Mx:4M'_O!IKIoII :2.BjfJ.iIrL~~~~ ~~,~D~~~

3·112 COMPUTER COMMAND CONTROL (WITH ·SCAN")

COMPUTER COMMAND CONTROL (WITH ·SCAN") 3-117

[I] OASH AN CI rOE PAN.el OJ eAA<;.n

[i] RfT.AINER

m ELfCTIlO;·m; CONlllOL. MOOUl.E

Figklre 3-45 .. elea:roo{<Contrcl MOdullflc(PJ

COOLANTTEMPERATURESENSOH Figure ,·46

NOTICE: C.(Ire mu,sL be t.o:kCfli, wnen hJli'Ld lin f!! cQol .. nt. !>ensor. DolmD.Bt! to eMkuu Sensor wi.1I Dff.eoft ptO-per opl!:_l'~i~OI1 of the fuel oi::ont.rol!!r,)l!::wm..

E3 Remove or Disconmtct , Negative bl.tl,.wry eahte,

2 Druin cuullng !j}'~mbelow Iavel oi:s(:fusl1r_ j. Eletl.l"i"=.ul eenneetee rcll!ll.S,l.n:q-llX'king tub .a C(lul.un.t l!ien~r.

E3 In,tall or Connect , Sensor in eng! no.

Z r'~l@(tricill cnrmeetoe.

;j l~e'lll (:~oll.tnt s'y~m. -I Negcuiv(! OOl.ter'Y c'nbl"

MAP SENSOR

Figures ]·41 through 3·53

(lLher l~.o:n C'h~kinl{ r.g.f loo~e nO!'lOIl u.nd electric;! I t!tlnn[!~t'f.I";S, the on.ly serv iee 'pQirsibl. is !,It,it. repfneemunt, irdi8~nC1Si~ !'ihjJw!l,.Rt:fII~r to be rllolly.

8 Remove or Dis·connect

L ~r:ltuLiYl!! rmlU;:l",Y eahle,

Vueuum h~rfi~S D5;5emb1v

l I'~ I eetr iC"u l cnnnector rctees ~ng lodln~ w .. b,

~. BuIL~ t)r r()I~3Se lock tubi> und remove sensee.

E3 Install or Connect

I , Sol L~ or snap sen!I(Jr' on b:rJl-cke t 2_ Eleee-leal C()nR~~t.or

.3_ V..3tulJ.m h!llrnC'~3

42 Ni:!ga~ivf! oo,tI.Vry eable

ITJ COQUINT "''''PeRATURE """"OR

IT] INlET MANlfQl.O 18 391 $-6fi

Fi'!!i ynl! 3-46 ~ Cootiiln't Sen SOr

Adjustment

1' • .\1nve ~he- !'I "",it<h hQI"lI':iing toll the way iowa.i'd "low gw-r" push.iofi..

2, Mova gMr seJ.e(!oor to "park" pesnten. The m::);n hcusing and hous~l\g bu.c:k should. l'MdHit. providing PNJP~I' :::;w~'I..(:h .udjwtment.

8 ftemove or Disconnect

Pleee gear selector In "neutral"

'J r~tl!t'trie;nl ttJf'H'I(:l('(UI'1P_

.1 SpJ'oQ:uj lun~:ill}n hDuo:ill~ and P1J1~ :o\wil'i:h

POWER STEERING 383.1

.118 COMPUTER COMMAND CONTROL (WITH ··SCAW)

:3 Install and Connect

Align aeuenee on swi~h" with hole in shift tube. PI}SlUl}n '1'"i;!.i).fWUm 'J)Ortion n-(~he ~"",Lt..eh (1:~l'tnett<Jr ~ic!l>!ll ~ fl',:i,i'\~ C!Jt.O\i1. ~1119WlGr jfiekiot"

PWih down o,n rront or swtteh to encag-e the two lungs,

:vIo~'~ g~l:..Ir satecticn te '"pof"k'" and sw i ~e~ is "dj",t,ofL

r~lt(;trli;U1 I:Cnnt'>Cw['s.

)WER STEERING PRESSURE SWITCH gll,@J.60

Th ..... i~h is , .. MOd in l~. ,.I.t pi"" of UI~ Il"wor eer lng gear

3 Remove or Disccnnec:t

f!J~tlJ"iCOI 1;G!:'"ectol" i"elt!.l.1JinR" lockin8 wb PGWCI' SW"'l;'j"gPressurc switch.

3 Install and Connect

?i~W(}( 5tct:.;i.ng Pl'e5S~ I'C -swi~h.

EIC'ctrlCii.l cannecter.

[!] QUTr,.jI~:T PJP'E

I]] POWER !iT. UifilNG G!:,II," m 'NLnPIf'!i;

m II'OWtR!3niE:RINGP~':;SSURE5WI'TCH []J !i"'EC:Tl"IICALOON.p.j~"

DIAGNOSIS OF POWER STEERING SYSTEM

ConR£CTIOH

OJ !!LiiC'TRICAl. CONNECTOR rn Oil :PflE'SSLl~'E M LAY

m M;AELAY

r-el.AY BM(JI;eT-

a Ul~U.O CCNNECTO~ rUE L PUMP "~LA V

!i5288i-ti1f

Figure 3,67 - AIr. Ciu(<h Control Relay· (SID AlCGONTROL

2. My fDB.tBi·lo-rnetal mntaCl:!l throug" ftexiblB ooupUng.

1. Them 1> "',.., ooisa In 011_ '_"11 SW.fi!IITIO, Oni DI the mott 03mman is 8 hi55- &,g soYOd m(1si evldEH"ll al :It~sUlt paridng, ~ 10 • hillh rn.qoonOll_ •. Tho_It pn!IfiI~I'l'! ~n ~ry vallie- Il!!'Id r&5lIlta lrnm high ver0c41y 'fMe !)BS&:lng v .. 1'11'10 orifice Bdg6!J. ~ 15 no relalroo .... ip botNeeo this nQi50 1Ii!!!~ ~rfoImar1cB of Ih61 Mooril1(J, "HEss" may bli1i lX~wh:Bf't~ri"Q wf10Bllastil;lndOr ·'r§.~ or wllsn 'Slow!" Iilmfng 61 sta~ll,

00 no! replaca vallie unlS6&- 1lis6~ 1tJ· ex~ tremot~ gqactiOO(ll)lOo, ,.. reoeoerrenr \Otlva WMIIItso .... '"1 OIigilt _..001, ro181"0)'ll i. !:I"i!'e for ihe ObIectiDn.

2,. Nlgn ihe 8teeMg snllfl and g88r '0 thfl 'Iext .. tte coupling rQta.to:s in" iI flat Ilklne .an:! b; n,ot ~l$tQrted BCIi Ih6 iSt1all rmetea

_IoOrCh_ lIoiN In SIeot1ng

-

RefE'f to i"igtll'e 3-67 and 3--6&, fOI" eeplaeemonb of the A/c clyt..:;h COi'ilJ1lJ rt1lllY o-nSlr 'T'rm:.k and M van.

1. GBBI k:o&e on [he frame.

3. P:ro88!!11!Jre Milia LIJuchlng .,.11'1.' "arL'S 0'1 wnlda,

<lc l.J:Iose p:l1man AmI

5. rmprcp8' O'll'ei'l(lunllilr lfdJUEt'lI'N}.I"II, A a.!lgl'lj ntUle mer occur OIl lums ceea.we (It Incr~(~8ranmo.ffl~-1lIghpoil"l: Thisla I'IOnTI8l a~ 0IaarBnce mu~ ~t be raduced b8low ~frad IlmllE. to elimlnato Ihls. :slrg~l rattle.

I. ctmek h ge'.st mounUng bolts. 'Torque lM IlOilO 11> .pedll •• U." e.

2, Cfll'lOk lr"ks~ ~rvol poinlS b wear, fleplaal U rieQas.lIE1iry.

S. Adji;&11 .. h"". po,Hloo. Do ooIl>ond IUbing tiyhllhd.

4, bFQlJe Ihe plbnon arm bolt. 5, AdjuZiI, to ElP8C.li'k6UOI'I:'&,

PARTS INFORMATION

1. Air In !he eystom.

2. Stesr111Q ,,98.r'fJ'lOUnllnti 113IJsg.

3. SI8Sring lirltage iOIrrts WOrn,

4, ftol'lt _heel beanng!llncol'l'Clctly ildjUSIBd CI"

"""""

15. SteBr1fIQ g.8ar Imr:-mpeIIV atfJus.!.ed.

8. Worn or miealng Ql)PPofJl vaj~ ~9jea1'i"!:I

gaB". -

7. SlBBrhg gear llei;jbIa CiOUPIlng 100 1oo!J8 Of' IhB EIflatl or-me ~i disc motIJ'lllng eerer.ve 1005B.

8. Oarne,Qed' or wom 1nBering gear.

L Add 011 to file pump r~~ ilnd blulKl.

Check hOse com.ctD~ '9' ~i' ID!'lIUD.

:2. Tl;1'l1M1. SU~et'illlg bolle. Ip filp9I;ll"*l ~rQloIlil', S. A~lace I~ ~j'ls.

.. , Adjus1 the bWrtnoso.- f8pIacoe with now PlUg ill!! rII!oCesaary.

5. "'~ll!ll to5:PooHtca!oos.

5. Replace tl'l& ~ 'VBl~.

8 Dl8.~ml:ihi BAd repair ij11) itOOM9 9'i.v: aa atI1dntC In lfle UnIt ~ m~uA!.

1. AOluOi In ~I""

2. Repdece 1"l1li 9.99.r val~

PART NAME GROUP

C.pl"ltr(llll!!'t, ~CM •••• _. * .... r ~ ~ _ ~ ••• ,. 3:670 C'lllhl"Q;lDr. Pll0M •••••••••• ~ ... ,.,o ~, • ~ 3.6:70 StO:-l4'ir. CooJuftl T(:tll~ .••••••••••• ~ ••• r 3.670 S!!'nI!i(j!', r:::;:<n:o,u::;I._O~,\I~"n ~. ~. * ••••• ' ••• ~ 31370

Scnsrrr.MAJiI ~~~_.~._ . •• ~ •••. , ,.3.610

S~nSflr. Th'rottJe Position· Purt'cf

SeriMr KtL.1'hroL.U-e Poetuen •••• ~ •..• ~ j,. ;] 4-.tO Swilck. ~,;p"r,.I 5l & Backil'i~ LP * •• ~. ~ ••• ~ :i!:.69-S

"'o'd. L.ucio Tl> 0.110 _ Or Tho 01i>0<

(~ln_TIoo _And_

c.,ndltlOn.l. 1M! TIM \IoIr .. ,Going~ _Dl~On'" FioI_.

1. F"''''.nd ,,"UBIV>ed.

2. UMoalanaxi 51gering gem vS;fV.I. II .tris Is cause. , •• ertng dort wilt ee very 19m. n dl· rectl~n o. le.d and heR",), In 0FI1;)O:!II!!1B tII_>

3. ,SleOmg .hl~ ~ ''''' [0 01 tI'lo wah

4. =~ inkOgo> "0' "".. \

3. Allgo the oolUrTIIl_

4. Adjust as raquired.

IIonwntrrry 1I>OIWUO In __

'lllm1ng __ 1

Qolciol)' 'to 11111 Righi 0. Loll

1, low oli i~. in 1i:1E11 pwmp.

~. 1'0"'1> boil :I1lpr;ng (~ USO<1).

a High int.mal linkage (S:le$(lng g8ar or purn_l·

L A63 ~J' staEring fl'Uid as r.l'8a. 1. TI;:l'ltotl or replace bat ..

3. _1o'P_rSleo<ing ~'I' _.., 11>1$ sOdiDn.

.~IL

3B3·6 POWER STEERING

POWEER STEERING 3B:J.

DIAGNOSIS OF POWER STEERING SYSTEM (CONT.,

CORRECTION

DIAGNOSIS OF POWER STEERING SYSTEM (CONT.,

PROIILEM

PRI)I!LE:!I

COAllECTlOfI

POSSIBLE CAuse

I ~ Tlra 1Ifl(Jal·lnfJotOd.

2. Low9l' eoupilf'19 nang,t I\Jbbln_g 8gein!! the S[BIIIring gMr adj1Jst., plu'_

3. meeting wheel ~ agel"~ diroctiO!'1;lt

signal housing,

4. lldllor frozen st98nng ~haft b8i!rlIlQII. S; Stoor!ng linkage or ball Joints o;o<!Irtg, fi, Sl88ri:ng gear to column misa.!ignmenL 7. 118 rod plvota no! centralized:'

1:1. lack or tubrk:arlt In ,he eusoenston balrjolf1IEi 111m. the !illeerfng linkage_

B. Stlci<y or plugged spool """'e.

'0" l=iut»et:s:~rblndilllJrflt1lBl!illlfttLJIJEI,

11, Improper rtont 16100 allgnmml. t 2, T~hl ""ri1ll "".11 boorin!l.,

13. StBflrfl'lg 08t1' 8dJusted too lightly.

14. Kink Ii'! t8lum hose.

1" I"rlalo ~o sped1J,", pre~.e:.

2, loos.en tne pinch boit .nd a,semble P'_r1y·

a. ~U'" the .. ""ring J"""""

..... OIiP......,.._ To .Md"!l:Ii GNr~ R.rTo"Pawer _ngS_tp,·

'" Ttl •. ' Soc:Uon.

4, Aep1M. ih. bbariAg$.

1;. R.p1ao. mo aff.ectOd ~rt$. S. Afign me $I:(J8Ang oolumn.

7, MjUS1 no rod enCls U rOCllJ'ItOdi 10 centsr pii'lcLii.

8, lJ.II:Jrical8. ReJl!llr to MAlNtEN IlNCC: ANO lUBRIG~TION (SEC aBI,

g, Rema'la and cleM or replace tlMI vel .... ,

10. Make oertaln tl'Mt epecer tB pmperly Sr3atoo.

Lul::M1C1lta Inslda the .cllame.1er wilh i!iIlhtio:~ k.JbIi!::BrJt

11" Check and adJust 10 iSfl'BCl!lct1UooI!i. 12. fliepIscB ~8 be-.artIlgEi.

,~. ,A(jJUSl ceer-ceme, and thrwiil bII!IilIil1{l rgo"' bad 1'0 Bpacl~ic:stlon!i,

14. Plepj8C8 the hose,

LowOIl"""",,,," .. ToS_gPwnP. RtNr T!Ii! "Poww S_ng Sy"""" Toot" In lhll .s.ctIQ:n.

-ngSU",",-o._

""""1Um."g~ EJlQI .. lWnning ~IaDy_lna

"""'''9

f Low 011 level in po!Jl'J1). 2.. lOose pump boll.

3. Sticky flow ocn1JOI valvO.

4. InauHD8nt pUfll) prnsut ••

POSSIBLE CAUSE

'11. Pntssure Io&a In cylinder clue 10 Worn plitoo rlnll or soorBd hoU&Ing bore,

a. l.cIllkB!JfI.11le \!aMI rings and valve ~ to the worm seal.

3. 1...allkage et the vaNe body or a. 10000e fittmg secct,

4. Oamaged poppet valve.

I, FkJ'tN' coo~1 .... alvEl :Eiluck Dr' IrKJp9ra.flvB.

2. ~~r:8 pmte ren flal ~Bin!i! !he earn ring,

3. ~remi!!l wear IX cam n~.

4. SC:ored pregSIJr!e plata, Ihrtlsl plats 01" rotor.

q.. 'llSnes 81ick1~ lin rotar !JoUl-

6. ~ rollnBlelled ~rDp9rL)r.

7. Alp In oil.

8. lOW Oil leVa!.

9. '--"_

10, DemagBd' ho&B!i Of steer1ng 99.11f.

1, ~mb:!i Illiiloollng iUrD OU1J!ned lfi<tilfi!l_"ffia""'t i>OI>O<IlM!'!1g. -OV ..... A.pIiO. IIlO 'ffootod """,

2. ()j~miigle 5-teitfing gear and riP-II &.ttaI5.

3, IlOpIaoo the YUM;,

4. IIoj;Iaoe Ibo POpPe' vii",

1. ~crele.ifilh9iJBJ"".

2. Repl8.C9 r~ pres:r;Ur'Ci -piQ[(Jo,

:]. Repl8.C9 and fk.is'h ItJe syst9m..

4, RopIaoo parts. 111 mIor, "'I""'" wilh '"toll

~roop), Fh.J:5h·til:ea)l6tBm.

5. fd'QB'l,jp.~ removlnlJ burr.dl. 'll'Ellrnl$M 10' d

6. ImlaJi p:rD~y. RadiUJil ~o 10 1110 OU!sk

7. LDCB[9 SOOrt!9 cilBak lmd oorrtd.. SI88d t

5)'-!iI!1JfTL

8. Ac:ld PO~f StBlllril1g "uid .as: rtJoQutred, ,9. Adjust tMIs10n ID IPOcifiClltlOn8. lo.R~liJSn~ry,

ctllrp No ..... SIN,I", pump

1. .A«ust bI8t tensIOn.

" Add power &taeriJlg IhJkt 5B rBqulmd. 2, Aqust tenaloo to specHlc8tion.

3, Fteplace or clean the oontrol vaNe,

ill. Reforto-Power Steering SY6lem TNI'"ln tiiIJ section.

13. Reptaoe LM gear relief vain,

_Sq 1

IPortI y

NoUOHb. ~t ,",Ull _llt ....... 1'<1 _un PIJIdng)

1.l<Ioa'" fO!llricllon..oo oom!cL Rep""" PIli neceBB.Bljl,

" Low tire prG$Suru.

2. Lack Of lubricen[ tn ~~nBIon Of ball jotn.t&.

3, Sltll.,~ ~ to cehnrm mlsa:llgllrTl6rll.

4. lOOt. pump bell.

5. Low ili,liclleve~ In reeetvclr,

1, AdjUEit the- lire prea~ •.

2, LlIi:JriGaie.atld reluClric&t!ll ,,, ~per Intervala-.

RlJrur fo MAlNTENANCE ANO LUB~CATION ,SEC, OBI,

3. ""!lin N Ilileerir'rG cob,urn.

4, Millo! boll 1",,_ 10 OI*I!loollo ...

So F1111Q1 JJi'tJpet' leva!. JnelpecI [OB and Jalnls- reF ... 1.maI_go,

6, R.I.rlo"_.rSI.orIng SyoIem'liost"hlllls ' 5DCihiilrl.

7, Re~liilI;U (It (li:tlan U'lo w-tth'o.

B. koaaen iha ]J~nc:11 ~ou ;!!Inc!' aassmbl., pro""rIy.

a. AdjulSl ovBM::lJflter II~ lJIrwt bewing pmload 10 apocIticaiioo a,

1 C. Check.and adjust '0 6pocifioeJiQn9.

1.~beIt.

r. Exces.;slve IJBck pr-lilHunrln roaN or iStl)Orlog gear caused by rMlrie1k:f1,

1.~1~iillflSIO".

Growl NoI .. ~~

S ...... '" Pum,P! IPorII<IItWfy NoIrootOlllO ... , Silndldln Pdlng)

s. !irgn In[lrnifll 1e;ll.1t:S-!:lEII (s~e.tuinQ Q6Iillf '11 """'Pl,

I 7. 5tiCIq IJOw QDnlrd valve

8. LowBrIXliUpU~ll~nge.rullbing;Bglllnsl'a1-Bep jng gear adlU"8r plug.

9. .5teafIng gear .dlu:.nod 10:1 dglit.

10 Improper from end Qugl'lJ"l'lo0nt

t. Scored prtllS6lJlB pla.t'8S, lh~5J 'Pfi61e Qr roio.r, :!, EXlra:rne wear aill-itfi f!i~,

+, RfI?100a parts and flush .sy.m.m. 2:.. ~iI;ip'lB>CB parts.

GlIOI..,1 Nol •• In S1M1'ing PUmP'

1, "del power s!aaring fluid illS, reqLllrtJ:d.

2, ~ tl'li& ~_nnector. ElleBd 1hII11'5t0lTl.

I 1. l..QW' 011 level ..

2. AIr In tn.~ oil, POOl' JHtl68UJe OOSBcoflJ'1edJon"

RotIIe 0. Kn_ NolulnS_rlftI Pump

I'o-.glltlll<y_ StMr1ng fluID; Low l..nwl And PoMlbl8 LIN' PrUsUNli

Swltt! ffoIft In $1Mir1!1g P~mp'

...,. Oil Pr.a:ur. DUe 1. Check for king Ino too ~B,

1'0 fiHIrk:Il:oo tn Theil 2. Foreign Dt.jed sllotCk In ttM!I. 'hIJso

-

Alr In dle 1luld. and lo5sol IIulci dl.iOKt jn~mw purrp leakage ca1J~fl!J O'Y'UrlIo_",

Oileck lor leak and ~. ~ syslsm. Extremely cold lemperatlA'ol w\ll eeuse sys. tem aeration sholoAd tho o!! !evel be lOW. noll 1S'le1 is oorrect and pul'!'lP !J:t!ll 'oari1s,.riij'iI!.IYI pump from veliele and ,t~B.ts fSMfVQlr 'rom housing. C1wck P.P@F'~D!1 plug' jiilld I'IOIIJsi"Qtorcracka.1r pj!l9liJ lQoseorhOUililg 10 cracked, rep"" l>oIoo!og.

Wh",,,,,,,,1n ~pgmp

1. AamoVfl 'the' klr1k1 or rIP1gpe the 1los8 .

2. ~emove lI'IliIo ~Igrl otII~ Dr r-aptBCt 1i'IIlI hCI58_.

1. loose· pump j)tJlley nut, ~

2. P\Jmj:l ViMt 1!16ctMg In roti:lr BIotI,

3. PrillUfQ ~O" 'CH)ching Oth-8f parts of _,,"

1, """" .ran,

2, Frse U1' by relM!J1l'Jg bUf1'8, vwnlsf1 or ~ J, NliOSl ""'" peoItion,

\, ""","",,1""'-

i , AepIsce the hOU!iing BOO _haft. Flush I 0)'01""'.

383·8 POWE9 STEER'NO

3"3·12 POWER STEERING

FLUID LEAK CHECK

BLEEDING THE POWER STEERING SYSTEM

1. With h et19he on. wipe Itie romp .. ., power Bisating S)'tMm dry (gElar~ pump. ~, and connedm&J.

2. Chock Iho nuld 10v.1 in the pump , .... ""'" and a<ljllOl as di~ In ~FllJkt Laval Adjll&tmenln in 'Illis section..

3. St~i1. D'i~ .flrtgJnI!I and "turn IIhB ~1(!iAtlnv wheel lrcm ,stop to stop M'¥'fiirall~m,". Do not ~d .he W!1eoel Elga.ine.~ the ~ u, this may dam:!lgd tne PlI"IP.

4. And the 8~acI (UB85 of j(!i1kage and I,I~ the rBOOm~ mended method ·of repair as snown In figwB 5.

POWER STEERING SYSTEM TEST

Tt:e pDWef steiMg :fY'§l~m may bel lested I.$l~ E!lthilr J S17ll-D P<rwer S'O.ong Gago .r wiU1 J 25323 Power Steering Ai'lBIy-Z:M, J 2~ wijl fI'IQ-~(O the flow rate In odd1lion to lb. ~ .. ur. (fI'IYfO ~).

The r;IOwiBr :MQ:8rtng :S:~lem 1BSt IS u&&d 10 Itjen1ily and 1w1.te l'lytirauUC dl'ClJ~t dltflcblltle&. Prior 10. ~erfOfl1'lirl9 !his- 1 .. 1, tho IclloWlng InspeOlI"" 000 "'''''''''''"S III ...,.ss.aryl, ",.,.11)0 mad •.

m In.,,-

Pump reservOir lOT proper flukt lavel. Pump bill\' lor propat te.nekm.

TIre, lOr COfl'&Ct 1M' Q~ure_

~er !irtasringsystem. repiaclng part.:; M n,e(:6513ary.

ill l!11f1Drlant

• All t&St8 are made '.;.>Ith the 8IlQlna idling 8t ngnna!

Qp8f8ln,g lamperatur(t, Check the Idle spe:ed adjlr.llSirn.9(I.l ,W. II necessary, 8dju~1 1.0 tha carr&e1. s~lli- 0111100, Ref ... ", CARBURETORS (SlOC.&C1).mllhe FUOI. DrJvesbm1y &00 EmlO8lon. Se",I"" Msouol,

'lEST' WIDi J 617&-0

1_ PIBCe I!Ii conUliner under till) s1~firlng gaM Of pump fa catch ,he fh,Jld when discon~til"lg or' conn~ctl"S Ine _,

2. WI!h 1M ."grne OFF. diSO:lnl'led Ihe pre.s:;urtJ ho~ iii !~ st8MnG 91l1sr or porN&f .I:eellng pump and _. J S1n-D to bod'I _ u9lng adapt •• fll1lng

J 5176--20, The gege mw:1 be betWeen the Shutoff \I'~""D ~nd pump.. Opeon !he ShUtoff ",.tva.

a, _. Ih. IIIIor cop !rom lho. pump ", .. ,,01, OIId check Ihe ilukl leval. Flit the plJmp reEi-~Ii"YOIf' Wllt\ power sll!Elring fluid io the lull mark on the ~tp5\iCll:, Sl8J1 t~ engina and, mQffiEInlwlJy l10tdlllQ the 5'90r· Ing _I agaloSltho """" tI18cI< 111. ",,"',_ 011 J 517f1.D lor iOakllgo.

rn In1por1ant

• 00 nQt i'lQld 'I.M Wha-el r;rgBins'l too 'stop 'll;Jr moro lhIIIl'I G ~ ~ the pump ea.n be damagBd I_V·

4, Bleed the system. Refer to ~Bleedlng 'nu Power S!eer1119 System- 111 lhiS s.ectk:ln.

S. I~se:rt tht;JlJ1'Klmeter J 5421..Q:i! In the re~rvolr IiUer opening, Movs!he sh .. Hng >liMe1 from .top to"'OP several limes until the InenflOfTloter indic'ates thal "'Ie hydrflullc: rt!,Jidln l~fI rssEJfvOir !las reamed " 1~n1pUf~ ature .tes I.~ 77 dogr ••• C 110(1 1<11711 dog""'. f).

m,mpofUlnt

• To prewnt sa-LlDbing flal .spots 011 the tir9!i. do Aqt rum Ihe steering wheQl more lhan frve limes withoul rnlling lhe vehicle 10 chBrlge the tirs·tor 600r Don~ erea,

6, Cheock LhoE;! pump flurd lillfI9:I. AdO power .sI,e13_fi'ng ftuid It ~ulred_ When [he enginQl ~!I !III l10rmal operating lelTlper8llJrB.j the inftierl Pf'KSUfl 00 1f'Ie 9age (villV8 open) Should"" In !he 5500860 kP. (80-125 psi) mAge. II the Pl'8!1!1UFB \6: tn excess of 1-:380 kP-.a (200 pol). oI]o<k lila boaes. 1o r res ,,;otIons and tho pcppol valve faf I)I"Qp8f aSSflmbt~.

NOntE: Do INU hNi ... :s .. IIJ!411 full)' eiDSMIIrH mo,,,, Imn 6 HCdndlJ IHI (1M pump eouh11Xt ~g.N' m,."..JJy.

7. Open and (lIooQ ttllJ 9MB vaIY8 fully J Urnes, Record tn~ ~Igh.e&, p~~reB attaln.m aael1 time.

• 11 the pra!t6UfIEIs ISOOrt1OO arill.~lthll1 t'hs sp9clrl.

C811one: at the end of this sectlon, and the range 01 re.aljl~ is wi1hin 345 kPa (~ ~s:i), the pump Is l\lretionInll wltllin aplc:ifk8lion!;t.

• II 11M> "", ss ur.s recordod .... high. btiI <10 .... fepe;eiwlthln 345 k'Pa (50 (:!iiI), [hl1 flaw -control VI'II\'6 iPiio sik::klng, Rtmovi! lhiill yQJve, c(.;);an it, artd remove any burn, LJslna. ~ cloth .or '" 11 n,e lu;ma, If the syS"!efTl «!In~rns ,&omG cllrt llush It, ~ it is .xooptlooa!!y dirIY. !><>III "" po<mp and Vetlf muEil txt completely di~i~mb'ed, cleaned, flu.hed and r.a...."bfod betore fIg-

---

• it Ihe pn3~s f900rtled are COflEt.lI1tbU1. mtW'e

than. 600 kf"s (100 psi) below t'he- minimum listed 6lpediiDaUcn, rgpl~Ce tIl'a l1c-w oor.trQI va1ve 3~ r4;!lcl1e(:k,. tp tho pre5Sl.ll8S.ar'8 stili k)'w, fepLeee the rrnaUog group In 1he pump.

8. IT 11\. pump checks Wi!hln opoeifIo ....... < loavo1h.

ViiIv.6 _o,pon and tum the st9!r1ng wheel \0 bOlh stop!i. RBCOi'tl' lI'IiI blghe!;ll_ PIEls.!Uf9S Bnd compEl19 wllh !he 11iBX"1ffi,i,J:;f'n PLlml=l pfe:I1I&ure raecrded, I I lhijg: pt9S!IH.lre ~f1fiiH bo b4Alt," allhe-r (01' OM~ .st(je Oof the g:e!lf, the geaf if; klakjl"j!jl Internally and muSl be distl!;:~ernbied and fapaJroo,

9. Turn the ong:lF'e oft, .remove the: lesfrng g •• I'OOOrtnsct Ille pressure hose. chook h Rvid level arKlfQr mak&l lhe nerooo repairs.

1~. II lb. P<OllIo", stili .><lslfl, lb. 51 •• nOp 000 1TmI ~ pensj;qn mlJtL be tt!QrOl,lg,hly 8)t31m ll'led. Rgler 10 '"CiBgnOsli 01 Power stM,lng :sy!::temn In Ihla sectlol'l.

Wl1en a ptiW(lr "'&81'1"" pump or gEl8f .11as bEen removed or '111 gil [jn$ I'lAi!1 been dlseonn.ect&CI. the aIr IhaJ has Jililliter"ii'd tI1li1 ~:t~~m must De baM OU! before Ihe vehiclE Ig operQ'~e4. II :p.ir is. atlOWElllj 10 t~malrl ~n tne ptWIEIf S1eeriR~ n.", II/.t~m. ngi"JI on<! ..... 11".""'''1 """,aU"" .flll. sy.' tem IT'§," re!!~II" Blaed air from Ltre Mydraulk: system as folio"",

• \ftIhen bl@edlng Ute ~ya.tem. and any Ume Rukl is 8dded to Ole power 5teoa:ring sy&tem, be sum 10 use only po-w-er Sle:erlng fluid as r:,:pEKliflEPd In MAJN.iENANCE liNt) L.UeRICA'nCN (SEC, OBI,

1, fill1.M pump ilukJ re5efVt;Ir to the proper 18'1181 and lat 619 nule! sma for al leaSi two minu1B!i-

2. SlarllI1. <>nglne """ 1<>1 it N" for. tvw """,,"<is. Ib.t; turrrth.l3"",ng!M~.

3. Add ftuid ~ n"",,""'Y,

4. Repeat the above proC8dU1'9 untl! !hlll Uuld te v el remClinl;l- ClJmtaf1i aHilr runnil'iQ iho ong1no.

5" RaI,* 1i'1e front 01 the ",ehiC1a so Itle w"ools ani cfl the grwJ>CI.

6, St81'1 the engine. Sk)wt~ ium the B1ee:l'i1\g WMol rlgt'll HIId I.~. lightly oonl.othg !h. _I olops.

7, C~,*!JlQ fh,rlo ~ev91 and add lIul'd 'II MeeSs:m.ry.

8~ LO'Ner the ve~icI.e BIld jum the &l:eefing whcBlI siow1y lrom lOCk 10 lOCk.

9. Stop lhe eng:lf1e~ Che<;k tniii' lluld kfoiet1 aM flllill asreq"lrw,

10. II tn. IlUld I!II ,e~trernely fQamy, allow 1"18 "'eh~ to :s.ta~ a leW' mlnUfe5 limd rgpe.al :the :above prooOC!ure.

Il!1trupc1

• Beli. for proper tene:lan,

• PulJey lor lOOSe"ess or dema.g,B_ The JM.IUBy JhOuld !'lOt wobblB w[th Ine e"Qlna running..

• HOties so 1!leY Bf& not toLiehlng I:Iiny other pari:B Df uH. vanide and are properly socur6t1.

• Flukl leva! and tIn to the prop!;llr level

• Fluid for 81f. "present, blt;ed ~ system is, d~cribed ahov •.

FLUSHING THE POWER STEERING SYSTEM

i. FIaI ... !he In,"1 ot Ih. ml"l. oil Ih. 1J'lI""" ""t;I "'. w~~I, arB freteb turn.

2. Remove thg fluid rnrul'l'l Ijf'llft at 1M pum,p jn&et cormaclor 8J"KI.plug 'the ool'K19CtOr port on the plJ~. ~Oo5ilion 11'10. II"B' toward a!iUlJo a)nlain!llr to -catch the draining nuld,

3, M-.ils an assl.sbm1 is filling Ihe r85e:tvolr iwlUl ~6W powBr steering 6t.Jld. run the engine at Id~e. Tum the ...... Ing ..-1 clos. to .. oil .top, 00 NOT _Iact _ ",01" or hold Ih. wheal "" ... slop pooiJloo or nlJ5d WIlli stop and 'the pump wiil be In pI"e8liU'~ rellot

'mod.a. A -:!udJj~ ... ~1i11ow 'rom tM rMr8rvol,,' mi!l~ dalJalop if II'IG wnl!!i!lt t:a I'H!Iild a! ,a, -Stop,

4. Install all Ifl,e line,'. !'lose, and coropcnenre ilf removed) OIl ~e vehiCle, fjtJ !he sysrom with ~ pOW;8r steerIng fluId and bleed the !Svstem {III} •• ..,.bod 10 -SI66<llng 'Tho POW01' Sloe.ng SV>lom" In this section, Op9_,flt8 thlBlElIn!jline tor aboLII 10. rnlnUIB!:. Remove- [h!!l pump relutn Iknl9 .at thB pump lt1lel and plUV !he o;mnec1ion on the pump. While rdlh]Q Hut reservc!r, oheck the dreinln9 fluid tor <OI'1.mln.lloo. If lora]gn malBrilll is !tlll evjdent. repla.ce an Ifnes and disHS611'11:Ue a.nd .alean or replace t~ po'IVct" stoo,lng systom com-pon_er.ts. 00 nO( rO-IJ89 any cjrakn8d ~r SlMirtng 1luf(l,

STEERING GEAR HIGH-POINT CENTERING

1. Sel tne lrorrt wh .... " "'" SI .. lght ahead po.'ion.

This can be "".""od by dtMng the vehlct •• "horl distance 01'1 a 'ilal st.rrlat:e.

2, Wllh the lrenl Mi ee I ••• , .1nI!\1h1 """ .... on"". lhO poolll"" 01 the mall< on 1!1<> WQrm"""~ d.'i9"~~"11 o1o"'lng goar ~Igh polnl. TIll< mark """'Id be 01 Ih. lop .Id. 01 !h •• !>aft .1 tho 12 .'<look pos!tJon .n<! Ii ... up with II •• marl< In til. ""PI!"" ~ cIo'llP.

J. On fi. G ancI P-Modltl •• ''''PI P30 ,,11h RPO FS3 I~OOBm 1ronl aJ(te. II ms stee rtn~ year h85: been iTlov9d 0" high poInl when :se"~n!iil !h19 wheel In ltIe straight ahead position, lOose!" the adjuster tube oJampo on bO!h lho Ion aM '19'>l hond tie rod e, TUfTI b04tI MjUSl19f wbos an equal number of turns In ths samfl dirodion to orlflg me 968r bA,ck on high pc!lri1.

m Importonl

• Turning tI"IO adjuster tubes an uneq~aJ numbler or twns ol"'n OiU.renl direotlorl:' will disturb the too settinG til the wheel".

4_ On V and P30 mOdelS wrth APO FS3 t",boam 'I'OI'1t EVd8~ it the gBCi:r has btittn nlOV6d 011 nlgn .pclnt when satling thQ wM~1S In Iha ISlraignt anead posrtIOr'l. l'ooBI3fl, 1M ddju-shl' lLibo Clamps on Ino conneatll"lg rod_ Tum ths .tdjus.ter tuoo to bring the gear back Q1 high point

S, Ch..,k and adiu.t!DEI, RBI", 10 FRONT END ALIGNMENT (SEC. SA).

8, RDf4! 1.9TEERIr.lG LINKAOE ISEC. 3Bl1 I.r B;tf]Llirer liuM l:lAm~fng IflISo,ructlonl_

POWER STEERING GEAR REPLACEMENT

B A,ma,,! .r Dt."""~ [FlgureII 8

Ih'Olllln 13)

II Piar;e II dJilln PM1 below dle- 61.earing Qsar,

1. NegatiV8 batlBf')' cable,

2. Hoes'rom trlB s.1ilering gf!W, Raise ths t\OM: up to ~,enl oil drBii'iage.. Co~ or f;fU!!e Itle t;I'.~ 0'1 the ttose 000 gem fiflng< to pro.onl Itlo .OVW»O Qf dot

POWER STEERINO 3&3·3

SPECIFICATIONS

STEERING GEAR ADJUSTMENTS

""I .. iIoa<miJIy /\rod Se.1 Dtoo ...• . 0.1.0" N"" 1'" In, ~

'IilMl _1111 P- (In exo... O! \IaJvg _blV Iu1d ""., Dr>;) .....•..... , O.3-Q.' N''''' (!j-<I in. t

Plbrllin Stlaft Ovar Cetlt8f' PNbad

NswGiUIif' 00."'.' .~ ••••• " •••••••.•. ". __ • __ ., .. , ..... ,... ••••. . •••••••••••••.... 0.5-1.2 N-m (6=-10 In, It! ~~ ••••• , ••••••••••••••••.. , .•....• " ••••••• "." •.• ,' .....•• , ••••••• , .• , .• O.4,o.5N'm(4·5Jr1,Jb

Anal 0.., Co .. ", ~'0CI1ng (lbIoJ'Moximum)

-- .

UsIlldGear ""'"''''''

TORQUE SPECIFICATIONS

.. ~N·ml'8 1C

........... , .. , . 1.6N-m (141".10

S~~ Gin! TO "rams •.

HgI1 Pn...o.. WOo f9Ui'Ig I'" G~~ ,

Il!I RoIlO1l LIM filling (~I Goor) ,'

PI~lnW' Slwfl AdjlJlSiB1' 6Grew JEIiI1l ~ __ . , ,

Sfde Covj;j" fc HOUSJug BDtI .•• , ,

_stori'll>;lN.n .. . .

_'Ila·I !l'tJmp)......................... .. ..

Flow COOIrol Fhllftg I """,p) .. .. '

_ Hooo("'l'Ilmp) , , ' ' .

_, s-;ng Pump. To Boost .. l.... • .

800stBrb GSBrUBB._ ..• , , ••• , .. " 0 ••••• , 0.'" ••••• _, ..••... _ .•••••••••• , ' ... ,

Return lileAt Boostw AnO Gear •.•• , •• , ..••... , ...••..•... _ ..• _., ••• ~ •••• , .. " .••.•...•.

CoupIOig Aq. ""'" , ,',.,' " , , .. " ..

Co\.;>IniI~.pjochBoH , .

..,..", Iniennodl." Shaft Pi_ 8cl1 II"'''''''.Q , ,.... .. .. , .

Uppar mternlildiate Sh:aft PInch 80h (G-MocIefJ .•. , •••.•. " _ ~ ••. , .•• , , • , . , ••• , •.

~LaIB Shaft ptjctL Bahs: (P2O + SOI.4il1 E"JCctudlng fS31 • . ....••••.•••••• , ••

In_LaIo Shott PIncl! IIO~. (P30('2)Fs;l1 .. " .

lOAQUe

34 25
47 ~5
00 ~
11Q '.11
4B ao
.6 as
27 20
.. 25
3-1 25
3. 25
21 ~
.2 31
62 4Ii
.7 :IS
102 75
10e 00
.......... 3&3·36 POWER STEERING

SPECIFICATION·S (CONT.) PUMP SPECIFICATIONS

MlnlJMlffI MBlIdmum
Oup.' (I) OutpU! (2) R.11Id VIIwa s.ttlng.
Pan M1nimum MU1mum
Vehl ... Number Modo! Cll'M WIlli n, C;PM LiMIn. PSI loP. PSI kP.
71!3~~ '3~-P-'_~ 1,3:2. 5.00 9.1·9.5 11;7·192 1200 827' 1300 8004
7831!!134 132-P·123 L32 5.00 3.,·3.5 11.7-13.2 1350 83M 1450 9Il98
78JE19J5 132-F!'·124 1.12 5.00 3.1-3.5 11.7-1:1.:2 1200 8274 1300 6964
7eaE1aae 13z-P'12S 1.32 5,00 S.1·3.5 11.;·13.2 1350 93011 10100 9998
7!1:.l~7~7 1~-P·14~ 1.32 5.00 5.1·3.S ".7-13.2 ,35g ssoa 14SO 0_
78:19798 1~P·I44 1.32 5.00 3.1·3.6 11.7·132 'JaO 93I:lEl I.SO !l9QS
7_799 , <Ie.p. 1., I.a.. 6.00 3.1-3.15 11.7'1:3.2 ,aSll 1006 ,_ 89M
AN 7!1oJ91loo lSH·He 1.32 5.00 3.1-3,_ 11.7:13.2 1:<O1l S274 1300 89e<
M<>IIlI 192·P·1-4'l 1.32 S.1-3 .•
7~~fIIl~1 6,00 '1.7·13.2 1200 827' 1300 Sge.
783QM2 132·P.1<g 1.32 0.00 3,1-3.. II ,7·~J.2 1200 827' 1300 89~4
7M9004 1:l2·P-15l1 1.32 5,00 3,1-3,5 1 ~ ,7-13.2 1200 fIZl. 1300 8ge_
71l31181a 13H·,59 '.32 5.00 3,1-3,.5 ",7·,3.2 1350 jjJOO 1~00 me
78!l\lll'Q 1~-P·1B1 ,,~ !.OO 3.1·3.5 ; 1.7~13,2 1~50 , 9300 1450 99~8
7839818- l:i12-P-163 1.32 5.00 3.1·3.~ 11.7"'13.2 1200 827. 1300 8\lE4
20000518 '3E-P'~!lD 1;12. 5.00 3.1·S.5 11.7~'3_2 1200 827. 1!lOO -
78'1731 Isa·p·2Z! ,;12. 5.00 S.I·S.S 1\.1·,3.2 1350 9300 1450 9996
G 78'2049 132~P-22B 1.32 5.00 3.'·S.5 '1.7-19.2 .350 9308 1450 9900
Modol 7847618 T11a.-Pf~ 1.1.5 4.35 3.'·3.5 1'1.7-13.2 1350 9308 1450 9900
7841;229 13Z·P.,,$i ,.~~ MO 3.H.5 1',;-13,2 ,350 930EI 1450 9900
78S[lSQlj ,:)g.p.,:;.) 1.:12 5.00 2..4-2.e 9.1·10.8 '200 827' 1300 .....
7839800 132·P-1.5S 1 .. 32 5JlO 2 .. 2,8 91·10.8 1200 8l!74 1300 allS4
183Q8~2 1 J2·f!'-, sa 1.,32 5.00 ii!:,4·2,,1Il ~.1.1[1.E5 1351'J B30B 14SQ 9996
:7E138B1'f I i32·P·11li! 1,32 0,00 a,4-~.8 'EI.,-.~.~ 1200 B2:74 ,MO 8964
P 7~21)~ I 1~-P-226 ',32 O,CO 3.1-3.0 11,1·13.2 ,200 8274 1300 89B4
Model 1:3:2·P·227 1,32 11.1-13.2 an. 1300 MSO
7$>.0:)3 0,00 3.1-3.,fi 1i!OO
784;;469 1:32-P·23Q r.aa ;,0lQ 3.j·3.~ 11.7·1~.2 1200 6'214 1000 1lIl~~
7S4<14.ij 102·P·23' \.:J:! 0,00 ~.H.§ 9.1-10.~ 1!:JSO Q~ ,.!iIl 1lGlt9
784::14g1 1S2·P·292 132 6,00 3.1-3..6 11.1-13.2 ",00 1l:!7. 1300 81lE4 1 =- 0lI1:j:CJI o! F'tlwDf SteerIng Fluid al32"C (9O"F) !ElmpBl"illuf'Ci whon oporatl~ PUI'T'IP at 4ij5 rpm a;g.alll,1 458.&-51);18 kPa (005-735 p:;i) pt't$$urt,

2_ - 0IJ(pu1 of PO'W1IIf S'\t;C1!f1g FIl,lId ai jz~ (9O"'f) iemperaWr(l vmen OP.~tlng PYITiP ~11$OO rpm .tI9"'n~1 34S kPs (~ paij pres&lreo.

POWER STEERING 383-3

STEERING COLUMN 3B4-3

SPECIAL TOOLS

DIAGNOSIS OF THE STEERING COLUMN

~ Syt_ W111 11;;1 " Loo~ bolt .omogeG.

"" ... ~ 2. M.al!uno1io<>1O!j Ioc, "IIlnd., 3., Com&llOO ""'''fIII,

at. 0''''*-100 or QJlrapl5Bd :69C1Or. 5. Da'""9od,_

Leo. SYOlOm Will ~.. ,. Lot" boli "'"11'!l fa broket1,

L"". Ol. D.1maged'- ,ooth,

~. ~ilIJIUM:ti':mlng loc-k cy~oder. 4, D4maQIitd bOUJiIr.JQ

S, DilmflQoo rack.

6, IrliooliJI1iACII between lhe bowi lind' ~uplrrtg, 7. IiIrIUon'- .. "" k,

e, ActualOf rod fMI~oQ or bent.

9. Tran6mismoJ1 [;n1!;ageadJUS1mool iriil10lJrrecl

LocIc S~tblIm - "nat! I. ~ eyl1nder Is milllrl~nctlanlnil'

L.ocIc alor1 2.. 1'liJl1ltbl .!wltch j~ rnuirjJn"ffig

3. Rac~ pn,doad .!iIJ:lnl\!g 1::1 tlr'Okcm or week.

4. Burr& on too~. r,ad(, tIoufilng, BUppotI.

tang of the :lMt ga_tOOf actuator rodooupting

5. Bent sedor $halt.

6. DI5tor1ed ra1;:k.

1. MIHIlgnlT1{tl"l1 or Ihe ho~I"liIlctIiaGD ... er ~till

onlY).

B, Dila1or1eod ~log e:lG1ln InB rad!; (iii only~.

9. Bam or f@slrk'te-d 3dua;tar rod,

10. ignition awl.t'*' IlKNflling tlifackelm bent

t.oc:k CJllndlir - Hlg~ " SUrf on tmlg o! ;tl!f1. ,9o.t9.

EftOit hiWMn Thti 2.. rn.~9rtod rQ.ck,

"Olf" _ "011 .... k"

'POiHl!6Oi

1. ~ J 5176-D 6. ~ J 23000.B
.~
7. ~ J 6219
2. ~U~ J 5176-20
.. I (DC J S42H)2 ~
3. +f"'!l) 8. J 7624
iI. ,"20 J 25323
9. ~ J 253iM-S
5. ~ J 29525 10. ~ J 25033-8 1. Replace .he ~ 004t.

2. Reprl;!loe or tel!lillr IhEil lock cyl~'Qr.

3. ReplsQe the hOu!:ittsl. 4, Replace \he !l&dor. 5, ~epiBoe the .raCk,

" Flep!6~ thO :;pnng,

2, RepI!liGe (J1~ tudor tooth. 3.. Aepl~C8 tt1t!1 lock; cyilmder. <t. FlElpiI~co ·1111 hou:s:irtg.

5. ~8p1aco"'o fack...

6. Adju$10rr~ 1. AdJU5I. or oreplacs.

8. Adj\J"St or ~&sce

9. Mj1J:;l.

1. Replace .he lock cyl~r. 2:. F\.fjp:i_aos. ~he ignb swllctl :J. Flcpl&:e.11o spring.

4. ROrtl0'V8 1he burrs.

5. FlQplaLe the Bhatt

6. Roplat8 'the f8Ct.

7, Repl .. C8 eitO&r or balh.

8. Re-pl~ Uw rack.

9. SttaJ!itttt!lr1 orrapliilCil the rod.

;0< 5t14iJlhtBn 0( repl~ 'fie br..-,Qket.

I, R~lf1eoo1T. 2. ~i'l~ IhD ractl,

stleb. In "'Sblrt.lt Pot:IUotI

otov C."not Be

I ~:o~~~-r:on

1, ~ua:totfQdb~. I. St~t..,or'lJPlaGllth6fOd,

'2. ArfY high eft,gn eo"'~tIQn. 1. Sse "eorrOC'fiOI1· \lf1def the high effort

dtagnosla.

I, 19nilian switch is not set 1::OJ'1"$GIly. 1, AdjUst Iglllllqn ~

2. Msllunctlcl'1lng 10clt: qolinde,. 2 oR~a£:9 Ihe IQeJi qtndUl'.

Tht Loo, CYlln,,", C.n 9i RlIhnOVtd Wft""'" c.p'''''ng 1l1iI Fhlblln ...

1, Mellunctlolling. rslalner. 1 ~ace the I(Ir¢tt <V!l.~

2. Burr oviQr !he ratajner slol In ffie RoUist.!'!g 2. Remove tile bu!T,

cover.

I.Oek I8QIt t11!. n.. Sh:aft Lod In1"t1w ''Off'' And "Part'" Potftloflll

1, Power SlB4:trittg P-ressure Tester

2, Gaugo Adapter l!lrnm Power Steering

3. Th<Irmom,,\ef

4. I'<Iwer Steering SY5tem Analyzor

5. Power Ste.ling Anal~z,.,. i i'.mm Adapt~r

6. V .. Belt Unlvsr$a! Tension Gauge 7, Pltm"" Sh01! 5".1 Instoll.r

B. Beail"!! Pi"V10Bd Spall""r Wrancl1 s, Wowr Pump Puller A.movor

10. Pow.r Ste.ling Pump PuDO)' Inotall",

l..OO791

[",nllim swilctl is 1\0' !Jet correctly. Adjl1st the Ignillon swltim..

3B4.4 STEERING COLUMN

PRQB~EI!

DIAGNOSIS OF THE STEERING COLUMN (CONT.)

STEER!NG OOLUMN 3114-

DI'AGNOSIS OF THE STEERING COLUMN (CONT.,

CORRECTION .

POSS'B~ ~US~

liQ1.!Ih'9 $(:raplng, On Th._mlt eolymnJ

~. 001"""' .... ""rv<lly .iIl~,

;}_ QI1a' ';;!~k I", Qfl~l)I"IIQCk ~-!;t1110:l'l 1!Ii_i"id! ~~ ~o!! i:tW'!~g 'iI!'~ ~ M"Y~_

". HolT! r::Q"'~ r11'i(J MI~ 1L!~~tol}4

5, 1.O"'·of 9' .... on 1M ~OM~~ or ~"""g

"""' .

I!. w..lt ~!I!tii " 1iQ!>\" I .... n,

1. UoOM 011011 ~ Ii tiQlll .. ''''''n, B. :L.0dI~!ate Fell!lllnli'i!lj i'1fi!ji I~ 00l -Z;1Iil3ll-&d,

g. 'Bteen~~ :shali ~ iiJig 15 r'!01 eeeted,

~ 0.. Slll'tloolllr lliItJairIQ 18 loose.

11, Sheered lnfermedlale :s.llaft jllElBlh::: Jalnt

4, Jt1slallltlo ::t'~1,

15, flePl<!L(;(t iJi"Ol08a SjYlng, 6. Tighten to Sp,6Cijl(;a.1k1r1s.

_S_h o.mot Bli TlImiId Off

a A!I~' 0000<II)',

S. I.lJM •• ,.Ni .. ,ogo oM ... !O, 4,. A(J~'Me U'li ~rrilr t\Jbt$.

CQRIIEt:'l1ON

t, A!t;n 1"(; eefiJffin and mplilca Ilia 'ile;:wiible ",,",I!'g,

2" AUg.fi 'llie ooluirm.

], ~ ~31~ng a1 'IJlfll toeli 'bOff.

StMr!ng WhM! ",.go" Evory O!horll" _on (11" eoj"m.)

4. L'lJiJrieall),

S. L-\Jbri~!19 1Ii1B baBrlngB.

S1iO"nij eo,.",;; Will 'No! I.OOI! 10 My 'Ill! 'ffi,Ui>fi ('I'll! CV!U"'")

1. L_uI:lrkriJ1E1,

i2. R!JjJIEiCa ifm Ult bumpers.

IS, Repiaoo, fhe beadr.g. Inspect tile lJIlalf BIl:d reptace II eceted,

'I. Roplaos the ~In~ eeee mbly.

9. FmPLB,GB.1hei re:talil!1l9 r1ng.I~pe:ct fQf rJ~~r BEiMIPlQlnlh"gr~.

~. Roplaoo, Iho ,n.~ ~. '"'1""1 '"" oro"... aflatrl'lgln.lhe!il'f~

'0 .. 'T1g'~n rTII;I\lriling 3\:j"j}WS.

t t. Ropo.Qfre~Ia .. 'h e ., •• Hog "".tt Align lhe ~IJ,II1'In,

'Nolit: WMn 'mUng n.. CCh.iffii1 ('fIH Ceilillmo)

~, Lad mDljjI grOOii'lE!Iii ,maY have bum;: or dlr1.

2. Look.:a1De :s:pr1ng i8 weak Of' bfDllen.

3. Lock 000. .0IZvd "" II!; pJ"" I*>

~. Till spiil\9 rubblno;g 111 !he I)ousing., 2. Till bcmpera ara ...... om.

,. FI~'~ ~1i!lOO8 al'Jd dean jhe ~ ;;;;:. FI~ou 'Itl1iJ .f;~ring.

:3. Ar:t!l1\CO bcifi locJo:; OOGlaB.

1, R~ 100 (liV01 plne, 2. ~aG9 Il:m :ap-rTng.

3, ~nthBowtras..

S'lHrlngi WhM~ F.II!l To R .. tum ~, The TOp 'm"""ltIo.o(Tll1 COI~mh)

1, l1g.ti!sn or re,:.tsce. 2, ReacjLi:!it.

3,. Replace.

I!lfIh Sl...,.rn.g .holt

Ef!QI!1 .

1,~oo"",'''',

~, Ro~ ... Ih. l>o;lrloq>,

3, Re-,p:a];t Or r,~~ ~ IfI~OI1liI!Jdl;jiM-~hart. ..

1\.rrn !S!gllllli WIll Hc;!t I Cincal

" ,Cql'um Ii III:Bsembly Is ml'sEII'~i}ned In ~!111;1- v~~.

a, 11gtI! W rro2.§l1'lI,lp~;pr QI' I~~ I;i.I;ISiring~, 3. mndln·tI Il"it!tJmt;ds.~ ~H U-Iglnj~.

'Olmr.rlBr Switch WIll Nol FuncUon

,. PIVCll pf.~ Wi;! bouru::!' bfP.,

2. ~I: IIIL eprlniJ r~ m~lll;Jn.;:tl(lflll"lS.

:3., T"IH:I tum fIg.l"L9~ §.wl~ wiJ'Q1 ~re (00 (jg;tl'.

,. tceee CCiAnectr:;r 8.1 the dlml'ftl;d' .s:w1tC: .... :2. Improper BidjUElment

a. In;~emall~ dBm.l!l~acr:or wom ~wlt.clh.

,. Colurnl"ll .B!I$E) rT1 DIy 1(1; mii!!-~I~gn ~d ,I" .l'IoQ-

~~~,

2, ~r~! ~MI"I~ !IS not ~~I'I~ 'CiOff~!y, 3, Ul:~. 01 ~~ .... "" m. Do.rtn; .,,..oJ "'~ .. , 4, lIMI" t"~ J> t><onl or ~""'"",

~r.gpir 'ftiiiiiiiillii!gj'j,'St'itfti,

1. ~e~lii(i ttl. ~~.II' t\.ib; .!5t:Wffibly.

2. MltlSI' 1~61 IIi'iKagii.

a. ~OI)IiM!ij U'ili) ~r1IU tubG ,ftM8f'i"iDlY. ~. ~eplac:e U'lIi :s~1I1 tuba oIiSSl(id'i'ltlPI".

llIm SfglUlll'Dlffleull , Til 0p0rWUI

t. ,Snii!ITl!Jt1 g~U ti,I~ loil'i_t.

2. !i'np1op61' lrlMm[-S:Slon Ilfik.e_ae a(!}:li$tme"l.

3. Looso Jowl!i' ~!t ICillI'l:Ir.

4. !SMa.t'&:I ~r Sf'!,Pt ~ wedel

L..1ih In MOu"tllMI:

COIu.mn ".liiitl:l'bly

1. Co.iI,Jrl'l1"'l fllOl,I'ilirl~ bra~ 1;;DIIs: 'kooe. '2. Brokan wald mJI!3 ·on me fac"k9t.

~. Column t1r.s:dre:t eapSlIle sttesrm.

4. LoELBII3:Ei1loBs: hl 1M hou:BlnQ (111.'1 on1'p'), 15,. 1...o[)gEi' till hscl[~ IlLvot pfna (Iitt Dfll~).

1. i1ght:arL to speclfll::ij.UOI"S.

2.. ~epl8ce Itle ,a'Cke~ :El8SBIlltJIV. 3. '-'eplace tile 1Jra.;::lI.et ase;.emllly. "'. l"Iepla.ce me shoes,

5. ~Eiplaci9 1t1,~ pjlJot ~.

DI1VM elln Loe'k Stse:rrnliliin The Seeo.nc:I Q,jnn lM.nU41 TraI'lIlnIIl:IIOl1 ColumlUllJ

t, M9Irun~lrnin.g upper shiN levE!Lf, :2. MJiltfufl~kinln~ :!iIh.lfi IB'ItaI" g.als.

;J., !'oo!!:Ei re~y levew on "ilia l$'hIIl1l.Jba.

1. I=IElpla~e ttle '!3~1fI1ave-r.

2. ~epl;llce ttl.;!, 5:~II' I~er gate,

3. J:iI~pi:pt::8 fne S",1I1 tl.l~eessernNy.

1, Loose SWi'k:h mountlng, se.r8\l,':!j:. 2:. Swi.!cll. IJr SOCni)f 009S98 broken,

:3-. Broken, m:iJ;:3~ Of out [iI' ~IIf_(ll'l Clete1"Il, rerum Of cancelling I!;Ipn~.

4. LJm:WBrI ELr Incorr.ed CiIIncal~"'9 esm 10 C61"L.CEIIlrllG' :!3llrmg Inlijf{enm~.

" AC'llJl3llor·rod loeae.

2 'ilIbI broken ur dl&tolH"li9d.

.:3; loose cr mlsplaced sprl~,!l.

~. F~re(gn 1JBor18 anoor materials. 5 5v&ch mounted loosely.

1, T",!'11111n scrilJW"S;O ~.e N'm [~[n. JIlIs..). 2, R.el'i:lU!. tl'IiII .rwtk:h.

3, R epo-s,' I 0 FI C! I' reJlI ac.s , he gp,lng.s .s,:

F9qLlii!'G~.

,;t, A~I..ISlIt;1Ii swjlth ~M.

'" Ift"1I~,Ift108~9l!!0g0rrec1i!1l'1d5Wlk:h~ $'!!II riot eMIc8~ 1ii~lgcg tl1e sWttcl\.

• rr 1!":1llii~Bl1l111l"Ell'lce ~OO'I be oornKrlM b! ttl., :!I ...... lle:t'l adju!SlfTli3Im, 'Blpl;lc.8 if!ilil Co3Lf"lC.D.l ll!'lg~"'.

1, n!)'tllOti mo-yflli~; I5c!r"lllW itl 1.4 N'm (1:2 In

"",,)

~ R-apI.a.ee 'U\e l!iwlt:c~.

.!;t. ~srtbl or ,re.,l~ee (1'18 SfIllI'lgE: •

11. R.{!~e 'Il'ieforell;ln parts BliQ!cr ml3.lenal I). ngt1.e~ ~l"Ilil'[g $CF'E[W.!l !e 4,.0 N'm ~:l6i In

Ib!!i.).

rum $tanal 'NLll NO'! Indtcr!ti l1..li"", Cl'lange

1En:enlva Play hi llio MI)Ul"lted SI&er1n'i!l COluml"l (11t1 C'oll.imn~

1. TbjIhlel'l ~Si)I)CiI1C1i!lIJrn;. 2.. llghllflil') 10 Sl)l)Cif1l:t1l1o~. J. R~pUi_OO tlbtt plVC1 plf1!, 4. ~~Npin,

n.m Sill"'" WlI) No! Sta)' tn 'fUm Polilliori

3, l.oo:riao maul1l1ng 6Cf"QW!iI. repoaJ1N1n base D wire!! and tighlal1 !It1e screws to. 2J3 N'n 125 In, Ibs,),

1. ColtJmn lTIourrtlng bf6di:el bol~:51 100$8. z, 1.M)$6 SU!)POrt serfjl1l'.$.

3, ~ !I~ heM! plVOll)lrl5,

4, L.oooo 1001< ...,., ~ in. I .... pport

.... utilng: LooM (TIH CohllTl"j

1.. ~_c.oul...-e (;lear8lnt:e b(,tw-oon '[hI Itofos In !hI) fl;uj:lpo'l .or (,h(j 1'IDt!~I'i~ B.ncII ~'IIO' ~I(I

tIlai'hloltOr. -

2. M!.lflJnctiO(\l~ (!f'rIj'IMI't'~pfirl(j li'i I~ C81'i1'!:1t' In!iil sptlllllteS,

:3. UlJ-P8'-r blBli!l'ln~ r'iI[jLt ~lJiiillJlljjj In ihlil b!t:.l1I~

,ace,

., UlijJer bBaI1li~ lilT"!9i I'EWI3I 5IIal 'ili~in~. 5, Bearing; preloiid sPf\ilg btoi(uft

S. LDOIIiI3i :su:ppon SO"ffiIlS.

2, _""I"".prln~ J, R_,bOlh.

~ BrokEiA jane d1.aI'IgEi prassure PfI(l ~r ;:p~ h:arlser.

2, DFOIrei'll. mlss1~ ~ ml~ leJ1e d'lal'l9Q 'pri"ll,

J, Jiiii"J1ii1l3d IiB.se (It" 'NItǤ;.

" Fcrer{irl il1BI.erial Dr !oOS.IIII .~ Itnpua:f~ riIOVeiii.(I.,t of ~h9 .~ •

.2. BroUn or ml~'ih~ a~hlnl (;It <:fll1eullil'l!iil spMg&.

3 NOOBL D1 the abo'Y!lL.

Foreign m B.IElr1.al tMilw1!un h i!..lw l!iuPDcrl c:a1"lC!3l11~legBrl(j~e.

FlIIIIJJ1OVoB 'ftle foretn mEilefial. Ir 11~ rouOdi rgp!i!ICe Iilllll [Urn SlgruaE :5.~U_GIl.

3B4·6 STEER!NG COLUMN

STE£RING COLUMN 384.'

PROBLEM

DIA.GNOSIS OF THE STEERING COLUMN (CONY.,

CORRECTIOO

PRO!!~EM

POSSIBLE CA.'USE

DIAGNOSIS OF THE STEEA,ING COLUMN (CONT.)

llIm 'Slgnall :t.lgr.ts FlB~ VMy S1OWl¥'

" ...... ~.m<fi WIll ... t SUr Qjj Or DltHoo"'lo· ruin Ott

a l'n~I}ri'61I"9{1C13 Mtl, other OOMl'Or'lElII"lI!L :l Fl!)t.ai",n mBteripl

4. NCr1e 1j)1' ells iII~Q

I. Re.~ItCfi' IY56 end ~h£,cll: OJ1'I!!flllb't 2. ~atttact;l!11u lam 'S:19~i,lI fluaher;

~, C;onnecl' ~!Ire.ty, dI'Jek I'Jpe.~.ror" "'. ReplEte!!! !til) .sl~na'i ~t(:1l

H.o ..... al~nal Wg~i.o Wlti. Not :Fi.Mh - furn Signal FunmlDn. M:nmllHy

1. F!:eJ;IliIca illEilli and cl1ec:k operalior1, i;. ~ IDB hiil.tard. Wilmir)j;J Ilal!ih8f.

~. Coo"~ Meurely and ched!: eperarlon. 4. Fki~ thil turn slgnBi e.witr.h,

t, Btowl'l I"'S6.

2. Il1CIQ1:Iva.ti'.'EI tum SigMI ir.B9t1e,.

.s, LOOM- -c;lia!ials '10 oCalllrDn ~i'lI19C[{lr. 4.l:ilgOl"lnEicr colsrrm 10 CIls.S;Si!l OOfIno!;!etcpr.

C~m6d nBW ffiIIIIt.ct1 to chas!its BllI:! ~[~

~I~ Dy heml U al'Jlds IlghlS [l1JW ,opoar.atg

flafl'nillly, .!Signal s itdl la ~.nop9r'aliVEl.

:5. ll"'llt'iicll3lligl'll[ij: OOllot lJ11IE!~al.tl, cheek fl'l.J:Ssi:Si wj~ fur open" IIIlllulld!l. elc.

ikop Ught ffGt On IIIblPn l\fm ltKIl~t~

1, B!JmMCll,llfu:lll!l.

2. ~med IJLlt I::Ir diim.i3gflO fum .sign8lt bisl!J..

J, High ras.ia!8I"1OD c;onnElctloo [(I, _graUn(I.:it tile bulb aQf'k~:I,

,I!j, U:x:its.e ch;es:';ilis to oeumn OOfInec!.Of,

;6:, C~nn.wtoolldll'lfl"mlh(lmll38fseeil'lne;;:tcu"_ Cormect , flew 8WT.tdl ime. lhe 8}'SI_um IIIld Ij)f)e=.ra,[e tn1) Iiowi't~ IW li.;]nd_ [f 1uP'n ~aI I~hla: are f:IOW en Bl'1d fj;'].'ih, IhB IA,Im ut!;nsl ~h ~ looperaWe.

6.. If 'Yahlt:::.'hi!: ~ghta d'cJl BOI, operate. Ch0d!. file maB&i!il Wiifng h:Bme-s9 to !igJJI ~8t:1i1 ffI~ cpe1l~, 6Ir'GUm:is. ,ete,

C-DRRec1'l0frl

1. TfQhlen rnounlrr!g :e:.c~ew!!; II:iI 2'.8 N·-m

f25." It" I,

:2. AemcV!O '[he fn~arlltIllll"lOB

;" Rcmo v e 1bl3l f8P"Eiq, ITl.iltBrt.a.1 ... , Rtlplaoo Inti 1>WT1Iih,

TLlnl I"dlc:lkl, Ugl"IUl 'On. BuI. N'ut Fllllal'llrwg

1, Re'lIr.l!~ ~ lum j1'a:!tlEl~.

2_ COIlfl'ElCt ::iEI~.m~iy '!il.rid -chEK:K aper.aliDrl_ 2. ;Rap.la&:~ IhEl' turn siijnaJ 8"Ni,l:(ill,

4. ~!!JG. ~gN'.Il swhoo..

1. Ing(.lorailv,8I lurn rl;;!sher

2.. l...oo8f! Gilas"!l;I3 !O cchatm COOp1SClfon. 3. InQ,txtratl'IEI I_U'" :>ignB~ :rwlli:!h.

.;1'. 1b ,dgiBmJJnelr jurn l!!fgll;ijll·jwitcb bil mally!lC"tlonlng. !lubStilulEi Ell rewswneh 11"110 [he oIrti!Jlf and ~r.tlEi the ~wll~ by "a~. It Ihe

:7~~~;~ :~::~I@>l"Iorrnal~ the $ignaJ I

.6. 11 11'1(11 yohlclel :Ir!jlhll!i DC "01 qJElrB.!s. -eI1ECk jl6lntoo:ckfll~ lor l'iigh rlE!81sl~ rorlrlE!Ct)Oii:!l. ino chaeela _wlrll)jl for ClpUns... grm.ll"lds_ me.

Front Or Rear' 'tUm SIgNI LllhnI ..... N", FI.!l!ftl.Ii'i5!!

5, Repair II'KI !Ofl.1:ssls: ..... Itlng.

T~Alllnn'~'NO'I ScaOd. WIth K.r ""Ilf 1IrtMrm! In LDGk· Cy1lndar WlIh 'Drlvllllr'. I)OOr OPII!!I'i

1, ~pIa~,~ and ~di; operauon. 2. HElpr~~ Llji burt).

:a RBmoy~ Of !~~ir 11"I1I.'I1;:iulry ccnnenlon Ii!rId M~d!; Ot:!ir'aIKlfi.

4, Coon~1 ~urely and dud:: OP!1FBtiCl[l. 5, HElj!J1aCi fn.!!! fiJm e;ignaIBWI[~.

POSSIBlE CAUSE

1. fnoperatlve rum Bignal nssoor z, :5~tBfll Ct'l8:rgirlg wllag.& low_

3_ Hign reaetance nrounu ill ligHt eocaets.

I!! boolia Gl"Jassls 10 column eonnecnen

5. DiscQnneC1 column 10 c.ha.gsiB connector, CaI"lflec1, MW ~tGh.into :6Y51Elm wjt~1 rem(lving old. Operate I!IwilGil by hand, :If ftaahirlQ occure <It ool""Pllal rete. the I!IIgnal awltcih ie mJlI([ll"'Iclionlflg.

B, If It'll<: fhilstt'ing rete le !il1~1I filli1remely !!;I:IOw, (;tJ..ed!: ~aB8l:!1 wrnng llamas, from Ih;e eonfI~rltl ihell~t'lt.sOO~iS fl)rhl!:l_h rt::3i5l81lOJ-.

Rftpl;)CU!hB [UIIl sfgn.a.l If.a:sfler

r:nUOMIl .... ciIl8~ 10 soscncauons. Ael'er 10 (S-eC. 60 ENGINE 'ELECTRICAL] In 1t1~ m;flnUal,

3. Flep!J:lr high ~i31"fll:_lilI griJun.d:!; ,a.1 !l':Ia 'liQIlI SCCkeli.

~, ConFl6't't :fi;~llOJlr ill"ld' ctllillJk. Op,aJSit1DIl, 5, FI.;:pjtlce' 'i!)MI $WkI,(;tJl,

6, lUC:iil.h;; a "d rapalr 1;1:; r8Q,l.Iir-eod. f.lele.r 1,c CHASSIS ELECTRICAL (SEC. 8BI.

5. FhJpllilO!il 1'-l:51111 block. 'Refer 10 CHASSIS ELEG1RJCAlISEC. 6B).

1. ,Bu..-rW'QII1 'LJIiB..

2:. 'LDO!;i~ OOl.lmn to -qhi1SSi':Ii COfIl'lectlon.

:l. Dla..:.ol"!II'iiill(;.i GDlum~ to t:hlils.!ilfs 'cot1nBetftl.

CcnnitQ1 'l"W BM[-oh lrnc I!I¥B[8fn wilhoLI.t re.mQlIi~ old, OpE!'fllill1l :awilcll bV MM . ., ti!'el(,& 11111"113 "'fCirk willi ~'I!'jl~ til ltie ILrm po.!3l1tofl. signal ~.;;Il f:!;l m8Ituncllon~o,

<'I. I~ b:tal«i fil1hi:a do frOl w.ori<. di~ CD.I1llBf:'IQr rill' :ii1"Qj:I !Igm, t~ sor,;-t..et; IDr:grolJiiod's, ~fl:~ II!iIjc,

t Re~lE!ieti fuse ~ ~Elck cperarian.

2.. COr'lil'l6el i5ecur~y titi!d' ciJe.c;:k IQPBrBliotl ~. Re-~~CB 11;181 !1Jgn.a'1 ~h.

l.nnlhi:ll~1illirP,1i'\iI1 !!Ihtl Not FIaJM'a

1_ Replt.c!li ~h~ gyJbS, ~- Repl"", '1\0 , .. ~..,.

3. looate and rtljM]r Be mqiJlrod,

1, E!i""!TIOO oul bulbs,

-.2. H~(e6isl~ Ig'Qftll:.mdaIIJ,Ci biJlb~&:i, :;}, Oi)m&, QroLI'fld..s ifl' 'wirirly hamEliSS Ir.gm 1l"M

ri'Q.'it tum ~nai tiu:lli ~I [I) rhe indicator ~shla,

1_ ~awn fu&ll~

Z. rn(l~flralhtB l1alaN:! warning i£e,.,.1-tef. :3: Loose ah~rs '0 coumn (;Ort~~

4, OI:SC:011nb(!1 !:!C!LII'nft te c:h13l6,1$ oonn;e.not, Connect new ~(;h II:I!O ,~tetr1 Wllt'lOI.l' ~. ~r.g~. DC,QIfJ"D"le r-1~Uil1'lIf.arniir1Jtbui. fOI"I..and oi:t6en"el he ,h;e:;mtd we:m1ne li.{itilS" II thl!!JY -now wotk; no.rmally. l!"Ie H,Im ~igr-II! 5'WltcP'l"mijrfun~tonlt'lg.

5, it 1il611~hl~do fIoOt fEash, ci'lOOk .... irJr.g: Mi'tllt:ts: ;.:. Io-,d ~bi'O ..... rr) 10t OPll'-" :N:i''I'I'~n tia:z:oIiid n~her and h:JfiOOf'llca cOfu'Ieclor. If OPill~, fu1;(lIbloc:ll:~m{!11iJi'iCllol'Ill'l!il.

'1, ~'QOiij;')i)¢UOi1.:'1! 'tl'i.{t 1On& al;'!!li'fn,

2, VOI'ags 1"101 l'lisjtablC 10 Ino IOfl£t IililiID.

3. MBlfWlGtirmlng tenD aJurm.

4, Doo. ja.mb:swf1.C:h en 1M d~V6-l"~:!Iid'e la malEldjtJalElld.or ioo.pBfa~viJ.

5, Short 1(1. 5h13l ch.a56i:!> wirill:Ql,

B_ SnOri; or (flul, In 1118 ~ 5wllch Wiring

7. Chlps.ItliJffil;, l'ore:lg_nrna.1Elrlal are pr~'1ng aC1:uat.or i.Jp fu~on. ~OTICE: Key musl tte ru~ (II" thO cyUf'I~r -s;~t lin, ~he "run" poPJi. liOn, t:tefQl'o€i feJ'fl(lving th@ IQi:;1i: (iyll_fldlli!lt.

6. Mil'JllUl"ldklniM lOCk t:~~r..der.

1. COfIlOO1. B91Jurel:.'.

2. Chack rna IXInliliiJlly 1:11 the chaeela win", IBmii reoesr as. reouaed,

~, Rspilace me tarn .. atarm,

.!]; hij~5I. or reJ]!ace ElB requlred_

5, Cllec;k 101 eepereuua C~i8 II) column UXl· nectcr, Ctlr11lBG1 E :ar1d if :femEilla ccrnacts or

::~~~~~~~~-:I:':U~tJd:'W::' ~

oot.. locate ElJld repelr iijhBsS.B w&rIn~

6; Connect mWei E end Fcon.t.acta ,or ~1'Iec'ta1 wii1l100 jumper. Check buzzer IliWItcn pad!! wrth Ihe-ohmmeter. II contact ie made.june tlon ~ normal. 11 ect, rejnece 111013 alqna ~wlt~_

7_ FI:lIlmov~ cttlP~ an(l burr,iiI_ Fle.~~bla BIK f:l"le!!l::k_

3B4T8 STEERING COLUMN

STEERING COLUMN 3B4.1"7

I.OCK CYLINDER REPLACEMENT

13 Re.move or [H .• connect (Fl!Jure "15)

• ptaoe th8 rock cylinder in the -AUNn poemcn.

1. Steering 'WIles!. Asfer 10 -Stoaflng Wheel Rep'~' mellr In this sactlo,,_

2. Tvm signal 5Wttch. Reto!" 10 "tum Signal S-wHctI ROllI.cemo";· In ,hlo •• 00ion.

• II is not necssss:ry te eompltllBly rQ{JIovt thl turn Signal ,swil(:h 'rom tM ooi'l,Im n, Pull tn. swl1c!'l rearward lar eMug" '10 sDp Il O'IIer lI"JiIii MtO of thE!" .shaft 00 I1Qt Wljllie !'1F1fl"1I1i1~ out 01 Itlo~umn,

3, Re1ail'lil"9 screw aM the lock cyllndet' set.

rn Imporbnt

• M' tllQ ~n'ng ;&CIr'eW iii droppeod 011 i'6mO'Yul, II oouki I~I into Uw column. requiring a complete ~mbfv to rotrievl3l lhe S(lI"'@W.

PRO!lLeM

DIAGNOSIS OF THE STEERING COLUMN ICONT.)

POSSIBLE CAUSE

TOflii AI,rrn Doii :Not Sound Wit-n Kly FIlI1V II'IMrtBd .Ii'~ LcK:k Cy'11'1de! wnn Driver's ".0< 0po" lCO"')

1 '[ inapera!iv8 lone atarm f;:wllCh ('Switch a.ppeara g-ood lnn win 1"101 maka tne f.l)tl(I illcum 5Wlldh hJr'IC;!jQn cbeck)

11 Confl@el the oI1mmelOf leads 10 1". tone alarm $WitQh prcces, P·r'&~ on 1J'Ifi actuator pad unU! [I'!e ill1Srlor fIOIn15conlBct.. It QOniBCI ~ ncl mMia, replece !he 11lfiel alarm SWitch.

12. Reset IhO [;()IlIac! g~,

13. WlIh V~ laul, l.solalad in ihe column, dis· aalilemtJ.l(!! II'le- u:pplE!r ond 01 me a;iuml'l untll the si9nll t;wltctl mounUng screws have '6&en 19l"ri<;1vm;j. Uh ltJo ;&witGh arul CI'lOt:k Ihe probes of 1M tooe al@!M switch to enSU19 ~ood CI!Inlalli1 wHh th, lJB.d~ If! Ute $Igni11 .swllch. ~rn;I ihe probGs, if reQ(lJr8d. then resea\ lM- signal s.wtlctJ and install the mrae !SC·re""!!:. Ct'lEl'l:k tl'te1l,1nclian,

14. SeUlng the OIXl'olIC1 sao. Pre:$$ a 0,75 mm (0.030 Iper,} wife IYPO spark plug: gap wlrawith 11~1 ~19ce o.f sloe!!; onlile Bil!toolGr pad. jf conteer iG net m eo 11-, adiu8I1 ewJl,eh until pbslt.",O ct;mtacJ: I!;I moo~ (use Ohmn1SIIM), WIth potiIllveCOl11ae;, i1I\ 0, 7~ mrn (0,030 inch) use i!!I 1),% mm (0.005 IPlGh} plL,lg gap rffirEl benea-(fi Ih$ fiat $1;X:k. No OCH'UI)CC ~cllid 0Ccu1. AdJ.-:s.1. WhElf'l I hie Ewitoh wljl rn:8.kil g6ntac! ~ltn jhe 0.7$ mm (0.030 Inr;:h) wlrg and nc~ wllf'l ihBl 0.6-!I mm (0.025 Inch) 'lVirtl', the to~ OOm 9wlld'l is set st tile lOW IImll,

1 a, Tone alBm~ $W1!<;h oon1,d ~8,.p IE 190 la:r.geo

13. Hlne 10m, ali'lrrn tllolt tI~$ not yei bet3!'1 dei:8Gted, ~"I"@(;:t 8 COfIhnUlty me.er{[)frl9hl)to ihe male e aM f conne(:tor contaets. '''~I ihe Hey Ih~ t\lU cepth (mo the-locI( ~II~I", Ir content .,. mildH wilt! 1M ~y In, :and ~ I'1Ot made wllh i1 Out. li10e flJnCiiorl i!s: J1cwmal. !=l.~ ItME!llhe Inl!ia.I dragnosllc steps. If COI"IIa:clle net BBtabli:shBd. t.he raul! IS In IDe CQllJmn.

14, iJ the fault has Rof yot been IsotlHac Bind repaired, connect chmmarer 10 '''e tone alarm switch prceee. FIJI~ i...,89,1 sf\(! fiMllave ihe kay ItOm Ihe lOCk ql"mdsr. If eontaCl II made wjlh 'lheIl;8"!J1lrt •. !lfId 1:61 brokol;1l'1 with ~ out, !helul"I(!tion iSIlOfmal, RelraD~j the dfagnDSlle S1ep$. if rortlBCll, noll1'J.B.dlB. the taul' r& In the Ic::d; o:.-li.nder or 10ne alarm sWilGl'l.

Tone ,Af.nn eon~I:nM't To 0 ... ,.,. Wllh !loy In 'Illo LOC" Cyllndo! wan fljj. Driv,r'. D_ Ell!;., 0",,0011 O<C_An<!

Co. __ ~~!o

Rtmav.d

t, Door jamb 6W;tctl 0/1 d,lver's BiOi(! maladjUfill.d Q{ InD:peroU._,O.

2.. Vitro 1~gm signal ""non lo door i3mb sw[1Oh 9t1(1iiOd,

Mjum or f{ipIa.oo ill,. I'OQlJii'1:!d

2, lton~!iWi1ms.ide,r~51gnJ;ltSWftoh, Ir r!l" (:~.S$i!i .fi1.ot1tl1, lind gOO r.epair,

Thl~.¢OOOi.Mn~t-El5thBbckoy~I~()( to/1e ~ .fiwltct.ls It rtwR, To V'etlJV. ChecI( for W"i1!nuI1y at the e- and F male OOhf1tK1lOr ~f'lI~t:l Willllns koy fOPlm'ud from Itt", q1111· det". II Dj'mAJRy 1itX1~:s, U,IB !allll Is in 1118 collPfi.!'l

TOI'IiI' .lIBrn'! eonllmilli To 01""1110 WIIIIIWy Out, BII! S!opo WI1.n DrWl!!i," 0Ci0c1' Ii Cb~

1, ~ ~Inder bfndtog (ttrm Ioc;k Loward -Slor I DOSition, If lOnE ala.rm slaps in lMI run wei· Ik:m Of 'M'tt'ln nrmed piS$! run IDMm;1~ 1110 sferl, the p:roblem oI!i 8 S60~ IDCK C~I~ l!IGtuator).

2. CI1Ipo. fO'<rign m.[eJla1 in be, c:yIir>do< boro, a stJoky lock q'IIndaf m&tiPial in !oct: eynndEJr bore,.

4. OamtI!glJd or bfCJkt'j,n lomt alarm a.wlletl. S. ibae.alarm I!XM'Ilact ~ is [00 Clt;I!!J:e.

o

2. ROfI1(Jve. q~!'I"Ible and reChecK function.

3. Roj)Ia<e the loci< cylin<ler.

"". HOI. III. lock cylinder 01.0\1. an<J rotate 1M

}!;oob c.lOCi(wlSe agajn.st .h:e stop.

e. Lock CyIIM., S .. , C CyIlM"rK.~

D, W¢~ Rol4!ning 50rew

6·D7394

4. Replace 1M· \.ot"!" alarm ,wilctl, S. A.dfuSt as l'I~ied.

FJgur. 15 -- lJ)d( Cyllndef Ina.ta:n.tlon E3 Inll1." or COnnoe! (Figure 15)

,. lGC5C cylinder' sst

.. Aiigfl 1t..e cylinder key with tI& keyway in Itt, i'1olJslng, RclalB as 5howr'l In ""utili 15..

• PU$h 1M lOCk. all the Wfl,\j i~ 2. R~talnlr\g IiClBW.

WI nghhl"

• Sc;rew tel 4.5 Nrom (40 In. 1M.) ~N[]n.'llJl C~· Llmn!li).

• So,.w 10 2.5 Nin (~ In ..... ) (n~ Goium",,).

3. lum ljIfgruu sWitch. Reter io. "Tum SignJ;l;J SWllct Rep'811:;~·rng.nl" In Ihl:& eectlen,

4. SlseIlng whe.,. Ra'., In "S;"ol'iflll Whe., Aet>loc+ manr' tn n,i:g seenen.

TONE ALARM SWITCH REP~CEMENT

E3 R4IImQV6 Dr Oli!l;;Onne:C1

1. StwrJng wheel. Reter io ·Steerlng Wheel Flo9'~aotF men'- fn d1i!:i section,

• Pl,jlj 1110 tern srgn8/" !iWllch up Ii;" oooug'h to illkJIN eceess '0 the tons ~ktnn switch. Reier 10 "Tum Sllilnal SwllCh Rl!!lplBlcernenl1o In IhlQ 1iSi3tl[ln.

• The ~(t alarm sWitch rn~y be removed w1tl1cut rem •• IM 11>0 100, eyll"'OL ",. 1001< oyIinde< muol ... In "'. 'RUN" """Ilion.

2. Tone alarm 5Wilch aS6~mbr)r (33) (t.lgure 1 7).

• Pull Ine tone alarm Ewitctl IiIf1Iifght out 01 \tIi9 hDLJsl[}jJ Lf.5rng 6 papet dfP or !lj:lmllar tool. AnAl spring wedges the switch toward the lOCk" cyflnder.

rn Ilfip<ii1anl

.. Be carelu' not (0 let Che: flat firx'Ing fall down Into !he nolJsinll and do not pull on tI1B Bw[tch contects or plastic malerlal 01 lhe :switch when removing.

E3 IMtBIL or' COnncot

1. rOIl'\(: nlatm .s'lNilcil 'to Ih.o spring clip with tM lormad end oflhe dip around tht !O'i¥1!r end of tho switch. The sprJnl1 js bussed away from Ihe swllch.

• Lay lho spring on the 8wilCl1 npposhe the ccmects,

2_ Tone atltrm s'Nit~ aM spring Into Itta hoi., with lht conlacta tDwArd the &ock qrlfnde:r bore,

3. Turn signal ,wiigh, Rot!r In "Tum Signal Swlt(ll'l R..p~ment" In tt.1s Kldkm.

4, Stallrln.g Wheel. f:te!.' to- "'S~Bering W11~ RQD1i!!CQmenl" In thiS! ~n.

IGNITION SWITCH REPLACEMENT

The igl111ion o5I'lYftel1 151 mount611 00 !Cip o~ thg GQlonm Jacl<o' ""or !he Iron! of 11)0 4Mh, InoIa$lho Oh8"""'_ Df Itte brake ~I eyppqr1 •

1]1. sw .. ~ .. .,.;,y!l!ed .~ • ,oa and .. " ......... biy, A portiOn of the rack is ,~ aiid engaQ~ 8. 98BI' en 1M .and. Of rl'1e lock c.yGndiElf. ThIs efiablea the fO(j' ~nd rank 10 ba mO\f9d .axially {wf!ll resPQd 10 the column) 10 adLiiUe thB switd't when 1h'Q; loc~ CYlinder t& ro~ted.

'B4·t 8 STEERING COLUMN

STEERING COLUMN 3B4.2

3: R.li;tmDYEI (If DI:i:t.:OH.n;aCl

.. Lower the Gteer1"9 oCQ4l,Jmfl. Refer 10 ~N Model or O,.MocI~ ;,St8l1i1flng CQI:l.Imn Repl8,CQmQfl1·ln 1):,1:3 :58ClIon. I, Is "01 ne:-cessary to remove the- steorlng. wtI,e:eL

[!]Imp<lmml .

• !"!"Ope")' suppon. the st~rlng column ~ ~t Is no. romo~ , .... 1M "81111; ie,

.. PUt !he ignitiOn fiitd'! In tM ~LOCK" J)OSltIcm.

• h the look cyBAdilf was 1'8R'lCNOd, lh.ct 8C'ua"l'Ig rod to the swltcn shOuk:l be pull9d up unUl U'1O'J(I Is a dsfinits stop. t/liiIn movOd dI)"",n OM Ckl19nf. which i!S the NLOCK" posiUOrt

1. Two ignHro.n switcl'i strawS. 2_, ignition iliWftch .fl:'5l:iBmbiy,

:3 IMIII! or C_ IFlguro 1&)

---; PtJt ihe ignLticn 5vtllGh in (he "lOCK,· position {Iigure 16J.

i, AG1iv!llli'1Gl' rod into 1hB igl1ioon switch,

2, Ignnl"" ,wI!<h .nO ..,_" to ,,,. oo.mn.

3. S~e.01ii"J'ti (;(lliJi'i'In a55am~ Refer to w511E1'11nr\g GeliJ1n1"l Rep!Eiooffiiinl" ill !lite eeenon.

A

A. SwlKO I.r The Lock Poattron

20. ~emIn9r

21. NUl

g2, Loci< PIal" C(!Ve< ;!3. R.taln.r

24. Lock Plate

25. Oon<9l1ing cam

26. SOaring Preloa~ 'Sp""9

27. Tum S~gmll Screw:$

28. r"" Sor"",

29. ""'wator Ami

30. Turn Signal SWltcl9

31. Tum SI9"~1 F1q~rl!J So, .... 32, Waw,

sa Ton. Alarm Swlloh ~4. A.tamer C~;~

35. R9t:a:lm;lr Sor~w

35. Ignll",n locI<

37. AOlU~lo' Soot.Of

3e. Key Relem;e Sprll1!:j

39. Ko)l Ael.ase l.Jwe' 4lI. Key Role ••• Wasil.,

41. Houslr,g As..,mbly

42. Bearing

43. Bushing

44. Hom CooIacl

45. Uppe, Boarlng Relainer

46. Dimmer Plvor And Wlpe.- Swfl(:h

47. 8M" Lode Boll

48. Sw~ch R.ot< Preload Spring

49. AOIuelor R""k

SO. Aotuator Pivot Pin 51. Washer

57. Gear So;" IiomIng

511.. Signal Swll<h Mounllng Sor~w. 59. G.arShlft HOuSing

62. Jankot

63. WI"ng Prot"""',

64. Aotu.'or Rod

65. Dimmer Swllen

66. I'l"itiil<l Switch Sotew

67. Ignition Swlleh 611, D .. h S •• I

69. AdaQter

70. s...i1ng

71. Reinforcement

72. Relalnlng Clip 73, Shall

81. Belt

sa, Nut

9:1. CoiJjl~ng 94. R"t~Jn.r 9~. Bearing 9El. Spling

97. W .. "" ...

98. Pin ss. s...1

100. Intem'tadiate Shaft

1.00755

Agur .. 20 - $tlnCf.IJ'G Steer'"g Column (AN Model)

3B4-24 STEERING COLUMN

103 105104 ~

'\\~~\~~ ~ \ lJ~~~0562

,-"", _ l07'OS

o

13 \

~~"

109

Flgure 21- Stondard S"",'ngCo,I.mn (C· Model)

STEERING COLUMN 384·2

20, Ai!I'air1~~ 21, Nul

2i!. Loot.; P1Eue Co,,6r

23. Fiilet8.lner

24. loci': ~Iale

25. Cancolli ng C~_m

26. Bearing P.reioa,g Sprillg 27, Turn Signal Screws

28. Tap SCrE!W

29_ Actualor Arm

au. Turn Signal Sw!t~h

:,H_ Turn Stgnal HgU5ing Screws 32. Wa:shE!lf

33 Tone Alarm Switch 34, Rel.lo.r C"~

as, Rei alner SCI-E:=W 3tl. Icnilion looK

37_ A-ctuttlar sector

38 Koy fl.'~."" Spring 39. Kev R~leo5l:$~ LilWtlf ...:I.a. K8~ A.ele6l~ Washar

41 HousIng ASSIQ,mbl"l 42 B-earln9

4~ BU.hlng

4d, Horn COflltll;1

45. upper Be;flrlnQ Retainer ~6 OIl"Ome-r Pivot And

Wjp~r Swlleh

47. Shall Lc<k B~II

48. Swl1ch Rack Preload Spdng

49. Actuator Rack

50. Aetua'or P~VOl Pin 51 W~:hilr

~2, Shill Lever Galo 53, Shill l"ver Screw 5~. t-Iousj~g Cover 55, COliS r se rew

>fl. SMI!t Lo"or Sp~"g 57 Geo' Shin Hou.lng

58. Signal swllcn Mou"tlng Screws

~R Gear Shin snrouo

61. Geaf ShU' Hoos~ng

8earing

62. ","Ok.'

6"3. WlfLng Protector 64. Actuator ROd

6.5. Dimmer Sw.ltOh

66. Ignition Switch screw 67 Ignition Swlrch

6B. Dash Seal

102. Snlll Tube

103. Washer

104. spring

1 O!5:. Aaapl~f 100, Be~ring

lor. Reirllo~ement 108, Re,.'n'ng CUp 109_ SMII

110, 'a •• nnil washer 111 Retainer

112 AUiomalic: Tlansmisslon 113. Manual Tran!l.misston

UJ0756

figure 22 - Stan<'.rd Ste!1lrtng Column (G-Model)

• MSIlU81 Transmission (COlumn Shin);

• Flemr;tve (he IOWBr be.aring adap.tttrj bearing Ind the fiM rEV8rSe mitt tever, in. ~.,..(tr bearing ""'Y be ",moved Irnrn 1M adapt.r ~ l'IIn, pro.· SlJJ6 on fha bearing outer race.

• Remove the 111rellil' ~:CI"BWS Irani \M bDiDrlng at tM lower eng iIOd !SlidE! out the sh.ln lutl& ... omDly.

• R9mo,V6 the ..geElir shirt hOOEing klwsr boarlrtg from Ih& upper end 'Of the mast jaCkal.

Agu ... 24 - ignition SwltGh A,ICtL'ator Sector RO'm9''f31

384-26 STEERING COLUMN

FRONT SUSPENSION 3C·~

BE Ao .. mbl. (Flgu .... 17 through :ii. 211 and 27)

• Apply a thin coat 01' lithium 9'8B:5.9 to aU frictiQll surtacas.

" .seclor uuc Iha tum !Signal and lock cyllndeJ' hOUSing, II In51E111 the I5BGtDr In ~ loc;K C)flindor 1'!I0I8 eve! thill eecscr .shaft with 1he ~aog end 10 Ins OulSide ollhe nola.

• Pms.; 'he seetor. over tM Shan with III bll..lirt 1001,

2. Shift j!!lve! 4e~enl pl6te onto !he hOIJs:i!'1Q',

3. A:a.ck i:Jreloool !Spnng (413) Into the Aouslng from tI'IG bottom side. tte JOT1!} soctJol":I shOUld be tOYl'tli1d lila h.s~1 8nc1 hook onto Ihe odge 01 the hoosiog (fi!l"'e 26).

4, 19cklng boU !47) 001"110 Ihe Cf~soye~ erm On lhe ra,ck (49) and Insert \M r.de OII<J 10<" 0011 .""'mbly Inlo 1I1~ h""slW tram lho 001lom with tll.leeth up (loward hand'wtloo:l) and toward the cer1i:BrlirlB of tha ooIumn,

.. Allgn tM r.1';!;1 tooth 00 lIle sector wlfr. the fl'5f toolt'i 0., 1M ra~ if aJl~ J)fO,perly, the. blQClk !Mln wllJ line up wfi.en I:h~ ratlk a~~fr!t.lv ~ PU&1'ied all the way in-

S. RSliiilie, (45) and bushing (4;]).

6. Gaar shift i'loU$&-ig fowEfJ bli!OIrI"IJ. Insen the bearing from Ihe vsty end ct Ihs jackli!l.

• Mgn ItLB IndanU!lion51 III the "ring w',tn 1M projectlQm OIl the j8()k.et (figure 27). If tho bear. Ing Is not Installed correctly, It will ncM: res-t on 1M SlOpS PfCIvllJe(J.

7. 5111« ""or !IIN1ng (!illlinto 1M goo, sl1lh fay.,. (Or look lube) hooslng.

S. Ho.u.1ng (57) and shroud (59) a_mbli •• 0.10 Ih. upper end 0111\0 masl 100"01.

• Rota1a 1M- l'IOu:s:I.,O 1.C be. aura It Is sealed In tho bearing..

9, Turn signal end lock cyliooer' housifl9 onto the jaqkel

• The gaar shin IlO1.Ji&lng should be In the ·PBIk" pDBi!lon and the rack: 1l1l~llIId downward.

• !3ie;at the fum 5;igllaj ooLJ5.ing and m~tan the four ",r,,,,. (351.

10. Lowef bearing frno Ihe adapter 8$Sembty.

11. SNf! t~be ossornl>lV 1"10 1110 low., 0'" ., II>. j."'.I.

RoIO'. "ntil th. UIlPO!' ol>l~ IYbo ~.Y ,,"!<I .. InlO 1M """.Jog koyway.

• Alit""",!I. and F100f Shift Columo.s:

• tnS:lall !~~ $prln'Q and 10'1,IIifh' be:nrt~g adapl~r .... mbl'llnto tho bel!om 0' 1M IOCk.t.

• Hold Ihe a-aapil9i" in ptacs aoo install tI'I9 lowar bearing r8IntOf'Cs~8:fTtand rstalilBf dip. Yhs dip .sJ1ap:!i raID the jacket ana relnlorce.menl alota.

• Mlilfil,J.aI Tra.r'EimlsEiton (corumn Shm):

• l.cQaely attach the three S£reW8. in tha jankel srxt shift tube beallng.

• .Assemble Ihe rfffl'l re'l,i'el'ljIB lever. 1000000f b9ating and adapter ~!1IOly toto II'I~ bonOlT! 01 lha Jad<ol

• !-I01(I1f1@ ~d3P-l!;ir iA place and Insta1i the beilring ~nfQ~~llflt Md retaining dip. The c6p i5J1e:p5 jnlQ ti'»e llickef a~ reln'ol'Cl!.«.tenl slots.

• AtlJlJ!!I:1 Ihe lowe' tJe8tlnv. Refer til the "'Manual TransmIssion (COilJmn ShIM) lowef Bearin9 AcI,luslmentft In tl"liS: S9C1ion.

12.. Back.·up swltc:rr Of r'I,a:ulraH.ale'ty iSlwit-Ch. RefElr to

CH:AS;;~S El.ECTRICAL ISEC. BB). 1~. Sleerfng soa.~ into Ihe column.

14. Upper bearing washe, (:r.').

is. fgn"rllol') swhc:h. F1sfm lc -Ignition Swiu::h ~eplace· men' m lilts section.

'6. Tone alarm !Wilc.h,It fQmoiu'etj., RQfef to '"Tcne-AI:arm Switch Rep!acem8rlt" in Utjs s.egion.

17~ Lodl: cylioosr. Rlefer to "Lock Cylfnder AB;pt3CsIt1911r in lhis: eecnon.

18. T .... rn :fl19nal <5wi1ch.~erer IQ wTum Sl:gnal Swi~.Qh ReplatfliTient- In 'lhj~ ~n.

19, Stooring _wh:eeL ReIer (0 MSt.eerll'g WMot Replacemal1l~ In !his :seGl:IOIl.

20. Shlh.lever and phtOI pin..

• Remove ~hi!i!l ee!!.lmfl 1(01'11 1"'(1 vl1:;v.

2-1. Dash ~~, br~~t an{l $(;fews to the: column.

--

DIAGNOSIS OF FRONT SUSPENSION

(:.arrection

t. F'mm shOOk absorbeir!i: Bre def9diV6. 2. ,.."." baD jOlnt8,

J. _ boarir'!l • .,. InrorrscIly ~iU>t.d or worn.

4. Whesl and tirO Is out of balar!c8.

D.. ExCBBSNI) ~ro or wh&91 rullOut

, . aall loin rs and ~lflil!ll ring II r.kagolEl need h.Jb!1csth:m.

2. lOW' or UJlIB\I9n f'n::I1t tire DtMtIUf8.

3. 'neCifrscl lrant \N't1~1 :11lg:nment (manual .... 'Iog).

1. lubrIC ... , .. b.l~ join .. ar<Ilinkage.

2. ll1fli1lQ ,jrO$ to tI'Ie reoommanded praSGy.rj).

3. Check. 9fJcI ,tlgn 1h8 front eueceoson.

PClOt' Olreetll!uul S"""rty

1. ~lJo<i"".,. "'. boll 101 ... and IlnkBg.,

1. 88111 ,,,tAt!li and s1s'Dflng Iinil:~!;I(II ne:ad

l~bt1calion.

2. Low OIlJnsven front a nt~r tire plB!latlra,

3. ~ wheel beiifings.

4. Irxorrec1 from wheel o1.fVntnGn1 (OfII~ter)

5. BroQII ,prirg;!.

s. tJlaUuncdonlng mock ilD6(;1I1;:1*)(.

7. Brok9Il "'ab~lZ8r bar or B mtssing link..

2. InflBte 0"'3- 1(1 the reoommended pre$5I.!~ 3, Adi'-l$l tl\0 whOOI bearillgS,

4, Ch9ck ami 8iign rM Irani :lMJS:PEn~, 5. ABp1lii1lUl.I'IO ~pt'Ir:tg&

e. Replace 'ItIe I~k~,

T Replace ltJu stabillz:et b\1T or Jfnk.

Front WhiiII Shim-my (Sn>oaIh Road $~.ti.l

1. Balance 'nu tft9ti, chedc run-oul

nre:;md W~.1!J9 aut 01 ba!iIJ1I;;I- 01'"01,/101 rOLlrld.

:2. Worn!.'lr 10018 wheel Dea1TtQ:s.. 3. Worn 001' foInta.

.tI. UiLlhlncticning shock absorber.

•. Adi"'" the """'" "".rI"!lOo

3. Ilepl_ ilia boll 101 ....

4. Check and JBplac:o Iho ,hock absomillr •

1. Inflste the tlree to the r!!,!commende.(

V"'1cIa PIIIhI to 0<>, SIde (No BrDtng o.tIan)

preElEiure.

2. Frant QJ ruar brll)ces driloolng. 2. fto4uat 1119 brakn.

3. ~d!;Bfl or' sagging (roo'1!Iprifl9. :3. Replace the :iP11"1Q1.

A. inCOfl'ed iront wheel Sigrwn811t (~r). A. Cllectc and align U"!o front BUBJlE'nsjQI"~

1. B:aJI jlilni_t I!In~ Sl8Brrng 1Iok.;GQB rH~od 1. Lubkafe at Ihe r«Qmmend.ed interValS. lubrk:ation.

3. \Nom CCiJIIft)! :arm btlShlngS.

4. WOrn Dr IooA Wheel bearings. &. u,oss smblllzuf btu.

16, Loose wfllll91 rluts.

1. Spring is imPl'(IpefI~ positioned. 8_ l.oos& ampanslon boks.

2.. n~hten the bolls Of replace Ihe $hoOl

aI=d>ar.

3. Replace the bu3f'llngs,

4. A411!i1 or replaQ6 It'\e wneel beatillV$.

$. ~lBn III~ Ihu M;ftblll:u,r bar atti.@;iiOrTt$: a TJqf1ien lhu wh~ ,,. .. Is,

'f. ~Eipo&lb tho- $p!ttllg.

IJ. "TiJItlun (g ,pod'l~kln6- 01 fij;lli.c..

WhMllNmp 1 _ Tli:B BrKI ,1'10 'W,.,~ BIB aul of boJanc.. 2. Tire and 'M w~ are 001 [If KMoIlld.

J, BUEItBif (]( bum!) 01\ ~h81 liflll,

4. lmpropeJ shOOk ~ actlon.

"I. Billar:t)e the WhHd!J.

2. flopla .. 11>0 "0.

3. floplaOOll>t u ....

4. Repraoe lhe: :shocJ!; I!!btarber.

Figure 26 - Rack Pr-elo.ad Spring In.mUaUon

Exeet:aJYII Of Unov.n 1. Ur'!derInfLeJ:ed or overintiated iiIW,

TIN w..r :2.. Improper !09=in.

3. 'Whtiol:S :(Ire DLIL L1l' Dal.nc;e.

4. M.a:rcI dlrNlng.

S. a-to_ m. VBhiolO

1. fnlfaljltl.ll"'tothlr~ndedptM$UfE 2, Adjl,;5t 'ae·il r;.ot~.

Ji. &le:nca tne wtJU8'Js,

4. FCiliow propel: driving tedmlt::;ju&!!iI.

5. Do no. 8XIJ8EId the n'lblrnum rect:lmmendaP'iylOO(l rating,

I. TO&oirl !$Inc:orrect .

2.. Excosstvu ~ 00 luma.

3. Tires al'tllnl)f1;lJl'Br1y irI1IBtad ..

1 • Adi ... t Ioo-In ""h-1Il.

2. FallOw pr-pper (jrlYkli t1PO~~Els.1

3. Ifllir).to the lifs!;: 1Q !t'lt' rlEl'COn'u'ii1j1'ldE!i ~reMiJre,

4. RoQl!8ce the SU5pe~ p'nn.

Flgu .. 27 - o..~I!t Housing ~_ r 1.0111"'"0.

t. R8pJ~ the shook Bb:softie~, 2. ~pt"". tho ball iointo.

:3. AdjJ.I-lrt or IlIptaee \hj \!I'tII!1!ol l;N!arif1;gs. (aLI ruplaG. U'le race6).

4. ElaI ....... the _ olid '"",

5. Ch~k Ind mmpeli$td" I~r rnnout,

3C-4 FRONT SUSPENSION

SHOCK. ABSORBER BENCH TEST

SPIRAL GROOW;: SHOCK ABSORB ERS

1. Purge lin:. elf from (he preaaura dlarnber.

• Ext_ 11\0 .nock _1","'1- !i>p <'"<l up.

• Tum the iihOCk OYer' and oof]epsa It Verlle,tty-

top Emd cown. .

• Repeat tne atXIve step five limes.

2. FI'~BOO tM ~"0dC abSOI'tJ@r In ;a visa Wilt'i l11113 jawli damped 0111.0 't~G- IhlClrCk' .... MiLorn i'i'KXIfit

• SI"<><I< _or shOOld b<t ~lljo'O<I v.rtlcally n-th. vi .. - lOP and up.

o 00 not ~.mp !lie " .. ,.w. on m. "'ock~. m.""'" lube.

S. P""p Ih. on __ ., _us .81 .. 01 speOd

..,.,. obootve In. robotmd ''''''''.

• Rebound force 15 nDrmally SLronge-r Ihan Ih~ comceeaeicn I'c:IrQa 'appro:llimel'!l~!JI 'tWQ to ono).

• ~1>o"no _"""'10 .. om<lOth Md oonBlllni i<>r .. "'_ .... I.-

4. Comp'" with • 900d sMt< """"_.

5. If Dne of the follomng atG cbserved, replace tile

shock ab""ber.

• A S1dp or lag al rovorsal near mid·stroi«l.

• A seize lexooplnt It'll) extreme- Bflm of travel}.

• A "" ... (9'"" or squeal) 011., _,Ollng ""e lull ,!lQ1<e " boI~ dlraetl ......

" A clldlf:ng non at f_BlJt ir~1.

• PurQrag alr from nOf1-5pJrfll groove :ihoolc acs:QI't)O{:!;, ~ not nSGB.!i6Elry. Dle !!hock abSGrbers have 8 _gaS~fili9d ~I in their resal'VOlr3 (as oppo~ 10 Ihe aif·tllied cog in (he spiral groove ,hOCk ilbromer resatvWs),

1, Place Ihj) .silOCJl absorber In '" vlsc wi • ., 1M J:&WS c:1amp6d on !he :&ihoc;::k. .Bb~rb~s top 1T10titlt,

.. 8tLook iJb:sor:be, ~hould be "erd v(JrtieAl~ in d'I~ vlse with r'lJ;; b(M1om end up,

• Co nDI clamp h vise law~ on tno sl"took·s ret;mvtIiIr1ube.

2. PLwnp Ihe .,hook absorber at various rates of 5peed and observe OW rebOund force.

• Rebound fOlce Is normally stronger !nan the conpre.sslo", fore. lappr'Oximiilsly I'i'iQ 1:0 ooe). ,. ~boond rOi'1::.EI .shoul'd be smooth and CCln5tanl klr 9ach :sM'DkEI rate.

3. Go:mp.are with a good :shoo:: aosol'b9r.

4_ If one of the 'ollowlng a.re obsenrlld. replace Ins

ohock._r.

• A skip Of fag ill re'Verssl "e s mld~s1",*e.

• A eejze (except iIIt tlw eXimrne ends of traWl'I}.

• A noise (gl'lJnl Of squoat) a.fter ccmpl9tln;g one fun U'Oka in bf:Jth dfrS(:lloo!L

• A GI~ldl'1lg norse at fa~ 'revaf!N3.i.

Wh9n dlAJ;jllOSing wJ:tuB4 bu.1.rhg COfl[Ift'iCIl. keep in mind .hili ~·eneraI ~ilion or IilII parts during di!Ia9EBmbly arid

DIAGNOSIS OF WHEEL BEARINGS

"~. U •• Flsvr .. 1 inroogh • to <-tv ttwll"IUrO. EIfIfJ fOllOW IJ'lI) r~nd'ed repsl, prooedures.

FRONT SUSPENSION 3C.1

1.11011

2. Wash.,

3. Nul

4. Il<ln

5. W;J$har G. Bolt

7. Washer

8. Rail'1foreemenl

9. B'OCK"I lU. NUL

11 Rivet 12_ Flt!ing

13. Upper Sail Joint 14_ N(Jt

I~. cono, Pin

16. NUt

11. Wa5he'

1 a. S~lm Pock 19. spacer

2{). Shock ADsorbar 21.801t

22. Washer

23. Nut 2 •. Nul

25. Waslwlr

26. _log ~7. NUl

26. U!'Por Control AIm 29. Pivol Shaft

52_ Bracket 63_ BI,i$t'iing

54. ElQIt

55. Waohor 56, Brsck.ElI 57. Wash;lr 0lI. Nul

59. S1.bin,,,, Bar !l0. Boli

sa WBsher

63. Nut

64. 8rac<I

60

55

63

54 53 52

3C·1'2 FRONT SUSPENSION

45

411·

'.I3~L

2. Wasll.r 12. 'Fining

~ 7~ washer 24. NiJt

l5. wa~~",' 30. Bumper 31, Staaring Kn.udda 3~. Coil Sp""Il

33. Bumpe.r

34, C01!~ Pin

35. Ilul

36. L.ower COl1trol Arm 31. Lower 8.11 Jolnl 38. NUl

39 •. Washer

50

40. SY-~ifl9 4:2.8rv.Gket 4(1. Boil

44. u-sou 1'55. Rivet 46. 6u.hlr.g

47 Brackel 46, WElsher 49. Nul

00, Pivot ShaM

28

4. !lQlt

5. Wa:;;h(lr

6. 8.;Jlt

9. Eirsckel 11. Rival 112. Flttine

13. U",* e..11 J<lin!

14. Nyl

l'S_ Cotter Pfn IS·. Nul

H. Washer 16. 5him p.o ek

19. Sp •• er

20. Shook !lbsorbor

21. Bolt

22. Washer

23. Nut

24, Ny, 25,W ashe r aa. i;lu""1n!J 27. NL.:I~

26.. Upper Conlr~ AJtn 2g PiyQ! Sho,_~

4~, Rival

LW061

FRONT SUSPENSION :le-u

~Iltspecl

I. Wh •• 1 _ngo (1~ "n" 7G) 0"" 11\01' ,"""" IT. 000

132) fOr (lama.ge O~ woar.

.ReI';M' to "'01~nos'19 of Whe.el Beufngs" In 'INs ~If.:ln.

II!I' 11 ei~hi:lf 8. bearing or li!;l: raoo Is ~n'illig~ or wurn, ~a~ both,

2, Hl"lb/«Ilflr lor ~;ITU;l9Ii!d

.. OLJI.01.;FQ4.1nd Of ~ ,oond~tl~ .. ... PI't1lI"l!il or iI;;:,~ti(:g:.

E3 In_blii or Connect (F1g"~. 111 aM 17)

ToolS :AequI.ad,

J 9092 Dtlv.er H~ndle

J 84'67 WMI!!! BI;!!IIIt1n,fij: Race Instaiim" J 884~' Wheel ae~rlng Ra~ !l1$Iijllle, J B746--Ol' !'Iul>li1l>tor SLWCrt

36. Nul

39. WashEl:r

40. Bus,n.ing 4'. WasM' 4~. Clamp .J. sen

52. Clo:mp

53. !lu.hln~ 54,6011

55. W..he, 51_ Washer ea N"I

!5~. Sl,ro i lite r Bar

3t 71

72

\

&0

85

82_ lnnor RacE: 83, ElQII

84. Wat.:iher 55. (3._

7@. Ouler Wheel a""'ln~, 77. Washer

la. NUl

ro. DU81 C~p 80. Co_ Pin

at. Woool Hub/Rolor

3t .. 8rearlng Knuril<le

71. Shield

72. S<!oJ

13. !no'" _I -"'l 74, Wh ... 1 Hoto a,,11

75. Oute' :Ral,;@

L001

3C·16 FRONT SUSPENSION

FRONT SUSPENSION 3C.11

NOncE: Stan thB' ~ .:fQ!u_idIN1iy IMId., t/NII frub/rota,. ,a a .. Dld drli'~rt_Ir:UI •. tld pG'ailf'~'8'

~.

L -.. tr~ .00 B2j ;ma iJ1. hull/roto, (81)_

~ Fl'lace !hl:J' ~u..D'rotor 00 J 974S-02 iIIIJ'1IIJ res. li'li!! assembly on press bars.

• U5. J a.lS71<l dlivolh. OUIl>, ~@fng OUl", """ (7S) !oW pooI!lon (flgIKe 17).

.. Tum over the hub/rotor, remove J 9745-02, and dri'1f8 ., Ihe 'rmer bearing OIJt@f race (82) with J 11449.

[] Im...,.n.nt

• Use M app~OIIed hfgtH:empenllure front wl1eBl b8E1r~ inQ 9f'H.S8 10 lubriCBle the bearil1gs. Beter to MAlN-TENANCE AND LlIB!UCATlON (S€C_ 081,

• Do Ji~ M:': ctlKMIU1t grltMIt5 as mil:ing m.y ~oglB (hI!} gr'M~'.s prop6:J'tI'!3'S resuttlng ~ poor poe;.rfQlll"r.B.OOEl.

2. ,,«>11 a 1~ln 111m 01 g"' .... "' the SI •• rlOS knvckl. ",Indio .1 111. OWlr _I I>o.'ng, ... 1 ond .1 'h. iillEllr' ~i bearing SM1. shoulder, and seQI Ebe.at, 5.. Put a ~iH1 quantity or gUllaH Inboard 0' Bach woeel _ng duO! cap (1ll).

tH}flCE: FoIiu,. 10 compio",ly tMck the ..IM.JinQ (~ IDIIorw. .tId ""90) .. Ith g ....... .,111 liI.ull fn ~ture wheel __ 'ng we.r _ .._.

4_ AIIsBCh Wheel bearing (COle aM roUer .assembly) full qf9r~.

• Usa a rorte·type grease mactllne Iha.l fOrC8.fi \}I'9U6 Into th:e bearing.

• fI' it oon&-typfI i'-Oase m&d"!.1,,'Lt i§l I"IqC a'Villil8l;tle, ".ok 1M wllool b .... ir>II by """~.

• When pa;ol<lng the wll8el bearing by hsnd. work tha gli:l.1:!lB Inlo Ihe bearin:gs blBtW8S11 the ro1Ler!:. 00I'\9S ancl the cage.

5. Inn", wheel _ng (73) In'o lhe h.bll_ (8 II.

• Put an adcIldomll quantity argr~ilS9 OLdboa.!'d of 111;" I>oMng.

e, N ......... (72),

ill USQ <Eli 'ft~ ~~~~ D. 01001( to Instan Ih.,. leaf 10 OlIO.,. It "' """" wi., !he htJblllllo.r ft""fI".

• lJJtricale the se.al1ip 'NItti a ihln laye, ot grease.

7_ HubirolOr (81).

• Do IlQI damage lM £teenng knuck~ .wIndle Itt_B_

o. o..ter wloool oaorlng (76)_

.. srid., "It OVEr Ihe splndJe urrClllhe wlleet rearinQ (7fii) tully seats agalool ~e hublrOl« outer race {751·

NOTICe: s •• 'No'i •• - an po,. aC·l of Ihl. 8'eGtlgn.,

S. w;>O~'" (7n, nut (78) and oolt.r pin (80).

• Do not ptBce the coner pin throug" 'tie l'I~e In 1he, aplndle unlfl Ihe wheel be8l'i~s a.ft! • djllSlBd •

m! Tlgh18n

• Nul (78) ID 16 Nom ~12 ft. Ibs.) wl'1ile tumil1B the huhi'rotor assembly in eilher directicm.

.. Put ar"i a&,ulon:al quarjlity of grease Olltbovd of tl\& "0001".",,111; (181,

• ~U$I Ui9 whillBi bsarings:,.

• Ro'., 10 Wheal EI6.rlllli Adju.lm<ml' In Ihls sodton,

12, 00,1 cap (79) DO lhe h.birOlor (81).

13, C.llpgr. A.'.r '0 MVDRAULIC ~OUNOATIO~ 8RAK'ES (SEC. 6A2),

14, Woo., OM tl", .... mb!Y and Iow.r I~. voh""'.

A. OU:tcf Wheel Bearing Rece

Figure 17 - Inlilt.lliling the Out.f WhaaI e..rtng KKo

loo57 •

LOOS75

F1guno iii - C!Iooo_ng ... lo ... r Bml Jalnl

B' lfil!<lU or Conn.ci (Figu ... 5 through 13)

'Jg_~~~;::::.:.'~ So.- Wf>l~- on_

'- St •• 'lng ""_I. (3i) 10 '~e 1.".61 ball foinl (37).

• Press 1M !ii1~t1ng kiju~ld6 OfllD the lower ball foi", (:37) unl!' ~ I. fully .... I.d,

2. SI""""s """"<1" (31) to the u""",, baJIjolnl(13) .

• Lower 1ITB u_ "oll!,ol atiii (28) to sea lho "!'PO' ba" jolnl (13) into 1M .lourIng kn_._

J. Nu", (14 and 35).

m! TJghl§!!

• A 11111 50(1, Gll1/lSOO ond =00 mod.,.: - NUl (H) 10 6S N'n! (50 ft. lba],

- Nut (351 '0 122 Nom (90 'II, ",~,

.. .All ather moda16:

- 10M. ('4.'0 3S) 10 122 N'ITl (901L 10..,• CoII.r p!n9 II. ""0 34),

• T!;IlI1on tile nulS ""',. (1' ond 3S) to .llgn 111. ootter pin, 11' n89d:ed.

rn Imp<J<hnt

• R'0I1§OO. (310/1&10 ard G20!2SOO ,.,.,..,.., - Nul(14);"""'1"",,"~Ib.llgntheco! _ lB' pin" '22 N..., (00 n.lbo.).

- Nut (35): maJ:irnl,lm kirque to align Ihe ,cot~ I", pin Is 175 N-m (130 It Ibs.l.

• AI! ottlBr ,"Odels;

- Nuts p 4 and 35); maximum lorqu8 IQ ali!]" Il'Ie COUer pi" ~, ·175 Nem (130 n. 1>0.)_

• Remove tha rioor J.<K;k..

5. Tle (od and to 1t1& steeril1ll1 k!'1uc](Jo (~1).

• Ao!., 10 SlEERlf.iG LlNKIIGE ISEO, 3111). 8, S~,..'" .hklid (11)_

t. W.sh ... (94) aOO 00110 (Il:jJB!J Tlgh10n

• - (1lS) to ras "'Ol (120 Ill- lb s, ). 8, liubl"'taf """'m~.

• :0::;..'" _.1 HubiROIDi _mllly" in 111,. 9_ ~[por.

• A.'.r", HYDRAULlC fOUNDATION BFlAKES (SEC.5A2).

• AOJUSllha w~." i>ean"ll"

• Heter 10 'WI'1a:al Be.arlt\g AdjL.l&lmen'l· r.n Ihis section.

III Olea.: tna front :aJ1gi'1il1il:1nt'" and i'HSt h required.

• Ra1", to FRONT END ALIGNMENT (SeC_ 5A1. 10, Whoal and 1!,e ~Iy,

• Lower tt1-B ~eleL

3C-20 FRONT SUSPENSION

COIL SPRING

B ~Br or DIleo"""", (Flgu ... 51hmugh 13 Tool Required:

J 23il2&-~' S~ R"movvr

• _ v.; veh 01. w>d ouppo~ ~ with ""~.bI ... rely .lando, .llowlng the """,,,,I arms to hong ''''.,

I. W~I """ Ore .... _1)'.

2. SIlod< _ (20) .1 .h. low .... no MId """'. !

_e.

a NUlS (00). bofts (43), &he,. (41) and damp (42).

4. SUiI>!!"'" ~ (~) ItO", loW., _I om, (3~),

5. N ... (49) and w_'" (4B).

• lnotail J 2:l02lHll on a ""ltatOo Jad< """'he. •. mder Ihe lower oonJrcl arm U shown In FlgIire ~l

I!lI,.....,rIIJIl

• ,....,11 • chain "","rid Ii'Hl QO! 'prl"lt (32) oO'ld "'rough 11>0 '''''''"I' eontfOl arm (39) .. ""'.Iy F'<~.

CAUTION: Flllu I .• ncu ... J 2Il02l-11110 • aUR-

1l1li _ )Kk Id .... uR In po.t<IiIlllnJiIIY.

• Rate lhe }ack to remove the lOr\$ion (rom (he· k1wBr oontroI """ flIWt shalt (50) and .. """. tho "U- boil •.

• .__. 1M _ arm by slcw.fy ....... ng iha j""~ tlI>tiI 1ho sprt!1!l can be ",mowd.

• 00 not dam.ge In" I:JalI join' (37) by "!'f'y;ng too mLld'l 1orco 0f1 h.

6.. SpIl"lt (32) ...., "'<My <:tool", only afte, all CO<np"'" ,00 i. _ !rom tho 0"""<1.

• Prnpsr n'l8J"1.o9UV9r1ng or m9 sprlr'lQ IiIIIII Bilow lI!Iil!iYrSfl"lO'li!.!.

36

36. loWEll Control Arm

lOOS1£

I'Ig",., ~ - R_~.lng ."" Coil Sprl""

8' 18,11111 or Cann.al (Flgu, •• s .hrouUh U and l'Ianc~, Ff>< omp. :f, 5 and 1, .N .,.f/a- "" _ 3C-1 01 1M ..... rlOlr.

TOOl Rsqul,od:

J ~a-o' Sp~og A&mo_

1. CoIl 'Ilri"ll (~) !"IO pooItIm on Iho lowOl ac.~01 arm (36).

• u ... J 23028'()1 boI!9d on • flOOr jack.

m Importsnt

• ... tall a CIUIln lIOurui lila coli .",Im I3l!I and IIuough Iho IoWor _ erm (36) aa • ...ie!y prlCludon.

CAUTION: fallur. to .qeu,. .J 2302&-01 to" .utt .. !ibM ftODl laclll: COIJ.~ I'BflUlt In person •. 1 Irtjury •

2. 81ow1~ urt Ills lower wnlrrn firm Inta posltlOl"l,

• Llne ur;J thai frrJnl' Indexfng hole In the 5!':111ft (50) With tha """"""mber altaCl1log studs.

• gg nol <!omas. Ihe lew., ilIli 101m (37).

3. i,I-!>oI~ (.t4) ... ..0 ... (46) IitId "lito (45).

I!iJ TIgnlan

• 010/1500-2012000 mod61o 10 88 N·m (65 n.

Ibo.),

• All"",", mode" 10 11 S *'" (85 ft. I"".). • Law., lb. fIoo<loclc. IitId ,.mcwe J ~i.

•. StaIJIlizer bar (59) 10 'h"I""", 00,"",1."" (M).

S. Clamp (4:1). w_ (.,). bolts (~) arid '""" (38).

~TIghlon

• NIJta (38) 10 aa N'ITl (24 It lbo.).

iI. Sho<k absorber (20) II> tho low., oonIrol arm (39).

7. W_., (221. bolt 121 I .nO "'" (23).

,001 TIght.n

• ~-ModeJ!iI:

- Boll (211 10 eo Nom (59 ft. Ibo.). .O·M_:

- 8011(21) 10 1113 N-m (80 n. Ibs.). • P·Modol5:

~ t>lut (23) to eo """ (59 ft, los.). • 0h6ck "'" front en<I oJignmon'.

• fllIf.r to FRONT END ALIGNMENT (SEC. :lA). 1, Wh66'l n lire g,nd lower the vehicle,

LOWER BALL JOINT Il!I !.,"01. (Flgu" 24)

1. RIi!I~M 1h~ WIlI",I!II Md wl'r\QVi ,,"1!iI wh@el IH'KI li,.g .,.,."nO!y. s..~~!l tt>._,.;ghl 01 P,. aan~QI '""'" o! tho ""'001 hub ond drl.l1l.

FRONT SUSPENSION 3C.:

2. ~S'_~ure 1M di:9i'811c:e betwEIII;iIn :tI'Ja IIfJ IDf ttl:eball jOint Mud oUInd 'lha tip 01 tn{1 grB8&;!1 'Hntng below Itle ban jOlnl (lIgu" 2o).

3. t-to'llEi 1M lIUppott to UndLglfPloalh 1"8 control arm .11" .. I"ll 11>. wheal hill> afu;! ""'., to h",,!/ I, ••.

4. Measutfl lhe d[5tllnce iii in Slep 2

• tt thB difference Iil me:aS:UrtJrnents eX060da 2,.36 mrn (:lI:'l21-1. 10< aU mOdels, "'. b.U J<lirI! I. worn an<l muol be .. p~

5. If the ball jolnl S8a1~ BfB Cfacl<M. ClII. or 10m. replace Ill ....

A. Mea.-$l,Jre This Disraf1ce

LOOsn

FIg.,," ~. - In.~g tho Loww n.n Joint B :~~ or DI"""'_ (FIg ...... 5 th ..... gh 13

rods RequI,ed:

J 23742 Ball .,IOlnt S~rl!.tor J &519-7 881 Join! Aemoue' J ~~19-2i 5Ia~ JOin' Ro""""" J 21414-30 Ball Jatnl FlxltllB

• R:Bs:a 1I1Ei 'rIBnfc:!e on a tloi:al '11l1li frillT1iE1! ooh~J;'II$ iJ6ed II wLil be ~ry 10 !Support lhli1l !ower central arm with 8 !'I'oor siand.

1. Wheel ano ti,e ~r;v.

,2. Coiio< pin (34), .... (36) and g,ea .. fittl"ll (121.

• L.oo:ien the ran (35) two tum:s buI do "crt ,emove 11.

a, loo"", Ihor ball ),""11 ...... _ring knu<1<lo (31).

• Usa: J 23742: botween th. batr lolnt studl (figu," 22).

.. ff may be OBCM8ary to r~ Iho- caJlper and wire ij to ;i'Ut frame to gwn olearance for J 237.2. Rol., In HYDRAUUC FOONCATION efW(!;S (SEC, 5A2).

• ,,- J 23742 untll "'. I ..... ' ilIli 101m (37) In_ ,_ IlCh1 th. OI .. ri"" ''''Il0l<1. (an

• 1'1....,.. ili<I nut (55) .nd, J 23742 ..

~, rluO/rctor(el)alld tho kJ1""<J ..... mbly,c~lh.,lo blilljoi.im).

• !"Iall J 2147413, J 9519·7, J 9519-28 .

J 9519.00 (fgu", 25).

F1gUf'& 25 ~ RAiTI(lYlna the L'owlr l!iIiI Joint

5. Ball jot.t (37) fro", Ih. _, conlrol .Im (36).

• ...... 1 J 2141<.13, J 9519·22, J 95,9-18 • J 951!j.3() (fig .... 25).

t Tum Ihe hex h04il.d scntW IJAlM Iha ba:l1 Jo.m freD Qf the bwor ro:ntn;al 8ml.

• ""''''''',. 'he '001 •• "" tho bail joinl (37). ;

E3 i:l:"-Jhf< Conneel (Figure. 5 Ulnough 13 Tools Aequirsd~

j 951 g.., 6 Ba~ JoinT In~f;alll&r J 9519-Gl) !lfi!1 Join! FI,IUr.

1. Ball joinl Ill) li'IIe to. iow., _lreI arm (36).

'.' Start the b911 Joint lriitQ tPD DOnlrot arm aM jruitl J 95fs·,a aM J ~S'I!-30 (ligu,. 261.

• Poolltor:! the bleed vent In the rubber OOOIIa:cir Inward.

• T"",!!Io M> ho.d 3CrtlW "nlil tile ball JniOi SB.~'ed In tnt; ~r control ann.

2. Boll joo.! i"IO !he ~ ... ri"9 knuckla (31).

• Mal. 11M> s","ring """"kI. (31) 10 too I""", Ilfl joint (37).

J. CoII",,'(1f "'''''''''''',,

• R.I., III I1YDAAUUC FOONDAnON BRAKE'

(SEC. M2).

NOnCE; s.. "NatJc~· on IMg. 3C·' 0' 'hi. -"",.

~, Nul (35).

~ f'lg"len

• Nu' (3~) to 122 N"" (00 It :Ibo.)_

3C·22 FRONT SUSPENSION

1>. Con., pill (34).

• TtgMan lIie nul (95) II neadeo:,

II]lmponanl

• Maximum torque 10 align {hI! COnsr pin I:s 175 t+m (130 Illb s. ).

B. FlttinQ (i:!).

• Lubri.,.i. ill. balll<>ln' (37) wili> ruoomm",,_ lubrlcant

7. 'rMle-ei and tire M!3embfy. • Lowar the vehlcile.

fig" .. 211 - ... taUlng Ih. LD ..... !loti! JoInt

UPPER BALL JOINT 1L!I1n_1

• '"'" _, ball 1011\1 113)10 ",,"09 Ioadod I. lis so<Kot.

Repl ... 111. Ilall JCirill1 the'e .10 "nv ~~!aI mdvomMl cr d i~ can be 't'Ml5oted In itJ ~et wkh 11'10 ,lnOClu'ti.

• The hB.II Joinl ~a151~r e\lts or tNlS.. A.pr:amt tM ball jofnt If any.re 1000ooj,

8 =';Jf D. Di_nnoet (F19UfelO S throtlgh 13 Tool Roqulrod,

J :1:1142 a.1 Jell'll s.po,al"

• A!Idse 'L'Ile ve:hlcle 01':1 a hoist. It -B htune l10iEii 15 Ul5oo. &1J!lfIOr1 Ihe IoWIIH Mnlrol arm with I!I rJOQ( jack-

t, Cart., pin (15) I""" me "PDO' bAir loinl Ill).

• Loo:5e'n Ihe- nut n4l lWei lvms but do noL remove, 2.... Caliper.

• Aere, to HYOMULIC FOUNO,t,TlON BRAKES (SEC. 51\2).

3. Upper ball joJnl (1:3.) from th9' slesring lulucltiB (~1~.

• Usa J 23"'42 iQ ,~pil;rattll rhe upper ball joillt fr'Ofn !he :liIEle-rtng k]'ll"lc~to (figure .21)_

4, N'Lit (14). and DftthBUPPP,li COr"l!rol arm (28) free 01 thl!!i s!eafing knuckle,

5. eau pint (13) from .l"Ie uppel OOi'itrol ann (28).

• oml 6_35 mm (1/;4 Il"liCn) MAp holes In the rive:1 Ile.ads usin9 8 3,17.5 mm {lIB inch) diameter drill bit

• DrJU 0'" the rlvel heade 1I5irlQ a 1'2.; mm (112 IIKlh) diom.lo, drill bit.

• Punch out 1"0- r'N(l:ti; .a.nd rElmO'llB the upt:fElr ~II Jalm from too Uppl'if e.ontrol SIm.

B InS1all or C:onne01 fFlguru. 6 tntough 'J

and 27)

NOTICE, For .,.,.. 1 and Z, .... 'fiO""- O~ _ SC-1 t1' ill' • .-.elton.

I. Up""r 1>011 fait11 (13)1"10 tho UPI'" oon".I...., (28),

• Posftlon Into 1M iJppB'r ron~ Qfm lind Install Iho four .".Ohlng _ "no "lito l'lIJu,. ~n.

~ Tighten

• Nuts to 25 Nom (113, Fl. ~:ll

2_ Upper ~;aJ_1 JOint 10 the l5lIesIlflQ knUCKle (31 J.

• Tho uwer bail jolnl must be fulfy seatOd tnla tho SltietlOg knlJCkle"

3, Nut (14).

~~ht.n

• A1 Oil 500, G1 Qll 000 ..,~ 132Oi25QO mod.ls: - Nul IU) "' .a N"" (50 ft. Ills.),

• AJI other models:

- Nut (~')"' '22 N-m (001\, ""'.). 4. COlts, pi. (15),

• Tlghlen .ho nul (14) II .... oM.

II]lmportllnl

• Rl IlIf 500, (31011500' and G2[lJ2500 mod.~, - Ma~fmum terqun to iloJ);gfl I..hD colle[ pin I~ .22 ""m (00 ~, IllS.).

• AI' other modols;

- Mrulmllm torque In aiign the cotter pin is 170 N'm (HlO fl. b,.).

S. U_ balli"'"1 Q"' .... rtlling (I 2). 6. "" eas 0 1I\. upp.:;r boil )oli\l ,I S).

.. U~ !ho reCOmm.eMlad lubricanL

7. Caliper.

• ReIer I. HVOfiAULIC FOUNDATION BRAKES (SEC, 5.<2).

fl, Wheel and llro ..,~~Jy_

• Chack Ihl,1 In:tnl fitKI alignment a!'d rf!!jel as rBquire(l. • Flelor t. FRONT ENO AUGNMENT (SEC. sA).

13

14

13 UplXlr Soil Join, 14 NUl

a·ow·1!

FlgUni: 27 - lnataillng the UPPIff Bltlll .lDbi'

LOWER C{)NT:ROL ARM PIVOT

. SHAFT AND BUSHINGS

R10J1 §OO MODELS

II just 1110 OO'~lng. 146) 0' IhO pltiot shah (50) "",d replacement. Ihe- Iowef" control arm (as) does. nol hays to bfI removed from tM vOhiole.

E3 Remov. or Dloooonnoci (Flgur .. 11 tI:lraugh 13,:13 end:!8)

TroI$ Rooqul,ed:

J =8001 C,,11' S~"f1'I Ram""",

J 244SS-2 L6Yaler Oonn-al Arm Bus.n~rlQ SpaDEI'{ J 2:41113!j~3 Lower Control Arm Bl.Isl1in~ Remover

J 2443~6 I..<>WVr Co!!Uol Arm BUShing Spo"'" J 2443.5-7 lDWB,- Conlro1 Arm Bu:shil"g Fbrture

• R~I50 the vehicle OIl a. oolsl and support.ihe fre.me @O th(! klwer OO'Illro:l .arm! hang free.

CAUT10N~ Fe~11J re 10 I rUiudl J 23(1.2:6-01 i.o.!!ll lI5Iult-abl. ti010 r JIDc:k CDtJld I't!IIIIul1 In persona! Inlury •

1. J 230:iZe:Ol to a liuitable IIoor jack 8Ad raiS43 It 1f'l!Q pOSitfon (under the lower control erm (36)), Inboilrd ot the spfltJg ~ Into the depression or me t9VfO( t::Ontroi

erm.

rn tmpo","",

---; In:sJat) a pMtn ever the upper control arm ~~8: ir100ati:1 01 ure 9labil.l:u!'r ber (!iQo) ano OLltbc91.[ of LI1I1l .!il'iock ilbsorc;Ei r (:20)-

2. Nul 12!l). " •• M, IZllI .~d ""II (21).

3. Shock ao:soi"ber t:aO~ from the lowlBl'" oonltot arm (:2'$)

4. Nulsl38), wao!1e", 139 .nd "), Cl'mp (42) a"d boll!

(43).

S_ StEiblJiZBI" bar (59) from the. K:rwl;!r control arm (281.

6. loosen lhe ~lv[]llShaM. ond nyte (24~; i:!o not hMT'IO'II'!!I

7. Nut$ 149). we,M ... (48) a"<llJ-boli. ['41.

8. Lower control erm Ir'O"m the I~~me_

• SlOWL V laWai Ih6 lloor ,k1t~ until ElEl ccmprDI oion I. [@i •••• d 11m Iho w1ng t~n

9. St~kfi gn the frot1I. bu&hlng.

• U:5g J 22717 Dr an oqulvaJem 1001.

'0. 6ushlngo (46) and Iho pl.iot shall (50) hom tha I_ ton.trol arm (36):_

.. u.s:e J 24435-2. J 2443~3, J ~s..8 MI J 24435-7 Ifill"'. 28).

• Tlijhten !he boll on J. 2443&7 1:0 rei"i"JI::M!I. t11l OOSh"'-9.

• The plvoi .haff (50) "III .11d. out oJ IJiO I .... con.tr~ arm after 01'10 bushing is !'efTlOvOO.

• Leave Ihe piVDt shan (50) Ins:Id~ the lower tor trol arm [96) Ie nmiCYO 1"(1 rema.lnlng bustJir'lC

J6. Low ... Coo.rot Arm

FIg.'" 211 ~ A ....... ,ns or Im.tallln9 tho t.o ... , Co"!",1 AmI B!iiilllngi (Rl011~, (>10/1500 .....

G21lf25OO M ...... I.)

2.

lC·24 FRONT SUSPENSION

FRONT SUSPENSION 3C.8,

3 ~"r:r:Mofr Connect (FTgures 11 through 13 NOncE.- Fo.r ."ps 3. 4, &.nd I, 6ft "Notice" 011 _ ~C-l Df fhl. -U.",.

TOOl. Hequlred;

J 2302&-01 Coil Spring Compn3~sO!

J 24.485-4 Lower ConlrOI Arm 6iJshlrig Inslallf1f J 24435-6 Lower Control Arm BUShing Spacer J 244~~7 lowljlr CQIltroi Ann 9IJshiny F1~LJra

1. Nih" l>uSI'O"g" (49) and the plV<il <halt 1M).

• Use J 24435-4. J 2443S-ti and J 24435-7 (flQIHB 23).

• Tlghtl8l1 the boll on J 2.4435·1 1.0 inall1l.11 theblJ5hlnss_

• Ins.ial! one 1::IIJs:hlng. Ihen Inset1 the pifYol s:hlafl and irl5tall the remaining bushing,

• Malee 81..1'"" J 244S.6-6 I:s Ii"! ~:5IIiDf1 to IXtwnl

ca(l~p;!ITn9 tl"le .:;ontrol e.rm..

• SI.k. Ih. ",",1 IXIOnir>g In ., I~"" two ptecea,

CAUTIQf!: Foil.", 10 J 23028-01 to •• ull ..

oble II"", J""" .001<1 , 11 In per.o .. 1 Injury.

2. Lower oofl"01 arm ~36) to lh!i kama.

., SLOWLY raise tl1e nocr ia'Ck until (he front Indo><ln~ 1>01810 In. pl<Ol.hafi (SO) II"", up wllil Ihe ercaamember aH.achf:ng studs.

• Do no.! da"'"1l0 1M ball Joi'" (97).

!II J zao:ze...o1 115 boltsd to a aultabl"a floor jaak ..

3. U.boliS (44). w .. hera (48) .• nd nut. (49).

1£1 T1ghl.~

• 'U·boll .uta (49) to 115 N'm 165 n. 1bS.1. 4, PIYOI silaft end nul. (2~).

1£1 TIghten

• Nul< (Z<I) I. 85 N'IJ1 (70 ft. Ib,.).

5. Slablilz", bat (59) 10 'he Iow.r connu ... m 128).

B. W.,"""C39and 41). olamp (4~). boI!s('I3) _nulo (:le),

~ Tlghtan

• No .. (98) to 34 ...... (25 ft. lb<>.).

7. Snook __ (20J !!> 11>0 ""'.r «><lIra! arm (36).

6. W .. hO,g (:12). bon 121] and nul (23).

~ Tlghll>n

• Nut (23) to el N..., 160 n. 11lO.).

• GItect Ihe front end' 31191"1m0n1 and, reael ee flHj\Jired_ • FIeI", 10 FRONTEND AUGNMENT (SEC. M). 9. Wh ... ond tire .......,ty.

• Lower too V6h1fl1(J.

SPECIFICATIONS (CONT.,

G1 Oil !iOD-2D12500 I.!OOELS (E)lC~PT 21112«1D MODELS WiUL DIESEL]

B Aemove Qr DlooonM<:! (l'!!Iures 5 through 7, 11 through 1 J, and 28)

TOols Required:

J 24435--2 Lower Ccrluol Arm 8u$111no Sp~r J 2:4435~3 lower Control Arm 9uiS;olfig RemOller

J. :2"d43!5.-6 ~:OWIU GoI1~f\!Il Arm 8u&.tllng Sp900r J 24435~ 7 l...O'ivef CQRtrd A:rm 81J&.ttinQ Fooure

1. Lowsr contro.1 M'J'I'I.

•. F!'ofor to "lower COfltrol Arm'~ in hi§. 9(I(;:!100, :l. pivot shah mns (24) ar'K1 waahers ,.as),

3. R ... r _iog (46).

., PJEIIC9 the Iowor cootml arm in an IJJ'bor press,

• Pres. u., Irool on<J e Ih. plvql oI!!In (00) 10 ramnva llie rear bu~ing.

• The pivot $100ft can be removed al1ttls lImo,

4. From busnlng (46).

• Use J 24435-1, J l+l35 .. 3, J 244:15-2 ana J 24435-£.

• Tighten J 24435~7 10 rernov's IhQ bUIt'llng (Iigure 28).

E3 Inol8l1 '" CoDDec:1JJ::1lI.u",. 5 lh",~gh 7. 11 thrDugh 13.28 In ~J

TOOlS Requll'~:

J 244~:H L.o ... ' G""troi Arm Bushing In.tall., J 24435·6 Lo_ Coot<QI Arm Buo~1n,l Spa .. ' J 2M3!H Lower Con"" Ann Bu.11ing FI.t"",

1. New bu'I~'8 ,461 .'"ng J 240135~, J 2443~4 ond J 24435-7 (Iijju., 2e).

• TI!l~1sn J 244:>5-7 "mil jhe Duohlng lully eeets.

• The outer tube no~ ·miJlrtbe .Iined up eo tt reces

to Ihe- front or lorwam 10 the 51B~ bu$hl:r.g.

• Slake IJoJa front bLlshing In IiII (But Iwo piacea,

2. Prvol Ijhtdl (SO) InlO lns.ta:lkId bushing.

G, Romalning IHmhing (46) 1010 1110 __ I """

Ciolil_. (C<>.~)

i;puh Shio.1d '0 ~UOIdo , ..

LDwor c:o.'''1 ......, eLUhlng, IOOQ/3011O """y1 •... LDwor POtot Sllall EM PoM3 (Exo. G3Ot:l5OO) •.•• U-POtotst\BltU·Ilo!!_

O'lOl35W ,,'

.1I0tl'Ie'~eI8 __ ..• "._" •• ', •••••• , .••• " •• , •• " •• , _.,_,., •• ' ••••. _.

Uppe' eo-I AmI BlJoI1o.g1 (GOOI35OO on'>') ••...••.••..••..

U~' _I Shofl E"" Not>!E>< •. G30/~) . , .

UIfPO' pj"", Sl\an n",HlolI N .

G3Q/l5OO _10 .

AlOIho<Uo<folo _ ..

lI1'IIO! !!olt .I.l01l. Uppo' C<i<\tf.1 AmI , , _ .•.

er...rn.mbo, 10 ilo""" FiWne 1I.a11 ..

C~rnbGr 10 Std. FfiffJe RBII • _ . __ ••••••.

S\J..,.,...,.~r , , .

~"'" Ie SIiWO~ Slruto ..

I·BUII (RPO F~) :FRONT SU$I'ENSICfI

P3D 1IiIode'. ShoGk AbSOrtJer to Frame

Shock Ablorber 10 Axle _,

stabUllor~ PrBJllB .• "

SlebIRHr to StabIlizer Ul'lk

SpIo>I1 5hlold to _ Plato .

Bt88Ifng AJ1f1 to _ ..

Co;ps. fO steering KnucXls _,. • •

I.ociII; Pi1 ID SteElnng KnUCkie , .... _ " ..•

Spong to ~., ,,"is ..

Spong to Sn"""" NuiS ..

<Jprlng to AxIo u·".n NuIO _ .••

ShadQe 10 Frame Nuts •••••• , ••• _ SlApanalon Bumper

1'OO1t WHEEl. CftIVE .FR.ON'I SU_SICIiI

"'~I.

Shock ~ 10 F,@I!l@. •••• , •• " •••••• , , .••• _._ •• " ••. " " ••.

SIlOck _ to kM

W.n27S0wuJ~ _ ..

AJI-otn8r'~·~·' ._ ", " •• ,~." ••• , •• " ••• _ .• ,

~Oil~er It;:l FIVIlI

~ , , , , ..

AlOO!o<_ " .

S<o!llliJ" I. ~ng I'I&te • ..

~ Knu<k)e 10 Uppo, Ball JolI1l (EI«:. V_I ..

S"",""" K._o to lawv, Bon JoInl (I!i<o. V3(J13~1 .••••...

RaIl JolAt CoII., Pin Align"""" (E"". vaoi:l5oo)

Uppor Ball JlIlnt - Moxknum , .. " ,' .

~JI!Ilt"l1 RJno;j to Spindi. (e"". V30/35001 _ .

C!loo 10 Sieed"ll _drl. (V3040il0 onlyj· , _ . . . .. . .. . . •.. _

f<Io,g PIll 10 Krwoll. (V00i3500 only) -.. .. .

_ Pialolol<nucklo .. ..

SiOOl101JAAnIo_ , .

l.!:IckPlrI1o,stftringKnuckie , •••••• , •••••• " •• ~! .•• ,_ .•• , •••• " •••

St>mriio~fNui' , ..

~ioSliBcl<I.N .

SpiIrljjio_U-BoiIiNcrlo _ .

~ i.e FrarDIIHutB _ __ .••••••• , ••••••• , •• '" .• .;. •••• , ••• , ••••••• " ••• ,.,.,

Su&pemloo Bumper , _ " ..

Tcfl'BfrIiEI ._ .. __ _ _. __ ,

10 FlBrnB BracI!;.el •••• , _." •• , •• '" •••••. , , ••• __ ••• _ •. _ •. ro., •• I, ,., .•••• _ .. _. __ •

NonCE: Sell ·H,O"r; .• •· Gil pilgi 'C ... 1 of 'h.i. ,jpe.'IDn.

4. Pivot MaR w""".,, (25) and "Wl (24).

I3?J Tlghlon

• N ... (241 10 156 Nom tus ft. 11> a, ).

S. Lower control arm (36).

.. Fi:efor to BLowM" Controt A.rm~ in thi6 section.

H'm 13 J19 t56

Ft. UlL 10 Z80 115

115 M

- IS;;

B5 S5 1110 11&

142 95 2S 122 118 ZO il

105 TO IS 00 60S 15 00

108 45 I:I! 6iI 16 312 1

<0 125 125 109 125 34

65

120 88

70 95 180 13. 40

52 70 .33 100 :!O

1:!C 50 eo !;5(1 S5 90 '60 90 90 'SO 50 15 2. 15

GM·~...a.

3C.62 FRONT SUSPENSION

SPECIAL TOOLS

ng J 24435·A 9. [We
1. ~et!; eo
2. ~ J 23448
10. ~
3. G~ J 23454-0 A
11.
4. CW J 2.687S,A ~
12.
5. ~ J 6368 13.~
6. ~ J 7817
14. ~
7. efI J 689J..0 ~
15,
8. ~ J 6627-A
16. ~ t. Needle Bean!19 Ins.taller

2. ~noor Beruiflg ~a~e; Jns:lalEer

3. 6all Joint Romover And Installer

4. WII."I Soartng N.I Wrench S_ Oul&r Be;arlng Race InS18tlcr s_ Front Pil"l~n Bearing InsotaJlor 7. Wn. .. 1 Beating NUl Wroncn

a. Wheel SIu<l Am;! Tie Rod Romover

J 9.~1!l·0

J 23742

J 2.2301

J 21465·17

J 8092

J 23447

J 9746-02

J 23028-01

9. Ball Joinl Remover Aoo In.staller , o. san Joint Separato,

11. King Pin Bei!.nng Saal tns1a1I~r

12. Ei •• "ng 1"'I"I~r ~ 3. Driver Kaodle

14. Ball sue NIJ1 Wrranch 1.. Huh/Aol", Su PP<'" 16, Spong A""""eI'

L00614

SPECIAL TOOLS (CONT.)

FRONT SUSPENSION 3C.6a

17,

J 8457

21.

J261171

Hi.

J 8849

22.

J :la871

19. ~ J29040

20.

J 2344ft.A

L.Q0615

RE.AR SUSPENSION 3D·S

18

12. Spring W • .ner

1 3, Rea' Sho<~ Absorber 14. Boll

1 5. Spring Wa.no,

16. Nut

17. Front Kange, Support 18_ Front Hanger

19. Axle Bumper

2(1. Bumper B •• ei<ol

21. W:e.-she,

22. Nul

25, Rear Hangar Aeln10r0amenl 21> 1.0;01 Spring Eye

BU$r,~l"Ig

27. seu 2B. Nul

29. Nul

30. Il<lll

37. spac ••

38. Boll

39, Spring Cilp

1.llraokat

2. Boil

3. Washor

5. NUl

6. "" .... Shookle

7. Anoher PI.'.

8. U·ooli 9, Shim

10. L •• ! Sprln9

11. Nul

11).6 REAR SUSPIiNSION

t, Brackel

2. Boll

3. WiISliG'

4. l1ear Hanger

5. NUl

8. R ea r Shackle 7. Anoner Plate e. IJ·WII

10. L. •• , Spring

11. NUl

12. Sprlft\l Wa.he,

13. ReOf Shocl< Abs<lrixlr

14. Iiott

1 8. Front Hanger 1>1. ""'0 Bumpe,

20. 6umpor Brockel

21. W!iSI>o, 22, Nul

25. Rear Hanger Reinlorcement 26, Lo.r Spong lOY.

Bushing 27.6011

28. Nul

29. NISi

30. Boll

1

FUELCONTRO~ 4-'

SECTION 4

FUEL CONTROL SYSTEM TBI MODEL 220 - V6 OR va ENGINE TBI MODEL 700 -l4 ENGiNE

CONTENTS

-

FU@IP!'4!1i!iUlIE!Re,li.fP:nxedure 4-12

Full S_yUi!'m Prenl"lr~ T~ ~ ~ ~ = 4-11

Threi!ld L(u;k.i ng Compol.l n.d •• '. • • • • • •• 4~ 11

MOOEU.OAND 700 TBI U~JTS _ •••••••• 4·15 C:ontroileG Idlo.S".~dChO<k ••••••••• 4.17 Mii"llMUIl'l tdl@Air Rate Chet;k • ~ ~ ~ •• ~ •• 4-17 TSI220(QMPONEN15ERVIC< FUU

METER COVER AS-<;E;MBll', T91220 .... 4-18 FUEL INJECTOR ASS€MBl Y· TBI 2.0 •••• 4-U f~El METER BODY ASSEMIll Y •

T91 2.0 ••••.••••••••••••••••••••••• 4-l1

THROmEP05ITIONSENSOR -

(m) • iiil UO 4·21

IDLE AIR CON"TROl (lAC) VALVE·

TBI 220 • . . . . . . • • • .. • • • • •• • • • • • • • .. 4-22

THROTTlE800YA~SEMBlY ·TBJ 220 •••• 4-2J 781 '00 COMPONENT SERVI~E •••••••• 4-24 FUEl. INJECTOR ASSEMBLY - 'tSI 700 •••• 4.24 PRESSURE REGULATOR ASSEMBt Y ••••• 4-25

FUElMETERASSEMBlY .,'. . _. .... 2~

• THROTTLE POSIT!ON SENSO .• , •••••••••• 4-26 .IOlE AIR CONTROL (lAC) vAbVE , ••••••• j..~1 TUBE MODUlE ASSEMBLY ..••••••••.. 4·28 T .. ROTTlE BODY ASSEMBLY •••..••••. 4.28

FUElPUMP , .. ,., .. , 4·l9~

HUEl PUMP RELAY. , .. • .. • • • • • • .. • •• '.29

, FUEl MOOLlle _ • .- 31

• OIL PRESSURE SWITCH 4-31

fUEL FilTER 4·~2

In· Un~ filter Rep(a("golTl~t'1t ~ •• ~ • ~ , ~ ~ ~ 4-J2 in-Tank filter Repl.a-cernent I ••• ~ ••••• 4~32 AUXILIARY FUCL TANK CONTROL ...... 4·34 S.etll!ldO( V31vII!' and Meter SWitch •.••• 4-3.4 PUEl HOSE AND PIPE ASSEMBLIES ••••..• 4-14

M'aterial ••••• ~ ••. ' •• - •••• ", : ••••• ' • ~ 4-3.4 Fuel Line Repair ,.~ •••• ~~.".~";;; •• 4-]4

fUeL TANt:: ]5

Ot:ur'lI;'I9 4-]S

R~plaetHfliE!'nt •• • • • • • • • • • • • • • • • • •• 4-15

PurQing ••••••.••••••••••••••••• 4-35

FUEL ~Y5 TEM Cl<AllmG •••••••••• , • •• •• J7 in-une .Fu~l ~11t.E!lr •• ' ••••••••••••••• ~"4.o

LlI8:!1k rl!!'~\ .110

ACCELERATOR CONTROL •••• , •••• , 4-'10

A.u:elerator Control Cable •••••••• .,., 4-40

Accel.eralQr PeLle I 4..11i,

PARTSINFDRMATlOII "-'13

SPEC! FI CA nONS , • • • .. • • • .. • •• +44

Z FUE.l CONTROL

ENERAl DESCRIPTION

'RPOSE

The ,ruel e~ntr(lj ijy~Lem i, c:ontrollt:!d Ill" lin Idnrnc l!::oi1trol module CECMl located: in rhe saengar compar-tment, The ECM t!; the ecntrol 'tar o~ lh:e Computer Command Control !iI)i5LCli'll md in. Set lion "'3" which provides 8~ditiono.l or-million abou1 rue1 c!Jntroiand deJl\'e~ . - The baale funetien or the fuel Cionttol system iiS to

ItnJI ruel a~ljvery to thee.ngln.t!, Fuel ls dellvered til ~ eHKin~ by '3l:hftlttlc!: bod)' inj£lcUdn (TBI~ uniL.

_1h~ t'ftfii_i\ mnt.f91 ;5onsoT15lhe olllyg!n (Oa' :s:eO$<lr, (ch IS locatttd ill the eJ['haw>i manifold. The 02 taor ~U:li the ECM the·llml)n.nt of Ol(ygun. In the'!: taust gaa,lll'ld the- ECM c.ha.n(Cs the ai.r/fuel ratio to ! ensine by eo"troning thfi fLl.i1 iD,jettflf. A L4,'jl:J Ifuel rQt~o IS ,-lj]qR~r'ltd ror efficient cat.alytiif; rverter eperatfon. Because the rnHBI:.nr.IL mea:su.rin8 I (ld;~ting at the Birffuel r;atio/ tile rlJel injcctlQI:i tern IS ealled e BCtosed. Loop"s,y'st.cm {FigUfl! 4-11.

'~ES OF OPERATION

The- ECM m-oniwn 'VQIt&gcs Irem se .... eral eenecre ieLel"lninc: how mud. fue I to g1Y~ the engine. !'he I is dciiv@n!d. under one or EI!-Verat eonditlcns <a,n@d xios" AU the mooes ere contrQlled hy the SCM,

l.tiny Mod.,

r-~hcn t.nlil key i:&; fir8t turned "ON"; the 20M turns the [\1(11 pump n!l.&y fot" two sl>Cond:!i, and tnt r uet np buUd!ii up p1'essure ta Uu~ TB[ unit.. The ECM ~fs !..he eQG!~n\ Ump~rHI.I.:rc nnSOf, "hrOI,.t.!t Ltl,On. s-e-n.._"I(IIr !TPSl. manl ro td flht;o luto pressure

(MAP).:;.eflS!){", IIrld ~r"nk signal; then detertninee the proper ulr/fll~l ratio for starting. This rangaa from 1:5:1 .L .as-c (·33°FI t. 14_1:l. at 94'C (201'Pl runni:ng tempe.r:a!:ure-_

The EC.M ~J1lrol:ll tM i!!rnQy,n~offlJ~1 gcU~'tr",d \11 the !Jl~rt~nlJ mode b,Y .Q~~nging how h:Jr1,1]: ~ht': injll<:tor is ~urned "ON" ilnd "'DPF" This it; done by "pulalng" t.bc Inj@c-t.orroJ' Y-Uf}' ,nortt.im~

Clear Flood Mode

If tho ongi"" no."-,. a] ce r il br. ~".hlng .~~, oecclcrntor ~al down all Lht:! WKY'. Tfi@ ECM Lh~ puls~ ,the inj~tor.at 0 20:1 airff'uel '".tio~ and hot It OtT ll\l~ctor rate as Ions: 8..!!1 the t.h:r~ttJI!i $Bf~ wi .",n, ~n<l u.. en gin. is bel.", 6UO .,,"'. If I~e "'jtl pqi,itjQn. beeomes It11 Lh.an 8K. the: ECM r"tUJ.m!I

thd Storting m<Jd ••

Ru Mode

-

The. Run mode h~~ Lwa condjtiol\..~ e.alled "Open Loop .. ..-.d -Clooe<l Loop",

Ope" loop

W~ef1 the engine [5 fil'5t5ta.red, and iLis above 400 rpm, t.he system gee., [n~ "Open Loop·' eperation. in "Open Loop'. Lb. ECM ignores the .ignnl rr.", Lh. O • 8tln_!i~Jr, and. elltcullllL&S tho alrlr~.Dl rB~ig bI.:Bcd Ot] inputs from the II:DQlan't. ~lJmp:era~u[e: and MAP eensnra.

The u.tlem SUY!i in "Opera Leap" !.T,n.ti! the followln.g eondilloft. ute met.;

I 1'hl! Q..,j ::SG~Go(" hae vu.rylnB vult-Jigiii' lJ-ulpuL. !iflOWing that it is ho," enough to eperute properly (Th.b depends on iemperature. J

The C:'loil:lnt ttmer;p.~Llrc l!Ien,ol" l~ Dbo e

I.. € . emporatUTJ!,

A speciCi-e amount Dr tLm~ has i!lapie:d afhr Sltnrting the engine.

The 7.41.. tll'\glne is de!lillned to operate "Open op" .lil id.le. The! s:vst~n'I will go to "'C1G~ e -d Loop!" w en the rpm i.s iru::r~.Euii.edalld,,1 cQJtditio-risElioove ari! t

OosedLoop

The spe-c:i:fic values rc!' the ebeve C!onditicn51 vary with diffe!"e-n~ engi!iif'li, and are !;!Ito-red. in ~he programmable feud. only mem(lr'"Y (P R.O-M} , W-hcn th@l:iill! (!oD~:Ht1QnPi are mel, the _s)'st!!.ms g~el!i into "Closed Loop" 0pufI,tioq. (11 "Clo!!ioE!d Loop", the EC.M culeuletes ilie 3ir/r~el t"tIItil} (injec;:t.or on-time} bond on the ~gT'Ial f r om the ()~ sensor, Thi~ :!.Hows the ~ir/ruel nlllu to :rIit.u.y very cJo~1!o La 14,7: l.

Acc.Jer~don Mode

FUEL CONTROL 4--.3

'Pbe ECM lflok!l .at re pld dH]:r't~n .. -s ln ~IUl)lUt poaltlon and mafllf"ld prueaure. MId pmv idee E~Lr.l1 rUI:!I_

Wlum cl-e-ceJe~UOil ueeura, l~C rU1:I1 rflmaini_"g hi lhu intake m.'3.i'!,lfold -I:I.U'I enuae ej('~:t1ti~(! e-mi!s:!iliQfl!l !1(l1d bn~kfirt'PI,g, Aguiar lh!!! ~CM looks at c:bGngl'.i:l!I- ln throtMQ poaltdon and motiifold. pressure und reduena the-llmll'untDUuel When decelamtton is 'I.',crl CDSt, the ECM ceneur aITfuel c[)mplet.E!!y for short periods.

Banery Vellage C"".ctiol! Mode

W.fm.1'l b;!llttery 'If.otl.age i1l 1'f1w, thlO BC.NI can companaa te fee D. wo!}Dk 5pBlr~ d~liV(!lred by H~t dia:r.:dhu~l;" by:

• 1!l!':~::l'ngl.njE!ciDr Con i.inl(:-ofrueldel.1...-a~

" I t'!{;M<li!i ng the id te t"p [II

.. tncre:ili.!lin~i.gn{tio,ndW'i!ll time

Fuel C;utllff Mode

No fuol is ,de!hrered by Ln8' injector!!. ..... lil:in tllEl ignlnon i8 "OF~". This pri!ven1.:8 diegcUI"Ig', Also. Iue! is ll:oL delhie~d' if no r'er~!'"en~ ,D'g'~t~ Y,Ht seen r~om the (h$tdt.utor. whh:.h rneans ~!JI! ~11!;inl!' jg. ntH run,..fng, Fuel cuto" also OCCL,m:i IiIIL high enl{ine :rp:i't1t to PJ'OOOC!l lrrternal el'i!fifl~ ,,=gtrlJ)[J!lS~t..Fi from ajlj""~!lgt

FUEL CONTROL OPERATION

The ruel OfIon~t"\11 ~~t.Vm U'igure4."l) :C:tJr';J:iik;tl:i ofthe rcllowi:nj{ cetmptlTUlf1 ~8:

.. Throltl~ body inj(!!t;ti'(ln CfBn lmlt.

.. FUII!I pump

'" Foe I ~lJmp reilly

.. PUI!l;~ Lank

• A(~ 1'Ill'ato.r c:o n sm I'

• Fual Hnua

• 1il'llllpai'iiU~a I!'mlSlli.on li:ontrQoj :iJysbrm

Tht r\,II:~j control system h:;;..1 en eleetrtc fmd pump. ltJ(:uleci In tha rue! wnk w'Lt.11 thlJ' gJJ.g:I' SE!ndin~ i;.Li'lil. whjeh pumps fuel to Hie TBI tkrou~~ Lhc- ruel i!upp'l:y li:I1E, ltt.;:,!"i lh1'O!dgh and in-~jni;! ry,e! I1Iw the pump le d:~-lrtn~ tOo prev rd e pr~s~'Uiri,ttd rue I ut a bout ! 2,5 k Poi;! ~ 18 'P8H. On vehidc.1!i with lwp, Iuel tanks.. l~et() i.J I.Im:rleC'U-ic: fl.t(!! pump :lind E:D.g1!! !ill!mH!l~ unlL 1." oBj,H~n

(UI:!'J lil.nl,\[, .

flg,LJre' oIII~2 - Fuel 'C'o~;roISyH~ni

A preeeure "~"I"dalCJr in "he TB[ kecos fwd evailabte to the ~Ilj{ldlilr3 at D. I!ons~~ nt. neeseur e bstwaen 62 Ul'Ld 90 kpa (9' nnd l j psi). F'1.ie~ In £-:':~Els:g: of itlj€(!t;(jJ' needs is returned t~ ·U'!t- r..Lo!ll ~-Eink b}' J3. !!:tpu;rn~B ltne.

The: ECM I:Cintl"Ols thel.nJoOclQl1II t.b.at IUO;~ Ia-t:a.ed in Uie fuel meter kuxiy !:l:J!ill:lmbly Ortb08 TB,f. The tnjo('(:1On deo,live:r:f\i1)1 i!l oficdslB'!',!!'E'Bl modaa.eese .. il)edabo"'IL

11'1, ordm' te pn:qH!·r'ly ~j)n.trill th~ fUitl :;S.i,i'pp{y. t.he n .. "l pump [s operated b}' U'l'l: !-:C.M shrnugb the fue] pump relay and ni] ~re:"'IJ~ tlwlt,ch [aeu "FUI!!l Pum-p Bh!l:tdesJ C~:reuit"l.

MODEL 2:10 iBI UNIT

MotiIJI 12;(]. used on V6, ;And V8 e"'gJ.n{!~ I Flgurll!! 4- ~~, OOr.l.El::;ts or th_~rn-;.'!jCf"e-as~; ~ g-assembl iee:

• Pue I me ter- ~OV1l: r- w ith~

Peessuee regulator

Fuel injeetora

• tnT(] ~tloI!I bod:t wi Ih:

Idl e air ,!:Q!'ltr~l ~ I A CJ vill 'for, Throottle. P<i':.l'~~ioll senecr (TPSi

I\I!QQEL 700 TIll UNIT

Madel 700, used on U'ltl L4 -C!n!l;l11-:! 'Figure 4--4,'1" is rn,adc up of lowo ll'LrU e r -c;u;'tin!;l: aasembl iE!.EI:

.. Fuai ftiuior 11i5-oi!TIi.~I;y witt,:

PI"',""5a-ure ,r'i:!gulaoo r ruel Injector-

'" "hI raLtle bod)' with: rdhl:o.ir eori~nl~lAC)

Thttlt.tle pDsHi«l.$(l:nsot fl'PSl

4-4 FU E L CO.NTR m,

l OJ PUE'I,. iNJ~C:"'ORS [!] TH~ OT!l..~ DC.~V AS. ["'.U

m T"'IRGn"l.E P-OSrnONSENSOA (TP:S,)

m II:H.E ... IM CON11iIOL (I .... C) VALVIe A:SI!IE ... el Y m FUEL tdn"t;FIi BODY ASS~B!..I(

[!) ~UElL 'METIER COVElli, ASS!!I!!!!Ii1. 'f

IilgU:fll!! 4,,] - Mod'!!l 220 lBI Unit

The thmttle OOJy portion (J( bQth 1'61 •• milS mny ~t)n~jft ports [!)cQled above, Or below the tnruttlll!; vnlve. TI':i[i$i iJ6fl;S ,!len.iirult lim vacuum :t;i,giiol_'Ii! f(ll:" UUl CI~hall!!l~ ~'IJJ:i' r~eirC'ulatil[ln LEClR) valve, MAP sensor. and the eanlater 'Purger purge :!iY!item_

fl!ei Injecoor(5)

The fuel in.jBGtors; [Figure' -4--0 and -!I-,S} "are aalenoid-operated devtee, lC[mtro~ted by the i!:CM. Th-e EC.VI tuee.s (In ~he .9DlctlOid, wnie.!i Bfts G, no~:m.lJ,lIy <::1i)'S.r:::t! bi:i.ll ... -a.h.e orr il :!IciJ.l~ F;,jof![, Un:dfr pi't:Biur'ii. is i nj~J;:Led In -iii. ,~,onL~1 :S-Iilray peuem Bt the WH,III!> at the thruttje bcd,y bere 8.00'{of! the throttle v alve~

[JJ nrm, MI!:TEFt ~SSEMl9l. 'i

[1J J"1lE.S:!;:U:R.~ H:e,GULATOfl COvlR ASSeM!;I.i.V [}] ruElINJ'ECfOI!i 1~;SSIEMBL V

~ ~~R.Onu "(I51T10N S4:~"O~ iT •• 1 ,:n"U~C'TT4.:E IBOo.,. ;l,SSIEMHlY

Tuflf MODuLE "'_SSE!M6U

1D'L1i AJ~ CONTHOl U,II,O VALV~ IIS41!ii!l8,fj'~

FIgure4-:-4-Mcde! 7()OTB.i lJn~t

Til'!: fMcol w.nl<:h i! rlDt used by tho injtc-t.ort! pil.~-6015i:!1 ~h!"Qugn U111:l prnseure regulator bosfon belng returned I.Olho f'1J.e1 tank.

Pre ss u.e Regul~t'"

The pl"lJ:!iEiun!; l".t!gullilLlJr Iaae f','gu:tl.i: 4-i5 and 4-fl~ La a dlaphragm-cper atad ealfef 'VaIY-E! with inj!!'cl!ll" pressure on one :g:id:iI! B.Dd nLr d~Mo£j.r pril!.sg..ure- IlIn lh_..;:! o-ttl-eJ'" Tbe fg~tion g[~. '1;"'lIl=gYl;Q,i:,(I!" i:l! W l'Q;@inw..ir.- ~ ~nlSt3!'l." pressure Q.t tht injCl.::tU.S ftt. oI.l..ll ~~ml!J,:!i. by COI'Hfcdl1ng UiIJ flow ln 'lhil return 1 in.g (by means o f e catlbmtad bYJl:ll8's),

The preasu ... e reE:1JIa.~or on 81 'TBr 220 unit is eeevieed as p:l~t Qr Lhe rue I meier eovee end should n",~ be disasse mbled~

The pressure rClgul_at'uJ'" oOn ~ 'TBI '100 Il.ir:lLl is servleed ae p:ll.rt,,(Jflne Iael ml!tEir 111515I1!1mblj' and,ea.n be di~!i:s.e eibled ..

Idle Air GQntrnl System

AI I I!ri.gine: idl Ei 5'~S are Ciof1trolll!'d by thoil EiOM through the idle air !rontrol (lAC) vlllvlI! mountEd: an the thruttle body (Figures 4--7 or 4-B). 'The ECM sends '1'01 ta ij['e pulses ki Ute lAC motor windings eaul!rinR' tbe lAC l'I'(lt.or sbQJl il.nd pif\Ue to meve "'1N"r QI' "OUT" a gi \fen d:.J.~ta:fil:~ {fiu..'mhcr 6f Slept! (;or C-l1I!h p.1J.1~. ~ ealled I;:(;!.unbit

figi.i~ 4-5 ~ TIU220 Unit C1=i~fa-tion

FUEL CONTROL 4-5

ITl fila. ...... ."."" l.Il f1JI'L .. LOT

W ~a METER .u:SI:M:IIIl,V t!J FII-EL OUTLeT m PU1UlEi FlbTBI

[IJ' !NL!1T "'LU.

[!J TttROTTLIi BODY A.5SEMlUL.Y

m P.AE$SURfi M:Quu, TOil! coYER ASSDotBl. 'i m Pft~~RE A£GUUll'OFI SPADfG

[!] PRESSURE AEGUL,l"TOR DI~P44RAG"

Ir.$.$Oi,jj;L'Y IIPO]JQ.'St

figure' !1-6 • TBI 700 Unit OplQr.tti On

This movemeee «ntrols uir.flrJw 8l"Ound the. Lhrnu.l~ plute, whleb in turn. controls engine- idle Spm, eLlhe,!" cold m" hot. lAC vu'~e pintle posiLion t.'Ollrlt-6 ron be ~ctm using a '"&10" tool. 0 counta correspenda to rLLily cl~ ]);lSstlg@, while 14.0 eount.8 or muea ~dl;!pp.ftding on i.ht.appli('atian) eotrtspendl; l.O full nDW

• Actual or "oontro~IM"jdl(l spe~ is {lhtuirl!}j,j by Lhe ECM PQ-IiUi'llnin_g the lAC ...-o[ v e- pi.il.le. Re!'iuhi.ng ~dle speed i.JS g1tnDrElt.ed from Lhe t(]l'l;l.).1 idlo uir n.IlW IlACiP4,f!:lUgC! + P.CV '+ thrQ .. tJ~ "ldv~ + sueuum lenk!!!I_

• COIHroHE!~ lcU-= ISp-tcd is ulwo.ys .'i:'P~Qi nlOd lor ner-ma l ~P't.rIillUng ronditicms. NO:r'i'tIlll epernclng wmHtiQIl i:lo ccclant t..empe_l';;)turll' In. opO!'raUng l':;Ingtl. the NC is "OFF'·, manual tron!imi:$!lL!)tI l~ in neutral D'l' .nu~m4tie t,runsmtsi!iliott in drt..rlF,!! with proper P!llkl.Nuulru.15W'it.ch .adju'stmcnt. ,\ high Dr low' .:001 a 11'- temperature. or NC clutch en.~B~ m_uy :signalliu!! ECM to change the lAC eounta,

• Th:e minimum idle ilir rate lS $i!!'L at tht fOCKll'"y with 'it stop iiCrcw' to permit enough ~h" now by Ute thrQtUe. yahoo; to cauae the lAC valvo pintle to be po!iiiLiiJmm a eallbrated number or steps! IrounLsl from the 5I.('!at during: nQrma.j ~onLrolled [dl,f! DparnLillri 01.1. aij-il level nr- low oltJllJdt en OloH engine with mQct ~hiln.500 rnllee. 'fhe fAG ccunee will be hi,,;ncr g.1l iI.n engtne with JC!li~ l hu n 5tJO mttes, ;J,n cnginl! f.lperoti.nl{ m Ili~h ijlllLud&!' »e un engfne wh." IIlnoe.~E!S:5iQry IOl)d !IIuc.h UI:; .(.h~.LI J~rn_llt6r, Me. poower :!jli!!l'rir)g 11)1" h,.~nl·~"Hm:-t~ hntkl'.'1lLc-f,L1.JlL'Wd

[!] FUI!L MeTeR COVER 3; flODY ASSEM8UE~ m THROnlE BODY ASSEUBLr

[2J 1Dt..E AtFil CO~OL. V,6JYE ASS:E:U8U IX], FI"1UEIl AlA 'NI£r

m PI'flU:

@] TlIRQTfY! V~

@] VACUUM PORTS .. FOR 'ENGINE OR ~III:~ON CONTIIOU;

flgI.He4 .. 7'1ldl~AjrCOnttol S~~m (TBI2~O U"!fl)

[!] F:UEl.. MUI5"R A-Ut: ... lY m Tt\1I\OT'TLE 1.00r "-SSIlYBto v

m ID_Li. A. [A CONI"ROL VALVE fI1.1t."'GI AI~ '"I.fl PINTL£

[£] .'_CUUY fI'DAT.S FQ1I: !"(i.INe;

. Gli D.!IIISSIOH COH'Tl\O\.S

[!] THROTTLE VAl..vE

m £L!CTAICAI.

INPUT $.IGNA!..

i'i~lI.lre 4-8 -fdle Air Control SYSHl'fn (TEU 1DO Unit)

4-6 FUELCONTiiOl

Throttle Position senser ITPS)

Tnt! throule JXlSlLioD sensor (TPSl. j~ mounted on LI'U.' side or the theurtle 'boody "'Fpo~il€ lht:' t~rO~t.lc lever uss,.embJy, III f'Y"cllon 1:1 to ~en$oEi Lila I:IJITEn.~ Lhrou.le valve pt)s-itlon and rc11ly Unit. Intormation to the ~CJ\1 hue Flgur@ 4-11 and 4-12). ThrotLle position [nfermatlon ail-ow!J. the- E:CM to geoeraw lhc required lnjector ~ontroi siiuols (~ge pUIM).

If U\e TPS senses 0. ~ddl!! op(!n throttle. a voltage t-lignul indiGllt,ng "hi!> conditiDn is sent to the ECM, The ECM then lneraaaes. the injeot:tol" base JWise width. permittinG inrr'!'8!{ed fl,lel now,

Ffgute4.g .Id[e AJfCOntrol (lAO Valve [TB.l 220)

m T£RMI"'~L P1N$

m !!I,l!,.!" E!lUH1N.o A,SSE:UBLY m Sr'U.TOJll l&SEMl9t.Y rn ROTOR A,SS HUlL Y [j]S'RING

[!J PI"","" [iJI.I!ADSCAfW

OJ TERN INA\. PU.lS

m BALL RI!AAING A.S5EMDLY [!J S'TAT04il ...ss:eMSLY

m flo'tOfi A1i'I5Ie:."BL' m~PAING [I)P'NnE m GAINE SIlI~1.!> m lE.AO SCREW

j'\:rg l.h~ thrcttle VD.I,,!!' rntetea to raaponae til mcvaman! of the ROfE!I@FUWI' pedul, the t.hrot.tle shaft tranSrE!:fS tkis rQ~a.~i{lln mQYEmenl ~o tblll- 'l"PS, A P'Dtentlornet.er [vartabte J'lUi,E.or) wil.hin tno 'TPS assembf)' c:.hangi(i;:!i ilS OOCSi3taMC (Uld \lO,tage drop) III prcpor-tian tG lhrottlo mOVCIDent.

. 8y applying B reference voltage (5.0 voltd t4 the TPS tnRut, a varyipg yoll;f.ge lrenedini' ~hrGttle position) i:9 a.vallable at theTPSOu.lp~l, For e~am'Ple. approxl-m.o.tcJy 2.5 'IIolb .es111Ui Ircro (I S(1) throttle valve opcnin-g (dcp~ndIng DO TPS c.il.LibratiollL The vottage (lutpu~ f'rom the TPS assembly is routed t.o the BCM Cor uae-in determi.nin:g t.h.rotUe pofi.itioll..

OJ THROTTLE V,UV'!

[1] fH'IIGINI! cONTIl'n. MOOULIE: (£CM) ~

W~H"01TLE 'OSITIOI! .~

GENSOn (TI'SI •

c.

2

01190321 -sy

~9I,lre4-1' - ThrDnh! PoJition 5@ntor(T8I220)

lIP1l316..sy

F19ur~ 4-12 - ilu-gttle PO!!iitio-n Sensor(TBI100)

FUel PU MP CIRCUIT

Fun CONTROL 4-7

The (Ut] pump Ia [l turblnu typP., low pressure e-Iec:t,r'~ pump. meumed in the fuel tank r''I,I~j i~ pumpM at. B ~Hi\'e pressure <.,.hove 62 kPa or 9 psil fi'llm Lhe rod 'Pump thFDU4lh Lh.t: ln-llne rater to the pruseure eegvlctcr in the TBl unit \sr!€- P."Lgur~ 4-J3)' ExceBS fuel is returned I..Q lh@ fuel l(l~k through Ihe fuel return line.

Thll!l fuel P.'~lT!.p liS uUa..,;:hcd to ~ht rU'I!!1 gage sender assembly. A rU~15ln:llBer is: Cl:ltnchod to Lhf,' fU("j pump in1eL line and praventa djr~ paTtiel.es (rom entering lite Juel une and tends to separatl!i Wl!Lel" rr'I!i'" tnlJ rue I ,

On vehielee with lwo (u£;l t;j,lnkl, there ls 15.1\ elecii'icCuel pump and ~e.send,ing vnil. in each taftk.

Vopor hxk problema EU"e t't-duwd when WIl'g an elecu-te gI'Utn'lJ because the Cuel is pushed ftClrtltnll! LBnk under- pressure tUher than beiT\8 IhiUiid under vaeuum, D conditiOI\ lliQt, predueee .... apo.-,

When the .k:e}' Gs fil1iil, ~urned "ON" ""Uhmlt the engine running, the ECM tul"l\S 0 Iuel pump Ifelay "ON""for twc secocds. Thi!J: build;;; up 111.e fue-l prt'":55Urtl ~uiekly [f' th(! l!oiMigin~ i~ no1. &l:;llr'''~ 'wU.hln ~wo n¢Oii.ds, the £eM sh!.its the fuel pump "OPP" and 'Waits untll the enllim!1 .slam;. Ag soon as the engine is cranked. the eCM tnrna the re'lilY "ON" o.nd runs 'he rue[ pump,

On tnt! 5.1L engin~ il1! the G van and all o.Lht.- 5.7L or 7,41. cnglnieSi in ",~bic:h!a ever 85000 CVW. n iuei moihll'fl will a-Ye.rr;ldoC tht! ECM iJrtd the- juol pump will run for approxi.mately twenlv s<icond:s. 1'he- Iue.l module eol'rlX:lS a Im·t l'"estO,rt -(l,IoiI.PO'- IOc'k I durinl{ a hig!l a.mbLlliftLtond,ltioI'L

wtJ:en UiOC engtne is crank.in~ Or' running. the F:CM reeuivea dt~tributof" rarerence puls.eti which In turn energize lhfl fuel inj(!C-UIFS_

As u baekup fI:,vstern to lhr: fuel pump rehiy. Lhe.: juel pump @'l"I ulao be turned on by an oi! eeessur e ::iwh.c:k. when the en(i M 0 it praaaure reijn;:hc~ ubout 28 kPn 14psi}, through er-ank..ing j,lRd ~hll! fuel pump n!lny dees nol (:om'Plete the clft\l~t. the oU pressure ::;witl!:_~ will elese toNmpl~tC' ~_bc cin:UtL w run ltle (u.cJ pyrnp

An inoperative futl !Jump .-elay t;).f1 ri!!~lL in 'ong cro.nkillR Limes, particularly if the tH'IBLI'Ul is ~(lhl. The oil p"e~\Jr~ l!IW'i~b will ty"'" On dit) ruel poump il:;; soon ~i5QII prcAiJrE! reac:he3about. 28 kPa(A psi).

FUEL fiLTER

IM·line Filter

CAUTION: To .-educe the rbk of fire and p()t'sonill ioj_uy! It is nr,-t6!l.tl-dry to illiow foei p~n"'r(Ji lo bloved o1T

hefDre- se.r-vlejng (u.e,j i)'.!ihJI componc.n ls. (See "Fuet Sys'tel PN-SSUi:e Relief Prceedure."]

The tntlne filter is 1()t:8ted in tbe Iuel feed Ii.tl.c. I pre ven ls -tHrt f:rom el\~ ri.ng tbe TO I unit,

In-Tank filler

A woven plaarle !JJte-r is tt)C8.lCd!)n the lQwer (one ( the fueJ piekup tube in ~hc fuel ~s.nk. 'The IiIte I"reventli dirt From entildng lhe Icel line and, Shit i~Op5 water, unlen ~hF1' ,rUter become, cGmple-ter submerged in water. This fllter lS self-cleaning EUlI normally (equ.inI5 Oil msrnteoeeee. Fual stoPP3R'e. ~ tl1Jfl p;cint, mr:l.ieataa .~ !..be f'iittl Uuik conll;1in3 fil @b,fl,orfii.iJ amount of lIerJ;im!:!nl 'Or water. lbtl lunl shol.lld. therefore, beth.o.-oughty eleaned,

FUEL AND vAPOR PIPfS

"fl:tot Fuel Jeed and return p Ipes and nose:EI exlendec from the fuel pump .and senderf to 'Lhe. 'r-nr unit, The., am sC'Cured With ell,mps and an route.d a10ng tht rramCi Eid.e membl!lf'.

'I'he vspor pl~ und heeee ext.end Iram fU1D1 pum~ and lilendcr unit. to the eV8p!1t"Sti_ve uoiuion eontrol vapcr canlster.

FUEL TANK

The flIe! t.aI1k. at the rear of the unde.rt)od1, j~ hold in plal!C b'y two metal straps. Anti.tqucnk pi(!css ure usee on lo-p Qf Lhe tank to rt4ml} m1tltoli.

FiIICff.led<

To hl;'Jp pmv!2nt [I!.fuel,ins wiUit I~a{!.a gaE.6line, Lhe ruel filler neck on " iA-sohnc engine vehlele has oL built-in reatr'ietor and deflC:l:-tGr. The {lpen.ing in the rl!!'BtrktLor wLll oardy tldmU, thi' smaller unJe;~uh::d 8111> nozzle !Jp<)1Jt, whlt;h must. be fully i.nse.t~d to byP'l\s,-; ~h& den ector. At.t.emp~ rerl)tli~g wUh il leaded K~ t1ojlj;l,b. or failure ~o fully j;n:sc:d. l.hl' ulIle.a,ded ,g(l~ nO&'l.le. w-lJ1 result in gnsoHol: ,splD.!ihing back' out of loe filler neek.

Fuel Filter Cap

The rue[ ~.nk uller n!:{;k: i:s !!'quip!eed with 1.1 !Kf"W' type Cll~. The. thrcac:iea part of the cop rcql,lire:; :!;:e'J(,!'I';.t( tUm! '(:Qunti!r,e:I()tkwise til refTIOI,'1l The lon'l:

Lhre.f.!.dcd iUCIl WW! dC5i(lnitd to !;tll{l-W .uny remalnillil; ruel t.nnk presliu.re to e~ij)iJ, whrl(l l.h~ r.np WJltiheil"!IIl

4-8 fUEL CONTROL

THA:QTTl,i; SODV :P-1\t'S~IJ.R1i REGULATOR

I~OLIN'/

FUUFl.TU

FU,Etlll.F,'li,.IA.NLIHE

/

Fig" re 4-13 Tllr foci Supply S~".'" (Typic.l)

Fuellnje~tors

t~movad. A buill-in torque.limiting d~" v tee prevents ov~.-tighte.r1ing, To LneUH. turn ~hoe c(rp c:loc.kw~!M} until s tUcking nOl:$e I' Ilene. Thi~ ,-tpals that 1h(: ~~~ taeque hM ~'fHI reeehed and the t:ap 1$ flJlly !i~!I!!~.

ACCELERATOR CONTROL

Tile ;i.oceleratoE"" ';:()Il~rol eystem ls B. control cobIn type. Rlbiched to 4i accl!'lerator pedal assembly.

EVAPORATIvE EMISSION CONTROL

Tilt ey:stem. tran:a(,aTS ruel vapors ftum t.he Iual tank I_"lo Ill. vaPQF canister and t:he~ vapces ~ purg.ed 'nto the intake ma.nifold aiJ' now and CQiuumcd in eombuscien. fUlfer ta Se<tiCi\ "'5". fot ndd 1 Hone I lnr(]rmIll.Wo.n. d:Lagn.o.5i!i, Gnd nn-vehiele service.

DIAGNOSIS

FUEL CONTROL

Tho dtn!lTl(J5i.!i pr [ual contl::,D~ a:.nd th~ T!3l unilli in Sc-ctiOFl "a". because tha Computet' CornmAn.4 C"mt-r'DI 1iystem oontrol.s: fuel d.elivery, Thi& f!yst.en, hili; 0 buill in d.ia,gno~ti(; lY;l-.ern. .in Lh& ECM to I.odicnlEl 0 rnilt:<l tirtuiL Th.i3.fiet:lllln will cxploLn &.he sy.stem Ilheck and ihemdes misted to fucleont.r--ol_

Tho fuel t(]n.lrol ctLn De l~ reD-ion lhpt ~ho c-n.gl!le c:r-anks. but will fi.6t. nm 3f'1d the d.iagnDsis ts, a.IM, tfl Seeu.on "3"', Ird.hlgnQsi$ ifldi!;:utc6 that the engi.ne- will not run hf'Ol!.l:!il!! l.here i.s fi ruel de!~ ... of}" pI'Dbll:!m, Lht. dlillgno!!ll:t of l~e fuel sll:6tl!'m is, ols(I, in~!l.H~cd in. Secu.on "3".

Testing the fuel lnjector drcul,t is in CHART A-3 ud odditiaru:Ll d.ifl.gTlQsis in CHART A~~ ill Section

"3".

A fuel I,Jlj1!d.or which does not open may eeuae a.

I'lO-5~ ecndltlon, An injector 'II,1'hl~h is sl.uck pilr~ll' epen. eould cause I(I~ ofp'rilt!i;sut"e alter sitt.ing. 00 lQ(lg f'r'3.nk Urnes would i)(l fiotieed on -SfI)i'iW engtees, Alec. di~~cnng nyld i)I!;CU"- beeause some fuel ceutd be l.it::I lvered ta tho englne arter tho key is Lurncd "OfF",

TuHnG the- pressure r egutatnr circ.[J[l iJ; in CHARTA-3 .",IA·4. in $oelion -3'·,

Ii the pressure l'egulll~o. in lh~ TBl 5UppJ tes ~[,·E!SSL1re which is too 1.1Iw ~h('lolo" -62 ~Po. or 9 pel), poor pe.rfOf'tnflnee could f'l}sutt. II the ptcs.::.--u~e i.!;I too high, Itl!:i';!(;s,s emis-siPlls nnd unpleasant exhaust. odor may rlfsult,

Idle Air Control

The di-agflDS(S or Idle .1.ir eceercl can be found 1ft Code 35, ~don "3-, (Qr l~ 2,5L ~nR:ini:!: iind in lhis section [0 t' all olhe!' engi fiBS.

1 f Ute lAC valve b di..&cOflHei:ted 0'- connected wIth the engine running. lhe: ;dle rpm may be wt(mg. l!\ thl:5 (rui~, en engine-s with TBI 220 mdts, t.nl:!! lAC .... (dy€ mny b:c rcsct. by hlming thl!l ignition ;5wit.e;N "ON- for ten seromis 4nd. U:len "OFF". On engints Il:!!in:g 0 r B I 700 uni~ .. u'e hi te rpm LS '-I!set Cit II 'Speea ,bo •• JO mpn (08 'mlhd.

The lAC \'i)ive o!feclS Oi\ly lh(l title ehOfuderigti('$ DC the engine. r[ it is: Gl'cn r-ully, too '''_'ych .... ir. will bo ,.dIDwo!!d l,.fj. l.t1c mnnlfQM and idle sp;r::·od w~H he.hLgh_

FUEL CON'TROl 4-~

t.r it i.51 !fLl,lek I.!I~d.lOO- little air w!ll he ~lIo1'1wt"ld 1r'J t.be mD.nitoltr, tlnd Idle speed will be l(r(i lew, Ir a is 5tul;~ p;}rt wEly epen. the idle may be .-uugh. -and will nol ~espond to engine load changes.

The minimum air rate is set at, the factory with. a stop sc.I'£"W The ~oop SCrew should Mt b~ adjusted. unless e r~pl.tl¢~moiU. !.ItrljotUe body a.ss;'emb1y Hhu.~ haa not b~tn prcsc~ at t..ha rai:ltD'rY) L:!; installed Dr LIm mii"t.fml.lpt air rata does not meet ~-pc<:inCBliollli.

An lneerrect resfljus.trnent with B. high minimum Ilir rate will UU$e Utl: lAC valve pin.i,.le t.Q 1;orUI~nLly bQtt.~Iq on i13 scat and may result in earl)' (AC valve (~it\.lt'{:, A mlnlmum eir rate thAI. is t.oo low mBY l'!':mll in, .a no-start co.ndit.:ian ill (old weather.·1i :ltall a:i'Wr "tart or a stall during deeeicrtllian" ~'8.U.BIQ Clr 'pt),gr airJfu~1 di,Hribl:tion 1..t'ltQugh the throHte bore. Throttle' v-~Jve dti(;:k.ing may etee eeeue.

Vlll;uum leaks will eause the lAC valve ptntle to be "5wpped" .doser tD the sea t Gr L.o 1;(1 ~I05':!d agai.Mt ib> &eal in D,n lUtl,:m:pt te DlaJnlaln cDntrqd led idte speed,

Throttle Position 5en,or(TPS)

Reter- to SeeUon -J" for dilignO:Sls of the LhroLtie pcs.iLion ~Um50I'",

Orivea b iii ty Symptom"

rwf~r to SeeUon "-2.", ror additional Cu.el contrQI di~Rn051:l,

fUEL PUMP CIRCUIT

Relet" lo s),sle.m dlagnmd:s in Seetlan "3". (or tuet pump d.lagn03tSi.

An inoperative rue~ pllmp would eause 8 M Start. condition. A (rael pump wl"li.(lt\ does not provi.de enough preagu r- e C@,n re~tla u- povr pcrformenee. (Sea. "Pl1e1 SY!IIte'rn Pre,3tlJl'c'Tdi't""' procedure),

Fuel Pump Relay

Refer to Iuel pump relay ciNWt. cheek in SecliQoI\ "3", for Iucl pump relaydiagTlosllil.

An inoperative r,.;J.~1 pump r'oloy ~fll'L r~':StI!t in lon~ cranking time,!, pa.rUe'Ul.trli ifl.JHl englne;a cold. The ail P(e5S-..nt :twHc:h will turn on tAlE! Iuel pu.mp as. $OOn .IS ell pnt:5sure reuchefi a.boU.l28 kpl;l cilp5il

Oil P re •. su,~ Swit~h

Reier to fuei plJT&lP reluy circuiL dieck in Sect..ic ~3"'. for' oil p-re:ssuro switch diagno!iiis_

Fuel Module

R.erf..r til the dtagnnsls sectlon in Seetton '-3" r. fuel mo<lule ch(:(!k.

Fuel Filter

The di.tt~.l·Ul!i:i!l. of lh1!l fUoDl nltEtr is. cnvared i Seetdon "3"', ~s I};j;rt oft.h~ fuol.:;;:-,!:l-I:!mcliag~G.!:Ii:;.

A pliJggtcl fil'i!l liIt.u may eauee 8 t'e~tr'il:~e-d rUI dell "(try, or Ii no SLarL condition.

Fuel Pipe,. and Ho,es

the d.illgnOS-.!1 o-f gusellne odor may De II, eouditfc or .. Icn.kjng {~,ml Iced, Dr return pipe or heee. FUI pipes lb8~ .ara pinched. plugged, or mi5l~rol,llOO mo cause restricted fuel detlveey.

Fuel Tank

'ThE! diagnosis ofgasolLnlll odor may be a cQndlti~ of 11!4ki.ngfuel tank, filler neck, or filler eap.

A defective filler c:!~, Q. plygged er :plfi"hcd. Yllpt pipe eon C3\ISt j Wti3'PSed ClI.tl tank..

Loose mourltillg straps, or foreign material i tank, may 00 the cause ..,ra.ratLle ab the ruel tank.

ACCELE'RATORCONTROl

Cheek 10," t>Orn ... set enbla muting. Of' bindlng, an correct as ne;i!l!lssnry.

EVAPORATIVE EMI5SION CONTROL

Rufer lao Suerlon "'5", for di agnoaia Dr th Evapcraeive Emis5ion.CGn.~1 S;;"3tem_

10 FUn CONTROL

l-J1-l17

IDLE AIR CONTROL CHECK

AU ENGINES~.&a.

f(ujtOe5uiption: <,...,.j '1 s."1L

The EeM sends voltage pulses i:.o U1a lAC motor wind~g ~!..ising the motor ahafl. a.nd valva to muve "in" a "(I,U"" ~ glvoEIri d~n.ce rOt ~(h pule (caJ.l.eJ I:!~untld eecalvcd. This movement eontroh! air now around U1e '!)Ltllill pblb. wh.ich, in ~u(n. ~QnI.rnISi engille idle speed,

SI Description:

Numbut belaw t(!"£er to d~i.f:d. numbocrii On the diQ'''Qosti~ chari.

"&8.0'" Lool must be tn epen iYIDd@durillg teat. Keep AJC "Of"pn during entlrn cheek,

'TS!it wit;h (!I"gif.lll!:! in dri1,.'E! and ~onti.nll-e with w~t-, e v en lridJ~ j,:!: ~rnLtiC', ~.ridle l!J!.Qo lowl "Scii.n'" will dis'phl.)' 80. or more. eounl'l·(u·sU!p:i. E:ngjnB!Op4!ed may vary 200 rpm. Or more. up ana dawn. Dlseonneet lAC. If the eeedltlen is unthanli·~. the rAC ig :nt;J.L at r;)ull There b :Jo Slystem p!'oblcm Pr!X:Qe~ i,.Q sitp .. ~~ below,

Wh{:(J the engine Wilft ~topp(td with ri,gnit.iOIl '·OFf'''. the lAC v ;(II"'t retracted 'more air) to :II fixed "Paek" pootition, for increased 8.ir niJ'* !lnd idle ,~ed: dvrlng Lhe next-engine 'SUlrt, A "Scan" will d.illphl.Y H10 or more mums

Be ~tJrC to dlseonnee t the iAC .... .0 I ... -e prior to this ~C'~~. TBS test lig .. ~t will L.~n(jrm the .sCM ~ignal:!l bra st.l!ad.yor fl4.:Jhi.ng ligb~.an ELI I eircu.il~.

'I'heee i-f ... remere peeetbltlty that ane or the c:;i·~uit.s IS shorted to voltage, whIch would ha VB betn Indicated by 1l9tead,. light. Dlsoonne£l EeM and. turn the igni.lioll "ON~ and probe .erm.i~~l!!! Lo cheek r.g.r lhlstOlldiltCn.

Ignostic Aids:

An unstable i.dle ma)' be: II. il-Y!:i"tem problem lhill ~(Jtbe o"erC'OmG by the- [AC. "Sc-an" t()Uflts will 00 \II!!' 80 aoufI'I.S, if ~oo tow, and 0 c:ouf.lUl, if ~oo high_

If [A.C 'Val\l'~ piaU" p;n;it..i(;m CDunts are Iq'ft' or 2.eI'{l, lI:,boeck with V!},_QUlIm lEaks at Villl!:utHI'I iiIUI'i~, loti ;,md hoses. ths throttle bodv u.nd lht! ;ntuke munifold_ to. bottomed. h,er-(> -C(lunl.l lAC vshlp pintle may re!lulL rn lin ld~~ :;peed l.!b~V6 spe~mC:lltiql'l. RtJrer ~~ mlnlmum .air ralctb€(k.

• rf lAC vgJve p;ti~19 IX'sJt:ion c-ounl:.:5 are h.igh, look CoOl' t:3f"boQ build-up in the [Ae valve 3ir Initl. ptI.}Sage er evidenee of tampering with Sf.4;p S(:["QW. Also cheek for law engine pnwfr or nCH51'1,1B uc:.c~ory loaM.

• SY5lem too lean (high tll'npipc air/fuel ratiol - EnIJ1ne speed may vary up and down and di~.I\n~e.ling t.OB LAC may f10t :Hta.bili2e eng1ne speed. u .. Senn' andio.l' V~ltme:ter ru..ds an oxygen. s.ensorDutpul,.le$~ Ul~ 300 In.,. (,3vl.li:beck tOor low regulated F\le-l pressere ~r w.ut.er ill fuel A COO!!! 44 (lean Q'l ~CTlsor) maJl be ~et. A lean taiJpipe e:lthalJlt. wit.h an c-xyge.n !iensor· eutpur fixed above 800 mil 1,8 v , could be Ii ~nlt£t:minlted lenlOt't U,s\laUy Silicon. This m.ay 3CL a Code 45 Crich Oi eenaorl even wilh le~n L1.ilpipc:: exbuust.

• SV!ltem too rich, (lgw t.Elilpipe cur/fuel r'BtiO} - S}'!UC"'·I obviau:iily rh:~h and ma.y exbtbi t. btft~k Hi\oii Kq I!,'II; hauet. "Seen" tee I IWdlo:r V (!HmlJter win read an DlI:ygen ~~r ,5ipul w;(fKi Abo-VII!! 800mlf L8y),

Chec:kror:

l!ljecLoi leaking orsticking H.igh fuel ~r:eS"5ure

Ai.1" leak in MI\P i.t-olQsdllesr line

ff li2 is normal or low, Lnspet:'L fo r IlLr boa-Lair pum:JMHll into exhttWit mllnifold in fl'onl ef Oa 58-nso,"(o;rexh~u.st l(!:~~'

• Throttle bood .... - Remo .... e lAC o.nd [nspec," bore (or foreign mot.(lrlul OF Bvid@.nce of lAC ... tII hl'e r:li"aggingtlie OOf(!!_ (Repair as requir!'!r.i)

• AI£.. C(l-mllr,e~l!Io'~ or ro!l Illy fJ-it1,! r.t; - S'I!IC Ale d.iaGTIOSl~ if circuit is ~hort&d LD grol1nci.. lr the lI'elay i!3 Iautty, Idlc problem may ulst.

• Refer l,O Rough, Unstable. tnl!orr"ect. Idle or Slalling. i.n Seetian 2..

Fun CONTROL 4-11

- ~tAN- TOCi. NUST IE lit{ OIlEH MOOIE tJU,I~JN6 THI501IU.

0) •• AJf.. ·0"" ~ID(G ~NTU!!f. tHtt.lt.

OIlGlfIII[ AT NORM",," IfHIfRAfutG TIEMJII'JWATURE ~,.O TU.NSM~SlONi IN miNE IAI1'}OJl NIEUTAAL(MIl).

.. HUQH!;) ENGINE! !~!_m, if mE IS tRKlinc OR:

UN:STjI,ILI,.IlU>! ill TO MONti p'Aif;ii~.

I

o .. IGNmOH "OFF" FOR.1 Q ~![COH:O.s, I

• 5TA"UMGIN[ APliDIMMI:DIATny Oln.VI RPM tN ,N';IJTJUlI,.,

IDLE AIR CONTROL (lAC) SYSTEM CHECK

ALL ENGINE5'E-~E~ll!nb

000d Lt 0$., L

RPJiII SA!'AE"'S IttCORCt[l) J IN FIRSt 5HP.

rWlUKOT~''TU~N10KN MC~o(O 1Nf:IUTSTf'.

T

I RETU~NS TO lPM IU.CORO~O IN ~IR:ST nil P. J

flDt[ Ida (ONTROL CUl:CUlT O'L *U~III TO ·PIA6NoSnc '&105- ON f.\aHG PA,(j1i.

o .. tGHITION"Off-

• DtSCOI'tN E(1' lA.( VA[.V( H"JlNESS.

• ~ITION ·ON" • ~Nll;iit<l~ UOf',t~

.. GjtOuN.om .... GHCS'1tc:liESfTEIt"' ...... t.

.. CIJN'NECT ... U5:T lKlHf lENin [,1011 ... 1::

H""NOS CONNECTOR Tfll.MlNAL AftO GJI.OIJMD.

NO UGkTl, ONE OR I M(JII.EQttWW5,.

o UGHf "'AD' I OR F'LASHI.NG ALL ORCUI1S

, QUiex li01ll OPIH Of!! iHon TO l 6.IU:lUND fHmClJITWI111 NO UGH1. AflII! "LLOiU:ijffS (lit?

CI-i.£CIril$I$TAHCEAOIOS'SIA(COU SHOUWRIE MOR~ THAN lO 01«""5 enwU:N lAC 1t'~I"'At.S (IJ!'J!Q!j.ITE "J.!itNfSSCONNfCTOR Tfi:WIWAlS -,,- TO -.'" AHD .c. ... TO -01"_

FAUIoT'¥'EiW J

CCiIolHI!Cl'IClM O~ tart

~'-'Ul.n lAC

(0 NtNEC1ION 0""1,11:; liMVf.i. CIII: PUlG('!;C .P"'SSJ .. GE,lfLlCttT ~PPf.A_A:5 ro !!IE STE .... D"', RU·lfl10TUT.!'iT~fI~ ON FAONG .. AGE..

1 •• Pl.ACE lAC YO"" AN ... ",T, I l,o .... oTO. I

r .'",-'cr,,,,, I

CLEAR cooU. CONFIRM ·(I.,OStOlCOP'" Opt:AAnON,NO 'SUII,IICI EMC~E 500011'" ·U(iHT,."'D 1J~):IIIF'YCONTROL.UDIDlE ~PlifO ,5: (OIUlICT.

4-12 fU EL CONTR Ol

ON,VEHICLE SERVICE GENERAL SERVICE MANUAL CAUTION:

• To prevent personal Inju.ry 0[' damuge to '-he ve.hiCle u the result of an accidel1tti.l start., dis-conlleet and reeona ee r the neg!llU'!'t! bunary ue.hie before- and ~n(!ir aervlue is (>iil"iol'h1(!1d (a.xeope. fQ[' these lests wher-e hllHel"Jr voJttLge i.fi requJred).

• To llLiniLni7.e t_he r-I!l.k of fire. a.nd perlu)nAi injury. r-e-lieve the ruer sy:!ilU:m (where Ilppli.~abJIJI befol"-'! liervjCing the fuel 'yjtem~ (Se@ -Fuel Pre5,5Ure Relief ProQeduf'e:"" below. I

I 1.1.'0. catch uny itl(!1 that leaks Old when distollne(!ting the fl1~J [JI"I~..! by C9'1r'ennlJ Lh8 nUjn~ with B!'!hop- C!!cth~ P~ace Lhedoth ill aR ;:r.·ppl"oved <.:ontainer when WQ['k Is coftllplll!!lte..

he roHowing IS genom! in(~i'lfiation re<r\lired when 'atking Oft r.he fuel :ly5!.em:-

A1wayt keep .. dr-y chem ieu l (Class: 8) IJre exti"gui.5her ncar the work area

f<~l.Ji:I! pipe fiLLings ruqutee flew o-rinp wntn u:;s@rnbl'ng.

All fueJ pi PEl'. m4sl meet Ihi:' aM S~dncalion 124- M, Q t i~ equb.·,u,J I!'nt

Ail fu(]1 hose must meel OM Spe.~HiCQti~n 6IGJ-M or-its Pqui\l":dlmL

Do not eeplece fue-l pipe with fuel hbst

Alw3j!1' gllow fucl preasure to ble1!ld Iln bdo.rt! ~rvi(:iQ~ any fuelliystem eempoaents,

Do opt do any rups).rs &1'1 lile rue! iI)'5tem Ufl,LI! you have rend thO" in_9lruttloflo:!il !lila ehet:'killu the piCLUntS r"!oi.;ll,.ii'i_g tp U~u.t rl!'poir,

Ob.'iIl!'C''Ir'I! .... Q. il Notj(:e~ and Ca LJ tiona,

All gusoltnc engfnes u re rl~silJnif:d. La use only i~ud~ gtLsoli.lll! t.o rnn:1nt.tJin proper Qmi5~ion cnntrol uem J)perntiQrJ. Its U:Sf! will • .d~o minimize A..pur&r. II' fg.uJiny; i'fl,d extend ~ngin(: QiJ lif~. Using leaded ;oiln£! ~t'I damage the e-mh:siDn I!Oftlfol S-)"!lir.lm and lid rr;!'!jIuH in IflI'il8I'1femi~~i()1"1 W~I"1''-'li~,y-r;:()''ertl~,

ILII Y(1htclf.)~ tdJ'lfeor'tld. ill tJH~. rnunuut uru equipped h cnd e ... ~pu ....... ~t.,e emlselcn :S.YSt:-E!m_ The pUiI"pO:s&jJj -tly-stem ti!1 to m[n.imb,,:(! Lh~ 1l5l:DIlE !Dr fuel V0'j'XIr$ tl;.l n.tmCi~pherfJ" Inform:ltifl.l'I (in I.h'~ system wHi be nd In &oetIon ~5"

TIu! TBr unit repair- procedures cover compeeem lucemctil. with the unit 00 the vE,hit;la Uowevl!f'. ;tttle body reotaeemern raqmres Ihal the- ('.cmplfl"Le ~ be rCfIlll"'f:!d reem the I.lfiglne.

RorC!T 1.0 U,C dleassumhled vlewe (l"[gltte 4-IA and ;i-15) for idlllnlifil;;tttil)n Qr pllrl.a dUrin.g repair procedures. &rvi~f repair 4;irlndividuol comp(tnenta is perform£'d withouL removing ilia TBI unit from the tngl.Dt. If remond, it is essential that ~nrl! Is tnken to prevent. damage to .. he throu.lc V8~W.t IH sealing 5udlice while per(arml.ng nny aecviee,

Wtrerlti;.."C" 6ervl~1G la perfQrmed on 11 TBI er- nny (If ilS -compgneni"4. l1r1il ramcve lhe air tih..nner. ru:fDp~er {if ap'plitublel. nnd sir (It'.aner Ifas.kllts, D1g.e,uro the gaa:kels ilnd replace t.h~m wi ~~ new enee berol".c rep !.u.-ci ng tbc: alr cl ~a.nllf BIter service is ccrnpleta.

WhP.fl discDOnet;;t.ln.g she ftJt:lliIlE-:!iI, be sure to IJ$~ a BilOkul' wreneh (J-Z9S9:B-A, or BTS2fi]~A, t'quivalcnt) to keep the-Tar nuts. (ram. lurni.~R".

Fuel Pressure Relief Proc"dur~

A fUftl dyatem pressure te.e~ Ii part ot~v'-'Fal [)fth(!

DiIlF{no:::;Lit CharUi und Symptom checks 1'n perfor-m tJljs Ui.~l. foJlow this pro<:ed.tue:

l. Turn 4jngtne "QfF''" to refleve ruel pr~!t1jI"I!'.

2 Plyg'1'H£RMAC vacuum por .. irreqvircd on 'rBT

[3 U.r,,;ouple ft.u:rl liup[)ly Ol3xible I'IU£!o in ~ftgJ ne cumpat-tment. lm:\illl tUOI!:J ~reUu· r e gagl!' .1- 29658A1BT-8':2{)!! 31HJ Ei;ci'a.lJter ,'~2'$'oaA-as between st~j I ioe and ila;:,:ibla hOBe.

'-1.. TiR:h~t:n ~.ng(,' in line to ensure "0 leak.!; occur dlJrtngtl!sling_

5. Start engIne lind ebserve fuel srcsscre rending. It ~hould he 62-90 kPIi. 1.9-13 );lsi), Ii not. refer In eli ART 1\-6 in St'Gliiln "':3" diagnoals

~, Relie"'l3 fuel pre:-i:liurl;!

1-14 FUEL CONTROL

FUEl CONTROL 4·,5

1 Re.n\DVI!! ru.£! I 'Jl [(;S:liI.l re gage. EL Rt'in!!';l.:lll (ue!l llne.

9 Stnrt-cflgt,ne and d:lA:~CK rot Iuel leeks.

lO. R.em.IJVc phHl: from V!lI:IJ,IJrn p:!rl. if irmt;uUed. and tnstall alr c:lt(J,;J'I.er with new g-dskel,

Model 220 TBI

MOOEL 220 AND 700 TBI UNITS Repfatl!ment (Figure. 4--16 ·throu!jh 4·20J

B Remove or Oisconne(t

1 TH£It.).t1A.C hose from@llgiAt tiUlng (ST S~ric:9J. 2, l\irel~'UI'lt!r, EldG.:pLttl und gask.et'9.. Oi:st:bord caekl:!l\'

~Cle"nin!j and li!jln.pectlon

A.U T81 (:OfPpqne:nt piirtt. with the t;!xcepUon of tnnse notC'd below, :s.h(Juld b4J ~ leaned in Q tID Id immcnion c.teonoer such 05 C.urbon X (X-55) 9l" equlvelent,

Sl;!rew A:III!!irt.lI:l!V - I'U-tl 'M~:[!or Cl;W4r A.RlIIc"'~ng - ~!iI ~ew AiI'tI,e,rnbrv - F\l~ Me~~r C;Q~r An.l:ihlng - SPlon

~e' ""iI~~r CI)\I.I AHeoMbiv G.II:fII - I'ual M!I1.o!i' C6vi!lr r.I:!I:llitl- FUIII MHlJf Oullel S!!Ial- P.-~Ylt. fi~,,~tt)r fH'S.~ !JUI ~1iiI1"i1&m.r

Irtjmor - Fuel F'iffer_FY!lllfljee'!lJrlnllllt

10 Q..r{nlil - ~elilili!!a[]rL¢wtr

1., Q.ring- fUIllIInJMiDru._

12 W~he' - Fuel Infl!!I;I'Of

13 Sclew ~mblv - !!'uel Mel~r Gaclf-Throt;lIItB~ !l&HI~hil1"V

fulll M!lI~r BDfJv AUilllj'i'lbly

15 O.stet .... n.,ol1111 IJDdv 10,

ful!!IMl!lt., .. U,od'"l'

, a ~!ii:j;Ir,.! - Air ~e:lnC'r'

'1 C.Ring - fYel Rillum U:fl4

18 NU1_FtiiltI0Ut1.et

19 ~RI.nG - fUII!~ Inlet Un.

20 Nut - F\li!I '"1M:

::! \ G •. ,lI:el - ~el Ot..rt.lq1 ~oil

2.1 GI:II~.L - fu~ 1"11f\: I"hn

2l 5;rew Ancmqly - TP$

AtrachiilO

24 ~1I(liMi' - TPS Att,efllMl Sa_

~ 5e.n91r - 11m:mrl!l f'·alltioOr'I

iWSJ

26 P'lu~ - Idle St~ Sa!!W

:n Si:lr..w Aue:m~y - 1:.d!1!!i SlQp

28 Spring - Jdle Slop Scr~

~ ,....,~'QInle E!oOt,ly A.:i;Zlmbi'll

30 Gu.I!:<e"t-FllInge

31 V.lv,e ~mblv - iI1te AI, C4)olrtJ;lfIACt

12 GWIi!!! _Idl" All' Conuol V.h'c Alsllmbiy

~ O-Rlnll -lACV'

JII SGrft\I A$YmbI'V 'IACV A.nld'lfl'loQ

NOTIC..: Th.l,hrnl,l. !><>"iU •• ,,1)50' (TPS), idle alr controi O.ACl valve, pressure rCgultlt.or diaphragm ll5.sembly. Fuel injl:'l(;totS er othar components eontu,lning rubber. :3hOl,Jld NOT be 'Pla~e.d in " 510hrut Cir" tka:ner bat-b.. A chemical rcu(;ttan wiH cause these pet-ts ~o 3we1.1, hqrden Of" dls:tmt. Do nol Bask.thu throttle bt:KIy wLth the. ~ye purts attaehod. If the throltJe body ;!l5seffibly rClp.tireg dtu:..ninJ), soule time in lhe. elenner &holJid b~ kept ~ai 11 minimu.m. Som1!" models have hidden ~l'(Ittle snafi dust seule tlint l;olJld los.e ~hcb- e;:(fecl:iYE'Il(!-H by extended so.:lking.

Cltun all metnJ purta thoroughly und bl~~ ~!'":y with shop i)ir_ Be! sure ltlOt. nil fue l end :o.ir pi\ssagez; tire ffee ordirt or hu.rfS.

2. [nspect mu~l[lg r,;:.:u:.ting liurf;(t(:'e-9 for- do.m;.l.gl! thu! c-ould. atrectga.skeL sealtng.

Th.ead Locking Compound

Service rc:;palr kits ant S1.I!9plWd willi a , small vinl of I,.hr"l:)ad locking enrnpound wilh dircdi~l't~ [ce- use rr mlll.(!rial Is not uvuil3ble. use LOtliiJ:! M'i, ,,"I"" OM part number l 0522624 1 fit eqLJi~D.len~.

NOTICE: In pteCCln~ing 8I::rcW5, do n.ot Ij~ II. higher strt"ln!!:lh lockinj en m p o u nd dan re~!)mrnC:i'i.ded. since to do 50 Itould mnkc eame ... tng \he screw eXLRmely d.iffiI!I,,1IL, or i"~~u!t in damul!·lng thl:!"1iCi'~W heud,

~igurl!'''-15· N!ode1210 TBI Parts.· ~nti1:Tcabo" (v., and v-a EngIne)

3. Elt:tU'lr:ol -t!lltlntotDI'"li - Idle air ecmrot 'll"aht LhruLUc po3-iHaon seosor. and rLJ.eI injector.s.. ,0 1~nl 220 un.its. squt'e~ plastic" robs on injcel.ol und pull :s1tni liiht up.]

4. GrQmmet wit..h wtraa [rom t.hrotde-OOdy,

5. ThrottLe linkuge. return "Spring~t.s). transml5fi\o contnl -c:·~bl€, find !fI."IlIS!!: eo. i'\VO I twhu.r eve nppllcuble).

6. vacuum hoses, nOl.ing. ~itiDnE of n(lse~,

7, IfIIlf;!t and Qu-tlct:. fuel lii1~ mas, uS~t':IlI eeek-u ", .. ",nJ.29698-A or BT·8251·A.

CAUTION: Refer to "Fyel Peeaau r e Reli!

Proet:da,are" (nbovel. ·~,e:fQr disccllnet;ti.ngrugl ~lnes.

8. Puel tlne o-riIlP from nulil\nd discut'd._ !:l. T.Blm,otJntinl!: blli.r.dware.

10. 't'BI unit From int.ak...c rrumiCold,

NO"rICE: rrl"l prtYl!nlciDlDt!)se 1:0 tr...o lhroLtle: .. alvc, is eSMlt'ltiaJ ~hDI. t.~e unit be ptaeed on holding n~.t.\Ire, hofore performing %rvi~

I 1, 1'BI flange- {Ma.n.ifDld m01.mting. gukeL

NOTICE: Stull'tJlO monif.ld Q""ning ~;~l\ • 'He. pt'e-v@ontO"sterial rrom el"lt~rin'R II ~~giner .and remove- lite o ld g0ls.k. rniltGthl! {rom auetaee ofintnke rnnntfold

Ii!] Inspect

.. Manifold bQ.-e for looilQ pad$3!"id forei.gn mater-is • Intake ml."lfi.irold sealing su.rfw;;. for eleunllness.

Q Install 0' Conned

Hr(].w·rBl nnnille (M.nn.rold moufll.lnli:] gu.!tkQ~, 2 .. TBI wlltt mounlitlR" hardware.

~ Tighten

• l-lfirdware.on 2.fil..e-ngin@, 11.0 K*tn 112.5 lb. ft.l.

• Hl:l.rdworeon 2,I}I .. engi.D!iI. 2~.O N .. m [ 18.olb.n.,1.

• H:;.-.rdw.n.rc (in 41.::3L. $Jll.. 5. 71., nnd 7 engines, l6.0 N.m( 12.Q Ib_fU

New e-rlngs on fuel line nuts.

-L. ru~1 lloe inlet .... nd mJ,ICL lI:Iui:;!;i by hb'!,~d ..

FUEL CONTROL 4-1:

I3Sl Tighten

Ruel llno nuL to 26.0 N·m (M_O lb. 11.1. IUs< buck-up wreneh to prevent TEl nuts f'ecm turnlng,'

5. V~et,l.um hoses. and bracket.

6, Thfijlde 1i.nkaA:e, rerurn springsls). tTttnsmi18Jo" 'i::1J'I1tr'ol ,nblc, l),fiij t;:rui!l:~ tlQ.nlrol {wbe revee appl icahl.) ,

7 Orommet, with wire hnTl1.ll'ss. to throttle body,

g, Eleet.t"ic31 eonuectors, making sure conr'lcct('lf'!'l ;;3,1"~ fully .. alOd aM 1~1.<"'"

9. Chet:k to ace ir Cifi:~clerr!l.or" ned3J i$ free, by depressing pedal to the !loor Ilnd releasing, while ~I!g.i"~ Is .... Ol'~f'l' ".

10. With fiogitHi "Ot'F'", and ignition "ON", check for

Ieaka .around rue! Un~ n!.l~~

11 Air cleaner. ndeptar-, and new gtlsko.l..S.

12 Slu;rt.oeng'foe and cheek again {or Iualloaks.

Controlled Idle Speed (he".

Berg!"e ~!'r~Hn.i.n:g thie check, the[(~ ~kould be nQ cedea disphl.),cd, Idlc= air- controJ ~'5te.m hill bt(ln cheeked and ignition timing cor-reeL

1 Set parking brake and hloek drivf' wheels.

2: CI)n.ne(:t a ··SCt\Nt> t.ool t-o t.h~ A"'O(~ I'!OnneClllf wl~h 1.001 in Open MDde_

:'I, Sl.ur~ englne ued hr'lnl{ Lt. to nermnl f)1l~rt .. 1n1l ternperuturu.

..:I. C fleck for I!:~rrn~l sw.t.e o( F'ar.'kIN eutral aw itch l "Seen" tooL

5. Check e'pec:ificaLicmi chart !.\t. U"~ en~ Dr th secelen tor controlled [die speed and .IAC va~' pintle po!ition (~tiuntsL

s. (f within s-pec:mutiang, the idle spited is beil cnreclly cofi~follm1 by t.h4J f;CM.

7. t,r not within spcGifi'l::at.ions. refer Lc HRli:Jug Un!iltable Dr Inecrrect Idle, Smllln(' in Section •• God eevlcw lnfnrmatil:m at tht!l l.J(!:glnniflg or tb eheek.

Mhlimum Idle Air Rat@ Check

C~~ek c()ntroUed idle "Peed and perform idle II c9ntrol ~y~~.", (.h~~k first,

2_ 50. pI1rk>ng bme and b l..,k drive ",h .. I.. .

J. Start enginB and bring it to normal Qptr.et11 tamperatum (8.5·~ lOO~) , Turn engine "OFFH,

4. Remllove Dir cleaner, udO~Ler' and gilsk;.£!ts. On ~ ~!'ie!j: vebiefe. !eaviI!! THERM'AC hD:!511!! ~oll.n'1'Ct!:! Check thiP_t the: LbrcUJe le't'l'l"r i;9 no~ I;toting bound. I the- throt.tle. TV Of" erulee ecnsrol cablea.,

!i. With rAC valve ~(L~ted, Found the dia.gnl):5l !'.erminal (ALDLCQn"'~tDl"l.

6. Tum "ON" ignitiun. do not §4I.rt engine Walt leMf,. JO seconds tibia 01l0w5 (AC valve pifiH~ OXlCfldo.nd seat in thrcttla OOdyl.

With ignition "'ON ", angina stopped. teat terrain sli. H groui't-dot<l, i:i is.eo'f'l nee t lA C val .... ~ e le~t!'ie ccnneeten. !Thi:!l diI~ble:!il LAC "'Rive in s'¢o.t! positia,n). Remcve g"rou nd {rom diarnos.l t.er-K1'1Inal.

8. Connett. Go "Sean" tool to the ALOL ccnneetcr 0.1 place in opcn mo-de. if a tool Is noL availah ecnneet a taahemeter to the engine.

9. Start engine. With 1.ran.smis5iDn in neutral, all( el"'g1 ne rpm tc atatrilize.

LO, Che<:~:rpm G8'alll5t 5pe~ifjea.ti-01\1! ot ll'l~ end or t~ !>l:'CtiOIl. Disrtgai'd lAC C(]unlfi {;In "Sean" tJlOl wi the lAC ~HliOOnnB~k:d., [r the enir;ini! ~B$ Its:. till 500 miles. ur la checked a.l ameudee above, 1,5! rML. the idle rpm with a seul.ctd lAC valve ahou be Icwer t.Mfi 'i/C!.lvt:lH3.t,OVS.

tl. II the minimum idle air rate is ¥.I~tn specHlcalIDIHi. no Iurther-cbcek L'iI required. •

12. If L-Ila mlnimum idle .afr fl.l,te 1!!Io nat wlth specificatioM. perform the rollowing proeedu~li!g:

L:J,. lf Ilnlse nL, remcve ::lWP screw plug b:y pl.rlt\'!tngwith an awl, then apply!.." leve-rugl' Ieee fiig\n'ofI zU, The se.rew iii ccve red L(I dl ecour a UDIlUlhodud. adJq.'9tm~nt.s.

14 With en,gi.ne it norJr!.tLl operating tCj'i'lperatu (8511~lOOttl. BdjU5L stop :iC:~w to obtain no-mil'! rpm pE!r't.pec:1Ji{!3tlOnll wilh seaterllAC V~~V6,

15 Turn Ilflilion "OFF" and r~c:anne.et lAC val etectr-leal eol'il'l~tor.

Ie, D i~tmneci,. "&:Qi"i. ~l Q r lachDmif!lt,cl'.

1l.-18 FUEL CONTROL

Fi.gurt!

17. Use silicon :SMloJ'U or aqulvalent to cover- etup screw hl)te.

IS. rrtSt.:J:1I air eleaner, :l!daR~er ;:],jlA ga:likn.

IT! UJ

.

o

~~ e"~'~ ~

CD .TT .. CHlflfG -'CAEW..t.ONG

m ATTACHING :!;(:Rew..sHORT tlJ ~VELMETfRCOV~1\ ~~!H.Y [!j covrn GA.SKET

ill OiJTLfT fJiAS!ClIT

GJ OOSTSI! .... I.,

rn pun M5TEA BOO-Y '-'SSEMB1. y

5517OQ-61i

TOI220 COMPONENT SERVICE

FUEL METER (OVER MSE MBL Y- T81220 (figure 4-221

The fuel meter eeve .. 3~.s:cmbl'yl:ontain!l ~e fLltl prcssure reguL!l~i" i:likmbJy The replator ~ been lidjusted "t. the fali:tory ILI1d aheuld onty be serviced aa II rompleLc prusem asaembly.

CAUTION: ()() NOT l"ei'i1,ove the Iou e SQreWli "~'I,n:'ll'l" tbe iPr~sl:lure r- .egu~atQr tf;I ... he r"el nHlt.er enver-, '['-he t'uc:1 pressure r"~gul&tor lnctuees a large spring under heavy Cllmpl"ession wblen, if ac:cideftla.lly rel~1i5edl could Q3USe ne reon al injury. Disassembly rrughl also l'"e5ult in 3 fuel leak between tbe diaphragm and the regulator eonlain~jL.

IH1 Remove or DiS(onne«

Mlc~,tdc:el carlin~i"S W rue-I in.io~wri;, 'Squee:l!!C!' pID5ttC'l:J.bi; I).nd ~I.IL15trilight up.I

Long 0 rid tha rt r uel meter-cover 'Screw a~$emb lies.

3. Fuel metor eovee aasamhly.

NOTICE: on NOT immcl'1'C' thu Cuel meter CQY~T ('With pnHiisurll rllgulat.orl 1 n ctccnee. as dumnge to the regulatordicphragm and Era:skeLl'!l!luld neeue.

4. fi'1J.C'J meter outlet g;l:5kelund pre~\,Irc regulator seal, 01 !'jCO rd 1l8S.kt!f.ij ;;I.mi~i'll.

[!j Inspect

• Fur dlrt, foreign material and casting w'Jj'"p~,eo

~ Install Or (annut

Ht!-w pressure ~gulh.LOr eeal. (ul!l meter flutleL 1];:]!'l$3~l\ g.o.:::;.kflt. arid COVE!C' gaeket.

'2, f'v.fJ"1 me~C'c io:iIl'i'.er assembly.

:] Attaching scr-ew ;).,35emblies, precouted WIth cpproprtate locking enmpeund to threads, (S.horl SCfC-WR are i'i&Jl:t.lo rnJeoflors.1

~ TIghten

• Screwusaernbliee ttl 'J.V Nctu ~28,O Ih. in.l,

Electrical eenaectora to rUII'!!J, [njll}t::totS.

WlttJ engine '"DPr", l.IJ1d ignit.ion "ON", eheek rnr le3 KS .UCi UJ'ld It;l~"'-e ~ and r uel line co up lings,

FUEL CONTROL 4-1!

OJ pUEl PNJECTOR m INLEl FIL11!FI [I] lCWIi!!R '''O''~ING ill UPPER '\0" R,NG

III "' ... ".R

W FUe-"MiiT'IR£f;ODYA$S~M!L,(

5$ '69B-9E

Flgl"lre4~13. Model Tal 220 fuel Injector Parts:

FUR INJECTOR ASSEM8LV - T81220 (Figu",s 4-23 to 4-27)

e;)~h fual ~njector IS@i! FiguN 4-23) is serviced aa u cDmpJ~t.e QsslDmb~.>' onl¥

NOTICE: Use care in remuvlng lhc rlJ{l~ injcdurs lr;p prevent damage to the f;!iecti-it::;:Ji eonneetoe t.ermin.ab, the j,njedlu"I1H.er, DJ1d tho ruel

FU~l MErTEA COVER GASJ( H AlEuOVINC "Us'l. INJECTOR

FfgUf(! "'24 " Rt-f'noving ,..., 220 FueE Injector

nu+ ... I~, The rua-I 1nJedor ts ser'o'H':ed ue eomplete .alii~cmbly ar1Jy. AJso, jiIl~t U inj!"~tors an aleetr-lea.l c()nlponnnts! ~hl should not be lmmefSCd In iny type or Uqu sctvem er cteane- eadamage may OCCUT.

r;:;J Remove or Oisc,onnect

Mleetri.esJ eonneetces La fuel lnjectoTs. iSqu~e' pla.sti~ tang and pulll!it.rBightup.)

2, F'!!cl meter cover Q,~se~bly. rouow·io-e abo· pt!X~dgrl!",

a, With fl.l1..!il meter tQVC.f sasket in plliCe" ttl! preve, dllmc.ge 'LD '~ru;ti[l', use (I.. K!'(:'i'I.'(trivcr and Iulrru tocnr,[!o{ullylin out eaeh injt:cJ..l)r ~F;gul'(l 4-24l

4. !..ower- (ematll o-ringa from nczale of" InJ,!?Gt~H·:s. Bl discard,

5. Fuel meteI' Cover gl'ske('and dlseard.

UT'~r [I.tI.rg~) O~l'ing!il and steel backup waahe rrom. top Dfrudl injtcOOf envtty and d.l~j)rd.,

Iiil tnspect

Huel ll"jCelOf Filter lOr' evidence or dil-L ar oorlwnlil'iatil)i't. If present, cheek for preeouee dirti.n fUofIllind an-d fuel tank.

rn lrnportant .

Th& TBI uniL lnatalled on a 4_JL VB engine lu LWO DlFFEREN1' rut_! ,nlcelors j lo!I"ith t .... DlfFErt£:."'I1' now r'I1tc!~l. rnjt}ewl'S hS,\J illS" pa num~r !j.23.s 134 ~'-calor oodctl. Of'4ft~e !l.1'Id. Orp.~ should be installed on the Uu:oU,lc le .... er 5id Tho~~ with po.rl number 5'235342 l Pink ur Brown) go on the TPS "ide (Figure 4-25)"

OJ TBIMOOEL Nu"a£R

m THROme POS .. nON SENllOA [TI THROnil' LIve.

CiJ IfU~crOR f .... N 62351].!1 IOIll.l.NUEIOR'E!EN'1

[i] IN.JECTOR. IIfN 5~J~34:2. rJJ,IN:Kf8.RCWNj ea ~9=6E

Figure 4<15· FuellflJeCl0r ColQrCDde.locations TOt 220 (4.11 E.gI"o)

4-20 fUEL CONTROb

III top "EW or INJECTOr;

(]J f.Afn ID.ENTIPlCAii"ON NUMBER m v.ENOOIiIi INOENlmr;ATIQN

W !UJILD LlATE O. 'IIE",A !!.o,AY

F· MONTH

Flgl.ife 4~26 ~ F'u-=llnjectDI' Port Humber La~t on lUI 21~

Be .5luttl te re p lace lbe i~jH!.01" wl t.1l one hu Y i nlJ (I n i(jerHicul pat'L number. ri\je.'IlWCIi trom other mode!s con .1.50 fit in TBI model 22.0, but are (:Qlibrnlw tor dUferent {low rates, C&!-I! Figure 4T26 ror p;nrt number ~oea.t1on:J.

r:;;Jnstall Or Connl!ct

Mubri(!(t.te n~w lewar lemaf l] o·ri"gti wit.h automat1'!: lnmlimi!isiml nuid and push on nozale end orinjoewl' untdl it. presseG ng(dnst injl'~tor fuel I11tcr.

2, Stee I i njector- bai;kyp ..... usher In c.o unti!l'roore or r oe I meter body,

C!J ,"u!I;;I.I!'.I.JeCTORI CD IIIV~" ~!i.Tifll-01)1i

Fleur-e, +2' ·lnl"lailing'rlJel InjectCIr. TOr no

L ubrlen te [lew ul'p.Ilr (r~ rgll' o-r! ng wi th 8.U t.f.I mil tle trIlIlsmis!li()C'L fluid und instal l directly O'IJ.e:r the bn~up washer, Be sure o-elng jg 5(!i!l.Le<I pl'1>pi.!!rl::, nn4 !-i flush wUh lop of fuel m~tel' hody surrece.

NOTICE": Baekun wasr.el"S ll.l'Id o~ringl'i must he irt5lt.(l.U~ borG"!:! 1 njolJetor1:; , Dr lmprillper!!leoti"!!: (!of Intg'l! o-rlng Could cause Jsel Lo I •• k.

~ Injeewr, nUgning. raised hiS on each injector base with 110D.oh in (ue-I mater- OOdy ~v;ly (lusli down On il1jD<Coor u~~i! i!,. Lg, rtJl Iy ~euttt;j in rUlI!'l rn.fter ui&!d, ~Pigurc ... ·27). (Electrh;oJ ~orm.ins!n 1)[ lnjectnr 'hQi,lld be purullel with throu.l@ !ihaO:),

OJ ",,""ACHING SCREW ASSEM8LV ill FUEL MEl'liR sao·y .t.SSEMIH. v "ill GASKET

ill OUTLET NUH .... ~ET W ouner NUT

[!] OUTLET "0" A:iiNG

~ INlET "0'" RII'iIG IN\£T NUT

INLET "itT !lASKEr

Figl,j!r~ 4-:18· fuet Mete!reody A:5se-mbly. TlI2,;ZO

·22 FUELCOflUROL

FUEL CONTROL 4-;

~

m IP~iH'R CQHTAO~ (1"1:1 ~'.l\IE m ue VA~"'E GASKET

m TtiAOTn:e SODY ASS EM SLY

~

[!J IACV ATT ACHlflG SCREW "'$$~Mgl V

m EXTE"N.'~ , ... ell O·RiNG

m o:liH;,i£SHIaJ)

UJS9HIi

NOTICE: The TPS is !l' ejeerrtcal ccmponern ;o:;nd mll.Eit nOt. ~111! M.ak~ Ln IiIny' 1.iqujd c:ll!ii.fi.(il' C1" B.fJ lvent. a!i damage rn:.gy ~1..I!1l;.,

EI In5ull or Connect

L TP5 on ~hdil~tlc 'body :Il'6!~mbly, ...,bH@ lin.ll\; ,YF TPS !-eVII!FWi.th TPS·4tlve lever on !h"!l~UIIi! hotI.y.

Z. Two 'fPS 0 Lt.8:~:h_i.ng :!IG':rDw a~embl lea,

~ Tignt!!"

• &:rcwas~:m.bHesto~.(]. N'.m(lS.O lb. Lf.ll.

J, Etec=tric;.alellrmecIOl'_

4, Ch!lX:k rg.r TfIS'EnJt~p!lt.as foll~'"I'9~

Conne~'t ALDt. scanner to ["C:illd TP9 I!'utllut volt:IJ.gc:.

W-i~h igniliol'!. ~ON" and eDlhle stop'ped. '1'PS voltage iioollid b{: less th,jCl 1, 'l~ ",,-oJ ts. [I !flO r,e than 1 .• 25 vults, N'pl~ TPS.

IOLE AIR CONTROL (lAC) VALVE· T81220 I,Figur~$ 4-10 and 4-31)

NOTICi6; The lAC valve la an -o1e<;U'~1 ICl;Jlm,ponlJnt lind. musr not be 8(].n.k,-td tn any liquicl chnlhll' "r. sulvent, Ol'.nSFWi.se- damage roLild :rHii.i.lt.,

II] tmpoetant

All rAC Yn~~ct (loti tBI MooE!'1 2'20 units (ex:t:!E!pt LhDEie (in tho 7.41.. cngin~') DN' 'Lhl'md·rfu:wrHl!!d and neve @ dua~ taper, to mm di~meLil:r. pintl'i!l. On. U1e 7 .... L engln:e. the' rAe vah'llll!! n.'rI:ie~mllunted nnd hM r,} l2;~m dtnmelar, duo.l raper ~intle_ An.y Fep~acll!Ifl.Eln~ ofi\n lAC valve mUJtnnvc: lhe eeereet ptut nu.m.b!}' ....... i th tl"l~ j] ppropd.u.liI: pt TIlle tnpeeand diameter ,fbI" pr<Jpcr :!iP,1!, tLng of ~bQ .... cd ... e j n rhe throtrle body_

r;.;) Remo'~e Qr Disl;;onnect 'H:I~Lrk:,;l1 '~onnil!!l::tor

2, Ihe •• 1 ••.

• On tl'lreadi muumed u.nlb, !.ISI::,~ J~ TQ.m (l1>'"1 wrench I F igure 4 .. ,J;ul.

• On nnngli!l~mol,jl'\l.ed un i cs , rumuve screw

a,~ml!:!li!!'.B,~Figurtl4g3t'

3. lAC .... oillve ~~k~t.,or o-ring ri~d 4i~ard_

~ Clean

ii, ----'rh read mouli ~~ 'Vo I ve • Old ga"llkct tn..I.U:'rl.QJJ [rqm tI;'.!tr;[l1!:e of thro ~IIJe 'boody U5i~mbly to lnsum prop4:t' seal ofnewga9ket.

'. F'hl.nRi""mOU~Wd VDI~'1!0 - lAC v ~I"~ sUfi'"nCE-S un I"Jwlltio bod)' W ~$:!I!ure proFit MO.! Or Iii!J'W o-rtng und c.onl!ll.\ltoflAC 1;'1.I'IVI! n_ang-e_

NOTICE: r( LI1I1j!; ~AC v¥-I ... e ..... ~!'I removed durinFJ eurvlce , h opc rat.lnn iTlIl;\' he ~~:lt,c-d I1llHll;fl-eo.lly w1L1l th(J JACtlSC MOM!"' Th511J( [J-31021 m BT-a~!i6,K1. no ..... ever. if ~tU! \lg_!'Ii~ ~l:!"H'[e i:9= ~~lendct;!;'~'I~etrt~~I'I}I, iL filu;;l olso k ftt.r!}l;t,~ elcl;trlCilIl_y BcfO'l"o in!itElni ng u r he vntvo, mauaur-e !.no diaeuneebatwaen the tip Dr tfUI" .... u! v 1! I=dritlc: !ll'id tl'le '''_iliU!'\ti:n,F_; :lurf;.lee-. tr thedlnHH1;SU:rn ,s ~'C'ro.~r Hi!.l.fi ~8 !'"!lftl H.I ~ lneheal, it. must Ira reduced W pre>'"titU. damage 00 thli! \l'B1 VE!'_ This mEl)' be denu ..;:tu~iJ:nI!}Il1:51ingnf\ Lfl.ClISC motor r:..~5t!!'f" (J·37027 or BT·i2&6!\1 ., ",."~ •. lIy by exertlng Ii.rm pressure, us shown 111 fig\lN: ""·32 or 4-jj. with 11' !j.j lght p;ide·lo:-!Iido frHII .... ement.on v alve p~ntlE! Lo rutruet it_

rn Important

No .physje~llldjlJ~tm.e"," of the lAC .. r-lii.!v,t 1l:;~i!!1fI Is ,j:.-il"ll:Illl;nh~, ~ndr lflit!illriU.6:i]. T~-!' lAC ""Ei. p.i.ntloe.i.!i reset by scening the lgnltaen "ON" (or .5et:!on~ ami then ".oFp·', The BCM then resets pintle 00 .. he c:o,rr'E!-(t Do,n.i(!oI\. P'["oper i rt!1:'i.i IQ,UI!IIIl Ioltoul a result

~Acl~~~I:n~ ~:~:~y.s follow"

• Trne(ldrml)'I,Hltoed va lve . I rl$t_a Il w~t.h n ga,'.(.

• F1Qn:gczmClu.nlt)d .to h/l!li • l~Sla H ..... ith ., lL,Lbdcl;lted c-rlng, ""Sing o.1.t:.Ii.ddi'lI!1:' !'-cr aaeembfiee.

NOilfE: New lAC VD!~e-~ have been reset at. flL<:to~)' .o.nd :sheuld ~ It'J:stalled Itt thr'ot.L.li b&dy in 0.1'.1 ·'!)S li" I!:('H'LdlU wi lhlJut any oclj-U:liilrnenl".

I!jJ fight~n _

.. Thruad-rneuntnd LAC .... alve Mscmbly :tQ 1.6.0 _,., (l3_0 lb. It.) with 32 nlm 11· t'l wrene .•.

• :F!_ange-molJ.nlMl aUEl.chin gscrtlw L'is:8embl lea to Nm l28_O lbe. i.n,)

2.. IE: le'Ctri.~1 (Olln-e-c:t-c-r lu lAC ... al V-E!.

3. Start ~tlgil'le .;).nd ullew engine to M;B.c:11 eper-at, temperatura.

THROTTlE BOOY A'SEMBLY"T812'}'Q r;:::;J R@moveorDisconnect

M51 "n.it.., Mllcsc:ri'he:d abc .... e.

2,. FUEli meter bod;'l')ot-{t,fhmttie ilOdy mtaching !;~I nssambfles.

J. FI,I~I rnetEir bOOl'.as~mbi)'.

4. '1'1,,..alUebady-t-o-fuel meter- ~ody gu!-!e~ ~ discard

r.t;J Di.assemble

Rps from "'Ia throttle body. Ila;ordii"i!!: to j}j"frv~' il"i!Sln..!(:ti~n~, rar reuse CIl new In:rottl@o bod,v- 11 lAC 'lfai'!'!il d~i noL I'lJl"'1ii! !,O ~ removed, alno n-ew one remits wlLh nrpJu.ooj'fu:~~ lhroU'I~l".lOdy.j

~ Assemble

Rrs onto reptncernnm thro~ti(!: bcdv ;)~:!Iemi::

aecordtng to provloue ir1:Elt.ru~tlon:!i. .

!;:'I I"stall or LD"'"<t

HoCw tllr'"1itUt: kod_' .... o·(ucl m!!-~r 'ooa:or ga5k-l:!1

2. f\Jt:1 meter billd:v ~1~S-~ffit.,.'1 an th eott le hJ~ l1fi:IiBmhl_...

fUEL CONTRCH. 4-~

'm·' R"'~I"~~ W~~C'J<1

.:. THRQTT\.E u:veR :sTUO

4 SPRING

'51 ca.aL.S"

II] SuPM.r

fig~.re 4-84 ~ <;Qntitll Cable!---".3L'& V~B

(;;iIR'emQve ar Dis(gnnec.t

MCl!.a.l.ncr It'-om ~nrQttle: lever stud vI' oijfi ;2 n~18ilSE1 enblo Crtlm ~u'tle.y

z. Ret.aine.f ~oc k ih,g tnngs from support hra.ckE't.

3. :ft~ta.iMr fram a-l::c~'i.g ra to'r pedlill rod Of' re I a ,!:;t,blef:rofll rOO.

4, R(it4lt'lllll"!" Iflckin!!; tan.k:s.!rom dralh JI~n~l.

,j:;';Ilnnall or connect Moll t.aiDlE"f to dil.!ih panel

2. Retafne .. to 1iI~li!lcrutor :ped;al roo or connect r;.f in roo I3!loL

3. IW~Jn~rt,Q ~14ppol;lrlbrB.tket,

4. R~LaI"i1it VI throitlll:: lever 'Ii~ud or- C'onn.of:Ct c:;!bi!1 ~UUB'y.

Atteler",or Pedal

(Figure~ 4-86 Ifl,ough 4-92)

Thill aC'cder;Q:tar pedal eontrnls tnt' ~hro~' xh ... cugh a coble. There are not Unk.a.go odju:stm, The throttle cabl-l! mU:r;t be .. epla~d wlth an idem r!i:pl"lIie"rn~nt. pat"t.

Alliinkages.ana eablee mU!l-tb~ che<:ltoed., ~9 ;iSS rr(t[l movtfflf!"il with IlQ rubbing. ('halin.g, ~ .. 'bInd The lh.rn~!.I!!! rnuat I:IoJloE!l"fiLi!' free-I.)'. wHhcput hindi between full-c::lo-seei, Q.!"Lrl wtde open throttle

4-42 FUEL CONTROl.

EH ::NG EEl ~~

w ",eu: [j] .. PAl. rn ~t""'",A

ObM!rv!! the' follow['I"!i!1, when perfO.-ming earvlee

OIl thl!vaCE-E-lero,l.Of p.t(Iu.l.

The mounti.ng ;i\i,i'fice bet-ween. the '9:U]l'p-IJrt UI!d Lila iila!loh panel. must be.Jeee or leeulation. ThE:: curpet B.n,dpad[jilfl~ in th~ pe_dal an.d. tu nnel area must bE' po!!,!;i Ijoned. to lay f1fLl find 00 {"E;I! of 'iYl"inkl~ ;Jno bunl!flct:.

oS] LP ~hlli!' a~~1i! l'I}riilor cont.to l t--IlbllC '~h.-Gugh t.h e -:;[lI)t ln the red, btfott 1n.~Humng the retalnej- in the rod. Milke- Sur" it. i.15 seated [Jl;'cpel'"ly. U!!re cere in pr-.ml5ing f,l!wner into the ho1e, so 'I.f.lc;:,uol(!o itllt)t k_il1ked~ct" ~JUO.~d.

Tiil!' Hnkage m""'~t 9Pcr1Itor" frc(ll,y.- without binding, be~"""(le" dostl.d tnrolt!(Io and fun LhrDlt.,!e.

Witt, ho,s !:! 5. cahJl!, and Dt.I\,U ne~ibl~ ~mp .. h;enl!io. must 1l9~bti:: pl~d wH.l':!in [3 ann [a.52 1nch~ or the-~bJ-e or ,rod.. Ilt ,(tily poim • In their ~ra\'el

FU EL CONTROL 4-43

[j] RI1.TAlNE~ [}] SPIlIINCi m SUPPORT III CA.'"

Figur. 4-92· A«oIerator Ped.I.P (32)

PARTS INFORMATION PAI\T NAME

GROUP

Cover, wfRc-guwtot. Fue! M(!ot.4!!T':

Pa,rt (]if Meter Kit. Fuel •••••••••• ~ ••. 3.73-1 Injeetor, Puel: Parlor

Pump, ~:"1,I.e1 IlnTe..nkl •••••••••••••••• 3.714 Relay. Puel Pump .,' ••••••....•••••••• .a_9su 5 ..... i1.(;11 , Oil Press. • ••••• • • • . • •••••••• I."SOO Threu.le BoOdy [njCC:~;Oll L'nit .•.•••••... 3.725 VLl I 'lie! Al5m, hUll Air C~ntfol; Part-Dr

C[]-Iltml K h .. ldlc Air vnlve •.•••• , •••. ;!.d',:!jJ

4-44 FUEL CONTROL
CONTROLLED IDLE SPEED
Engine Tran:sminion Gear Idle Speed lAC Counts* Open/Closed
(DIN! ~RPMI Loop· ...
l.SL Man. N 900(ST) 5·20 Cl
!!OOlM)
AiJto. 0 !!Oom 15-40 CL
6S0m
750{M)
2.BL Min. N !!Oa 5-20 Ol
A.UtO. D BOO S-30 Ol
4.3L Man. Ii 500.550 2·12 Cl
Auto. 0 500-S50 10·25 o.
Auto.!i) 0 SOiHSO 2·20 CL
S.OL Mli1n, N 600 5·]0 OL
Auto. CI 500 HO 0.
A"lo,(2) e S511 5-l0 o,
s .. n M~n. 600 5-30 OL
lundl!l"B500
GVW) Auto, I) SaO S·30 OL
s.n Man. 650 5-l0
(0"",8500
GVWI Man.m N 600 5-30 oc
.Auto. 0 ~O 5-30 Ol
1.4L Me". Pel 800 5·30 Ol
Auto, 0 750 5·10 Ol • Add l<ol.!~n tOf't:lIi!!'!f:liWlf.i'! Klol thMl SIlO "'_ J!IIjrJ ~ IOOI,;.ng for It .... ,)' , gog ft .• tJavr ~. IrYltl ,"..3 l..lnd VB) Add I (Qutlt facewl!fY 1QOOtt. ... bIJ .... q. r.v.1 U,Sl.ncl2 8U

• ~ lell!ng,ine Idle until ~C?pRf fu.! WPH;fOIi ftnld (OQII~ Joop) l' r .. Lk.d (1) 4,] Sf '."ft.

m J,.,......,~"" ;!IC10PIC\: ... p~~ed_I!r1'jllJ.i.oot; .. ndlVl"'!Rsy~t!1f'll (2) G t!lrl or'5~buf'b.t",wHI'h. :in'!';'!'!!! CIII:,dyb~ tDIF",..nllf.

MINIMUM IDI.E AIR RATE

Engln .. 'f.rillnsmis.sion Gear Engine Spe .. d Ope nlel osed
(DIN) (RPM) Loop'
25L Milln N 600± so Cl
Auto. N SQQ±S:r:l ~L
2.Sl· Men. N 700 ± 50 oi
Aulo. N 700 ~ 5·0 O~
4.lL Man. N 4SOf50 Cl
Auto. 0 400! 50 Cl
Auto.!') N 47H50 CL
S.OL Molt!'\, N 500H5 Ol
A.uto. o 42H25 Ol
... .u'''.(l) 0 425t2S CL
S.7l M~n, N SOO ± 25 Ol
(urlder 8500 GVWl Au'lo. 0 4lH2> OL
S.7L MIn, N 550! 25 Cl
lov.,85OO GVW) ALlto. 0 450! 25 ct
7.4L Mil!'!. N 'OO! 25 Ol
Auto. D 100 t 25 Ol
• lit ili"i!:i11'i4 .tllli! kJ;;~,1 ~Oil~; hlii~ 011~rQIi-ht~ 4o~"ltlond I.()",I)~" rl!'a.d',_~d
I!) ~ t.L5Tw~It!'~
ll'OLWlt'"-'1"rt.ItAIFlIl'Mt'1I:' 'SECT IGNITION 5' CONl

GENERAL DE5CRlP110N ;;'j

PURPOSE Sol

OPERATION Soj

Hall EffectSwit$ ~ ~ ~". § ~ ~ 1

D!AGNOSIS 6.2

EST SYSTEM So2

co~~~: ~~ I~r:=~~~t~~ ~~: ~~.~~~I~~ ~. ~! \. r

GENERAL DESCRIPTION

PUI\POSE

The ignitia1'1 §Y'stem cttnlroll!; rUiI,1 enmaustfen ~~ pro v idifli !!, 51p;.}rk top i,g'nhE!: Lhe romp!leslS4!!G airtfio,el mili!tu~ Cl.t the COlTE!cl lime. 'To pro ... idG- im~r<iYl!'dl c:ng:in-e peclcemence, rue:~ e(Oncmy~ and central or exhaust emlaston, the SCM cont.nJlIIii dlstrfbntor spar-k - udvanca (timin..Ql with the Electrcnie :Spal"~ TImLrI.;g lEST) 'y."''''

Only tl'ie EST 6Y!.1t.em will De clesc:riDed hue Add..UnDol information on the. igniiio[l5Yitem u round in SKtlon "60;'.

OPERATION

The lgnltlnn ayetem h," Q. disldbuoor rnoo.uJe with Icur Iarminala for the ~ 1)'i1IAm (F'igufe6-1 lind &-2.~ tn,at aI'1!' connected by the ECM.

'fo pro~i'ly II!:rHlLrol IgniLion/c"mbu,LiQn ~n:Ling, the ECM nec:rb l4 kMW~

• Crank!hl.n. peelt ion

• Engine epead (rpm)

• .Engine laati (m;IJ.nifold pre:ssut-fll Dr 'Io'iIlEuum) .. Atmo:l:,;!lh:trl, {b.o.rtlm.etn!Cl preeeute

.. eng-inC' PR"OO'Lall.t temperature

Allenglne.~~ ";\~"" '1 _~-_ I

'The EST"'1"Y\~:lr-"comji1:iL5 or the disiribullor rnoduJe, BD ECM.., and c'Onnecdng wires. The foul' Lenninahi rar EST &l'e Jettered tn the modut~,

The d.is.l!'"ibuto:r Co.i.ir tttfflina.1 eonneetcr ie tetter¢ J\·Il·C·D.

n DlS-TIWUTOIL r:J, !iSN. ee ' L n.IJtM!NA~

L2...J H!I MOOUl[ L!..J .........

I!J ~STft:KMi"'_I.S G:J II'.r;K~Uf'COIl. T!:RIIIII,.AU ]-15-115 '"5~11G7-,i1

ill Oln'HILIUTOFl: toll.

1M~1JLE C!l PICX.u1' COl L

CD HALL E~FI!CT SWITCH

[I] lo.NITlO~ COIL T~MINA.~

rn EST TE'RMINAllJ U 211!

figy," s-a- Olt;tlbuto, (~.sl SIT Try,.)

The deserlption nnd 6pe!"Btion or thl! ignitjon s-yst.em ea." bi !~u:nd ii'i St.f(f()l'\ ~6011'

Refer to chllrb in i.h,is. 2if1:t.iQl1 ror ignitlctn .)'s~em check.

EST SYSTEM

REAR AXLE 4B1·

DIAGNOSIS OF THE REAR AXLE

The mcn;t 95SBnIiBI part of rear ade SBMte, as wirh any ITlE1:ih8nlcal repair. IS proper dragnm.:l:!i c.f 11'1& prOO[9m. ln wd6 WOrk. one of rtlQ nlOM dink,utl ereee to dl8gnose 151 n~8. lOGaling a broken MIO iihaft or bfoken (JlffeoH1lial gear prts:se:rrtB ~1tIa or no probIelTl. bUt 1oca1in!J IiIInd IscHI'~ng moo t'lQisti can be lin ef1,tiretv Clllterent. metter.

~ .... o'NoI ..

An" gear-.drIVd1'i OFiIl, B$QIi;i@lly §fl automotive drive Wd6 where eng~il! lorque fnliltip~~IIor} gooof$ al a !)O degree tun in Ihe drtvellM, prgdUCS1 P.. Qef18..1n artlOtlnl of noise. Therefore, ar. !l"ih~i'p~§liiliDh ITI~I be macD for eacll 'II~h~ to de1em'1HM wt'Ietilor lh9 n"I~@ It normal Of if B j;lroblem i1ctUaIly ei!!lsts~ A flOITnil' w.nol.lnt or noise mlJiSi be e~ed IiIrld canl'lOt 3B eltmll'llited by oci"tYG:nlional re:p~rrs or adjuslm£jl'il.

Accep1ilble 00&9 can be dlf11~ed at; a al]gFrt no:i:se hl!liilrd MI)' 81 III e"naifi Speed Dr IM1der u.nu:5ual Of reroole corxn .. tlons.. fa( example, thll5! noise tends to reach a ~I<' at &p<Iod. tlnm 40 ~OO m!1e< par hour (60 to t 00 kmJl1~ ~r.g On rc)(Ig !itAd lad colldffioos. or gn gear tatiQ and 1m. !U:8. lhi:!l $140111 nolH ts ... no way indflcehV6' 01 trouble in 1I1 ... I._mb~,

Dfflelina ~ rMY baffle evoo 'he beJj;l dlagllOSticlan, VlI!Il'IiCle ;;~i5! ~n9 from lif'eil!i, irarn;;mi$.5Ion" pt~m !il'lall., ~I j!'Jlnls. and f.ron:t or reer wheel bBarjn~ ere Often m~~n for axle noise, Sucb pJ~ctl(;06S as; i'WSirl:9 fir" ~i"8B$Llr~ !rj Qlimloa~.e 111"& nclBB (~fi:hQU;i'1 tr"l~ will flO! &11B1lCQ ~ I"IOH ~ mlJd and SlOW ilre3). listonlrtg lor the OOsft ,~ 'IIilI)'los ..sprteds and ltJiI.d l;uri(l.teS, and IilIl drive, lIDot, ,,'" ""IlSI """"Itions will aid In Io<8llrQ !he sou"'" (}! oIlotJ<o<l .w. noI ... , Th"", SV<!'Y .Hoot .houl<l be marla to ~il.W the nol:se to ill spomfic drlvelll'ltl' oomponerJl illiSllSM Of JMkIng a random gUB5.'S 1h.11l1 I;OU~ bB a GooUy wasle of IIITI(I-.

DETERMINING THE TYPE OF NOISE

&tarnal Noise

When 8 mar axt.t it; suspected of bek-Jg nofa)l, II i:S Eigv~ ebI.e to mall:8o1l.lhOl"ooghLEl;tjl~toclet-ormIMWfie.lTiar I~ AOise originates In tn~ fires. rOllid BlJrI'~, rroot whB!;I1 Qf:6rIngs, englM, IransmiESion 01" rear axlo: tisembly. tofol!::lf! whlch Ortgll"'lales in c.hE~r plaoo$ eaMOI ba oo~11d by adjus.tl'ft(J!\1 or nfp'acem.enl 01 pMls iii '(he f@§r axle: ..... 01>1)',

Road Nol. - SDme roM SUI'l.Ele&S, SUch ~~ brick Clr rough.sur'fiEed CDf'ICfete. ~USi) "Oiie wl'ilt:h m~y be mis, tai(.gnICIlire or lear exJe noloo. Drlv1iig 00 a dltferent type 01 toiU:l, such as smootl'\ asphiift Of dirt. wifl Qul"*ly SAOW' whether lhe road stJi111O& 15 Ir1'l1l ea.ll~ gf .,Qi~. RoJ:td noise ui5UBlIV 1$ Ihe ~me 01"1 driVe O~ 00B§l,

T1re Nol .. - Tho. Mi~ maY' easily be rnb1a.~tln Iorre<D' axle nals6, il'Y8'f'i lholgh U1S rlgf.iV t.i~~s ma)l be I~tad on ""'0 frOti' WflOOIt.; Tir~ 'rt'!Xn unown11. or 'haYing si,.Irfaces on ftOf'I-skk;! div~rOflS worn In saw~tooth f.aWrlon. [ire usuaiiy !""OI$.lj IUfId may grOOuM vlbratloos which seem to originate

~lsBwttSfe In !tit vjtilc:!et Thb b Qartlc:a,Milrly true 'lVlth h !lr@ pr.essyf(l.

T1r. Nal" TNt - T,o: no;sa q,angm;. with dlffera ~ iSUrfB~. 001 roar Bxltl' l10isfll does nElL Tampc;H'81 1"liatir'lg ojl fi"'~ 10 3<15 ~I""""""t. (50 poonds per 0<1"' lr.;,) p ...... ure. f", 1 .. 1 pu __ onlr will materially .t

noise tau:sed by Ikes bul will m;Jt a.frael no~ ceueed by t rear axls_ ~e~ rode l'i.oli5Ei UsUally stops whEtn coasllng 'S:pOOd~ tinder 30 milM pal oour; hO'l"fWiu. fire. nab-e IX t\"nl.)M bul with fow« to~e as lhe vehicle speed is redOOt Rear axle nQ~ USUally cl1anges when comparing. "p~ arid ·~BS.t'"' bblt Uro noiSj remalna about ina :5al1la.

engine I'P1O Tflnsm[ifiiorl NolHI ~ Somellmes noise wh~h seems to origin;e.te In the fear axle ~ aOfOO c~sad I)y ftti& !E.r'lgirJe Dr nll:$mlMlon, To delermll'lO ...,..i'I~ unrt 1$ @"tyally eausillQ the noise. observl;l ~pproxlmtj vB"Ic!e ~$ and cOnditrOf'~ under which the I"IIDIse I'TIOSI prollOlJnCtid; then $IOp Ihe ~dl8 'In a Quia-; pf.ilCCl avoid irrterfenng naisB6_ Wilh \ho ti'llrl&niEsfon toO "OUV nil1 ~ enolnl! slOwly up a1ld dOWTl throu~'" 1he ongil spo~ •• ~ng to 11>0 vehicle speed .1 I'hlch ~ noi@e-was mo&t pranoonced. II a 5fmilar nol~ 15 prodUCt will! tnl5! vel'l[lc~ standfng, tt I:s Cilu;;ad by 'Iha fln;~n~ trBnlillllss!on and rlD1 the reer !Wa.

rrcn"!t WJWHI!I BearIng Nol •• - Loose or ruugn tn::; ~I cOO!lng~ will c;aU!W fIOl68 whfch may be conkJ!SiI ~t" roor aKte noise; however, front wheel be:t'lMg noh ~ not cn:afiQe When Ql)mpsrlng mpLlU" and "toast.'" Ug OQIlIic.ll<>n 01 til. brake, wilkie h<Odfrlg tho vehldo ,po. .1Q.dy, vA" .n •• oaU", tho w .... 1 bearing ...,1"" to diml !:§:h. ;ft;9i U\1s la:ke:a .a[)me waltlht Qff 01 the beAring. Fro wh.eI r.oating. may be .... lly """"ked lor noise by jOCl<i. op tho WM~. and .".,nlog ll1em. iIDd .''0 by sl1a1<lng fl whoCIll 1<1 dotarmlne fl 1M Il<>aring. ar. """" ..... 11' 1000

II<><IY 800m Noo.e 01" VlbnrlWn -Objoclloo_ "..

OOOm" i'IOJsiI Or vlbr.~on .1 55-65 mph (00-1Oii Kln'b1 '" ... oauood by Oil unbalanoit<J _Iler e!>ofl. Exoossi, ~ at lile epijn.o can contribute to ,11k:; unbalanct

OlhilEr imrns tltal ma~ al50 CIilnhiblJ1e to Il"Jo nOl:!ie pm tum MEl :as foilQ'W.s:

1. Uri~!lIrCQ8tlng (U mud 00 the .snarL cE'lU9if1

uriliilllD!':c;e,

2. Sha.f1. or pinion nange oa[ao~ weight5 mIMing.

3. SMII <Iam.g •. ""'h os barding, c."to or nlck ..

4. Tire-lVP8 roug"'l19SS... Switetl tlfeS from .11 kl"1oWII g<M: 'II'e:hbcle to d'etliirmlnlB a lire 1ault.

It, §fter making it rompo:hensi'lo ~ of the veh~b ali Il1dl~tlons point to ihe lear .pJI;1b. fui"l:'l'l'ar diagnlJSiJ-c 1itE!~ atllI n!Ke!}5a!y tQ determine thtl axle oompono.nl.& at IElU T ru9 r~m- Oks- no4se gEinefilly r~Jls irdo two categories: Q!W !l~e @nd bfla:ting noi5e.

RoNr ..b1. NDla.

11 a C8J8tul UJ.slOr t:hB whideo snows 1/'\111.11'\8 nolliiEl [!Ii I'IiI CBlI$ed by 0xt9rnal Items., it ia Ihen reasonable to assum 111., _ I!l =- by lOa ro'" oxlo ..... mbly. T'l'S1 111 !'Bill' axle on I. smooth level mad to avokJ road ~. It I 001. !ldYisabIEl1.Q test tho rail:( axle for Mise b)i running wil IhjJ I'Qill' wheElis J9dt:ad uP.

[81.4 REA.R AXLE

set "h<of1 will ~rod"~ I.tlg." lraolure •• r .h""k loao01g .."iofl w!l! ,.",,)1 In suddon lailu""

Noise in Ih", reoaf .IlJd.$ 8.s.wmoly tfll.~ OE(i t;a,i.JM:d by il .rneqo<i or unba1aoced prOpeliM <h"1l, rough fea' -! ~ wom or damaged i1ilfefBii\lili Or ~n'tOO sr:;aH beer~s., mlMJIgBmen'l OOIWetlii. ty,oO U-ilJints. or wgrri dlff"il'.r'~~lal de gears arid pinions. NipiS4;t rYllJV §.159 ~ c~ed by !il ~Bma.1ehed. IffiPropBrly adJi.I::!3led or' 900tBd ring af'ld pinion .... Me

RHrWhMIIJ«irlng N61,,- A tougH rBafWhssl be!l.rIg !:Ii'OCIuce5 ~ ""lmB.ion of grow~ ~I'i.i:'.' ::o.nliflueS witr, th§l IIIhl~B ~sllng ani;! rne Iran5m~10i'I HI neidraL A. ~nallW ~ar w;,eel baann9 eauSM H IO'ItiCk: Of (lRck a~p'm(lml;l:l~ty 'Hl"i two rBWjoliitiDii~ 0'1 t:l\1Ii reAr WI1~eI. I5.iFl~ fhli! be-~ IlkNii dO not \ravel af ~ same Speed as the rear @XI~, @I1d l'ijii~. Wdn ~ mar" wllams jaclUK! up, -&pIll Ina re~r wfu;!1iIE11;iI i tm.i\d ",,~(iB IIstafilfij): AI tile flUbs for PvkJ6floC@ 01 Q. fQY9n r bnnalled wt1ee1 ~f'ing"

DI".i'H'dJill Side GeM ilfi.d P'.ii.l'an NOi&e -lllffef@'l1T.!.jII1 de g,8Sra and pinions sBidom cause pct~ ~!1Qe their IO\I'~ Is ~~t[vtt!y §_I'lg,ht on ~r@igh1-gh~liI_d drlvij~9'" oise pi'Oduoad by !nasa gsam will be mQ!I.I pronpoyrQ!d on Irns.

PIIMon B$iil'tf11ll '!3Ei~Y~B can be di:itI.ogyt,hi!XI b~IJSA;!o ley.fD\atQ at hlgh~ ~~ t~gr; d1.ffe:~nl~ srd~ btt3rIDg!3 od .. 10 .~oJI ~., ~h o.ll<lnolIO<! IlInkm W81!ngs rW~ § Qg~.\.1I1J)QYi !QW P.i~.;h@-d whlrrlng cr :s:eraplng )10<1 wrtlr>!l 01 " ! .... _<I.

S!d'o !!4!.rlngo P'WUO<! • """<tont ",y;~ nolo" pltchO<!

WO' l~"" !'inl"" twilril'll nol ... S!!!e 1> .... lrQ ""I .. may .. nuolollto in l~ _ """ vffi ... 1 """109 I .. t,

•• rHoI ..

Thor. are two -types .f go er nol ... , "1M n rs ttyPl' Is 'OCiuood by b",'"", ben~ or iordbly dom.gecf.go .. looth >d is .... u .. y QUn •• udlbj. o~r tho onll", 'PI"'" rang. and

_ no ponle"iar 1If"lbl"'" In. dtognosl •. For ilIfIPIo.

IPOid goar ioot~ sooring g ..... "'11y resultS from t follow·

g: InstJi!kiOl1t lubrl"""l. i'nllraPl'r br.ak~n •• ;"proper l."lXl· Inl. ine.ut!idifnl gear badctash. II"n,proPI9[ nrlg ~ S:-lnJon M.r fI~nmBl'lt. Of lou of ortv. pinion nut to(quD. Ttta aoor· g W1il pro;;;jrSSSlvBI'y lead to compls1e ~km o~ thB ~~~ Olh, 0( geat tooltl plwng and ~tul!il ftaclurs tr ttta 1~liB:I nlng condifioo Is noI t:On'EId.ed {figUfB 1). Ancltler cause I hypold' ,roth fra.ctur'el!i 08'.x.tertded DV,erl'cmdlng' of tha gear

RgUM 1 - Clyte. of' GIll' NOtIt

DiH."mt!.1 pinion ..... oIc!e gears "".iy g". tIIlIJbIl, CcmmOO cause. of d!lfe,enlia! 1.llu", ore 01"1<><1< lOading. Mtended avertDading, E!EI'U;! M'lzl.!re of b ~1I'er(lnlf.al 1I1n:fans to UIS cross ~Eltl ~u!t1ng 1rom EI}':J(ces~ wt'IH' sptn and consaq~ent lubric,li9n bl'e!i!lkdoWn. Tt1Et socond ~. 0' gEllair nofss pl!lIiBlns to Ihs' m~ patt-emof the gear tHin. This. form of abnormal 9(t,r rtQl.5o WI'I be: roeognlDci beoO.",. it pred""" •• oY<llng pito~ ("''''''llnO will"" "''1' prooounced In IhEQ :$P~ r.angEl;! !!it which l! occurs, 11pprt8{· ing IIndar either "g,we, 11 or ""flQ§f' OJ ·coMf' condtUons. tQri\lg" is ~ISI'B.UoI"I Qi trei!ll""l~!iIJU. ·Co·,m" ~ wl1., a clClMd t.rottlo Rod th ••• 111<10 In g.a, """ "!!oar I. u.lng lust onough _ IQ ~ •• ~ l~" .",,"".Irom d~.r"Q tho "nglno; trio ~O! •• lOw. <1<>"," G,aduI!lv bUI Iho er.gi." .,111 pu!ls $8ghlly. "'.,. noi ... t •• d.IO ~"I< In .. ,,!TOW spo«I rolIgO or 'AI'!I •• , on<! w;~ !~nd to r"",.ln oonstam In pfl<l1. ee..rr.r,g rooi..., wUI v.,y In 1>11011 with •• "!oI. _d ••

R",., 10 ~res 2 Ihroyg~ 5 lof _ng alagn •• I ••

RE.AR AXLE 4B1.!

ON·VEHICLE SERVICE

The follo'lVing fe:ar .. "Ie procedUJes apply 10 \l'shlcl@B ecuipoed 'to'llh rear drum bmKtI::i;, HOWQV9" 1111'16- mods!r 1D be $iI;Irvlced nas rear diS(; c'aII;e'f'l, re-l(fr to HYDRAULIC FOUNOAT10N eFlA~ES (SEC. 5A2) 10' Iho appropriate bfllka-rel3J.ed procedures.

REAR AXLE ASSEMBLY REPLACEMENT (ALL AXLES)

B RemOVe or Dlsoonneet

• RaJse U')e vehicle Of! it htflr..t and support 100 jude 3..S$OO'Ib1)' wlln a $I.IitattlEi: littii'lg device.

• For 9 3l4rlMil ~ilig ,UElicU and 1 0 ~ I2-EncI1 ring 11;001' ~8S, n».sd the ~eNcSB and place Jack s~ends undQ r '1'10 t'ramo sidB mils lor suppol1...

• Drain 11'18 lubricant (rom the m:le htluslng.

t, PrOpell:e:f shaH. Refel" to. PROPelLER S .... AfiT

(SEC.4A).

,2, Whss! Ellld 'Ike QfiI;e:mb~.

3. Brake dtum Of hub arid drum.

4. Parking brats cable from the lever and at tho brake

flange plele.

S. Hydraull-c bl'ilke JInes from true' COi'iMdaf'$. 6. Shock absorbers from me .ruIO l:III'aCJk.o.ta.

7, vom hooe '",m lite .. 10 ... nl l"llfig I~ "'IulPl'ed),

8. Hergh.t-s9naJP"Ig and' braJ((l f:)roporlfOnlng Vi!.lIoIB tlnkll!;l13 (II equlppOCl).

9. SlIlbIlk., ollaR ,I! oqulppe<l),

• Suppo!l tho .as.oornbly with. a hydraulic aoor ja~. f C. Nut.!:; and wilSl'lerlI 1rum .he lJ.-boH:!i_

11. U.bOltt. Spring phites and s~c'!;lr~ framthe g_){I~ .. ""!Il>ly.

• Lower rna j.BCk Mathe exle a:;;FWrJ'IQ,.,..

8" tn,ltlltI or Conneet

2.. Spacer's, spring !~laIOS and V-bolts II) 'I\e ax as:sernbIV·

• AAIh: lila axl"", 1iI!I:S~y.

~ Wasile~:s a'1d nuts ~o !he U·bOlbi.

• Threen Ille nuts on flrmly_

• Adjul;il Ijtlgnmcfll 01 alds_

4. SlaDiftmr .hali III equlppo<l).

5. Haight-sensing end bralUJ proportioning valve !iok~

(il oql.ippedj. _

6. Vent hose to 'he 8:aHl vont rr1l!lng (if equipped). 7 Shock ~omer$ to U1~ axle brackets.

8 HydrBU~c. brak.e IIrt9& to Ihe cconecore.

9. Porl<l09 braKe cable 10 Ihe I eva ' ""d 1h.lIMg. plru, 10_ Whee' 'iIInd tlro gSSembly_

11_ Stake drum or hyb and drum,

12_ Propl!!liler !t'lafL ReIer 1,.0 PROPELLEFI SHAF ISEC 4A).

NOTICE, See "Noli",,' "" P~III' 'IJH 0' Inll sectJo,,,.

iii TIghten

i!I' All 'astenars.. R81111!1t 10 ~pecili.Mtlcl"lIf· a1 Ihe. end ~ tl1ls S&Ctk>n.

m Importonl

• Check axlelubJlcani level at lhe flllar P.lu9 hOole. Lubf c.ate as it99dsd_ Refer to MAJNTENANCE AN I LUBRICATION (SEC.OB).

• Blo(Jd O,e brake S)'5[!!Im.. cl)ecII opera!foo and adjust rHJCel5fiary. Reh. 10 HYD ~AULIC B FlAKE: ,SEC.5A).

• Ch~k. axle and b~ke' Qpera1ion.

• Cl1t!1ck lor nuid !eQi~ QfIQ road tail 'tbD '¥ohlcle.

" Axle ~ml;lty 'Under Ul-Q vet'l!~!Q,

• AlJg~n Ule ~I~~~:OATING ~L~'--~

_. (8 t/2· A~~ 9 t/2·INCH RIN~ GEAR) _)

AXLE S AFT, OIL SEAL AND J ZS689,>;xl. :>001' B, .. tinQ"R."""'", (8 11~

BEARING REPLACEMENT Inol1 'Ing Q""'J

J 29'712 Axle Shan Bearing Hemcve

(9 112·bJt:h ,"og ga.,)

E3 R em " ... or meecnneet (Fiyu, ... fi thrvugh 13)

Tools l'Ieq.'rod:

J 21119-01 Slide HOIfIJTI8' .. 1111 Acilijlto<

• R~!he vehlcle on B hoist.

.. crean aiM ~rOm eround rflllil' ~rrl@r (:QVE("-

4B1·10 REAR AXLE

10. Drum

n. aoil

12, Sh.~ 13, Lo,", 14. SeBl

H;, Bearing 16, HoUSIng 17, Clop

16_ Bolt

19. Carrier Cover 20, i>ae"n~ Pla!e 21. Bolt

FigU,. fi - 1UUe Shaft and Hou51ng Components

1. Wheel and l~r9 os:aeml:lly.

2. 6r.M drum (I OJ_

3. Csrri8r CO\IBr (19~.

• Catch the 011 in a dram pan.

• A.~ gasko:! rnalerfal. 4, So, ... (A) Ulg"'.' 7 and 8),

:;, PinIOn 6118" (6).

• Remove tl\9 8hafi: {Bl from t'h9 ceae on \l8M~ withOU1 • locking diffe'.nOOI.

• WIth a kicking i;lfflQrenl~iJilt pa:r-ijidl)' ftltI'lO'I'8 the .haJj (8) M<I iQ"~. IhO ease ""~I til. pin"" Shaft (S) ,ouon~. t"" ttwoiog (!igor<> 9).

III Use a screwdriver or ~m~ar llJoi to BI"'IU!r I~,.e oas~ end rtxete the lOCk ~G) unlil it aug"' wlih til. Itlf"," bIod< (E) (rlllur. 10J_

e, L.ook (13).

• Pu:s" me !lange of the axis :511$ft ~owmds. the dtffaffintlal. Del riot forcG or li:amn,er the :Eiha~ to me"" tho sh.oft (figUre 11).

.. Remove the iot* (G, from tile button ond 01 the ""~ .han (12).

7. A>lJo .,,,,ft (I?) .

• SliClO llie axre shutt (12) out, being car~h.i~ not 10 (jilmag:8Ilhe seal.

e, Sell! (14) ua lng J ~ee9 (figure 12). g. a..rlng (15).

• Use J 23669 ior 8 112·loch <log go.r BJ<Io (IIgUr>l 12) or J 29712 I<>r 9 112·IOOh nfl!l gea, (lIgu,," 1 S) ttl P"~ !he ""arin~ (1Ii) from 'ho Wile,

• Ins6l'l, the beeriFlS remo'llal lnol inlO (hO .aK.(e bol. "" I~at ij g",.p. ll.hlnd ill. _og (151 lilgU"", 12 a'l!! 13). Tlgh"'n the "u,and waall ... og.m.t III. 1.00 01 1M bearing (16),

.. WIIMtB.w the be!lnng (adru::hBd to Ine nl~

;! ~I ",;"~ J 2619-01, .

:J Inopeel

• All pai1i. AIl;lp1Ii1C1i11 iI3 n«:D:s.5a.ry_

FIg ... '1 - " .... o.lng the Loo:I< _

A. S<l,..,

B. Pinion Shall o. OJ,ffe reo' i al Cas~

F.oo63Ii

R.EAR AXLE 4B1·11

f1g:ure :I - Po.I.luning thtI Caaa far Sut CI.ansnoe

FIg.," Ie - "lIg~'"g tho Look

Fh,!"'" 11 - Ptiohil1ll In.. .... ,. St"dt 'n .. al'll

lOOJ51

lOO35O

F!gU" 13 - llI_g 1M W_ s..~ng E3 ~'l?~bfr Con"'CI (FIg"",' 5, 8, g, 10. 14

TDOIa Requlrad:

J 8092 Driver Hamre

J 2" 28 Axl<o Shaft oI!1d Pi";on on seal lo'iOI.U. J 2369C Axle Shaft Bearing 1rn;.1allar CB 112-md ""l! g891)

J 29709 .... 1. ShaH Be.ring InstaM •• (9 lIIHnQ 00g gaar)

J 2971 3 kd9 ShaH Seal' Il1s.ta1lar ~9 '/i.-Ina ring gear)

• Lubfjcots Ih ... I. caWty _ Ih .... , 11~ ,Ip

.od tile _ng (15) wllh wh bOllling '''''''''""

l'I.r., 10 MAINTENANCE AND LUeRICATIOI (SEC. OB).

1. Iloarl"g (15).

• Lubrlre1ElthBinsldedt:amelQro1tf'1t'~{1.! wilh whe.' b."';1lQ 1_1, Fleler 1<> MAINTI NANCE AND bUBRICATIOI'I (SEC. OBI·

4B1.12 REAR AXLE

• O.lp OOo'll'itlO (1~1 in rear ole D.tIl1canl. R&1t11r 1.0 MAINTENANCE AND lU:BRICATION (SEC. 001.

• Use J 23SOO for ih. 6 112·I""h 9611' .. ~ ami J 2-9709 for the 9 li2-!!'1ch rIng gear axle (figur.14).

• Bearing (IS) 11110 the ~Ie (16) Mousing until the tool ecncms again'J.l nUl luDe. Reier tg figult,!I14.

2. 80m! (141.

• W"""1<I 'th. , ... klo d""'oler '" rh .... 1 (14) wIIh whO<ll b6aJing l"brlcanL fl.I., '" MAINTE· NA~E ANO LUBRICATION (SEC, OBI.

• Use J 21 1 28 t.or Ine 8. l!2~irlch nng gear axLe and J 29713 'or ttl&: 9 lJ2 .. inch ling geST axlE! (I!pure 15).

t DrI", the tool Into the bore unm Ihe ... t (i4, boUoms 'lush with the end at tho tube. (r~15',

3. A>Io moM (12).

• I!Ie carerul not to dam~ Itle seal (14) 'l!'ffie,n iU.~lng Ih. ""'" "haft (1 21,

• SIlO. tile .. I •• haft (12) 1010 pi""", .lIowl~Q rhe Ip!fOOS. to ellg;pge the: differential &dtl gear (F) (Hgure 10).

f . .__ (IJ).

• Withou1 Iodf;lng dfflerentioJ:

• ~Iatle the lo~ OIl 11"10 butlon Qild 01 Ihl! ..... shaft (' 2), thon, pull tho .h.n nOngB outward to !eal tntII Del( in U\g ditlsl1!Inlial ..... gIW.

• Wrtlt locking ~Iff......m'ai,

• K ... p Iho pinion shaft (9) partlaUy wllh· ___ ~ drawn (figur. 9).

• P","",1116 1_ (G}ln the ",,$llfon"""" In tlgure '0. Pull 1I'00I ~ flMGe culw~ tQ ••• , 111. i0oi< (13) In Ih" "'11...-01 Old<; go., (Fl.

5. Pin,,", ,han (BI (figure 8).

• A1gn Ih. hOle In 'h" pin;"", .hoK (HI wilh tile .."ew hoi. In lhe dlHor""floi .... (Cl.

8. fifR" (A) (!igur. 8). ~ TIghten

• Set." (A) to :H Nom (25 ft. 1""'1. 7. CAttier cover gasket til USHd, Or RTV. a. CaNte, co •• r (191,

9. JI!III' (18) and Clip (171· ~ TIghten

• &gus (_18). in II crGS5Wlse pattern. :Refer to

"SpeclhMIIOnS'" m the: mtd of Ih!:5 section.

'0. ero"" drum (10).

tt. iM1O<M and II", assembly.

12. ~hllllubflcant, All to lI"i6 tillar plug hole I,vel, ~f@r to tMlNTENANC€ AND UJBRICATION ISEC. (0).

• LDWI .• 111. veh!ol ••

l

J 2~90 OR J 29709

flgura t,,. - fn'IllHng lMi Wlullel BI]IltIriJ"Ig

flgure l:!i - In:ltJIIJng the SUI

8RAKE BACKING PLATE REPLACEMENT

E3 Remove or Ol.eq""",,, (Agure 6) • Rai3fi! ~ vehlclQ D.n a hoi&l

1. Who.' .1Id tiro asss n'bly.

2. Bra"" drum (10).

3. ....,. '''an (1 ~), R.i er 10 • .... Ie 500ft A.pI"""",sn!" in tnl •• ootIQI),

4. Brak:e Um~ rrern thB cylirll:lElt InlsL

5. Brake oompo ••• " from Ih. backing pi ate (ZiI), !'tel ... 10 H .... DRAuliC FOUNDATiON BRAKES (SEC.5A21.

8. _ (21) ..... _IS from 1M 1»<1<1"9 j>I~" 120). 7. BUking plats (20, frum tht &1(1.0.

REAR AXLE 4BM~

E3 In.blil Qf Cl)flnairt

1. 880~1"9 ~~t. (2tJj Ii> 1M MO. Hooeing (16).

2. ilon> (21) ."d w.,~."' to 1M batl<!og pl>"'.

3. e", .... mllOl'onto to 1M _11Ii! ~Iate (2!1). R<>1., to IiYORAULIC ,FOUNOATION BRAK'ES (SEC. 5A2). -4. BraJc@ IIn8 'Ie !I:hO C}'[irld(tr InI9!.

• 1'1.1", to H\'ORAUiJC~RAK~S (SEc. ~A)ror bloodIng and >diu_onl proo.dlmoa.

.5. AXIl) Shaft (12}. Aefer to ~AXJe Sturn: napiacenanr' tn r:hJa aection.

8_ I8r,Eli<1f! drum ~~O,.

7. WhBiIi aOO 1iFl:l I1S:SE:m'bl~,

WHEEL STUD REPLACEMENT

E3 'Rom"" •• , Dlsconnod (FillY,", 18) T oel Rsql,ilired:

J 68:2.'7'4\ WhElIlil Stud Fktmgver

" ~Fi~ ~ vellidl;!l I;Ifl a! hl;l~ ;!l_rd ilHow 'he .:J_i;le fa.

hlingl,....

1. Wheel and II", esse lTbly.

2. Bra .. drum.

3. Stud' (Al from tl> ... I. "'Jl\l~ (6) .""\1 J 6az,·i\ (HII"",16).

A. Witoel,sUJd B ..... ,. FI',,!!"

s

FlgunI 16 ~ ~ ... Ii1g Out WhiNll ShId E3 _llgf C<>"~

1, 5t'" (Aj In ih ..... II~. ra) ~~ e. R.I.r tr> figur. I~.

• ,$laI1 I"e !lelA' s:t~d! (A) ll"lIQ' the axle 1la:ngi3i i8) horlt by :pr.eiSing ~.rmIy wilh YOU! hand_

.. Thm.acl on 8 wheel n~ wllll ~ flat !!iide to the

-"' ..

I!lI 11gt'ltefi the" wlleel !ll,.lt ~ dtiiw _'1h9 ij-tLK;l (.A)

MO<Ilnlo Ih ....... 01 !h. ~."!!. [B).

• Thread ItlEi wheel nul QfI.

,2. BrsJla dl'YrT1.

3_ Who.I.,.. Ike .... "'bl~. • Lower Ille; ¥etllcI6.

PINION FI.ANGE, DUST DEFLECTOR/OIl. SEA.1.

REPLACEMENT

E3 .~~~~ ~ 1l1~t1el;l (~Igurn '1,7 -- - -.g-- __ I

T""I ~oqul',,":

J 8614,..01 Pin.lonFJanglll 'H'~lI3r alifr R~iI • RaJ .. Il1e "ohi<1. on • MOI.t.

I. Propell •• shalt !rom 11>0 ...... A.I.r 10 PAOPEL1EF .sHAFT (SEC. 4A).

I!I iMiINIIJ.ure

1M l0I<lU" roqirlrmJ '" .. I.le Ih., pinIOn 11iQ"~ 11) R&eord 1I'j_~ IOfqLre yah,!ij floX larer fliirel'el'ioo.

m Irnpoftlrrl

Scrl~ iii line on jhe p.iniQn :!1I!lI!Im (A). plniQn nut ~ 'Ift,g piniOn !I~ aM 'f8t:OdI llie i'iUJJ:l!b~r Of 8XpctSEK 'lI\r~i!1 M Il'ii plnh:i~ :!J!i3Im. I1'iB::lcFl~~' .rel'8iij~ ;aM tM ~~M tht'iM,s "".11 lie u~idi;ig iU'i 5't{;1.aC!a U"" gUIdo I~g",. 1 BI.

:2;, Nul lJ~ng J 86.14-01..

• PoiSHioon·Je614·m on lila Range so IhaI Ihe 1GiJ """"'os on tho 10011..,0 1M 11anlI. rfl~"" ! 01

3, i'iaogo u.~ J 8614-0L

.. 1j:5!il\tii) ~aJl'iiJl Eif'ld:rol'¢i~Si::ljjiW fbI'~~ m. II~ [figlW 20).

04., 011 :EiBat, Use a IiCiB ..... drivEH 100 P'Y Iha- s,eaj o!oil 011114 ","",

~~"""t

4B1-'I4 REAR AXLE

A_ 5ocl(et

B. Torque Wreneh

A, SGO be Marks F.QOIISII

l'igu .. 10 - Su_ !!11m •

F~Unll :MI =- Removing the PJr'don FIBIl:Q9 E3 Inlt.1t 01' COnnect (Agul'8l!i 11~ 21 and 22)

Tools !Required:

J 861.4,0'1 Pinloo, REm~w Hl)Jd", atLd RemD"oli&l' J ~3El8 Pinion Oil Se-alln~tllllror {9 112-lnch rillg !N'.!i!r)

~ 22604-1 Pi.I"" Oll Seal SJ>ao ..

J ~Z936 Pifli[iln Seal tnstall.er {B lf2·lnch ring: g<ari

1. Dust de~acto! on !he UB.Il!JII!L

... Stak.t) n rJw den acto r !It ihroo tll!l'W' I8quarJy linHi~d posllWlns, St~king must be such 111211 thl!! seal OlIt11'<i_ijng :surfSDa 15 Jl01 ,darn~ .

2, on seal.

.., Lu.brlc9.L'B thE! ir.lslde dlilllfl~'Dr' or .he pi~ gil ~91 wi[/'! tlX!r'emB pn3SSllfe 'llUlllJm-b.ase lubrj~ni, i Position the.oll.seal iT]. !hebow. plat:B J 2'2804-1 0'Vat' the oil ~_I;l' and fia! agains[ the aaal flange [llg.'" 211 •

.. Use J 2:2~a fo~ thi:!i' a 1f2-IMh ,ring, ge:iF QJ'

, ~i=l~~ ~9 ~1~;U:g2~;.sr tQ ~~S Ih~

~um J 22f10~,-1 ~80 d'egU3811 t(4)rTI the tollitial itl5taltad poSiOon to ensura pmper tnslallallol"l agaln~ 1110 pinion 'rleltigs.

• Pack tl!o ... ~I)II>oIw"" lI1e plnl;i" stern, pjnlon IT'§I"!;1!3 !ifId p1n~ n'i.Jt waeher w[th a nOfl~f'lard· ."'n~ ~.l!Ior ".on ao PERMA'fE)( TY'P£ A '" equiva'l~n!,

a. FIiU1QO onto the 1'1"0' USing J se14~1 I~'" 1llI),

" PJace was:hor ra:tI:d nut on tile pinlol1l'lhl'f.rads ,aM lighten I he nut [0 the o~f;nElir S(;r1bod posftion LlSh'lQ II"IIEt sa1Ds mBf'k!Ii and EI;I(POSl:!tl II1Ir&ada M 8 ftrlll'J'Mnt::tI. DO NOT A~MPT TO ItAMMI:R THE fLANGE ONTI) Tf!ll Pl~ION SMAfl.

I!l M~l!J.tfre

The, rOHUlng torque [IT the p[rnon and ,oompare "",1111 .,.. lorqu. flIOOrd9d p",.lOl.lOIy fllguro 11).

\

l

REAR AXLE 4B1.1

I!J Tlght.n

The pinion mstln adrJitionaJ smell IncremefLts I,Jn1i1 me to-cue nete5S~ry to rotate the pinion exceeds IDe orlglnal recai'ded value by 0.135 Nom {3 In. ttl!L).

4. Propeller ~Mrt, Refer tEl PROPELLER SHAFf (SEC. 4").

....... r WhlOle Md (00<1 t"l.

J 8610Wll

Aglire 22 - In.bliling Ih. Pinion FIaIlft6

- - .._

,,,,r-- FULL FLOATING AXLE

~t (93/4. AND 10 1/2·INCH RING GEAR)

ThB rcllowlng roar IIxlo prooedlJrN apply to vehldm; ~ CllBiin

qu!~ ~Ih ~W' dnJm bm'kO$I Howevor, U the rncde! tD

>II .. 1'Il",d no .• rear dill" brake •• ,.Ie, 10 KYO RAULIC Axle .hol1, 1531 118ngo. Romolle ol~ f1TV or gasl

FOUNDATION SFW<ES ISEC. 5A21 lor ihe aPP'0pri.l. (51).

01<0-,.,.100 p~. O.utsldo f""" oll~. hUb (49) a".mbiy.

AXLE SH.AFT REPLACEMENT Il!I !""~I

E3 Renm¥e Or Disconnlf!Cl (Figures 23 and 24) , I. Bol., (551 (fill"'" 211).

• Rap the 01<1<1 """~ (&I) nonge lightly _ .00IIfaced hammer to loosen Ine .shaft.

o Grip 11>0 fib on Ihe axle """~ (53) 118ng<> >\110 " locking plier and twist (0 start shaft romov'al.

. ....1. oha~ (&I) ~om tho lUbo.

4B1·16 REAR AXLE

E3 .".!all or ConnoOl (Flgu .... 23 Ind 24)

t, A"s ""on (a~) with g .. k.1 (S,) (If uo.d) 6' RTV "pplled.

• B& S~r6 tnI .sliaft splines m!!l.sh In~ tho dlffstanlla'! Gielo gaat.

• Align tIiB axle shaft noiea with 1he hUb holM. 2. Boll. (~5) (rlllo'" 23 and 2.),

Plgur~ ~ - R ......... lng ... In.tllIIng FI'DlglI!!Ft&Hub Bolts

~

40,4{ .. ~41 ~~62

\Jb~3 44454!>~/_Q)\~'\9 60 61

A 42 5758

56

! \ A Dana A.)clm:. With Disc: Bral(;Q:s:

2 5" 50 49 48 B Dana AM Saginaw""'",

, With Drum 6< .. kes

40, Oul., ~ocknul

\"- 53 4t, LockW •• ner

B 55 54 :~: ~~~~~~g Nul

'~f

44. Out., !le.,;ng 45, Aelll1nlng Rin~ 45. Innor Bearing 41. all Seal

48, Dftim

49. Hub

50. $Iud

61. GaokBL 'I

52. SIla" (

&I ...... 1. Shan Flan(l<l 1

54. Wash.,

55. Boll

56. Relalnlng Ai,,!!

57. K~y

58. AdJ us II"!! Nul

59. Out., !learing 00, Rotalnlng Alng

61, tnnsf BeaJing J

6;>, all Seal (

63, A,t. Tulle

REAR AX:LE 481·

1. Wh .. 1 .r><! h .... mbIV.

2. Ad ...... n (52). Rel..-IO "l.>3e Sholl RepL_"" In 1111. 00<:t1""

3. NUl (+0) U5lfllj J :!222-C (liguro 25). gr ,VIOl"lng 0"11

(56).

4.l<>ok (41) .rl<oy (67).

5. AclJ""1ing nuL 142 or 58). R.h'f 10 IIguru 25. a W_rl43).

7. Hub and drum ('Ia and 49).

Il.!J In'_'

• All parts and repiacs as necessary.

f'!gy,. 2$ - R_lng Of I ... tolllng _,Ing AdJ •• llng Nod

E3 Inmll or Conn..,1 (Flguru 24 and 25) I'IOTlCEj F",. .rep' 3, " .Itd 5 _ ~Dtlt:8~' on IMP 4B1·1 of rill_ 14ICtIon..

Tool Re<!u_:

J 22:22.oC Who!!1 Beerlng Nul Wr@nch ,. Hub ood drum (49 and 49) 10 Ihe lube.

• BeSUIl3 ll'la bl'JiOIngs (44 EIIr'ld 46 or 59 lind 51) ancj Ih.e ell seal (47 or a2) lire poalt[oosd p,woriV·

• Apply ali!;iht cool 01 high molUng ",,01 EP "".,Ing lu_' to the """tad ... ~a""" and 1M our. .lIdo of the axle rube (63), Aoler to MAINTENANCE liND LUBRICATION (SEC, 06)_

2. Wash.r (43)

• E1"'g8Ge' tang In keywBY~

3. AdjUlUng oot 142 or 58). RDler '" figure 25.

III Adl,""1

• AdI)lOlIog n.1142 or SIl) '" '~I"","' 0' t!I!I ..-.d d Ih", ..,.;tjQri "liil" rumlng ..... ,u~ (49).

4, 1.00II (41) or key (671.

.. Band l!'is fang tQ ~ ft§L Q! (1)1;11 :!!.dIi.J!itJng flY' or m .. ~ !he k.V (57).

s. Nul (40) Of" r.loInlng ring 14<1). Ref.r IQ ~;"'" l ~ nght.~

• Nul (40) 10 "SpeeifieatlOI'!:IIi- .at the end 01' S&etion.

S. Ax", _ft (52). fI.l", It> 'Axle SlUrft Fl9pl aee rno, thiro &eetlon,

7. Whsel and tire assembly. • Lower the vshide.

WHEEL BEARING/CUP REPLACEMENT

E3 RI:mCIVII O~ DI~onn,.t:t (flgUrH 2A .lnd 21 TQQJ, RPt;lulred:

J 809.2 Otr,.6f HiU'itLIB

J 244.26 Ouler Wheel Be:atir'lg Q.{I Install • Rel:sEl the vyf1k:IB unlll ttle wheels are 'frBEI to rc

1. AX .. shan (52). Fl.I .. 10 'AxIs. ShoJI 1'1 ... -'-''' !his :6Bctlon.

2.. Hub 8Ild dnJm BlB58mbty (48 EIfIi 49). Refer to and Drum Aasernbfy Rep1acamei'Lf' in ft'Jit;; .sodl

9. Inner bearing (46 Dr 61) and D~ ..... (47 01' ti2;

• loy the drurn (..a) on allat .urf""" _ a t"""L 10 ca.tch 111& "" ... Ing (46 or 6t) and (47 or 62),

• Use a ctrtfl \0 remove the bQrirlg CI.,lP and 4, RotaJnlng rtIg (<15 or 00),

I Us.e.5rY19 "fig pU8ili to rei'fIO'iItI Ine r1r"tQ,

5. O.Ior be."",. [44 or oBI ullin; J 8~2 ""to J 2 (l!gyr.26).

• OrNe Ill. _ng (44 Of 59) and "-'I' I"" hub (49).

!:Ill Clean

• Old SSBllrtg compound frOm· M all .seal (47 11 bois In IIle nub (49),

• Be.arirIQ ~t:altea In: a solvent usin!;l a E.HH bru ,,,,,,,,, e Ihe old I_t Cry Ill. bo<I"- with prossed oIr, Do not opln _,

• LllD,loa"1 fl'om I,., ""'. 1Ul>& ($3) II!Id _. Ill! (49),

• G .. k<>t material (I! used) from 1I1e hub (49) _ _ftl52).

Il.!l ) ... poct

• Bearings tor WBlM, d'I:lpped edges or OInBl" i:ian Check for llal or roLlgJi spots 00 the rullare. Rt' wt1eQ1 btlta:t1ng d~oosls 111~ratiOO5 ill It'iis SI IJig_rea 2 Ihrough 01,

• ~ 10, pllllllnd ..... k ••

481·18 REAR AXl.E

• orJ "III I'g( W9iu or muphneas. AIIl:,pl.tln:9 perts as iieceasiJr)'.

• PiWII; Inner t48 O~ til) and OIJter ~44 Or 59) ~lI!wlfl9! wtdl wheel b&cal'lng lubl'il:::a,nt '05~344 (!d" ~YNll"'nl. Rale, 10 MAINTENAr-ICE ANO lU8F1IC",'T'IOI'! (SEC. 08).

J 8092

J 2442&

L-lIOO61

fig"", 25 - _Ing liM aublr _~ng .nII C"p E3 )nataii or Oon""'" (FlgWM 24, 77. 28 ... d 211)

Tools Required: jlioll2~Harldl.

J lt608 0.'"' PlrOo" aoothg Cup I",.tallor J 24426 Outer WIle .. Boorl"ll Cup Install"" J 24427 IMOr ............ B.",~ Cop 1 ..... 1 er J 24428 AxIB S:hd Seelll IMtallgr

1. 0.,..- beanog "'P 144 Of !ill) In'o to. ~utI 1491.

• Otfye Ihl!il CU!) into tha hub 1J.1lng J 1!!I092 and J esoe l!igur. :!7}. Be •• ,. d Il00' '- 1_11oG upakN do'WJI OR J doi:2 .0 thiM the cl1l1111-.fot don no" Clontlid IhiI baB:rlng' C\lP" Drlve 1118' ,cup blllyonii tt're n!lIEliining r1ng gmove,

2. Roh'KIlng mg il'l1O 1hB_.

• Driv"e ihe cLlp :back onto the rotruning nng tQ:0g J 24426 (flgu-a 2e].

3. I .• ner boorlng cup (4<1 or 61) using J IlOQ2 and J 24427 (flgur. 29),

• DrIw tho cup inlo pI&ee unllillis •• _ "!loins(

tho hW shouldor,

~, 1M'" bearing (45 or Bl).

6, NOW oil .. or ulling J 24428 (Jig"'" llO).

6. Hub aM drum,

7. OIJIDf bea~ng (44 or 5~J.

121 AdjU.1

• Beaf1ng pi'Bloiui_ Allor to ~Bearing ,AdJ~1J1'18nr Inthlo_n.

8. ,""" ""aft 1521.

LOOJ~3

i'igurrr 2D - SeoUog 0",,", 8"',lng Cup onto ~.l!Olnlng R.lng

J 11092

FlIl_ ~ -ll'Iololling In ... r 1I ... rlng Cup

RE.AR AXLE 4B1.11

NON-DEMOUNTABLE 'l'VpE DRUM REPLACEMENT

Oo['l!ilrUC!loll 01 the l1Qrl-delmoo1ltlllb~ type drum and hub assembly ts suen ll1l;11l replacement cannel ba done with the 1TLlb assemb'ly Insta!led oOn 'the vl;ln(cl.a_

18 Remove or DIIJCI;Jlliiet:':

• FloI", '0" ,onlcle.

,. Hub ,el')lj drum ~mblY_ RafQr to "Hub and Drum Assembly REi'plB.(:sma.llt" In ';hia Sa<::~I01i_

2.. Rsr.aJn.!n.g 1lOIIS, $tUd n.IJtS o~ wl"l6~ :I!lJds.

• Separai:a: Ihe drum. hub and DII dl9l1'8.i:tOf ,(II "'lU'woO)'

II PJeSSlhe wn"1 6,tLJd~ oLrl ollhe d..-",m, '11.ep1aoo ~illrts~~~ry.

E3 Inoiall 0' Conn~ '1. Drum lo. 1M mio,

• "'oK" ~MaI" 1110 drain MI •• ore .Ugned_ 2. 01 do'kd", ilt oqulppod) I<> m. drum.

II- Apply Jllignl' coating ~ ~aJii'lg eomPOLlI"II!l'lO If'll!! all deflector contact sur1at.:e_

J, RetaIning ba4tS, s-tu!;I [lUIS or wheal !l.tl..lds. • Presa tlli! 'iImee~ studs mo the drum

WHEEL STUD REPlACE.MEN,T

WMel stu~s iiiniI :!tlnat&!~ aM, i'fIit'; ale:o bEt .aw~1;!d In place; howl!ivar. ,tep'laceifleflt ptQOU:dLlrtl· r&11l~115 the'p;;:ame lor both Iyp9.B 01 IMlallaliOfl. Pi"BUi tl\(ll Wl'1eel slUds olJl or 1M ttu!:l, 11qEl, !!ian :p1'9~ new 'Ioifte:el .slu& Il"no !place. :n~ng 8i..JN of a Ign1 fit. Whan repl;ac:ing all ot !ne wl'LfliEil :rtY"d:5: Q!1I ~i,Jre ttull Ule huo. 011 ·deftector 01 equif:iped} is in osillO<1 urdo, In. _I ot"~ M.~ •. A<>for I. figu,.· 31.

A. Removing-"'!!l""I' $!\id '8_ I",i.alllhg 1'Itt.,,1 Slu.

FIg<I .. 31 - WIIMI Stud n .• pl ....... nt

WHEEL BEARING ADJUSTMENT

·Ii· Malee 8:lJfe Lng bfa:k9g; .are !lj~V raieasod aM eo !'I o'ag.

• CM"".'h~ whO" _r.g r>loy III' grB.splog tno tire lne top and ,PL.I[JIng and plJ!itdng bAd! Me lor1t1 • or I us;lng a pry 'bar undo, tM III'4J. l' thg Iap9fOO, roll bel.'llrlrtl}S a1''e propouy ildjUlilM, M01.iBli\Ol'lt of II ""' .. <l!lJm I, reI.1iOn to tho M.l<o llOng' pla'e wll'l _~ 11Ot1"",,0I. 0I\d 'M _.1 Wli !\1m , .... Iy. It II iiIO\IIl9Moot is ~. 9d,jLlS1 'IJ".I(I ooMngs.

REAR AXLES WITH !JRW!' BRAKES E3 Re!1iOve or nh!u;:;onnl;!'d (~(9ure MJ TOOl Roqulred:

J 2222-C Whil!lel Bearing Nut W'rertdl

.. ~§e !h~ ~ElhH;:l9 I,Inlil tM wr.eel IS free to splfl.

t. AxlPi!i ¢l8i~ (52), ABril' lo"'~ Sl'Iillt f:!iiplaOBfiU!li".il· 1lbI~ .BE!¢fioo.

It Be S-iJre !tia k~" llifef;ld$ ilnc ~d~tifIQ fi (sa) Eire !Clean and wee 'rJf chfp~,. bLiIi'3 in tih~ng$_

~. Ret.lm"; ring (SIl).

3. ~~y (57).

4. AdjlJ8tlng. nui (58).

1£l11~HI."

• Adjosdn~ nui (58) i<> 6a I'l"" (~fl.Ib .. ). TIghil "im J ~Z!-c (fl~u .. a2)"h~. "''''ti''9 ... hi ~S:S6mbly, maklrrg oortaln 'thebe~ri~ CQ!leB a ooa~-od alld In ct)r'llacl wllh lhe 5P~le ij'hol,lld~

[21 Adj~'!

• !laGk on adJulilihQ nul (56) 00111 I""" ••

• Rotate nul I,mitl nut's inlJOMtl ~od COr:'llaca ~ be:aring .coo~ Sht!uIdBF _ Torq,ue ,QIl' nlll: must I £e:rQ '1;11' gnI~ finger fiEjht.

tB1.20REAR AX.LE

::3 Instotlo, C""_ (Flgu~. 24)

1. ~y (57) 1010 MJ"OIi11g n" I ISS) Siol

• jr 5101 Is in ;i~nm~nt vAin ~rw~ In: IXl'e spin;dle" b.:Kik nUl 011 ;'I SJlgl'i1; a.mount, b!.ll not more than 0I'1.e s.l1J1., to ilJIgn ~.

2_ SJl8p flne {$) ,Ii~ ~rl'l'i:ll!:ii ,,;;~. Be z.ute ring ls- :3{!':6l0d, :t A:d6 shaft (52). AB1ar ,to ".AlI:r'e sltan RspiecE!Jmenr 11"'1 WI ~l9Ctiati:.

'EA,R AXLES WtlM orsc BAA!(ES

3 nemove Of 'DIr;.cO!ln:eCl; (f1g-ure 2J1) Tool Hequltad:

J ~.222~C Whed 6t"i:ar'iflg Nt.J! Wr~no'h

... RaiM the w'hllJla urltil th9 whe.el' i:s: rree :to spin.

1. A.Kls,siJart :Hefer 10 YAJ(]e :Shaft He,pla-cemffn,t" irllihie. _Ion_

2. Outo< _uI (4(11.

'" Oi~e 11'~ IOt;tt: w~~hi!i!r (41 ~ l'i!l7fii llie mn, J_ Lock wastie< 14t).

~. """,...vng nUl (42).

WI, l'!oh!e ..

• A_?jilOliJ>gi'iUt,42)tQ&SN""(50fl,ItJ._i. nghto.

Willl .J =-c willi. r~.II''IIIh. hub ... ombly. i"i'J:a:I(lil:Q ,rertaln; ttle waling, ccnea ere 6eatOO iIfi[f lf cCII'rl,BoJ;( wllh tI'le lipir1dl'e ~ulder.

121 Adlu81

• '8rEU:~ Q!I the .adjusllng nul {4.2), end relJgll!il'l Jo ... 1·54 N'm' '304[3 n. IDs.) wniJiI! hub ,Is roi.atad_

• B~'I;::k" Qft the adjll~llrrg nul (4'n, 1 as 10 ·f5.0 0"11 rees,

3 lMitall i)f CQnri~l 1. LOok wo."", (~1).

• 'Bend QI'~ tMg Qf roc~ 'flI~$her O'ItOf iEI lIat of 1m. odJuSlI"l! ""' (421. ~ <!oJg",o' minimum.

2. OUIO, Iooiin.1 14Q).

l~nlJlrle"

.. Ollt.g,r loolu'iu~ (4.0) 1(;1 as N"fTI' {65 n. ,lb.) millirn!.lm.

• Bend' one tanS! or 1:0<:11: washeir CNiE!r @I ~at 01 !r"i_@I curer nut (40}, 60 d'~1"M.S l'f,IinilT'!iYm,

.[). Axls shelfl Rl;!irer 1.0 .A,)j;1og Snail R,;,p!~n1'; ,n thle sec:llcn_

)INION OIL. SEAUPINION .FL.ANGE REPLACEMENT

The plnlor-. gil saal and the pi nion flange inlllY ba CI~ with Ule lA!:itisl'" ElSilembly Install0d In, IhB vshm.

E3 ~oya or IJI:iiiCilrU1ec~ (AgUrBB 18, 19 lII11d TOOI:s; Rli3qulred;

J 86'14-0,1 P-lii.loo H~J1ge' .Hold'(lr al'Kl RBl'TIO'I"er " Ra!se ~~~ 'I,IeI'Jk:f.9.

L propeller ~h~lt, Ratar to ~Ra,PELLER SHAFT (SEC.4AJ_

1]] ,,",,,,rtm!

Scrib~ ~ !!rlll Of! too plnIQn stem, plnon nut t;md1 pinion rlange 11;1 be uSSd as all frIslaniiOCln gLJfde (ti~vJe ~ 8),. 2, Nutu9.il1g J 8614'()1 (Il!JUre 19~_

Figi.lnt 3:2 - Tlgnl.-nlng the Adjultln_g N:ul 3, Rahg8 uslng.J !ii614-01 rfi~LJre 20).

.. U54;!', Ihe ~I nul and fordflg SCftIw 10 remm.r,e the 'IlsrJgo...

4_ Oil iS~E!l1.

• :;z ~:~~~EI~~=!.9 bNB. Do, not dam9go

II!! Tl"IOrolJgtJJyo clean torel;1'\ trtat.grlBI from f'h;e corr~ laO! area.

._. RC!pra~e parts a ~:sary.

E3 '.""'11 or C""1'I<I<i (figlml 33)

TOOlS Requ!tOO:

J D131 ~-cr 1 :Plnk.l." FIAri{je Hall;lliir !i!lnQ lilbirm't., J 24:]B4 Pinion Oil 5Bal In51atler (Oana. 10' 112~n~h r1P10 goat i8JdB-}_

t. OIi seill lnto jhe ibore U!iing J 243804 (fiIJUf8 ::13).

• Lubrlc;:IItl;} tho In~1'd9 rnamerer of ttl6 oow eMl ss.a..i WFlh eJ(treme pressure lub~lcanl St.I.a.1"I ali ~S03a 0' "'1uillalonL

• ~a1;:k ttHH:al,'ity aB!W\!3~:I1' th.gI p:J"~<ln~, ~liliiOF" ftan~e (mC/ pinIOn J"!¢ \f{§5l!ler wHh a Fiein-hiii"d en[flg SBafair SlJCh !;!i!i: PE:RMA TEJ< TYPE A ci '\>Quill"",o,_

REAR AXLE 4BMI

i. ~~. u&lng J !l1l14-0 1 lfi~ur. 221,

• ~ lTIark!! scribed previoUSlY' l. inStallation.

~. N.l, """9 J es, --0, (~gu,~ 191_

r - Use rruvM;s scribed prevtDu~y 'or ir'LS~altatlon.

4. Pr6pl!11er Sh4.l1. Refilr 10 PROPELLER SHAFT (SEC. 4,0,1,

",UF. 33 _ .nstJll1ng PlnlOrt OU Seal [.ntlll! 80ft.

AXLE VENT REPL_ACE_"'~~T

FULL FLOATING AXLE (12.INCH RING GEAR)

• Reiss th!! vehicle and pi8lO8 jack s.tands l.lIlder frelT'l.E' !3IdB ralla.

A Ihre,s:[isd·tYPB axle ,..enl Is u:!iiod on lhe FiOCKweH 12-lnch rir'l9 ga-ar axis and mli5t be l'e'ptacod It the 'Vent alP 10 d''''BI1ed ..- ".. • .mg-

II! Clem

• The area a.roond tile axle venL

B Remove or Dlsco:nnact:

• Axis vent Trom tile houslog_ E3 .".1011 Of COhn"'"

• AxJe; vern 10 Ine housing.

I AXLE SHAFT REPLACEMENT

E3 Romovo or DI.""nneGl (figureo 34 01'I-d 35j Too! ~",!ul'Bd'

J 2j;19-01 Slide Ham"""

1. Boll!! (70) and wBSh.,. (711_ a Hub_(72).

• 111,..0' J ~1 a-o t Into ihe tapped holo on !he , ""an (741 IIaoge (Iigu,e 35).

3. Axle .hoilI74] uo!ng J 2619-01 (flgur.35).

~Cliilifi

• Old IlMhl m8i:orl~llr.", \ho Ilub (00), hub OBI' ( I~ .... to shan (14) Ilange ond "",009 surl_ In hub (611),

4B1.2~ REAR AXLE

FlIIIII'(I 34 - R!XkwaU .2-'"on RIng Gl!lJfAXle and Hub COI'T'Iponent:s 2, G •• k.l (791-

3. Hub _ (12).

.- Waol1em (111 .nd IlOIlO (,0).

LOO$9

Fig""' 35 - R.,movlngliMtalilng the Aide Shin E3 Inmll or Connocl (Fl~ures 3.01 and 35)

Tool Flequlrod:

J 281!1Ml1 Slkte H8J'I'Imor

1. Ax",.i>aIt (74)-

• Tap 11'1e e.xr.Sl .sha11 (74) in'[{;l PQsLtion using J 26111--01 (fig"'. 351,

• Index \hi; m:1e 5hafi (14) splin6$ 1,,\0 the hlib {1\6).~HM'_

BEARING ADJUSTMENT

• !Yaks Wle tne !>raMS are h.,j~y r61~il58d and do not <iraq_

• Cheek !.he wnem bearin9 play by SJ'ASping th~ Itre m Ihe ro~ and ~Uing and 1>lJsI\1"1l O~Ok a.ad 1000h. 0< by UII;:lng a Pr1I car Unde'I the tlfe. If ttiB wfi~~ bearings. are Pfoperl~ adju:s!ed" movt}rni!lnl Of lhe I"Jljb or d~ will be 'o3fOIy notloeabla. 11 1M tTiOV9ITI@t ~ (t)(CM;' eNe, a;t:lJu:s1 tl'¥e baarings.

13 R.mg"" ... DI""onnt:!CI (Figures 3.01 ond 36) T~ Rtiqu:lred:

J 25510 Wheel Soaring NL,lt Wre!":<iI1

• Rals(!I IhB vahl~le unUl cne. wheel is frH tCi spin,

'. Mo .MIt (?4), Rei., 10 -""10 Shaft Aopi.""",onl" In Ihlfi:sectiOfI_

2, -N"' (~] ".;n~ J 21>510 Ilig"" 36)_ • Release !~UI tang_

J. Look w"""'" (S9) •

REAR AXLE 4,B1.2:

121 Adj •• !

• Nut (eal ""log J ~S51 0, Tight.n the nut (VII) 10 00 N'm (50 It 1",,_) .. hOi. Ihe hub to rOI.ling. 'Mak& StJfu Ihe bea~lng 6W"IaOBs .pro!;! In oonlact """ IMn batik ihe "'" (88) off 118 !;!m

8 InollLll Of Conn"", fFlgYm 34lnel as) i. l<Ick ,.",M, (B9).

• Bend a tang over a. hEU !:lIthe adjustinG nl1t (8.8,"

2. Nul (90) using J 25510 (NS"''' S§),

~ Tlght.1i

• Nut 190) to 339 N'ffi 125Q II. 11><.)_

• Bend 1 long tang of the 1«1i: waSher (eg) over a Ilal 01 11>. nut (90).

3, Axle shaft (74). RBCSI'"tQ ~AXlo Shaft R~lacemenr In IhI! s8otlon.

" Lower the vehiGie.

PINION OILSEA!.IPINIQN FLANGE REPLACEMENT

E3 Rtmo .... or DIKC>!I1IIiCt (Agure :m TQQI Required:

J Sli14-Q' Pinion F!ang' H<>1~" ond R....,..' Ii Ril" Ihe vettloJo.

'. P_lIor .haft. Role, to PROPELLER SHAFT (SEC 4A).

rn lmpartent

., Strlbe 8i r81BfORCO line DI1 the p(ofon sturn. pniOn nut """ plr1lon nang. (figure i 8).

l!. C.M, pin (91) and nut (92) using J 8614-01

(!Ig ... 19),

3. Pi'IIon nang" (94) (figu," 20)_ • , Bolls (lI7).

S_ OIJ ..,.1 .. lain., (95).

97

I

90. 011 8001 R~I!!I""! 96_ QII S""I

97. &11

~L Gon.r Pin 92, NUl

sa, Pinion SR," ~4, Pln"'n FliIl19'O

UlOO7C1

FlDUf1II 31 ...... Pinion Oil S$!It Com,pan.n ..

6. OIi "",i (96).

• PJy the ail 0081' (00' 110m 'the bore beJng carofu not to damage 1"'8 madllned surfaces..

~el-O";

i 'The.se.a1 coniacl area...

E3 In.toll Of ConnOGl {Fig ... 371

• LutJrit2te the [flslde diamfttM ot Iha new oil :s,e.al {96 lipS; will1 extreme pressure lubricant SlJctI as. 99S503I or II!qLllvi'lloot

1. OIl K~[ (96) Into (he bore ~ng 8 suitable 1001.

• Ba swa the seal [96~ b9'I'tQl'I\5 ~galMI nie tJc:ifIi

!Ii~DLlk:lar_

Z. 011 Selll relalner (95),

J. lI<>il< to !lie "101",,, 1971_

• PAL'k the CQ. v fty betweBn I~ pfnlOfi stem. plnior !I1lniga and pinion nut waiiher wlll'l a rKJn'"hard.e-.nln£ ualEIr ~u<::h ~ PEAMA rex TYPE A or aqui'o'aletnt.

4. PI;,iOn 1'(I(1g~ f94) !,ISing the wlbrod rnlcteflce marJ(.

5. Nui (l!2) u9i'll J BB14.(ll (fi!IU'" 19).

~Tlgh"'n

• Not (92). Align inti east9llaled l1ul 'W'ilh tha hale in the pinion SI'Iafl (93) ~em ana Ina refsmnce. m.art<.

il. Gol1e'pjn {ell .

'. PI_lie! oh.n. ~.for to PROPELLER SHAFT (SEC. 4AJ.

4B1·24 REAR AXLE

SPECIFICATIONS

TORQUES

DAN~
8WFf~GHr- Q~~ fU~ Gftr- 1!iI~":401Jf~ "'I~
G ... AJ:Ie-liuli
s.m1~AKIo Somi FlooDnll Axle Floa1lnQ
Nom f1.Un. N'" Ft. Lbo, Nom FL I.b ..
!'i!lor Plug 3' 25 24 '8 I' 10
1..Oc)i: 5cI'QW 34 25 ~. 25
Bra.'kEI Baekltt PlalE'll .7 35 '42 TOil '42 105
!bIe SII." to Mub Bolts '56 11S
Ganier Cover 27 20 27 20 47 35
"'". lite,", Pinl!! lfto .. F'ints Utel"8 Pltils
lLibr>o<!M
Oal"<'iIY 2.0 u 2.6 U 2.G 5.5 WHEEL BEARING ADJUSTMENT VALUES'

Ch ..... 'ohllt __ ll
m~nRlnilCijar 1Z' Ring Gur
As,le- Full IIAli- Fun
f:101Iing f1011tfng
N'm FI. Lba. H ... Ft Lb •.
•• 18 47 as
T02 lOS
156 115
., 00
L1t8f1!! Pint-51 Utw.r; PfnlB
3.' 7.2 S,B !~O
GIlfJBoOIBS.5-2l _fig AdJII'~"II Nu, TOfqUI tW~It! ROitIiDg_)

AdlWllMRut _-CII

0... Drum 9\4 .... ,a~ ii'd1 6IJ Nm (50 ~ h,l

SagilIHJ Drum 10''; IIt:It 68 H'm (SO 1'1. 1be.·1

~ r;,. I." "'" 6$ N'~ 150 h, illo.)

RI:reJlweI ~ 1C'iWIdi 66N-m(50ff.lbB..) IAlllrn

OON'rn(~ n, 1>0,1 3lI!IN·rnr.:OO~, lbo,)

'_hilg eod ploy _~ ,,"0_""'" 10 0254 _10.001 "'0.010 "'"),

"BIcI!: Dft l1l"i. tloSI. Rotats nul up~, ~ D:lne BIiOUldUt (l.aro klq.J1!1I1,

•• 'Ba!:t'otI'ar.:! rtlighLsnIOIiII1'S/I 'N'm, ~hl rDtllfilgwtlsal, ~dt~lIlrll35-100 d9g~.

REAR AXLE 4&1·2

SPECIAL TOOLS

1. ~ J 6627-A !l. ID J 2222-C
~ 6. @l J 24426
2. J 8092
7. e J 24427
8, CV J 8608
3. @~ liD @ J 8614-01 !
~@> 9. J 24384
4. ~ J 2619-01 !
10. J 24428 1. Wh""I'SbJ<I RerTIQV" 2.. Driver Handle

3. Pinion Ftango HoJ~ and Remover 4, S~df) t'la;mmor Wrth Adapter

•. Wh".1 B ... ~ng Nul Wnlnch

e .. Outer Wn~QI Boarlng CUp Install91 7, I(ltl~j W1HIel Bearing Cup 11"'I!!lIBllllf

8. o.t., Pinion B.arlng ClIp 10;;"'11"1'

9. Pinion en; Seai Installer , O. Axle Shilft Seal Ins.taller

Lore?

4BI-26 REAR AXLE

SPECIAL TOOLS (CONT.)

;1. ~ J 29712 16. <e:rlil J 29713
12. ~ J 23689 17.~ J 22388
13. ~ J 21128 "~ J 22804·1
14. ({t J 23690
(lp 19. (&-,:i J 22836
15. J 297119
20·0 J 25610 11. Axle Shaft B~arl!l9 Remover (9 1 f2,lnch Ring Gear)

12. Al<kI ShO.~ B<IaJ1ng Ro"",""" 18 112·,lnoh Ring Gea') ,~, 11>1. Sh<lft and Pini"" all S •• IIMtailer

\4, ... .,. Sh.aK B •• rlo~ I!lot.llar 18 112·1_ ~ing Gea'i 15. Al<ls SIlaft searing In.loll", (9 112-In<:h ~iil9 G.at)

16. 11>1. ShaK se.1 In,I<\I!., 19 112-1nch Ring G e B')

17. Pinion OH Seal InolaU., (9 112-lnoh fling G •• r) , B. fJlni:On 011 Seat Spacer

19. fOnlon S""llml1lll"r (6 112·1""'" Ring aoar)

20. Wh ... 1 &a'ing l\Iu\ Wrenoh

LOO373

5Af

SECTION 5A1 HYDRAULIC BRAKE BOOSTER SYSTEMS

The ioilowlng nalim applies 10 0f'I0BI Or more .step:&lrllhQ M!iWmbly prQCe:QY:l~ Qf ccmpcnents !f'! INti. gor1ion clltie rnanUi 1~!Cat(ld at appropriate locations bt the termk'lo!QiY ·NO-"nCE.: Se~ 'Ng.ll~· qn p,ge SAl-1 of Iflis secticn"

NOTICE: 7hb 'allfemrr 15 so ImporflnJt .n.chJng PIn In thst" crwld stf:et:l 'he perfrmnaf1cttof YltSJ comp.mvnlt sy.'ttm •• nd/or (:tJ(Jki "sault fa mD/W rwp_." _I(".,.H. "mv.' be repJIIC!ed wUh..:me 0' Ihe urn. ~jtt mlffi:t,ijf or ow" tqU/V.~l1t part it repf.scement ~0/lls.3 1MiC!CI' .... ry. 0" nor LI .... It replat:~"'tnr p;art Df /e,ger qllilify ~r -liIDltJ cin-Ign. TOfQV<II ~lJ}Ufl'B m_lIs' be uAHKIII!I:f .pecltlDd dflrlf1g N!ju'sembly ,.0 H.llilre propM nftj,UJQ,r:; or Ut/« ~

CONTENTS

Dlog"OIII 01 H~""_" Sr-- _ __ _ _ _ •. ,_.,._' __ . _ ,~._,, , ." _ .. 6.

HydfCto8ooat Syllem re!!Jta ._ " •••••••.••.•••••.••.••.••• ~, ••••• " ••.•• , ••.. ~.~ •••.••. ,.~_ ".,~_.,..;_ , ".:5J

Vacuum 8DO.l.In ~._ •.... ,...,_ u ••••••••••• ~.,_ ••••••••••• _~~ ••••••••.•• ~ _ _ , " 51

Daacrtptron _._._._ _~ _._ _ _.~ ~_~ _ , __ _,_ "'."

Vaooum Boo .. _, Reptactmern __ "' __ ~ ••••••••••• _ , ~_ " _ •• ~.ro_ _~ _, = S:,

HydrauliC Br.k. Booster {Hydro-BooBI} _ ~.~ __ ~ __ "" 5,

DBllcriptlon ~ ~ .. , ....•... "~._ , ••. ~_ .•.....•... ,,. _ _,.,.; •• ~ " •. "' 5,

Hyrl.ID-SODI1 Rlip:laGlment , _ .•.••.••.... _ _ ••.•••••••• _~ _ , ".".,., , •• , •• , •• ,. 5~

~=o~: .. ~~~~~~~~ .. ~.~:~.:=~::·:::::~::::::::::::::==::::::::::~::::::::::::::=::::::::::::::=.::::::::~-:::::::::::::: ~

DIAGNOSIS OF HYDRO·BOOST SYSTEM

Pl!O!JlEM

IlOSSIBLE CAUSE

t. @CClI!Ism.ot seal rrleHon In I:MXla:ler: 2, Faull)' ~Ol :tIdlan.

SJoliI!i Bnko Pedal RitUffl

1. ()V(Uha1JIIHHh new '~liIIlldl

2 Rush $10.ring S~t$1em wllile pu~ tm podOl

a.. AlJplQCO tine.

4. Replace I~D1.I1 j"Q(j i1I'\d !)Is!on ~_E!l,

3. RHlrlctiol"l i" tElIu,n Ilrte from ooonar 10 pump I'oIISeNOir,

4.,. DamagllJd A1p!.1l rod or'ld,

1. Faulty spool action (!Q\ISM by canlamlne.llon

In system.

2.. f:l"OWBf steefing pump bell sliP'$.

3.. Low ftuld kI~ il !)OWlDi .sleotfflg ~Jmp.

... Faulty I;if)OOl apoere.tlon e4'l.1!Mi!:I ~ -oon1amlfl8· ~ontn ~!!l,gm,

Gi'.IIbbyen,," OR

Booat-M' Chattwt - PedaJ Vibrato

, , Flush &le-IIflng 5y:li[Ml while- pumj:ilng 00

pedal.

2. TigIltsn baa

:3. fill reservoir iiOO CheCk kI!r ~emal 181

4. ALJ::sh s·i.99"fing :;Y~(lm wtrilo pl"lJTlP~ bn pl!l1[ml,

1, Conle.mlrHJtion in sl8E11tlni Ji:.odi'o,!}oo!3lt 'yo<""-

2. In~j I,~ksg& In aco.imiJlilt6F syi1Grn,

1, F'IUBh ISteenlllll ~BtElm wf1jlo llUlTlpfng I:lr. pedal.

2. o....srhaut unit uslflQ a.or:umutlilOI' r!!hulk: and seBJ kit,

~1,I1I'J1)ta.tor Li.k~ !)own Sntem Does Not t-iold Charge

,MTB<li 1_ C_. BII 'he polW<Ir .to.1fng 0110 brsJ<. I'P" cor

~omt 1m leaks or rEJStriaUons,

NOTICE: Powsr .turlng ~/uld .n'd "me flul c...,.,.ncl be mix.c. ff btBU 6fM1. conuc.t !l1eerin fluid Df' SlMrlng •• lIls ~ht .. C' lH.k. 1fCJl.cf. S8I d{lm~e will Ntsult

HYDRO·BOOST SYSTEM TESTS

1l'1~ Hyt;I:ro-SOOSI sySlDm roceilJ~ ita souree 01' powO( from '1'1(1; POW(!t ~Uta"l"g 51ysllem. ThBrefon~, a m@ffy:~nlng powfJi' $t,q.ol1no syscem may affect (h" oPU(alto!" of Iht bM&tet, juSI as.3 problem in Ihe booster r(lSY .a.fftlC1 the steering sysli!lftr., Poor 10 pertonnil'lg any tes-ts. the tt'lliJWtng «I~k!il mu.st bEl ml\'do.

5A1.~ HYDRAULIC BRAKE BOOSTER SYSTEMS

2. ·~~k and nil !he brako maaler oyllfJdsr wllil brake J, Check and fill the power ~eering rMe-f'iolr wi." power .5Ileerirlg" 'Iuld. It Huld eontaln9 aI, refSl 10 POWER S"~ING (SEC, 383) fo, tu~'.' diego"",",

4. Check power s.t~rln9 plImp bait tor wear and ten~t~i:~~li;:. it n •• dOd. R.le, to ~OW.F'I STEERING

• T!!InsiQn'f'g 01 Ule !!:erp9niine Btr-,gte.f)ejl aceeetiOry Ijijve $}"Starn" net needed, T"'~ s~tem malf1!I!f", proper 1ension .autom.atlclllly.

S. Ch~ '!'tll9lne felle sceed. ReHt:r to Ille vel1k;r.e's Em'.s~ sioJ'i CorrlrQl 1t'!1(lr'mafiOil fgt}e, fOr idle ~c.mcilticml5.

GL Ch-9C.~ stee ring pump preSSur9. Ae1~" to PQWE ~ S1EERINCl (SEC_ :3B3),

NOISE DIAGNOSIS

Tn .• foflowfr.g rlo:jS8& iii"? associated WI';' the Hyc!to.

Boosr ,and" mayor i'i'tsy llQt ba GaU5e for c:ustomar -oam. plafnt. !S0Il19 1"l00lt)$ &te nQl'1Ilal ,Q,j)[j for th., most part 119mPIOI8J)' lnr'lEi!l.Ire. OIhef nQ:i:5!e~ m:ay be f;I :5Ilgn of exc.assIIol"Q wear.Dr !he p'~ or illr j(l eliher tho 000l:i1E1 01' the stAttrmg systeiTi.

1. A moat!. or k)W fre-qultr1.cy hum USUally ilccompal'1tod by.a'l/Ibr'l.I~n in the pedal orsteerlng column may bel obMrved during i:lari<ing mane.UYSlr.a. Of other low I!ilpeed maneUY'efs. Tills may ba ooLJSed by,8 low IJuld MIl!'! U'\e power stDllrlng pump Of by air in lhe Iluld, 1-Io1(l~ IIie .pump ai ~ier pr-eSSW:8 (s[sering wyneel /'Ie!di aJllt'!e way jn ons df:rBcllOn} tOr more than 'ivB -seooooi5 will C8US6 air 10 enter lhO system. ChOCk .tle flurd" leVel and 11111r needed. Tl'le S~&!Bm must tnOn sit tar one oour 10 r1IIl"OOYa lhe afro Ii me coool1kl!'l par~.,., fSja, 10 ~OWER STee Ft,r.!(l (SEC. 383)_

2. A ~I-gll ~pe~ IIi.lid nolee may be l1e,prllj When ihe bid.ke pedal Is tully depreued. Thf~ CQndrflon ts I1"mli ••

3. Whenever mol} accumulauQrOSs.ure i:!Ji used tI sligtll hlsa may be Mliced.. It J6 tho SOOnd of 11'10 hydraulic tiu[d 1iI:!lCap:lnQlhrough 1he aO:lIJr'nuielor vaI .... e. .8Jldls co.mpl'eteIY nottnal.

4. After file aec:umuJilIor h& been emplled end rhe engfne . f:s ~ar1ed !;JI9a1n. another hI$1r.ng aound lIlay be heaid during Ihe first brake ~,ppIQ1ion or !he fifSl !JteBrlf'l9 n'Ia~sLNi!'r, Th~ l!i C"aU$Cld by 1118 Hurd ruSha Ing through thlt! gc::cumiJlittoi' crn.rg:lng OririCB. Ii 15 nor. lIlal .and w'illlJ1only be heard Cncl~u"hlfli!' the BC[:I,lmlJlatot Is I)mplfEd. Howe"er, i! Ihis $QUM OClfljjnuBa. even thollgn 110 ~.P'QarGrU a.crumulf.itQr pr'&Mure a"iSI ~Si rnadS. it COykl be an fndicatiQn thallhe accurrlJ,Jlalor i& flO( no.lding pretoo,.., aoo s:ilrJ;yJcl bo. .checked YSing Iha p~d!!!e YAccui'i1UJwCIf L.eil.kdown Tes.i" fn trli.s section,

BOOSTER FUNCT!ONI<l TEST

~i1i1 tna ~fi!;llrre off. apply t~o brake peQal &evsrat tJII16S unfJr th.e actumlJbto, rs completely depleted, Depress lM hr.l<~ "..,.1 0.1"9 180 N (40 Ibs.) ot lore ••• d .ta~ Ill. sQ9'Mt. The pedal wlJr fall end Ih911 push back agalni!ill your 1<>01.

ACCUMULATOR LEAKOOW~ TEST

t, Sl:art the engine and Cha.rge the aerumuJator by 8PPlyillti tlle _. pod., or by IUml"g 'he- '-ieori~!l wnosl from step 10 stop, Tum off UUII Bngine and" I~i In:e vehlole 8il fer one hour. Atrer DnS J'!oyr l"iJ.r~ S~"Ould be a! le~ f'NO power'SS$r!sl~d i!!pp.IrcatioJ't! 'WIth the eng:ina orf.

2. n Ihe r,~ system ""ill not ret-a'" a charge for 011& P'lOLir, .P!dt fUMtlOlls normally fmlTlOdii!llely following ~rg'"g, tim accl,lmula:for vl!lves are at faul'- ThE! booBt~ mLl5t be dfsas:sombled .and the acournuls.lOr v!ll .... es replaced,

:3. jf .he accumulator.ea.n be heart! qh~r91l'jg and dt:s. ~gjng but does nut hold Ii!i ct1arg:e, g-j9ftssemble the booster and ~aeo [hill MCumuratgr vaJ'r'e8.

4. ~ple'o- the acelll'YlulaiDr by pr~fng 1he brake psd31 ~VOIalllme.s., H lhe aooum.U:.tator can ha~ lOst irs gas ~ge, Ij i~ POSSible to rotato:.or wObble fho acoumulatQf can wllh fe:sptJCI to ll1(l hou:!iing. Atrpliiloe the ~lJm.lIoIrallJr iiII!J:i!6mbty,

seAL LEAl< DIAGNOSIS (Fig" '. 1)

A INPUT AOo SE_AL A damagoo :!ieaJ witl MIOw up as B t1u:ld Jeak fram trill mounting bmcker vel'lI hoII:. Th~ boo::mu mUSl be removed .rom IrtB vehiCle .ar.d d~ semb!9cj. The jnpi,Jl rod bore sl"Iould be C"Gekoad lor eny SCr'alC"lles [Oa! may be I"e- eeuse o! 1M la:ik, JI S(lr.at(lhers are present, 1t1e ~oosing OOYef mUsl" be repiated. II no ro.G~f v e saarche'$ are prMent, tn~n ~~~~:~3J kii can be vsBd fD replace Iha aWQ~

a POWER P!STON !lEAl.. />rNre, ~OIon ... 1 "<18m"9" \Y1~ bEi Ilotlced by n\lld Jeaklng out al the com.rnol"1 ~~~~ C}'flndel' brake booster vent. aM, pOiSlbly, et rldootrofl In power assltil. The bOOstsr mue:t be fUfhov~ ffOrn lfIe vehlC:lO and d'~5Se'fI')bled. The pis. ton .shoyr<l be dmcked for' any scratches tllal may bo 1M c-a~e ar (he leak. jj no 5Graldles me present the ~:-aJ kit can btllJ$M to replace Ihe appr~pr';I-

C. HDUSING SEAL If 1M hO'oJng ... 1 10 dBlTll>980 fluid will loak out belween !he two riotiEl4nqs. "...; boo~er musl be rerno,*, from the VGt'lltle and di5aS .• sembled. The boos:tef seal !til sf'l.oi.lld be u.slild 10 ~,:~:~e 'ha hOU!;llnYt Inpu1 rod and pOwer ~!3to"

HYDRAULIC FOUNDATION BRAKES 5A2

121 Cle.~

• 6Ietll"'a~ valve. Ci311pat bore, caliper pe~$B.ges.lilnd ~" Lon wUh denatured a]13ohol. Use dry, filiered com: ~e"ad air to dlY pans and blOW' out passage'S.

Il!Ilnspect

• Piston for soaring, corrosion and 8""1 dl:1m.1gB to the Chrome plalirlg. Heplaee il any of Ihe:&O oond1lions ara lcund.

• CalipOJ bOre lor scoring, pining or COI'YO~IOfl, US~ ct'OCU!i Clan, ID ~rsh OU1 any IIghl corrosion. Plupl.aCe caliper II lho corroSlOti cannol -be rcmov~.

20~

~ '\~.-., ~ l,()~

~ zo, 81000:' Vow.

21 Piston SOW

22, PislO<I .

2J,8"",1

FkJg_~ 20 - Caliper CqmponeFitB (Bend)!!:) E3 '''''tall or Connoe. (Figu .... 20 and 21) Tool ~"'lulred;

J .24S4e PflllJlQn SIi!"41 InstAller

• LLlM0lll6 1M. rtOW pIown •• ai, caliper born, piolOl'l ar.cl ",~I lips on boot wfln "' •• n bra1<e ftu;i

1. Piston ... 1 (211.

• Mate lure 'ti'le seal Is no! twlateclln tne caliI*' bore groove.

2, _11231 "" J 24~~.

• Place Ihe larqs diBmeter or !ne bOO! Olief tool first and caJ'elully work !he smailer dl!lm onto the t(i(II.

• Slide the large diameter- off the 1001,

3. :~~rge tip or the boollnto the groove It! the C8!

• TI'w lip 1::11 theo boot mwt be tlrmly seased In g~QQV9.

4, PI,ton (221 1",010 J 2_8 (lil)lJ" 211, 5. Piston haJtway Ink:) its. bore.

• Remove J 245.48.

• Make :!iiJfe the boQl 15 firmly Meted. e, Bleuder vatv. 120),

22. Pislor1

23. iloo(

SA2·1 0 HYDRAULl~ FOUNDATION BRAKES

DESCRIPTION

DRUM BRAKES

!M dnrm brake assembly':; a dlJO.-servo design, Wilh thu.; ~:rticull;lr dsslgn, IhlB [ora apprlet;t by Ihe whfilS'J evllndar to the primary iI5Ihos 'or-06S the feoolng e49a of Iha st10e ilitD oonta~ wllh tMi (OlatJrlg eJrl.Im, e8uslnla IMe -e..hoe tu If}' to rotai!lI_ Tbe .snOl9-, In lis: i!3iIlIBmp1 to rotBte with thl;! drum, tr.lll1Jilf~r\5 farat to 'lho- .saoonds."Y 91"11M1 fl"lrough the starwtll;ll[lt adjust". lhls causes U'!II!! Seeond9~ sflol;!'i!illeadlng e-Qg~ to "bIle" inlO tn. dnJm arid anernpi to fOlate, ju!3;t ee Ihe pri"nary shoe dOG&.. Sitlee IDe shoos cannot rotats. ltIey lend t9 wedge ,hams.MIS Into '''e drum. In thl~ WEJY, lh£l rotating tarqoo augments t~ bral(lng 'orce applied to lhe shoe-§. by the ~dl cy(lnd6t, Because Ihe snoes 8rt;! used kIr 1hl~ w~lJlng aetiOil1. 'It'Io system Is ai)led duo-servo. 1I!l: ~ to II sfngJ& UtI'VO U9:S1gr- 'Wtlere whee!! cylinder p:re~5Urlil' IiIlone is the- seuree 01 nfaldl"lg force.

The torque trom thil!l brake- :s:lK,ies is IransterTlid IhtotJ~fh fhriro ~'I"IQ pfat-FJ to 11"1& ,a,:lfJ 1ja_ng9. Bralt:e adjl"la,1mt;!lnle are i!i!ltqlll§tl~ and Ire madll!l during 1'6Ve~ brake applle.;rtlr:m3".

BRAKE LINING REPLACEMENT

E3 Remave aF Discoltneot (Figure 221

• ~8i5e ,Ita vshir:r:e Bnd support with suilable wety stand!;!..

... Ma'rk the llII!ath:JIli5ihtp 01 tha w'h9,a11 to the hub.

1. Wheel aoo tire a.s.r;embly. Refer to WHEELS AND

TIRES ISEC. 3EI·

CAUTION: See "Caution" DR page 5A2~1 001 thl:t. netlon.

2. Drum,

• Mark the relaUollship of the drum 10 thll axle,.

J, Aolum .p"n~. 1'2 ond '31· 4. Shoo gukl. \71,

S. Fk>Io_n "1'""9' 1"41,

6. HoId-dawn pins I')'

7. AcM>tor love, (10) and ,"'Ii" pl""l (10),

8. LevtIf retum spring (16). 9, Acloi>tQrUn1<1111·

(C. Porl<lrlg brake strut (B). 11, SIruI "1'0"" (S).

(2. A.lolnlng ri'lll (e).

ia parkl,g br.~Q loy"" (3) and ..... hI" (4). (4.511_(5"",,19),

15 Adj".!1"9 ''''OW ...... Illy 1m, '16. AdiU$Ung screw spring (18).

rn Important

.. Oq AQ' [n!~~h§:nge rlg:t-l !i!fld 1-e'I! 8dJ!.l!~tl~ §.CreM'~_

Il!Iln.pect

• All pana lQr d't9mlcratloo due to heat or st-eee, Replace If ~IY'

.. All parts for sIgna at wear. Repl!We" necessary.

• Wheet cylinder lor slgn& 01 leakage_ Relar to ~Rebu!ldjng The Whll;lel Cytlncl&.r7 in this .aecti(ifl.

• 'BrakE! drum tor ~corlng and ml;u;:hlning tolararrca. ~efer 10 "5ervldng TnE! Brake Drum" in this section.

E3 Inotall or cann";l (figure 22)

.. Lubricate the s,,~ ~, {lnd ildjlJ$1.il"lg Sl::fSW IhrBiids ..... 111'1 e lfifo COiI.~ {If ~lll1l1tt1:lyn'! grtt8Se_

1. Adjusting ..... w ((7) and adJuOllnq """'" spfing (1B} (0 both """'. {5 and 191,

• The coils of the spring must no.t tOUQt! tne

adJ1J6IIng screw.

2- ShOll .... _y,

n. Parking brak.e !9V&r' {31 ilI1d 'Wasti(lr(4) ~"to tf'r16 "noe. 4_ Reliuniflg r1P19 t~l.

5. Strut op<!ng (S) onlo the parltlng brill<. Slrul (SI,

6. Parl<1ng c.ok .. _I (8)

1. Acluator 18V9r PO) and fa'ver pl'llOl (15).

8. Actuator link [111-

9. lsvlBf reusn sprlng ~ 18). 10, Hold-dawn pin. (1),

11. Hold-tlQwn "I'nng' (14),

t2'. RetlJm ~pfing!i ~12 and 13), 13, Dnlm,

• Ati~n the marla;; madtl dtlring dlNss8rntiy.

14, Wheel and tire IilSSsmbly_ Refe, to WME€lS AND TIRES {SEC. 3EI_

• AJll;lrt lhe marir:s mada durlrtg d~tJIV·

• Adjust the cra,\(E:5l, Rerer to "'8rake Adjustment";n Itdtii SOC1.1on.

5A,2.12 HYDRAULIC FOUNDATION BRAKES

HYDRAULIC FOUNDATION BRAKES 5A2·1

SERVICING THE BRAKE DRUM

CAllT10N, &eo "Clutl",,' an Pig. S,l,2-1 .,1111, lM!O-1Jon.

t. Remove tne Il;lf\Ced :lfl!!le lil t~ brlke backing pI~tu.

• The metailancM area must be removed Jl'Qm Ihe bra1<,e assembly.

IZI Adj"",

• Br~kfJ adJ~ti_11Q ~w until fh!!l wheel tIIIIn Jus. •• """cd by hood,

• The bf'9:k{II drag ,gtloukl M iKjLia'! ~'t bgt'i Wl:li!llila.

• !lock on the adju:s'lloglScr.aw :33 notches,

[II !lI'pO""nl

• BfD.M soo!,!kj MVe no drag atter fh,@ screw has bOO.1'i backed ott abOUl 15 notch". 11 a heavy drag Is pre:t?(lnt refer to ~Pari(ll'lg Brake AdJljst~ Inanl' In fjVORAlJLlC B RAKES (SEC. SA).

2. IMdall an ~j\J::i1ffig hola CQver I~ 100 brake backing plal:il where !P,~ liltl'lotd area was removed.

3. ChOck parklrlg I:1orlIke ~ustmenl

14. Hold Down Spring Hi Lawu Pivot

16.. Laver Return Spring

17. AdjU.ling $C;~1iI As •• moly

18. Mjusllng Screw Spring 19, P~mary Shoe

W~~e\ler 1M! bFlIk(io dfl.,lm"3 @~ f8mo"fad, they liI"-ould be thl>rousl>ly ol ... ""d 0fId I~ "" omcko •• cor ••. d •• p grooves and OUI-OI~Wnd.

CRACKED, SeORED OR GROOVED DRUM

A cracked drum r. unsafe tor tur1tJ.er r;>eNfoo and must be ~a.oed, Do I10t 8Harn-pt 100 weld a cracked drum.

S.moolh LIp aJ1Y slight. .sooi'lng. H81I'YY 01 ex.10'Miive scorIn; wl~ cause eI:':ce:sslve bf"o!ke lin~ng Wellr, It wm prtlbillbl~ b:9 r'lEJCiB"iSi~"Y I; l1\8C!h]n& ~8 drum broklng Sul1aos.

If 'the b.r~e ~nlngs ·8r111 S:1ig:htly WGfl'I aM lila drum Ie: gHlOved, tll~ drum .sP\oold be poliehe<l wl,h tlne emEliry ckrth but stlQuld nol t:-" maChined. A, thl:s stage. 'limlnating 8n the grooves In th& drum BJld ~ood'tIng the ridges (m- the I.lnirlg would roqufm the removw o. 100 much metel a.1ld lining. If l.eft aIons; lhe g~ ~nd ridges rnaleh and 5ei1iS~ faciO<)' s.rvioe can be "",."ed.

If br!llke Ilnin-gs are to be replaced, .a grooved drum el:loutd bO maenined. A ~rOOV6d drum, II used with a n(!-w' lining, 'Wl~ nol cnly we;ar U1tIIIIJ'llng biJI wnt mak:e .11 dffillcLm.t 11 not lmPQ::.sible, to obt~ln l:Hicf6nl br.ike pertcrmanoe.

5

OUT.QI'-ROUND OR TAPERED DRUM

An 'Out-oi-round drum makes accurate b'ak~ SfiOB adlustment impossible aM If;: IIksty to ceuae exOfj~rv~ w~at of other perts 0' !lUt braks mechani:sm dUll ttl Its oo:;arrtric aetlon, A" oui~Or·l'Ollncl drum can al80 e:au!ie MVEHB Eltnd lJF~:ula4" II..-a Itgad weal ElS: w.p...ll U .;l pulSing tJrBke pedal, Wh.en 1M M:kfng wr4ace of .a. b(ru:~ "film '8'.lID9ti;!d9 thElBpecl rtCiitti"on limils In tape.J' eM/D~ bLJt-lll· round, 'hIS drum !ItlOuld be mElchln.ed. OI.l!-o1--rour"ld U well as raper and woor een be 3C(lUfBlely meft$ljrl:ld with ~r'I. irtSide rniCfQllTlO[or II~ with proper e::.rtemslon ~.

Whefl measuring a drum for oul-of-rO!Jl'ld, Ill!)8i" Afid waer t take measurements at ttm open and CI6S9d ~ts Of Ihs machined ·suriaC8 arKt :1.1 nghl angles to each otMr,

WHEEL CYI.INDER REPLACEMENT

B Removo Ot Disconnec't (FJgure 23) CAUTlON: SeE! ·'CtltuUon'· on pails SA2;.1 I" thl$ MOIlO"-

1. Btgk~ Imlng::sl. Refer to "Br.ake llnr:f\g R!!ipLacemenl" In

ltIfs iliEmticn,

Z. e,a'e pipe. 3. Boll. 156).

4, Whttel cylinder ~57}-

1. H Old !>OWn PI ns ~. BackIng Plate

3. Parking Bnoke Lev.,

4. Washer

5. s.,conda1)l Shoo 0. Retaining Ring

7. Shooe Guide

8. par1<1 ng Brake Strut

9. 81 rul S prl n~

10. Actuator Lever 11, AelyalO' Link

12. Return Spring

13. Return Spring

9

L0075

MACHINING THE DRUM

I' • drum 1. to tie mo.ol>I"O<!, only """"lIh molal "'wid bQ remQv~ IQ Qbtalrl oft tl'\l&, srn.oo~1"J bt'ai\ln!l :surtElt;;;e,. II a dnJrn do!17S nQ! c:[eM up wh-en macl1insd to ill maxlmurn """"'tor, H mllSl tie repl,..O<I. Fi<>","""1 01 mere motal will o_fleoI d!Soj~.11on of II.'" arid may ""OM dl.torti"" 01 'M

."' m,

A!! brake 4rill'i'\ii haVe} 3. maxlmllm dJameter cas-i Into

IhGrrI. me. diamater Iii Ins mi!!i)(itfiUftl wear cfiametor. Dc not machine a bfake di'Ufti that wlIl not meet the speclflcal1on. Refer 10 ~Speciijcatlcn-s~ In \01& s~on fer ma)(.lmum d'rJ"lrn df:imetaf r;:!Uni3tni5-lons.

BRAKE ADJUSTMENT

A manual .djU,Im.nt of the ",or Or.1<oo "' required aRe, th. !ellr 1.1'00 hiVe town ropIlIl)!Id. Tho Ironl disc braW !oqul.TO "" edjU.lilienl.

HYDRAULIC FOUNDATION. BRAKES 5A2·'

E3 :Irnltall Of Connect (Flgu7,e 23) 1. WhO., CjlIIr><iO' IS?].

NOTICE: ~ ·Nell •• • Do pay. SA2"1 0' '''I~ ~ ..

2.90115 (§~).

I!aI Tigi>ten

" Bolta !u HS pectncetlcre" at the I!iIfld 01 this. •• "n,,".

S_ Brake plpa,

A_ Brakl!llln1ngs_ :Refer ~CI' "'Br,aj;:,g, Lining Repiarel"r1erJl W In 'II1is $Scfion..

8. Bleed braJt:s ayatern RBler to HYDRAUUC 8RA_K.ES

(SEC. 5.'1), .

REBUILDING THE WHEEL CYLINDER

13 110m""" ".01.""""",,1 (Flg",e 241 I, Boots (50).

2. 1'l.1QnS (53).

~. ~1521·

4. Spong 8"","bl~ (56).

It!I,o.,,.ot

• tw-11ildEir oore for ~ng Bnd oo~il"aBfon_

• 5?rlJlg Bssemb:ly jdi" ai~na 01 rj]:soo!oralloll due Ic' heal. Relll-aca fI MCEI'SSary.

~ Cian

• "'.,~. 1M "1'1100.' bOO> wit" '"""'" <:10th. II/h. ""'" § :s.tm ~" replaca tllEi eyIllid':er,

.. Cytlnrll(ll' wit" ClMiI biaH:EI HuldL

B In.101l or cenneet (Fig"" 241

• LUl)rluki Sr)a/.!i afiQ t.:tlind~r I!JD~ WI1h I;:I~ !b

Iluio.

t. Sr>ft"ll ... omblV (55),

2. Soa:l< [5'21.

3. Pis\on, {53). "-154).

51. Bleode, V.IvQ SZ. Seal

53. Pislon

84. Bool

55. Sp~ng A •• ecnbly

B·om

5A:2·'t,4 tlYDRAiJUC FOUNDATIQN BRAKES

SPECIFICATIONS,

BRAKE SYSTEMS

J!lS~OW DilII .!I)slow~ JB7~liJJriiii JB&~!l.gl"1i1l ~~CI:lI11iB!'lIitJ:niill

il'MOO.LS O~1U6'1 '.19 .ALL MOOOl..S Oi$(: 11,86:\ 1.251 DiD(; 1.2.50 ~ ~ .2-8 DiSc 12,50:t UB [liM:: U:.!iQ:. ~·,54 Di5Cl42S~ U4

Ql\lml100;tlOO

[Iv1;J1"I111.15:w.2.76 ~i·I'''1.1~1(:2'76 D\.!m 13.00 :f:1'50 D\.irn la,O!:) ~ il50 v.Ic, 13,1!j!ll! 1.i54

JD!!.Ow iJ!ag JD5lmillrag JOG Cocrvinlfuni!ll ,01_ •• ,,1

D""'IU!l.I.~ OI&e11.00'it US! DO. tt.!D. 1.2i D",MO,I.2ll

Hydraul. - ""',_ H\'drBulio-"""",_ HjdraUlk - Ryd_ Hyd!'i!lul~ -li}l:Iro..eoo~

DRUM DIA:METEA5;

MaJ:lmum, Reiln(:ah

I19pIa_i (Ol ... ,dl

11.000 11.150 12.{IOO 1 MOO

~" 11,00·,,2.00 Uo\J"ll,I\.2,~. OnJfrl1',1~ ~ :2''l.So O!r.Iml;3,Q(i:t:2'.50

V21culJm - 0I..I1II 'r:llap.ii!gm ~um - Dij.BI Ol!¥ft''ilgm va,cuum - Oli(ll Ol~m H\'drBul'-flydr'H~ul.-ftj;~M

Mlnlm ... m _Afblr ~!rd.hl"'iJ

iRllliplliamlirit {OI.oonI)

AOWR THICKN~

TORQUE SPECIFICATIONS

N'm FL lbe:.

Co;IlipOr MOUl'l'li1'1!;l' 6IoIt _., ..•• I"~'" "~. " .,... q 35

SlJQpotl Plale to K!'l'IJ(;I(I';' ",. " ",.,' •• " •• ,' •••• ,' , ••• ',.. 1f1 10

Wll.e9'l C~lIfidOi to F1Mge Plffia BDI) (AJiE1ree~ JB5. JB6. JB7 and J@,ij~ ,... ••• , ,~.. ~,~ ~

iNh~d!1iIiI CyltnClorto fJltIQIlI P'lirts. Ekill (J:B5, .:IBft J 67.a00 JBe) , ... ,', .. ," L" ... ' .. " ... ,', •• ,....:2o 15

ReQf'6l'~Anclt«'Pin.{AIi ~CflpijB;andJB3) "., "'" ""_ •• ,,,. ,., ", •• ,"' •• ,.," 1EiiO 1~.o

FVi;ir,BrEi.'k!l',6.r'KlhOf'Pin(.!Ia7artdJ:B.8) ._. L',"'" ••• ',.,',.,',.,"",." •. ". a12 23:0

Brok.BI-.'V..... ...," " .• "_.",, " " " 7 S

!3j.ffiIo.D8sj.,,2I!.

HYDRAULIC FOUNDATIONBFlAKES 5A2.1

HYDRAULIC BRAkES SA.

SPECIAL TOOLS

DIAGNOS'IS OF BRAKE SYSTEM

Un~er.Bi'1IIM ActiOn (B_i'""i

1. ~ J26267

2.

J 24548

I. I'I"o~ $e .• llo5Iaii&r {3IJoot:lI0QI 2. Aston Selll Illstaller (Sendi;l{j

POSSI D~E CAUstl

1. IIlct:Xrgcllir-e _pr1ls!!;IJIlII.

2:... Front end our ~j a1igr'lrTlElIlL 3. Leese ~!.!~IQ" .par~$.

l.I. !Nom init bralta: lining.

s.. mooerect ~l'1rfl~ IlliIIllllriaJ,

6.. M atful'](;\jQflifl(l ua!iPiJr as~l1ltJl)",

7. ~'QiliP"EIrl!i.

a Glilf.ll<lJi'liilS:too bral«! IInir'llg:$,

9.M.am.mcticnirlij iDilJ bliJ~iJ!!i,

10, Lealo:J.llQ w/iEte:l i.Jr ~1~I!j)n ~1!lTd!9r' ~aJ. t~, Res'lricleod !brake rulles,Dr'OO:se..:;.

1'2. UllmiililfJl'II!~d IUs.!; 00 the: I5<!Ime s;;:Ja..

~. Illfla:toE!-~IV(j.l1:"""~-~~:s.tO$~lle:sn(Jn!!l :! ctJet;lk;PI'\(I;!!l~t.osrJ1)0i~c:allorl5.

a, C'leek 1)11 ~~~Ol'\3ion mo~-s.

~,_ ~I~ IN'ith, linif:'9 'Cir ~¢'I, ~~t~~, S. RepIB~ 'l.lMll 1[l'Iil'lgS or $:)i'fOC! m:a!eria!.

6. Ci1edt: fm frozer'l Qr swggl$h pis.!ons.s.nd 1f1i hrbrlcarlen or 1M fetalne:r acns. CalJpe,. :should e!1da,.

i. G1'iEt(;;k anI;! gqU:41l",

o. Rep.J[r'B:EI:n,eOllsaary. FI!Eipl~ Iln~!lincam pl'ele mete.sell!...

,g, Chec'k IIJT illOlJlBr.all"JB !lalf .s.dJuBtilr9... WEI.I I61Um 81lr111{1:5l. L·e!iXln~ wheet c:yIlt'lde~.

10. Rep.aEr as neceeeary,

11. 01'1 ad!: 'Qr oojl;§ ~~{ii(l n,J t)tJ~r MM5 CI dama.g1itlJ rJnes. R8~lr f1S fiik.OSU..- .... ,

12.. Same &lyieo nJe:5l wr1h t)bOut mO M~ t.rf!l_1t( 6.1'101,1111:1 oe IJ$OdI Of' 11'J0 $iltI"!O Q)t!8,

" Wtim aut Uliln~.

2. Gl!!~ brake' Nrtl~.

S. Haal spouse rolDrs nr creme.

4. Weak cr lncarram brake shoe retentlen 'I'"ngs

S. eonlamlna.t-ec:t brake ~nlrl{jili:.

9, leccrrect '1In~ matertat

7. Brah B'B:5:8mtJly enecrmerue ml!38lnq or 100"..

e. ~"L'I!V brake IlnlllQ' Dust

.. ~1>i",o~i'I"93, ~ ~~I;}{i~l!ni~.

a. CheP{:1( eer 1n-sn-IJC!IQr..S. IlwitJ'llr'lo SfKIOIllet!I. lilone mW1il'1oe th& l'OiIor or Ill\jm,

4, Repla.ae writ! now ~.1.(I1"I'tIOn stlt1ilgS.

~. :Rep.i!llr;M ~$ai)', fIflpl&~~_r'il~incoo-.

pl_a)i;l~ISi!i'S:.

6. ~epla:(:e ..... ii~ ilr"lll'l!lS ~- ... Ot!'.ttC~ rtulttl'i.-.I,

7. ~('Ip.a_lr:e~ n~I[!SsMY,

6.. CI~in cly;llrorn bralro M30~,

J. "'",_aj :s-potllMI rojOfe of·drlji"ftS,

4. It"IO;)i'I'OQI ~eol bMtil1G1 adltJ!S!.I'I'I8r'1t!l.

15. C1ulOfblJ.!lfloowtll)OI.1$$Qfl'iblye.ttacIiJiriQI"iti mi-Sm,Q or toose.

6. 5ra_klO' M:5al"iibly c.IHloCilmEl'nlS ml:!l!!ilnQ IX

-

•. Cr'lij¢!.: ~~ tri$~IOii!:3. II W'lft'fI~ :!~IIIU 1kIr.i; maehliili!! ttlJCl rG1.(Ir.

2:, CI160k per tr!s;tnJdiOiis.. II '-'IRhjl"l -SPilCIlICl! ~ fiiilchine tlilf!l r:lrum,

3, Chook nur h'nPtruCUOIl:3" II within ~r;.9r:i11l'cil ~ ifiathlfil3ilhB rotirf e~ dfi.im.

4, Fh:'ip~it.a.:!ii rlBoo.s.s;ry,

5, R~.p;!,ir as neCEl~y,

EMfaIitrI .... 'Pe!:b.I ErfoFt

1. le~ v acuum:sy.:.tOO1.

2. M'oItfuncl.ionfn{l ])rIJws.rbls.'kB unlL a, WDm 0U1 ~riing;a.

4-. M2IH'un~jonklg propCiJriiolllrtg v.fi'iYJ3:, S. Ino::ni'S!i:t6ri1l19.mi!i!S-rli!lJ

Go In~rEtd ~~ ~Iin~er,

~ I Afp.ailr a& l19CErSS8JV, 2, Hepair aa lIl9tEr:s.:5ery. 3" Replace linings..

<4,. A:'IIpair ea ,neoo§9.ry.

S, Heplace with, linl~ .gr correct m~iils. -Ii, ~pl,ac:e:wlth COO9C:t !Jb:a wll-eoBl C)'IlniiBi_

~. lru:uffic.l!tlnt 'lh.rfrj in m88.ler c.y'Ilnd9r raaarvolr.

:?, AIr In br~ke ,8~tem.

a M'St'l'unC1kJn100 ~I. adtU::5i1:ef=L 4, Maeter -c~.

0, ~ect wh~ bearin!:l .adjUS1mi!;!lllt

a ImpfO:POfly IIIdJ~lJleci m:l!i:;r'er cvHnl;ler """'1'0<1,

1, RI~ raaarvolr WlIfr approved Il.f.ah lIu[r:I ctiftGk rN te.aks a~ alr Il'IlhtjI ~teR1. ChecI

Indl_rligl1l .

2, etJeqI-: ~~q In ~II'I~, ~Icy~, 0

mB.S.tar cyjlnder. BIaed the S)'!I!.ilim.

3. Rwalr B.:!iI ~s.ry.

.tI. IbP.8OB Dr rapalr 88 1lo8Cle!t9Bf)'. ~. 1'Iepa1r •• """O"''''f.

G. A.r:Iju!;:1 ~t.tilr cyllnQer ~~tlroe.

5A.4 HYD.RAULIC BRAKES

DIAGNOSIS OF BRAKE SYSTEM (CONT.)

B~!I'kCi Im:Hcillor L1sht 1, All in jhe br.l!l~ Sys1~, t, C"'~ jr"ll~ la'l'li!Il. Cflec~ filr I"~ II'!i ~ne3,

Co." .. On wh.i'}tI! {;:y1Eti.d~rli" (lJ me'_er 1.':Ij1~!!ir, 9'J~ It'!o ~y$1.ml

2. MBtrLJ.:1'icttordng 1'fIi!i!.i!!8r l!'tIii"loo,F. g. CI'lec:1!; ror malfufl~iClning rnatartng .... 'i~. or

~~jn'El' Hepalr ea neceeeerv

5. Can!;limln:aI_'~JJ a.r If'F"IP'~ bC'w 11~ld. ~,~~r M rl~f)'.

~'. P.ar~ Ilralffl on OP riOt 11,1.11)1 !'9hJBSQ!I::L 4. C~JI; ii'ar~n:y t.r'i;ike. R!3I~r as neceeeary,

5.. WoI'fI QUl ~q Wf'!lf1i). ~, ~~!lcq IItl!iig~.

6. IlIt»IT~ ~.;.I ~;Jjlfllil ~U;""9n.t ~, RQf!:E!it es ~ary,

7. Matfu~E:I"rS 1(1111 adji.i.'S[8i"i!. i. ~;[!i' o!l-S; r'MlO!!SEli3.TY.

a BraK~ i!lS:S~Jl'itill~ ::uticl'lfniiJi'Uli mlsalns 01 eI. Ri!j;l!'aClil Of ropalr alii fl:eOBSBary.

-.

e_ 1"'~lop.~IV !]IjjIL.ith)~ iJii;i!ilir ~)'lllHlsr g. MUi1 ~si1K1id Imlgih,

1""""".

C-h~k rOr rrUll3r1 0[ :6luggll!lh pletcne em the lu~r1i:lIUCr'i lJi the retainer bolts. Calip,." IiOO:u1!;I Slldo.

"2 ~!Elp~lr (I~ ilItGe:s:s.ary,

3. ReplI;lr is 1'I(1I::aSRfY,

<4, ChElcc:k lOt cctteneed rubber ttOS13-!5; or

~~ tree. Hepalr B8 'Ile'Ce:SS8.ry_

5, FI~place 0' flllp;J.lr aa JleGEl58BJV,

:6 RfI~lr ;P_', nl)C:~y,

., ~epalr ee n't"¢i:)~ry,

S. Ad[us1 p.""rod I""g~

2. Cpnt~r118!i!!d g,. Im!';il'(.iper t:Jral«! 'l'i.lid,

:J Impr'apl2lrly adfu_~ Ila~ !:i~~,

4. Realrk:!~ brsk.3, W~ Q1 :I'iO~*,

15, MBII",ncllllll'llng ,PI'~r1iO['II~ .... ~~, 6, MBJI~I"'IC!!()l'Ilnr:J $EfJi MJY~!Ilf'S,

7, MelllJnI;:tlol'llng m~~r oeyllj'h~er_

e, ImprapeirJ~ .I!IgfY~~oe-~ t'I"'I.ael<tf ey~H~der P_l.I:Sh~9~

EIeI!i~I"IIII ElreQ PBdII! EH'ol'1,

II 1. lOOn at broker; PD'Y!3'r .EiIHling pump ba'll, :2. No 1iUia j", I!'!II!!! p;:!~~ .sta&ring 'I"9Bervair.

J. lUa!l!$ nll-4~th'1)o~t lube limntls,

L ;1<]"10".' "'Pi'" 111< !>oft.

~, ~III r:ij,%~r ~ oCl'md< fer vxterrlB.1 Ie_aka, 3, ir~hl~ mUri.~ior ft!I~liiii;iu niba iieiiJt. ir WOn'I

.... .....,0\1.

_., ~~~Ige s,tIL\! 4fId r.er.aliiljjlr.

9, OYer~1 with l'iew ~ea.1 'Dr input I1:!d end ~'1<>!1.''''.\ljIY·

a, OVtarl"ril~ willi i'iUw :5aBI ,kll,

4. iI:){1,!iUrliaJ ~~IB aL U,e ~cctlmula!Dr,

5. \IVOin .of' ~a.rTU!I.gil!l~ bioos.tEIr p~too seal ~8- itIiIl(ll!I~liIge BI the Doqs't!3r 1T.aI1Q9 vtll'Il.

8. 'WOrn !Jr !damaged booster IrIj:1_1J'1 rQd B.g.al 'wnhi Iilliilf!!ag~ :s_, rflBo inpu! rod EiOO,

], 'rlIIOm or dam.Qg8d boo:9t&r' (;Q\Ief ~~J wlth le.ltSge bEilWeell the 'hQi.,r~nog' SIIn4 CQ~~_

O. v.hlm (lr~ cIam~~' iJ?cB!~ ~l plyg sNJ.

e. tmmalll i'iUh epee! pfug , eel klL

:HYDRAULlCBRAK.ES 5A .• ~

:l.d_ ,Frame Aet.alnlog F'lrtgars 30_ ;Pedlll f::iel8.io~ng Fln9i1!~!! J§. CObl" A ... mbl~

n Connector

~4_ Frame Retelnl1"l9 F1ri9ia I'!i

36. Cabl. A •• embly

37. Boil

38. Glip

Ilc077ll1

SA·24 HYDRAULIC BRAkES

HYDRAULIC BRAKES 5A.25

3Ii. C.bl~ MMmbly 37. 6011

38 .. CII~

FI!lY", 25 - G-Mudel Front C.bia Component_, E3 In.t.l1 Of Con_ (Figures 2Z, 24 ano ~) 1. CollI. OSsemblV (36).

• Ma'Ke SUl8 all tl'ls fa1a10ing flngO'fI ai'e eem~I""v I~",ogh In. hot.

2. CoM<> .. "'. QodoIihondlo .... mIIlv.

3. ClipS laB) end bo~, (37).

B1J TlQhton

• Bol16 (31) to "SpsdfrcatiO(1s" I'.I! I~e end of this ""'Ik".

•. CO""",,W (3;1),

5. NUl (31) onto !he 8qlJaJlz.r (32).

121 AdJ"'"

• Parking 00:.)(8. Reier to "Parking BraKe Adjust .. men!"' in this sedion_

• I.Dwet ttlB YBhJcle.

~ENT!;;R CABLE REPLACEM£NT

:3 R .... ov;, Or O_nnool (Flguro 22)

• Ra.llSa .he- 'il9liidlll and auppon 'Mlh .suiJab~s salsty

.-.

1. Nut f31 ~ from IPie 'Bqusli:z;ef 132).

2. Bglt~ IrQl'll Nid rear oonnec::[o~:s (33). :3. Cil1l~eI.

8: Ino"'" or Con".'" (Fig. '" ~I 1,talll"

I!. Coon.- 133).

3. NIJ1 1311 .,,10 111. "'Iual"'" (32).

121 Adl""'

• pamng bra"ke. Ref&r 10 ~Pa'1dng Brah .A.di\Jst!Denl- fn thHs section,

• lDwer tho vahicle.

4. '~.Ium .pnn~ gulo.. (72).

5. HoId_n clips {65j.

e. HoId·"."," ""09. (64). 7. W_",(63I.

B. 1.0vo, o!N1 ISSI·

9. SUUl op<ing (571.

10. "0_ r.1lIlnlng ,rlt!ij ;6'11-

11. SI1 .... (ee).

12. AdJuodng SC!'Ow (611).

IS: .AdjUsU'g sere" .pring (SlI).

ll!Ilnspoot

• All parts for dl:s(loloratlon du~ ... to heal Of !nfess.

Ropl&oo ~ """""l}'.

• BrBkB drum ~OI :ICOrtog.,and he3t spot.!!;. ~achtne drum lr needed.

E3 I"'!~I.I or Don.,""I. IFlgur<I 28)

, Lubr1I;i.13.\-eI thEl shoe psda and ~u.s~OQ :mr~w thrliilllllCIii wllh 61 thin coat of whi~B lithiUm gi8as8. J

t. Ad)"" ng ",,",w (60) aM OOjlJSUng scre'" spiJ1g (56)

I. b<>th ....,,, (68).

2. SI1<>o .... mlJty (68).

3. Le •• r _ing ring (67).

4. l.e-ter oIru1 (SS) and .'rlJi spring (OIl.

5. w_,. (63).

6. HOIckIown 'I'"ngo (64).

7. ~_n 01.,. (85).

B. Rotum ,pring gOOo (72).

8. Rotum .wJrg. ISS .n" 71).

10. Drum (66].

11. Propo.llo' shaH. Rol., t. PROPIii~"eR ~HAFT (BEC. ~"'),

I21l1dlu;11

• Porklng brake, A.m.r 10 "~ ... ~ln9 a .. k. A<ljuol· manl'lnihi._

• t.crw-ef Ule'rolehIQI:e.

REAR CABLe REPLAC!iM~NT

E3 Remove or Di.connect (FIgure 22J

• :=s.d'te vehkJe 8nd tlIpPort J, Mth sLlI,tablB IK!taty

1. NUl [all ''''m tIie 0110;[,,", (32).

t.. Coon.""'r 1331.

3.. 6roilkl!l drum IiIII'lQ5Ihoos.. Refar to HYOFlAUb'IG FQUNn OATlON BRAKES (SEC. 5M).

• BerI<J I. 0AIll. ,.1lIlnlng ijng ... a" !he b.eIIlng plats.

4. Ftetafnlnll etJp .at the frBme Slolppott. 5.. G.alJleas:5am~.

B !no"'" ,,, Connect (Flguno ~) 1, Cable 6s56'mbiy_

• Make- eere all Ihe r&tainlng fingers Me com. pletely ihroug~ ,1>. badcing plate,

2. Relaln'lng c[lJa at the !rame support

s. Brake :shOes and drum assembly. Refet" I" HYORAULIC FOUNDATION BRAKES (SEC;, SAAl.

4. 00nnt>r:t<J< (35).

S. Nul {311 onro ,"Q "'1 •• 11 •• , (32),

12l' Ad!"~1

• PiltKl~ brue. Refer·to ~PElrJIfng 'Brake ~djuSll'T"IBIiU" in tht2il BSC'tJon.

• Lower the v8I'"1i~.

PROPELLER SHAH BRAKE REPLACEMENT

E3 Remove or DiseOfifiect (Figure 2:6)

• Raise lI'te vehicle one! &lPport wfth sultabifJ SiUtt)' sl3nd"s.

1 PropeJler shah. Rof!'u to PROPELLER ~HAFT

(SEC,4A).

CAUTION: 6M "Caut'on" on ~.g. SA., 01 thll ~on .

2. Drum (66),

• I i rna)' be l'l&OOssary to back atr 1he ahae IIdlll5ll. in~ screw,

3. R()1um spring!i= [66 ani:! 71 J,

PARKING BRAKE ADJUSTMENT

The parking tlrajl;es muai he adjUSLed wh:efl6Var [tile'" ~ng. blake ~es h(llw been raplMOd Of dlscanneded, or If tne btDe holding abmfy ig noi ad8qtlate, Before adJUst-log the parldng blakE!$.. check: the condition of the satva brakes: TJ\j: S(!fVic:e bI:a.ke:s !Ilul5t be aoJU!sted properly ~qre pr0.e6!ldlng with the parkIng braKe &djustmenl.

C ... llllllNSPECTION

Check !he Plilrkfng brtOOli sysl.Bm klr frEe oplualJon. The br:ake 1e~ muar return to tne released position 'Wiltt0lJ1 :s~c'k~.CN' biridlng. Ir rt problem Is preeern ChB(;jII, tl'1e CIa·ble rO:IJ~ foc kin'kIii· or blndlrl~. Clean aod Iub~jcala ~a palit;- 1"11 ",""" • ...,mb",_ oabl ... _ O~ BrM. WIll er lXIulllahJnl.

FOOT PEDAL TYPE

• "Sioek thai rronl '!NIlesl:!i!.

• RaIse 13iflld support Ills near aMte wi01 "BuitBbre BallI:!

SllInd:s.

t, Loosen 'he equanzsr md.

2., Set the ~3tkin9 br~8 pedal fa fOlJr dloM.

121 ..... 1""1

EClUilJ1!1,,. ~ ~. U1e wh~l!l1 rotate fOrward Witft I moderB.t§ dr§g,

3. Release the P8:rklrl!;J br.B~e and rotat8 the reer wheel!

There should be rit tQ.~ dra_g.

• Low&r tile var.lclE!'.

• LJnbIOC·k '!he lronl whee:16.

lEVEl! TYPE

• SlooK the 'fOIl! wheels..

• 'RaIse ano supporl dle rear ad·a wllh "Builal:ille safe~ MiIIICli.

1, TUm Ih •• dluS!lng moo en 11>0 parldng bfoke .... oount9rtFGckwls-e ~nlil 11 S10~"

• AW'1 parIL~ ..... e.

2. Loosen IDe equaltzar nut,

12:1 Adlua.1

Equai1lef" nUl untll alight drag is.eft While rotatJrtg ttl! wfleeJs ICfWorO.

Knob 0"-' the p;i3.fking brake le'YiBf until a dollnlle tnai over eer'Ite:r ~ fell

g, Ftfrlease '!he parklng brB.~ anCl rotate U"te roarwheel~ Tn.ere shoolf1 be nc b"akE! drag.

• ~r1he ... et'lic&a.

• Ur):blook ~he front wheElis.

INTeRNAL EXPA"O'NOl (PROPELLER SHAFT) CAlmON: _ "Csutlon" un pilato 5>\·1 01 1111, IliKUOn.

• Blcei< me trom: wheels..

• Ai!~e 8110 31Jppor1 the rear axlfI With UlilbiD 511.fet at3l"1ds.

1. Remove Ina (llavi~ p'n COIlinBcting "'e pull rod an rerayl~r.

2. Rotate Ihe br~ke drum to align l1'ie ileOOI$ fxIo!e wit u.. adju~tlnQ ~ew_

II M.rnral tmrumlA:(:OfiA - tho DJdJU$Ung &eM'i 13 1."""led .i !he beftom 011he >hoe.

• Automatic tlfllln.ml*i!ilan - me ad"Ju6tln 00_ Is located .. thO lop at Ihe ahoe,

• _n adjU5ifng ihe patklng bro.!<. 10' 1I\e IIIl ume, il wIll be noi;i8ssary to femar.'e the JatiCO area from Iha drum, T11.tI! drum must tm Fe.ifil!NIIII 10 ""'On <rut all !he !!IOIal _lr1(jo, R"I., I PR(lPElLllR SHAFT (Sec. 4"').