303‐07: En gine Ignition
Specification
Diagnosis and Testing
Engine Ignition
Diagnosis and Testing
Engine Ignition
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) index
Pinpoint Tests
Removal and Installation
Ignition Coil ‐On ‐Plug LH (18.20.44)
Ignition Coil ‐On ‐Plug RH (18.20.43)
Ignition Module (18.20.30)
Spark Plugs (18.20.02)
303‐08: En
gine Emission Control
Specification
Diagnosis and Testing
Engine Emission Control
Inspection and Verification
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Removal and Installation
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Exhaust Manifold to Exhaust Gas Recirculation (E
GR) Valve Tube (17.45.11)
303‐12: Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Charge Air Cooler LH (18.50.19)
Charge Air Cooler RH (18.50.18)
Charge Air Cooler Gasket LH (18.50.22)
Charge Air Cooler Gasket RH (18.50.21)
Supercharger (18.50.
15)
Knock Sensor (KS) RH (18.30.93)
Variable Camshaft Timing (VCT) Oil Co ntrol
Solenoid (18.30.90)
307: Automatic Transmission/Transaxle
307‐01A : Automatic Transmission/Transaxle ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Specification
Description and Operation
Transmission Description
Diagnosis and Testing
Diagnostic Strategy
General Procedures
Transmission Fluid Drain and Refill (44.24.02)
In‐Ve
hicle Repair
Electronic Pressure Control (EPC) Solenoid (44.15.51)
Extension Housing Seal (44.20.18)
Extension Housing O ‐Ring Seal (44.20.19)
Main Control Valve Body (44.40.01)
Output Shaft Speed (OSS) Sensor (44.15.41)
Shift Solenoids (SS) (44.15.50)
Transmission Control Module (TCM) (44.15.32)
Transmission Fluid Filter (44.24.07)
Transmission Fl
uid Pan (44.24.04)
Transmission Fluid Pan Gasket (44.24.05)
Transmission Internal Wiring Harness (44.15.35)
Transmission Internal Wiring Harness Electrical Connector O‐Ring Seals
(44.24.20)
Transmission Range (TR) Sensor
Transmission Support Insulator (12.45.04)
Turbine Shaft Speed (TSS) Sensor (44.15.40)
Removal
Transmission (44.20.01)
Disassembly and Assembly of Subassemblies
Input Sh
aft Seal (44.32.07)
Torque Converter (44.17.07)
Installation
Transmission (44.20.01)
Mass
Airflow
Sen s
or
Knock
Sensor
(KS)
LH
(18.30.92)
307‐01B : A u
tomatic
Transmission/Transaxle ‐ 4.0L SC V8 ‐ AJ26
Specification
Description and Operation
Transmission Description
Diagnosis and Testing
Diagnostic Strategy
General Procedures
Transmission Fluid Drain and Refill (44.24.02)
In‐Vehicle Repair
Extension Housing Seal (44.20.18)
Main Control Valve Body (44.40.01)
Transmission Fluid Filter (44.24.07)
Transmission Fl
uid Pan Gasket (44.24.05)
Transmission Internal Wiring Harness Electrical Connector O‐Ring Seals
(44.24.20)
Transmission Support Insulator (12.45.04)
Removal
Transmission (44.20.01)
Disassembly and Assembly of Subassemblies
Input Shaft Seal (44.32.07)
Torque Converter (44.17.07)
Installation
Transmission (44.20.01)
307‐02A : Transmission/Transaxle Cooling ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ
27
Description and Operation
Transmission Cooling
307‐02B : Transmission/Transaxle Cooling ‐ 4.0L SC V8 ‐ AJ26
Description and Operation
Transmission Cooling
307‐05A : Automatic Transmission/Transaxle External Controls ‐ 3.2L NA V8 –
AJ26/4.0L NA V8 ‐ AJ27
Description and Operation
External Controls
310‐01: Fu el Tank and Lines
Removal and Installation
Fuel Level Sensor (88.25.32)
Fuel Pump (19.45.08)
Fuel Tank (19.55.01)
310‐02
:
Acceleration Control
General Procedures
Accelerator Cable Adjustment (12.20.05)
Removal and Installation
Accelerator Cable (19.20.06)
310‐03: Speed Control
Diagnosis and Testing
Speed Con
trol
4: Electrical
412: Climate Control System
412‐00: Climate Control System ‐ General Information
Specification
Description and Operation
Climate Control System
Diagnosis and Testing
Climate Control System
General Procedures
Air Conditioning (A/C) System Check ‐ Retail Procedure
Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)
Contaminated Refrigerant Ha
ndling
Manifold Gauge Set Connection
Refrigerant Adding (82.30.02)
Refrigerant Oil Adding
Refrigerant System Tests
412‐01: Air Distribution and Filtering
Description and Operation
Air Distributio n and Filt
ering
Diagnosis and Testing
Air Distribution and Filtering
Removal and Installation
Center Registers (82.20.38)
Driver Side Blower Motor (82.25.56)
Passenger Side Blower Motor (82.25.55)
Plenum Chamber (82.20.87)
412‐02: Heating and Ventilation
Description and Operation
Heating and Ventilation
Removal
and Installation
Heater
Core (80.20.29)
Heater
Core and Evaporator Core Housing (82.25.21)
412
‐03: Air Conditioning
Description
and Operation
Air
Conditioning
Diagnosis
and Testing
Air
Conditioning
Removal
and Installation
Air
Conditioning (A/C) Compressor (82.10.20)
Condenser
Core (82.15.07)
Evaporator
Core (82.25.20)
Press
ure Cutoff Switch (82.10.32)
Receiver
Drier (82.17.01)
412
‐04: Control Components
Description
and Operation
Control
Components
Diagnosis
and Testing
Control
Components
Removal
and Installation
Air
Discharge Temperature Sensor (82.20.64)
The fluid reservo
ir:
Is lo
cated in the engine compartment, mounted on the engine compartment fuse box bracket.
Incorporates
a 10 micron, li
fetime, integral filter.
Has a cap
acity of 0.4 liter.
Has a dipsti
ck incorporated into the filler cap for checking the fluid level.
A new reservoir must be fitted if the steering rack, pump or fluid cooler are renewed.
Fluid C
ooler
P
arts List
The fluid cooler:
Is
resiliently mounted on th
e front body cross member.
Coo
ls the fluid before it is
returned to the reservoir.
Is
of the wire-bound tube type.
Has i
ntegral hoses.
Supply and Return Hoses a
nd Pipework
The supply and return h
oses and
pipework deliver fluid at high pressure from the pump to th e steering rack assembly. The
fluid is then returned to th e reservoir through the cooler tube. The high pressure supply hose contains two cable-type
attenuators, one at each end, to reduce nois e. The return pipe is clipped to the steering rack housing by a resilient
mounting.
It
em
Par
t Number
De
scription
1—Fl
uid reservoir
2—Supply line
3—R
eturn line
4—Fi
ller cap
It
em
Par
t Number
De
scription
1—Front body cross member
2—F
luid cooler
3—Inte
gral hoses
4—Cooler m
ounting
P
arts List
diverter val
ve (if fitted) and oil filter.
Main
bearings
which are grooved in the upper positions and plain in
the lower positions. They are manufactured from
aluminium / tin material.
A c
rankshaft with under
cuts and rolled fillets for extra strength.
Fracture
-split connecting rods in sintered-forged steel.
Brackets
bolted to the front of
the cylinder
block are used to mo unt all accessories.
A sin
gle, seven ribbed vee belt
drives the accessories.
An au
tomatic belt tensioner for the front accessory drive,
incorporating a wear indicator.
An advanced en
gine management system inco
rporating electronic throttle control.
The un
it meets the requirements of the CARB OBDII USA legislation.
Ancillary Systems
The an
ci
llary systems, driven by the engine, each have a
detailed Description and Operation along with Diagnostic
Procedures, and Removal and Installation instructions ; refer to the following sections of this manual:
Power Steeri
ng Pump - Section 211-02
Ai
r Conditioning Compressor - Sectio
n 412-03
Engine
C
ooling Pump - Section 303-03
Generator
- Sectio
n 414-02
The drive belt, idler pulley and automatic tensioner are described in Section 303-05.
The engine starting system is described in Section 303-06.
En
gine Management and Emission Control System
Engine Control Modu
le (ECM)
Engine
management and exhaust emissions are controlled by the ECM, which has the
following main functions:
Fu
el injection
Idle
s
peed
Ignition Ev
aporative loss system
Engine
cooling fans Clim
ate control compressor clutch demand
The microprocessor within the ECM receiv es signals from various sensors and other modules and uses a pre-determined
program to compute engine management functions.
Adaptive functions are incorporated in the ECM to cater for co ntinuous adjustments to its computations to suit prevailing
conditions. Because the system also controls emissions to suit all modes, neither CO levels nor idle speed require service
attention or adjustment, except if an error should occur.
On Board Diagnostics are controlled by the ECM with the continuous monitoring of incoming signals and the subsequent
verification against what the module expects to 'see'. Should a si gnal be incorrect or missing, the ECM will substitute a fixed
value to provide the 'limp home mode' and alert the driver of the problem. Fixed values may be adopted for:
Transmission oil
temperature
Mechanica
l
guar
d position
Throttle blade angle Camshaft position
Inta
k
e air temperature
Diagnostic trouble codes (DTC), including OBD II codes, are stored in the ECM memo ry and can be read by an appropriate
retrieval tool.
Should either the ECM or TCM fa il, ensure that the control housing cooling fan is operating correctly. Failure of the cooling
fan MUST be rectified before renewing a control module and details of a fa n failure should accompany a returned control
module.
I
nstallation
Tigh
ten each bolt to 8 to 12 Nm initial torque value.
Ti
ghten to a final torque of 57 to 63 Nm.
27. Check that the cranks haft turns freely.
28. Repeat the previous operations for each connecting rod
bearing as necessary.
1. Install the oil pan bo dy assembly. Refer to Operation 12.60.48.
2. Po
sition and align the oil pan gasket to the oil pan body
assembly.
Inse
rt the seal into the locating positions in the groove,
working around from a corner.
Press in the remai
nder of th
e seal, following the same
procedure.
3. Install th
e oil pan to the oil pan body.
1. Position and align the oil pan.
2. Install, but do not tighte n, all eighteen bolts which
secure the oil pan.
4. Tigh
ten the bolts to the correct
torque figure 11-13 Nm, in the
sequence indicated.
Tigh
ten the drain plug to 30-40 Nm.
Install a new oil
filter.