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    Haynes Ch1 PDF

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    Jose Maria Santos

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    Ford Escape & Mazda Tribute 2001 thru 2007 Includes Mercury Mariner Haynes Repair Manual Based on a complete teardown and rebuild Includes essential information for today’s more complex vehicles 0-3 Contents Introductory pages ‘About this manwal os Introduction os Venice idenifcation numbers 06 Buying pata 08 Maintenance techniques, tools end working faites 07 Jacking and toning 013 Booster battery (ump) starting ona Fraction/Socimal/mitmetor equivalents 0-15 Conversion factors 016 Safety frst! 07 ‘Autoriotve chemicals and ubreants O18 Troubleshocting 019 Chapter 4 “Tune-up and routine maintenance 4 Chapter? Pata Four-cylnder engines 2aa Chapter? Part B VB.engine 28.1 Chapter2. Part C General engin overhaul procedures 204 Chapter 3 Cooing, aeting and airconditioning systems Ea Chapter 4 Fuel and exhaust systems 4“ Chapter 5 Engine electrical systoms s4 Chapter 6 Emission and engine contol systems Chapter7 Part A Manual vansaxie TAA Chapter? PartB Automate ransaxe 7. Chapter7 Patc Transfer case To Chapter @ Clutch and cevetine sa Chapter 9 Brakes, oa Chapter 10 Suspension and stering systems 104 Chapter 11 Body tt Chapter 12 Chassis electical system ta Wiring diagrams 1225 index 1ND- 0-4 Haynes mechanic, author and photographer with a 2002 Ford Escape About this manual 0-5 ts purpose “The purpose ofthis manual is to help you get the best value from your vice. Gan do 80 in soverl ways. it can help you ‘decd what werk mast be done, even if You choose to have it done by @ dealer service department or «repair shop: provicesinfr= maton and procedures for routine mainte- hance and servicing: andi offers siagnoatic land repair procadires to flow when trouble oooue, ‘We hope you use the manual to tackle the work yourse. For many simpler jobs, doing yoursa may be quicker than arang ing an appointment to get the vehicle nto shop and making the pst laave ian pick itup, More important, alt of money can be faved by avldng the expense the shop must pass on fo yu to covert lobe and overhead costs, An added benefits the sense of sats faction and accomplishment thet you feel ator doing the job yourself Using the manual ‘The manval Is divided into Chapters. Each Chaper is vided into numbered Seo- tons, which are headed in bol type between horizontal ines. Each Section consist of con sooutvely numbered paragraph 'A te beginning of each numbered Seo- tion you wil bo retered to any Mustralione which apply to the procedures in that Section. ‘The reference numbere Used in Mustration captions pinpoint the perinent Section and the Stop within that Secton. That, usta: tion 3.2 meane the istration refers to Sec- ton 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text ‘re not normally repeated. When i's neces ‘sary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the ‘word "Chapter" apply to Sections andlor para ‘graphs in the same Chapter. For example, "yee Section 6° means inthe same Chapter. References tothe left or ight side of the Vohise assume you are siting inthe driver's seat, facing forward, ‘Even though we have prepared this manual with extreme care, neither the pub- lisher nor the author can accapt responsibilty for any errors in, or omissions from, the infor- mation given. NOTE ‘ANote provides information necessary to properly complete a procedure or information which wil ‘make the procedure easir to understand, CAUTION ‘A Caution provides a special procedure o special steps which must be taken while completing the procedure where the Caution is found, Not heeding @ Caution can result in damage to the assembly being worked on. WARNING ‘AWaming provides a special procedure or special steps which must be taken while completing the procedure where the Waring Is found. Not heeding a Waring can result in personal injury Introduction ‘This manual covers the Ford Escape, ‘Mazda Tribute and Mercury Mariner. The aval. ‘able engines are: ‘The 2.0L Zetec inline four-cylinder ‘engine, 2.3L in-ine four-cyinder engine and the 3.0L Duratec VB engine. ‘The engine drives the front wheels through ether @ five-speed manual oF a four. speed automatic transaxle via independent riveaxies. On 4WD models the rear wheels ate also propslied, via a driveshaft, rear cif- ‘rental, and two rear civoaxies. ‘Suspension is independent at all four Wheels, MacPherson strus baing used at the ‘ont end and traling arms, control arms, col springs and telescopic shock absorbers at the rear. The rack-and-pinion steering unit is ‘mounted on the suspension crossmember. ‘The brakes are disc at the front and ‘drums atthe rear, wth power assist standard. ‘Some models are equipped with an optional ‘Antilock Brake System (ABS), 0-6 Vehicle identification numbers Modifications are @ continuing and Lunpublcized process in vehicle manutactur- ing. Since spare paris manuals and lists are complied on a numerical basis, the individual vehicle numbers are essential to correctly Identity the component required. Vehicle Identification Number (VIN). This very important identification number Js stamped on a plate attached to the dash- board inside the windshield on the driver's, ‘Side ofthe vahicle (see illustration). The VIN ‘also appears on the Vehicle Certficate of Tite ‘and Registration. It contains information such ‘as whore and when the vehicle was manufac tured, the model year and the body style, Manufacturer's Certification Regulation label “The Manufactures Certfcaton Regule- tion label isaac tothe driver's side door ‘ond or post (se Iilustration). The label con tain the name of te manufacturer, the month Buying parts Location of the Manufacturer's Certification Regulation label, land year of production, the Gross Vehicla Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) anc the certification statement VIN model year code Counting from the lef, the model year code leter designation isthe 10m characer Gn all models covered by this manual the model year codes are 2001 2002 2003 2008 2008; 2006 2007 Engine number On four-cylinder models, the engine identification number Is stemped into @ machined pad onthe forse ofthe engine Under the exhaust manio Location of the engine identification number - V6 engine ‘The Vehicle Identification Number (VIN) Is visible through the driver's side of the windshield ‘On VE models, the engine identification ‘number is stamped into a machined pad om the right ond (driver's side) ofthe engine block (see illustration). Replacement parts are available from ‘many sources, which generally fal into one of ‘wo categories - authorized dealer parts Merial er Ot pu under ena. fos encom e Engine lopes while Idling or idles erratically 8 oo 3 re Engine misses at idle speed. 9 a “te ee ene Engine misses roughout svg speed ange 40s ait rerteaste Engine sues on azzalraon ; Hee toreea = Engine surges while holding accelerator steady. 2 . 7 eee 12. Transae ft town of hs bud sel ee 13 Generel shit mechanism protims "re tm ary. iy a vin Engine baste NM eee a Pinging or knocking engine sounds during acceleration _—— . hil estat rr ign neh i osu ion, See care se Engine esos contnues oun) tr swiching ot 78 Shudder or vibration during acceleration. 37 Engine electrical systems Vibration at highway speeds. 88 Bao wil rot holé a crag nnn 19 ‘Alternator light fils to go out 20, Brakes, ‘Alternator light fils to come on when Key i tumed on. 21 Vehicle pulls to one side during braking 8 Nolse tightened squeal hen te res are apc) ® Fuot system Brake roughness chat (peal pulses) 5 cana oan 2a let pada oe utes so hi ® Fut oakage andlor fl oor 2 Excessive bake pedal evel : S Dragaing brakes et Cooling system ‘Grabbing or uneven braking action ws cS Overeating ee 24 Broke peda fos spongy when depressed 6 Orevoata ~remrmmmnewnen'" 35 Brake pod raves tote floor th ite resistance & Extra conor eakege 28 Parking brakodoos noth ifoma cretat ookage ae ‘Comets sswnvenssrswvns 93 Suspension and steering systems. Poor coatnt Stan 28 Vehicle pulls io one side Pe Abnormal or excessive te wos 70 Clutch ‘Wheel makes a thumping noise n Pedal waves o floor pressure or very tte resstenes..-. $0. Shimmy, shake of virton 2 Fn wos ant oacr int over and nods 34 Hers 5 hid on eease eying SUSE $2 Poorretumabiy of sowing to oni m4 Peco pngy we nosso $3 Abnormal nase at tha rn ons 1 Unable select gears. 34 Wand or poor steering sai % Cc ips (engine speed increases win noose a Eat storing whon aig ” vehicle speed. Menewmine 98 Exess ping andor rotng aoind comers or Grabing (cating) os Gch is engaged cvs 38 ing braking aichennse 7 Transat rating (long) 57 Suspension botoms 3 Noise mich area 88 CUpped Wes nnn &0 Cth pedal tyson foo. = 39 Excoeave re weer en eulskoedge 81 High pal efor == 42) _Excosive tr weer onside 90. : @ Te wad worn oe place. Sens Manual transaxle Excessive play or looseness in steering system “ 84 Koctng ris tow speeds. 441. Rating or eleking noise in rack and pion Es 0-20 Troubleshooting ‘This section provides an easy reference guide to the more common problems which ay oceur during the operation of your vehi- ‘le. These problems and thelr possible causes are grouped under headings denoting various. ‘components or systems, such as Engine Cooling system, etc. They also refer you to the chapter andlor section which deals with the problem, Remember that successful troubleshoot. ing is not a mysterious black art practiced only by professional mechanics. It is simply the result ofthe right knowledge combined with ‘an intelligent, systematic approach to the problem. Always work by a process of ellmi= ‘nation, starting wit the simplest solution and ‘working through to the most complex = and Never overtook the obvious. Anyone can run the gas tank dry or faave the lights on over- night, so don't assume that you are exempt ‘rom such oversights, Finally, aways establish a clear idea of ‘why a problem has occurred and take steps to ‘ensure that it doesn’t happen again. if the ‘electrical system fails because of @ poor con- nection, check the other connections in the ‘system to make sure that they don't fal as. ‘well. particular fuse continues to bow, tind ‘Out why - don't just replace one fuse after another. Remember, faire ofa small compo~ ‘nent can often be indicative of potential fallure fr incorrect functioning of a more important ‘component or system. Engine 1 Engine will not rotate when attempting to start 1. Battery terminal connections loose or ‘corroded (Chapter 1) 2 Battery discharged or faulty (Chapters 1 ‘and 5). 3 Automatic transaxle not completely ‘engaged in Park (Chapter 7) or clutch pede! ‘not completely depressed (Chapter 6). 4 Broken, loose or disconnected wiring In the starting crit (Chapters 5 and 12). '5 Starr motor pinion jammed in fywhee! sing gear (Chapter 5), 6 Starter solenoid fauity (Chapter 5). 7. Starter motor faulty (Chapter 5). 8 Ignition switch faulty (Chapter 12) 9. Starter pinion or flywheel teeth worn oF broken (Chapter 5). 2 Engine rotates but will not start 4 Fuel tank empty. 2 Battery discharged (engine rotates slowiy) (Chapter 5). 3. Ballery terminal connections loose or ‘corroded (Chapter 1), 4 Leaking fue injctrs, faut fl pump, pressure regulator, etc. (Chapter 4). 5° Broken or srppad timing belt (Chay ‘ter 2A) or broken timing chain (Chapter 2B). 6 Ignition components damp or camagee (Chepier 5). 7 Wor, faulty or incorecty gapped spark plugs (Chapter 1). fb Broken loose or cisconnected wiring in the starting circuit (Chapter 5). 6 Broken loge or daconnectd wires at tho non coo fay ca (Chapter) 10 Defective ernkshat or camshat sensor (Chepter6 3 Engine hard to start when cold 4. Battery discharged or low (Chapter 1). 2 Malfunctioning fuel system (Chapter 4), 3. Faulty coolant temperature sensor or intake air torperature sensor (Chapter 6). 4 Faulty ignton system (Chapter 5). 4 Engine hard to start when hot 1. Airfiter clogged (Chapter 1) 2 Fuol not reaching tho fuel injection syé tom (Chapter 4). 3. Corroded battery connections, especially ‘ground (Chapter 1). ‘4 Faully coolant temperature sensor or Intake air temperature sensor (Chapter 6). 5 Starter motor noisy or excessively rough in engagement 1. Pinion er flywheat oF broken (Chapter 5). 2. Siarter motor mounting bolls loose or missing (Chapter 5). 3 teeth worn oF 6 Engine starts but stops immediately 1 Loose or faulty electrical connections at Ignition coll or aerator (Chapter 5). 2 Insufficient fuel reaching the fuel injectors) (Chapters 1 and 4). 3 Vacuum loak at tho gasket between the intake manifold’pienum and throttle body (Chapter 4), 7 Olt puddle under engine 1 Oil pan gasket andior oll pan drain bolt ‘washer leaking (Chapter 2). 2 Oli pressure sending unit leaking (Chas t0r2) 3. Valve cover toaking (Chapter 2) 4 Engine oil seals leaking (Chapter 2). {8 Oil pump housing leaking (Chapter 2). 8 Engine lopes while idling or idles rratically \Vacuum leakage (Chapters 2 and 4) Leaking EGR valve (Chapter 6). Air fiter clogged (Chapter 1). Malfunction in the fuel injection or engine control system (Chapters 4 and 8). 5 Leaking head gasket (Chapter 2) 8 Timing belt or chain andlor sprockets, wom (Chapter 2), 7 Camshaft loves wor (Chapter 2). 9 Engine misses at idle speed 1. Spark plugs wom or not gapped propery (Chapter 1) 2. Faulty spark plug wires (Chapter 1), 3. Vacuum leaks (Chapter 1) 4 Incorrect igntion timing (Chapter 1). 5 Uneven or low compression (Chapter 2). Problem with the fuel injection system (Chapter 4), 10 Engine misses throughout driving speed range 1. _ Fuel fiter clogged andior impurities in the fuel system (Chapters 1 and 4) 2 Low fuel pressure (Chapter 4). 3. Faulty or incorrectly gapped spark plugs. (Chapter 1), 4 Leaking spark plug wires (Chapters 1 or8). 5. Faully emission system components, (Chapter 6), 6 Low of uneven cylinder compression Dressures (Chapter 2). 7 _Weak or fauity ignition system (Chap- ter), 8 Vacuum leak in fuel injection system, Intake manifold, air control valve or vacuum hoses (Chapters 4 and 6). ‘11 Engine stumbles on acceleration 1 Spark pugs fouled (Chapter 1) 2. Problem with fel injection or engine contol systom (Chaptars 4 ana 8), 3° Fuel fer clogged (Chapters 1 and 4). 4 Intake manfole air leak (Chapters 2 ane 4) 3" Problem win the emissions contol sys- tem (Chapter 6). 12. Engine surges while holding accelerator steady 1 Intake air leak (Chapter 4). 2. Fuel pump or fual pressure regulator fauity (Chapter 4), Troubleshooting 0-21 '3.__Problem with the fuel injection system (Chapter 4), 4° Problem withthe emissions control sys- tern (Chapter 6) 13. Engine stalls 4. Idle speed incorrect (Chapter 1). 2 Fuel filter clogged andlor water and impurities in the fuel system (Chapters 1 ‘and 4). 3. Distributor components damp or dam- ‘aged (Chapter 5). 4 Faully emissions system components (Chapter 6). ‘5. Faulty or incorectly gapped spark plugs (Chapter 1). 8 Faulty epark plug wires (Chapter 1) T__Vacuum leak in the fuel injection system, ‘intake manifold or vacuum hoses (Chapters 2 ‘and 4), 14 Engine lacks power 1 Obsiracte exhaust systom (Chapter 4). 2 Detective spark plug wires or faulty coil {(Chapirs 1 end 8) ‘3 Fauly or incorectly gapped spark plugs (Chapter 1). 4." Problem with the fuel injection system (Chapter 4). 5 Plugged air fiter (Chapter 1). Brakes binding (Chapter 9) 7. Automat transaxle Mud lvel incorrect (Chapter 1). 8 Cuth sipping (Chapter 8, 9 Fuel fiter clogged andor impurities in the fuel system (Chapters 1 ard 4). 10 Emission convel system not functioning property (Chapter 6). 11” Low or uneven cylinder compression ‘Pressures (Chapter 2) 15. Engine backfires 1." Emission control system net functioning ‘rope (Chapter 6). 2. Problem with the fuel injection system (Chapter 4) 3 Vacuum leak at fue! injectors), intake ‘manifold, ar control valve or vacuum hoses (Chapters 2 and 4). 4. Valve clearances incorrectly set andlor valves sticking (Chapter 2) 16 Pinging or knocking engine sounds during acceleration or uphill 1 Incorrect grade of uel 2 Fuel injection system fauty (Chapter 4). 3 Improper or damaged spark plugs or Wires (Chapter 1). 4 Knook sonsor defective (Chapter 8). 5 EGR valve not functioning (Chapter 8) 6 Vacuum leak (Chapters 2 and 4). 17 Engine runs with oil pressure light on 1 Low oi level (Chapter 1). 2 Idle rpm below specification (Chapter 1) 3 Shortin wiring circuit (Chapter 12) 4 Faulty ol pressure sender (Chapter 2). 5. Wom engine bearings andior oll pump (Chapter 2) 18 Engine diesels (continues to run) after switching off 1. Idle speed too high (Chapter 1). 2. Excessive engine operating temperature (Chapter 3). Engine electrical systems 19. Battery will not hold a charge 1. Alternator drivebelt defective or not adjusted properly (Chapter 1). 2 Battery electrolyte love! low (Chapter 1). 3. Battery terminals loose or corroded (Chapter 1) 4° Alternator not charging properly (Chap- ter). 5 Loose, broken or faulty wiring in the charging crcult (Chapter 5). ©. Shortin vehicie wiring (Chapter 12). 7 Internally defective battery (Chapters 1 ‘and 5) 20. Aiternator light fails to go out 1. Faulty altemator or charging circuit (Chapter 5) 2. Altemator drivebelt defective or out of adjustment (Chapter 1) 3 Alternator voltage regulator inoperative (Chapter 5). 21 Altemator light falls to come on when key is turned on 1 Warning light bulb defective (Chay ter 12). 2. Faultin the printed circu, dash wiring or bulb holder (Chapter 12) Fuel system 22. Excessive fuel consumption 1 _ Dirty or clogged air fiter element (Chap- ter 1). 2 Emissions system not functioning prop- ‘ery (Chapter 6). 3 Fuel injection system not functioning propery (Chapter 4) 4 Low tre pressure or incorrect tre size (Chapter 1), 23, Fuel leakage and/or fuel odor 4. Leaking fuel feed or return line (Chap- tars t and 4). 2. Tank overfled, 3. Evaporative canister filter clogged (Chapters 1 and 6) 4 Problom with the fuel injestion system’ (Chapter 4). Cooling system 24 Overheating 4 Insufficient coolant in system (Chap- tert, | 2 Water pump drvebelt defective or out of adjustment (Chapter 1). 3. Radiator core blocked orgie reticted (Chapter 3). 4 Thermostat faulty (Gnaptr 3) 5 _ Electric coolant fan inoperative or blades broken (Chapter 3) 8 Expansion tank cap not maintaining proper pressure (Chapter 3). 28 Overcooling 1. Fauity thermostat (Chapter 3) 2 Inaccurate temperature gauge sending unit (Chapter 3). 28. External coolant leakage 1. Deteriorated/damaged hoses; loose clamps (Chapters 1 and 3) 2 Water pump defective (Chapter 3). 3-_Leskage from radiator core or coolant reservoir (Chapter 3), 4 Engine drain of water jacket core plugs leaking (Chapter 2). 27 Internal coolant leakage 1. Leaking cytinds ter2), hes gasket (Chap- 0-22 Troubleshooting 2 Cracked cylinder bore or cylinder head (Chapter 2), 28 Coolant loss 4. Too much coolant in reservoir (Chap- ter), 2 Coolant boiling away because of over- heating (Chapter 3). 3 Inlemal or extemal leakage (Chapter 3). 4 Faulty radiator cap (Chapter 2). 29 Poor coolant circulation 1 Inoperative water pump (Chapter 3). 2 _ Restriction in cooling system (Chap- ters 1 and 3). 3. Water pump drivabelt defective/out of ‘adjustment (Chapier 1). 4 Thermostat sticking (Chapter 3) Clutch 30 Pedal travels to floor - no pressure or very little resistance 4+ Mastor of release tera) 2 Hoseippe burst or oakng (Chapter 8) 3° Connections leaking (Chapter 8). 4 Nota in reservar (Chapter 8) 5 Hud level nreservor ses as pedal Sepressec, maser cinder certar val se isfauty (Chapor 8). 6 thors id on dust sal at master c- indo, piston primary ssa esking (Chapter 8). 7 Broken release bearing or fork (Chap- tora) 8. Fay prossue plate daphrogm spring (Chapter 8) fer faulty (Chap- 31 Fluid in area of master cylinder dust cover and on pedal Rear seal failu (Chapter 8). In master oylinder 32. Fluid on release cylinder Release cylinder plunger seal faulty (Chapter 8). 33. Pedal feels spongy when depressed Airin system (Chapter 8). 34 Unable to select gears. 1. Fauty wansaxle (Chapter 7). 2. Faully cluteh dise or pressure plate (Chapter 8) 3. Faulty release lover or rolesse bearing (Chapter 8) 4. Faulty shift lover assembly or control cables (Chapter 8), 35 Clutch slips (engine speed Increases with no increase in vehicle speed) 1. Clutch plate worn (Chapter 8) 2 _Chitch plate is il soaked by leaking rear ‘main seal (Chapters 2 and 8) 3° Clutch plato not seated (Chaptor 8). 4 Warped pressure plate or flywheel (Chapter 8). 5 Weak diaphragm springs (Chapter 8) 8 Clutch plate overheated. Allow to cool, 36 Grabbing (chattering) as clutch is engaged 4. Oil on clutch plate fining, burned or glazed facings (Chapter 8). 2 Worn or loose engine or transaxle ‘mounts (Chapter 2), 3 Wom splines on clutch plate hub (Chap- ter8), 4 Warped pressure plate or flywheel (Chapter 8). ‘5 Bumed or smeared resin on fywheo! or pressure pate (Chapter 8) 37 Transaxle rattling (clicking) 1. Release lever loose (Chapter 8). 2 Clutch plate damper spring failure (Chap- ter) 41. Fork shaft improperly instaled (Chap ter8) 2 Faulty bearing (Chapter 8). 39° Clutch pedal stays on floor 4. Clutch master cyinder piston binding in ‘bore (Chapter 8), 2. Bioken release bearing or fork (Chap- ter8) 40. High pedal effort 41 Piston binding in bore (Chapter 8), 2 Pressure plate fauity (Chapter 8) 3 Incorrect size master or release eylinds (Chapter 8). Manual transaxle 41. Knocking noise at low speeds 4. Wom driveaxle constant velocity (CV joints (Chapter 8). 2 Wom side gear shaft counterbore in dif ‘erential case (Chapter 7A)” 42. Noise most pronounced when turning Differential gear noise (Chapter 7A) * 43 Clunk on acceleration or deceleration 1. Loose engine or transaxle mount (Chapter 2, 2. Wom cifferential pinion shaft in case" 3. Wom side gear shaft counterbore in if ‘erential case (Chapter 7A)* 4 Wom or damaged driveaxie inboard C\ joints (Chapter 8), 44 Clicking noise in turns Worn oF damaged outbeard CV join (Chapter 8). 45. Vibration Rough wheel bearing (Chapter 10). Damaged driveaxlo (Chapior 8). (ut-ofround tres (Chapter 1). ‘Tire out of balance (Chapters 1 and 10) ‘Wor CV joint (Chapter 8), 46 Noisy in neutral with engine running 1. _Damaged input gear bearing (Chap ter 7A)" 2 Damaged cutch release bearing (Chap tere) 47 Noisy in one particular gear 1 Damaged or worn constant mesh gear (Chapter 7A) 2 Damaged or worn synchronizers (Chat ter7A)* Troubleshooting 0-23 3 Bent reverse fork (Chapter 4 Damaged fourth speed (gear (Chapter 7A)” 5 Wom or damaged reverse idler gear or idler bushing (Chapter 7A).* 48, Noisy in all gears, {Insufficient lubricant (Chepter 7A. 2 Damaged or worn bearings (Chap- ter7A). 3. Wom or damaged input gear shaft and ‘or output gear shaft (Chapter 7A)” 49 Slips out of gear 1__Wom or improperly adjusted linkage (Chapter 74). 2 Transaxle loose on engine (Chapter 7A). 3. Shift inkage does not work freely, binds (Chapter 7A). 4 Input gear bearing retainer broken or loose (Chapter 7A).* 5 Dirt between clutch cover and engine housing (Chapter 7A) 6 Worm shit fork (Chapter 7A)” 50. Leaks lubricant 41. Side gear shaft seals wom (Chapter 7). 2 Excessive amount of lubricant in transaxle (Chapters 1 and 7A) 3. Loose or broken input gear shat bearing ‘ota (Chapter 7A)" ‘4 Input gear bearing retainer Oxing andor lip seal demaged (Chapter 7A).* 51 Locked In gear Lock pin or interlock pin missing (Chap ter 7A)" * Although the corectve action necessary to remedy the symptoms described Is beyond the scope of tis manual, the above informe tion shouldbe hep in oan the cause of ‘he concition #8 that the owner can commu. cate clearly witha profesional mechanic. ‘Automatic transaxle ‘Note: Due to the complexity of the automatic transaxe, is dffcut for the home mechanic to property dagnose and service this compo- ‘nent. For problems other than the following, the vehicle should be\teken to a dealer or transmission shop. ‘52. Fluld leakage 1. Automatic transaxle fuid is a doop red color. Fluid leaks should not be confused with ‘engine ol, which can easily be blown onto th transaxle by airflow. 2 To pinpoint a leak, frst retnove all bull. Up dirt and grime from the transaxle housing with degreasing agents andor steam clean- Ing. Then drive the vehicle at low speeds so air Tow will not blow the leak far trom its source, Raise the vehicle and determine where the leak is coming from. Common ‘areas of leakage are: 4) Dipstck tube (Chapters 1 and 7) ) Transaxle oll ines (Chapter 7 €). Speed sensor (Chepter 6 ©) Driveaxie ol seals (Chapter 7). 53. Transaxle fluid brown or has @ burned smelt ‘Transaxie fui overheated (Chapter 1), ‘54 General shift mechanism problems 1. Chapter 7, Part B, deals with checking ‘ang adjusting the shift linkage on automatic transaxles, Common problems which may be atinbuted to poorty adjusted linkage are: 48) Engine starting in gears other than Park ‘or Neutra. ») Indicator on shitér pointing to @ goar ‘other than the one actualy being used. ©) Vehicle moves when In Park. 2. Refer to Chapter 78 forthe shit inkage adjustment procedure. 55 Transaxle slips, shifts roughly, is noisy or has no drive in forward or reverse gears ‘There are many probable causes for the above problems, but the home mechanic ‘should be concerned with only one possibilty = flud lovel. Before taking the vehicle to 2 repair shop, check the level and condition of the fluid 26 described in Chapter 1. Correct the fui level as necessary or change the uid and fter if needed. f the problem persists, hhave @ professional diagnose the cause. Driveaxtes ‘36. Clicking noise in turns Wom or damaged oulboard CV joint (Chapter). 57 Shudder or vibration during acceleration 1. Excessive tein (Chapter 10). 2. Wom or damaged inboard or outboard (CV joints (Chapter 8). 3 Sticking inboard CV joint assembly (Chapter 8). 58. Vibration at highway speeds 1. OutoFbalance front wheele andior tres (Chapters 1 and 10), 2 Out-of-ound front tes (Chapters 4 ‘and 10). 3. Wom GV joints) (Chepter 6) Brakes Note: Before assuming that @ brake problem exists, make sure that: 4) The thes are in good condition and prop ‘ny inflated (Chapter 1). ). The frontend alignment is correct. ©) The vehicle fs not loaded with weight fn ‘an unequel manner. 59. Vehicle pulls to one side during braking 4. Incorrect tre pressures (Chapter 1). 2 _ Front end out of alignment (nave the front and aligned), 3. Front, or rear, the sizes not matched to ‘one another. 4 Restricted brake lines or hoses (Chap- ter), 5 Maltunctioning drum brake or caliper assembly (Chapter 9). 8 Loose suspension parts (Chapter 10). 7 Excessive wear of brake shoe or pad ‘material or discidrum on one side (Chap- ter) 8 Contamination (grease or brake fluid) of brake shoe or pad material or disc/drum on ‘one side (Chapter 9). 60 Noise (high-pitched squeal when the brakes are applied) Front brake pads worn out, Replace eds with new ones immediately (Chapter 9). 61 Brake roughness or chatter (pedal pulsates) 1 Excessive lateral runout (Chapter 8) 2 Uneven pad wear (Chapter). 3 Defective cise (Chaptr 9) 0-24 Troubleshooting 62 Excessive brake pedal effort required to stop vehicle 1. Malfunctioning power brake booster (Chepter 9), 2. Partal system failure (Chapter 9) 3... Excessively worn pads or shoes (Chap- ter). 4 Piston in caliper or wheel oyinder stuck ‘or sluggish (Chapter 9). 5 Brake pads or shoes contaminated with dl or grease (Chapter 9). 6 Brake disc grooved andlor glazed (Chap- ter 9), 7 New pads or shoes installed and not yet ‘sated, it wil take a while for the new material to seat against the disc or drum, 63 Excessive brake pedal travel 1. Partial brake system failure (Chapter 9) 2 cient ud in master cinder (Chap- tors 1 and 9). 3 Airtrapped in system (Chapter 8). 64 Dragging brakes 1 ncorrect adjustment of brake light switch (Chepter 9) 2 Master cylinder pistons not rturing cor- really (Chapter 9) 3 Restricted brakes lines or hoses (Chap- ter). 4 Incorrect parking brake adjustment (Chapter 9), 65 Grabbing or uneven braking action 1. Matfunction of proportioning valve (Chap- tor), 2 Binding brake pedal mechanism (Chap- ter), ‘3 Contaminated brake linings (Chapter 9). 66 Brake pedal feels spongy when depressed 1. Airin hydraullc lines (Chapter 9). 2 Master cylinder mounting bolts loose (Chapter), 3. Master cylinder defecie (Chapter 8) 67 Brake pedal travels to the floor with little resistance 1. _Litle of no fluid in the master cylinder reservoir caused by leaking caliper or wheel cylinder piston(s) (Chapter 9) 2 Loose, damaged or disconnected brake lines (Chapter 9) 68. Parking brake does not hold Parking brake linkage Improperly adjusted (Chapter 9), ‘Suspension and steering systems rims and tose andlor rough wie! bear- ings. Vehicle pulls to one side 1. Mismatched or uneven ‘tes (Chap- t0F 10). 2. Broken or sagging springs (Chapter 10). 3 4 Front brake dragging (Chapter 8) 70 Abnormal or excessive tire wear Whee! alignment out-t-spectcation. fave the whoo's aligned, Sagging or broken springs (Chapter 10) Tire out-of balance (Chapter 10). = Wir strut damper (Chapter 10) Overloaded vehi, Tires not rotated regularly. 1 Wheel makes a thumping noise 41. Blister or bump on tire (Chapter 10), 2. Improper strut damper action (Chap- 410). 72 Shimmy, shake or vibration 1. Tire or wheel out-of-balance or out-of- round (Chapter 10), 2. Loose or wom wheel bearings (Chap- tor 10) 3. Worn tie-od ends (Chapter 10) 4 Worm baljoints (Chapters 1 end 10). 5 Excessive wheel runout (Chapter 10), 6 Blister or bump on re (Chapter 10). 73. Hard steering 1. Lack of lubrication at Ballots andor tie- rod ends (Chapter 10), 2 Wheel alignment out-of-specifcations. Have the wheels professionally aligned. 3 Low tre pressure(s) (Chapter 1), 4 Wom steering gear (Chapter 10) 74 Poor retumability of steering to center 1. Lack of lubrication at baljoints and tie- ‘od ends (Chaptor 10) 2. Binding in baljoins (Chapter 10), 3. Binding in steering column (Chapter 10) 4 Lack lubricantin steering gear assem- Dy (Chapter 10). 5 Wheel alignment out-of-specitictions.. Have the wheels professionally aligned 75. Abnormal noise at the front end 1. Lack of lubrication at baljoints and tie- rod ends (Chapters 1 and 10). 4 Loose stabilizer bar (Chapter 10). 5 Loose wheel nuts (Chapter 1). 5 Loose suspension bolts (Chapter 10). 76 Wander or poor steering stability 4 Mismatched or uneven tres (Chay te 10). Lack of lubrication at balljoints and tie- {od ends (Chapters 1 and 10). 3. Wom strut assemblies (Chapter 10), 4 Loose stabilizer bar (Chapter 10). ‘5- Broken or sagging springs (Chapter 10). 8 Wheels out of alignment. Have the 41. Wheel bearings wom (Chapter 10). 2. Broken or sagging springs (Chapter 10). 3 Leaking whee! ytinder or caliper (Chep- ter 10). ‘Warped rotors or drums (Chapter 10), 78 Excessive pitching and/or rolling found comers or during braking 1. Loose stabitzer bar (Chapter 10) 2 ee an enn, ter 3 Broken or sagging springs (Chapter 10). 4 Overloaded venice, 79. Suspension bottoms 1. Overloaded vehicle 2. Sagging springs (Chapter 10) Troubleshooting 0-25 80 Cupped tires 1. _ Front wheel or rear wheel alignment out- cf-speciications. Have the wheels profession- ally aligned. 2. Wom strut dampers or shock absorbers (Chapter 10). 3 Wheel Bearings worn (Chapter 10) 4 Excessive tire of wheel runout (Chap- ter 10). 5 Worn baljoints (Chapter 10) 81 Excessive tire wear on outside edge Inflation prassures incorrect (Chapter 1) Excessive speed in tums. Wheel alignment incorrect (excessive toe-in). Have professionally aligned. 4 Suspension arm bent or twisted (Chap ter 10) 82. Excessive tire wear on inside edge 1 Inflation pressures incorrect (Chapter 1). 2 Wheel alignment incorrect (toe-out). Have professionally aligned, 3 Loose or damaged steering components (Chapter 10). 83 Tire tread worn in one place 1. Tires out-ofbalance. 2 Damaged or buckled wheal. Inspect and replace f necessary. 3 Defective tire (Chapter 1) 84. Excessive play or looseness in steering system 4, Whee! bearing(s) worn (Chapter 10). 2 Tle-od end loose (Chapter 10) 3 Steoring gear loose (Chapter 10). 4 Wom or loose steering Intermediate shaft Ujoint (Chapter 10). 85. Rattling or clicking no! steering gear 4. Steering gear loose (Chapter 10), 2 Steering gear defecve. 1-1 Chapter 1 Tune-up and routine maintenance Contents Ait fter check and replacement. Maintenance schedule, ‘Automatic transaxle uid change, Manual transayl lubricant change. Battery check, maintenance and baring ‘8 Manval transaxle lubricant level check. Brake check... 13 Postive Crankcaso Ventlation (PCV) vaive Brake fid change. 23 replacement (2004 and earlier four-cyinder MOdOIS) eros 29 Cooling system check 9 Seatbelt check. 4 Cooling system servicing (draining, using and erg. 22 Spark plug check and replacement cc ucciwsonwnenoe 30 Differential lubricant change (4WD models). i 27 Spark plug wire check Driveasla boot chack i $2 _,andepiacament 2004 and err fourier engines)... 32 Drivabelt check and replacement .uigucmsnmnsrnewinams 24 Stgering and suspension check. 14 Engine oll and fter change. 6 Tie and tire pressure checks. =e ages 8 Exhaust system check... 20 Treratation % 10 Fld level checks. 4 Transfer case lubricant change (4WD model) 28 Fuel ter replacement. 21 Transfer case lubricant level check. 7 Fuel system check... 15. Tune-up general information .. 3 Ignition col check (V6 engines and 2005 and Underhood hose check and replacement... ate: fount ena. ae 31 Windshield wiper blade inspection and replacement... Introduction oe ng Specifications Recommended lubricants and fluids Note: Listed nere are manurfecturer recommendations at the time this manual was wnilen. Manufacturers occasionally upgrade thelr Muid and lubri- ‘ant specifications, so check with your local auto parts store for curant recommendations. Engine of AP\ "catfied for gasolin ‘SAE 5W-20 Unleaded gasoline, 87 octane eer SLIILINIIND MERCON® automatic transmission fuld, Caution: Do not uso Mercon® V or duel usage Mercon®/Mercon® V automatic transmission | ngines* fui Manual transane lubricantweesnininnnininsnnmnsnininimunise — SAB TEW-90 gear ol Transfer case (4WD models) ‘With automatic transaxe.... ‘SAE 75W-140 'SAE 80W.90 Premium Rear Axe Lubricant ‘SAE 80W.90 Promium Rear Axle Lubricant With manual transaxte Rear diferent lubricant (4 Brake fd. DOTS broke uid ‘lutoh fid Sarees "DOTS brake tus | Engine cooiant™ i E ‘50/50 mixture of Motorerat Premium Engine Coolant (green colored) ‘or Motererat Premium Gold Engine Coolant (yellow colored) and disilled water Power steering sy8t MERCON® automatic vansmission Tuid “Cautlon: Donat mix coolants of fern colar. Dang 0 might damage th col ystom andthe ongre. The manufacturer species other a green colored coolant ora yellow colored coolant to be used n these systems, depanding on what was originally installed inthe vohicie. 1-2 Chapter 1 Tune-up and routine maintenance Capacities Engine ol (nicking fier) Four-yiinder engine. sammeanam 4.5 ats (4.25 ters) 6 engine 2004 and earlier models : sonom 5:8 a (6.2 ters) 2008 and later models a 6.0 als (67 Hers) Cootant Four-ylinder engine Up 107.0 ats (6.8 ters) V6 engine.
  • Expels Water 22.40 With the thermostat removed, disconnect the Upper radiator hose and ‘lush the radiator and engine block with @ garden hose 22.5 On the V6 engine, remove the engine block drain plugs from both sides of the engine Garden Hose block to drain (see illustration). 6 While the coolant is draining, check the condition ofthe radiator hoses, hator hoses ‘and clamps (refer to Section 9 f necessary). Replace any damaged clamps or hoses. 7 Reinstall the block drain plugs and tighton them securely. Flushing 8 Once he system has completely drained, remove the thermestat housing from engine (see Chapter), then reinstall the housing without the thermestat This wl alow the system to be toraughly fused 8° Disconnect the upper hose from the ed ator 40. Place a garden hose In the upper raia- tor inlet and fush the system uni the water runs clear at the upper radiator hose (see istration). 11 Severe cases of racator contamination of cogging wil require removing the radiator (Gee Chapter 3) and reverse fushing it This involves inserting the Hose in the bottom radi- ator outlet fo allow the clean water to run ‘against the normal flow, draining out through the top. A radiator repair shop should be con- sulted if turther cleaning or repair is neces- sary 12. When the coolant is regularly drained ‘and the system refled with the correct cool- ant mixture there should be no need to employ chemical claaners or descalers. Refilling 48 Close and tighten the radiator cain, ‘4 Place the heater temperature contol in the maximum heal postion 45 _ Slowly add new coolant (a 0/50 mbdure of water and antireeze) to the expansion tank tnt the levels atthe COLD FULL mark on the expansion tank 46 Leave the expansion tank cap off ang tun the engine in a wellventiated area unt the thermostat opens (coolant wi bagi Now ing through the radiator an the upper radia Chapter 1 Tune-up and routine maintenance 1-21 oa 24.2 Remove the lower spla ‘the deivebelt {or hose will become hot) 17 Tum the engine off and let it cool. Ada ‘more cootant mixture to bring the level to the ‘COLD FULL mark on the expansion tank. 18 Squeeze the upper radiator hose to ‘expel air, then add more coolant mixture if ‘eoessary, Replace the expansion tank cap. 49 Start the engine, alow itto reach normal ‘operating temperature and check for leaks. ‘Also, set the heater and blower conto to the ‘maximum setting and check to seo that tho heater output from the air ducts is warm. This Is a good indication that all ar has bean ‘purged from the cooling system. 23. Brake fluid change (every 30,000 miles or 24 months) ‘Warning: Brake Mud can harm your eyes and damage painted surfaces, so use extreme ‘caution when handling or pouring it. Do not use brake fui that has been stanaling open (ris more than one year old. Brake fluid absorbs moisture from tho air. Excess mois- ture can cause a dangerous loss of braking offeciveness. 1. At the specified intervals, the brake fu should be drained and replaced. Since the brake uid may drip or splash when pouring I place plenty of rags around the master cyin= der to protect any surrounding painted sur- faces, 2 Bofore beginning work, purchase the Specified brake fluid (see Recommended lubricants and fluids at the beginning of this Chapter) 3. Remove the cap from the master cylin- or raservot. 4 Using @ hand suction pump or similar device, witheraw the fluid from the master cyl Inder eservorr 5 Add new fuid to the master cylinder unt Itrises tothe base of the filer neck. 6 Bleed the brake system as described in shield to gain access to ‘Chapter 9 at all four brakes until new and lncontaminated fluid is expelied from the bleeder screw: Be sure to maintain the fuid leva nthe master cylinder as you perform the bleeding process. if you alow the master cyl- Inder to run dry ir wil entr the system. 7. Refil the master cylinder with fuid and check the operation of the brakes. The pedal should feel solid when depressed, with no sponginess. Warning: Do not operate the vehicle if you are in doubt about the effective. ness ofthe brake system. 24. Drivebelt check and replacement (every 30,000 miles or 24 months) Accessory drivebelt 1 Asingle serpentine drivel is located at the front ofthe engine and pays an imporiant {ole nthe overall operation of te engine and ts components, Ous to fs funcon and mato= ‘ial make up, the bet fs prone to woar and should be periodical inspected. The serpen- the bel drives the aerator, power steering pump, water pump (oureylinder models) and fc conditioning compressor. Alhough the bat Should be inspected at the recommended interval, replacement may not be necessary formare than 100,000 miles, Check Refer flustrations 24.2 and 24.4 2 Since the crivebolt is located very dose to the right-hand side ofthe engine compart- ment, itis possible to gain bettor access by raising the front ofthe vehicle and removing the ight-hand wheel, then unboltng the lower splash shiels from the underbody (see illus tration). Be sure to support the front of the vehicle securely on jackslands 3 With the engine stopped, inspect the full length ofthe drivebelt for cracks and sepera- tion of the bett plies. It will be necessary to tur the engine (using © wrench or socket and ACCEPTABLE raeke Ruming Acros

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