Vehicle on Ground, Engine Off
UPPER AND LOWER COOLING MODULE GROMMETS, FOAM STRIP AND WIRING HARNESS (1991-1993 VEHICLES)
Refer to the cooling section in the "Engine Mechanical Service Manual" for procedures and replace the lower cooling module grommets with P/N 21030708 (two required). Make sure the new grommets are seated in the pockets of the cradle. if not. relocate the module grommets correctly in the cradle.
NOTE:
For 1992 vehicles, built after January 2, 1992, the new lower cooling fan module grommets (PIN 21030708) will be installed during production.
If the vehicle is equipped with A/C, check the upper cooling module foam strip and wiring harness along the forward side of the tie bar for correct positioning, refer to Figure. If these items are not positioned correctly, refer to the following procedures:
1. Remove the upper cooling module "L" bracket.
2. Position the lamp wiring harness forward of the foam pad.
3. Position the foam pad strip back into the cooling module slots.
NOTE:
A new cooling module upper mount "L" bracket assembly with a larger diameter hole (14mm [0.55 in.]) in the grommet is released for all vehicles built before VIN MZ123049. The new assembly, P/N 21030616 (two required) can be installed on vehicles equipped with the old type (smaller hole). Refer to the "Cooling" section of the Engine Mechanical Service Manual" for cooling module upper "L" bracket replacement procedures.
4. Check the upper cooling module grommets for binding or misalignment and freedom of movement. The cooling module retaining pins must be centered in the grommets supported by the "L" bracket(s) and the module should move from left to right, forward and rearward freely a minimum of 3.18mm (1/8 in.). If the grommets are pinched, loosen the "L" bracket(s) and reposition them. Make sure the locator tang in each "L" bracket is properly positioned in the upper tie bar slot.
5. Tighten the "L" bracket(s) fasteners. Check the cooling module for freedom of movement. it is extremely important that the cooling module be able to move freely, 3.18mm (1/8 in.) minimum.
Torque: 10 N-m (89 lbs. ft.)
DEAERATION HOSE (1991 VEHICLES)
Check the cooling system deaeration hose for contact with the front of the dash. If the deaeration hose is too long, it can be repositioned in the retaining clamps and/or shortened approximately 19 mm (3/4 in.).
AIR INLET DUCT, HOOD RELEASE CABLE AND HEADLAMP WIRING HARNESS (1991-1994 VEHICLES)
1. Check the SOHC (LKO) engine air inlet for correct alignment of arrows (Figure, View A). If arrows are not aligned, position air inlet tube and align indicator arrows at tube attachment points.
2. Check the SOHC (LKO) engine air inlet duct for interference with hood cable and headlamp harness. Adjust if necessary.
3. Check hood release cable and headlamp wiring harness at the inlet end of the air intake snorkel for interference (Figure, position "B"). Position cable and/or wiring harness if contacting the air inlet.
4. Make sure foam isolator is properly installed on the upper end of the air inlet snorkel. The small isolator prevents air inlet snorkel contact with the vehicle's upper tie bar.
A/C COMPRESSOR, SUCTION HOSE (1991-1994 VEHICLES)
Check for interference between the A/C suction hose and the corner of the battery tray (Figure, position "C"). It will be necessary to reposition the engine's wiring harness, located on the upper side of the transaxle, to allow downward movement of the A/C hose.
It may also be necessary to route the manual transaxle backup switch harness over the A/C hose to allow for downward movement of the wiring harness. The A/C suction hose must not contact the battery tray. Position the hose at the A/C compressor or front of dash as necessary to prevent contact if clearance cannot be obtained by repositioning the engine wiring harness.
A/C DISCHARGE HOSE (1991-1994 VEHICLES)
Check for interference between the A/C discharge hose, transaxle oil cooler lines (Figure, position "D"), and A/C discharge hose and front transaxle mount damper bracket (Figure, position "E" for 1991 vehicles only). The A/C discharge hose must not contact the damper bracket or transaxle cooler lines. Position the line at the condenser or compressor if necessary to prevent contact.
NOTE:
If it is necessary to move pipe ends at compressor condenser to obtain clearance, gently flex the pipe only enough to obtain minimum clearance. Over bending of hose ends will damage them and cause possible refrigerant leaks. Do not try to bend the pipe ends at the thermal expansion valve (TXV).
ACCESSORY DRIVE BELT AND PULLEYS (1991 VEHICLES)
NOTE:
Vehicles built since March 1, i991, have a new accessory drive belt and will not require inspection or belt replacement. The new accessory drive belts can be identified by a part number on the belt or by measuring the belt thickness.
Accessory Drive Belt Thickness
Old Belt - 4.3 mm +/- 0.3 mm (0.169 in. +/- 0.012 in.)
New Belt - 5.5 mm +/- 0.5 mm (0.217 in. +/- 0.019 in.)
Pulley Inspection
Vehicles built before March 1, 1991, require accessory drive belt and pulley inspection. Inspect the accessory drive pulleys, with engine off, for debris build-up in the pulley grooves. If debris exists, clean the pulley grooves with a cotter key extractor or stiff wire brush. After cleaning pulley grooves, replace the accessory drive belt with a new accessory drive belt.