wheel torque CHRYSLER CARAVAN 2005 Repair Manual

(21) Disconnect exhaust pipe from manifold (Fig.
7).
(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)
(23) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(24) Remove rear engine mount bracket. (Refer to
9 - ENGINE/ENGINE MOUNTING/REAR MOUNT -
REMOVAL)
(25) Mark flex plate to torque converter and
remove torque converter bolts.
(26) Pinch-off power steering supply hose at pump.
Remove hose from pump.
(27) Remove and set aside the power steering
pump and bracket. Do not disconnect pressure line.
(28) Lower vehicle.
(29) Remove A/C lines at compressor and cap open-
ings.
(30) Remove engine ground straps (strap at engine
right mount and at starter).
(31) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 to be installed under vehicle
(Fig. 8).
(32) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
oil pan rails (Fig. 8). Lower vehicle and position cra-
dle mounts until the engine is resting on mounts.Tighten mounts to cradle frame. This will keep
mounts from moving when removing or installing
engine and transmission.
(33) Install safety straps around the engine to cra-
dle. Tighten straps and lock.
(34) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(35) Remove engine and transmission mount bolts.
(36) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the
dolly to allow for removal around the body.
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.
(13) Connect power steering supply line to pump
and remove pinch-off pliers.
(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
9 - 14 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves and holes. All lower bearing shellsexcept
for the thrust bearing half have oil grooves and holes
(Fig. 47). Crankshaft end play is controlled by a
flanged bearing on the number three main bearing
journal.(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block
(Fig. 48).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
NOTE: If the crankshaft is sent out for machine
work, it must be balenced as an assembly with the
target ring installed.
(3) Clean crankshaft and target ring with
MOPARtbrake parts cleaner and dry with com-
pressed air to ensure that the crankshaft mating sur-
face and target ring mounting holes are free from oil
and lock patch debris.
NOTE: Always use NEW mounting screws whether
installing original or new target ring.
(4) InstallNEWmounting screws finger tight
starting with the #1 location. (Fig. 49) Make sure
engagment occurs with the shoulder of the screw and
mounting hole before starting all other screws.
(5) Torque all mounting screws with T30 torx bit
to 13 Nm (110 in-lbs) following the torque sequence.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
CAUTION: Do not get oil on the bed plate mating
surface. It will affect the ability of the sealer to seal
the bed plate to cylinder block.
Fig. 46 Crankshaft Journal Measurements - Typical
Fig. 47 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
4 - LOWER THRUST BEARING PLAIN (NO OIL HOLE OR
GROOVE)
Fig. 48 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
RSENGINE 2.4L9-39
CRANKSHAFT (Continued)

ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of four
mounts; right and a left side support the powertrain,
and a front and a rear mount control powertrain
torque. The right side mount is a hydro-type (Fig.
78), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the front engine mount through bolt
from the insulator (Fig. 79).
(3) Remove the engine front mount bolts and
remove the insulator assembly (Fig. 79).
(4) Remove the front mounting bracket from
engine, if necessary (Fig. 79).
INSTALLATION
(1) Install the front mount bracket to engine, if
removed (Fig. 79).
(2) Install the insulator mount assembly (Fig. 79).
(3) Install the front engine mount through bolt to
the insulator (Fig. 79).
(4) Lower the vehicle.
LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 79).
(6) Remove the left mount through frame rail bolt
(Fig. 80).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 81).
NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 81).
(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 80).
Fig. 78 Engine Hydro-type Mount - Right Side
1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
Fig. 79 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 54 N´m (40 ft. lbs.)
4 - MOUNT - FRONT INSULATOR
5 - BOLT - 68 N´m (50 ft. lbs.)
6 - BOLT - 68 N´m (50 ft. lbs.)
7 - FRONT CROSSMEMBER
9 - 50 ENGINE 2.4LRS

REAR COVER
(1) Install rear timing belt cover and fasteners.
Torque fasteners to specified values (Fig. 118).
CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
(2) Install camshaft sprockets. Hold sprockets with
Special Tool 6848 and tighten center bolt to 101 N´m
(75 ft. lbs.) (Fig. 116).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.) (Fig. 117).
(4) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(5) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 115).
(6) Install front covers.
TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Remove make-up air hose from cylinder head
cover.
(3) Raise vehicle on hoist.
(4) Remove right front wheel.
(5) Remove right inner splash shield.
(6) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(8) Remove air conditioner/generator belt tensioner
and pulley assembly (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL).
(9) Remove timing belt lower front cover bolts and
remove cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).
(10) Lower vehicle.
(11) Remove bolts attaching timing belt upper
front cover and remove cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT COVER(S) -
REMOVAL).
(12) Remove right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
REMOVAL).
(13) Remove engine mount bracket (Fig. 119).
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(14) Before the removal of the timing belt, rotate
crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 120).
NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(15) Loosen timing belt tensioner lock bolt (Fig.
121).
Fig. 118 Rear Timing Belt Cover Fasteners
1 - M6 BOLTS - 12 N´m (105 in. lbs.)
2 - M8 BOLTS - 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
RSENGINE 2.4L9-65
TIMING BELT COVER(S) (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/
switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
RSENGINE 3.3/3.8L9-83
ENGINE 3.3/3.8L (Continued)

CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Remove crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil seal retainer screws (Fig. 83).
(4) Remove oil seal retainer (Fig. 83).
(5) Clean engine block and retainer of oil and gas-
ket material. Make sure surfaces are clean and free
of oil.
INSTALLATION
(1) Position new gasket and install retainer on
block (Fig. 83). Tighten attaching screws to 12 N´m
(105 in. lbs.).
(2) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(3) Install oil seal (Refer to 9 - ENGINE/ENGINE
BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 84).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 84). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 85).
NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
Fig. 82 Rear Crankshaft Oil SealÐInstallation
1 - SPECIAL TOOLS:
2 - C-4171 HANDLE
3 - 6926±2 INSTALLER
4 - 6926±1 GUIDE
5 - SEAL
Fig. 83 CRANKSHAFT REAR OIL SEAL
1 - OIL SEAL
2 - BOLT
3 - RETAINER - OIL SEAL
4 - GASKET
9 - 132 ENGINE 3.3/3.8LRS
CRANKSHAFT OIL SEAL - REAR (Continued)

INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 132).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head
(Fig. 131). Install bolts to center runner (cylinder #4)
and initial tighten to 2.8 N´m (25 in. lbs.).
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 130).
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Position heat shield on manifold (Fig. 131).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N´m (105 in. lbs.) (Fig. 131).
(6) Connect battery negative cable.
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 133).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 133).
Fig. 132 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
RSENGINE 3.3/3.8L9 - 155
EXHAUST MANIFOLD - LEFT (Continued)

(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 134).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 135) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 136).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
137).
(15) Remove the engine mount bracket (Fig. 137).(16) Remove camshaft position sensor from timing
chain cover (Fig. 137).
Fig. 133 Measuring Timing Chain Wear
1 - TORQUE WRENCH
Fig. 134 OIL PICKUP TUBE
1 - BOLT
2 - OIL PICK-UP TUBE
3 - O-RING
Fig. 135 HEATER RETURN HOSE (Without Engine
Oil Cooler)
1 - CAP AND CLAMP (OIL COOLER EQUIPPED ONLY)
2 - HOSE ASSEMBLY - HEATER RETURN
3 - BOLT - HEATER TUBE ATTACHING
4 - BOLT - HEATER TUBE ATTACHING
9 - 156 ENGINE 3.3/3.8LRS
VALVE TIMING (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA
REMOVAL.............................4
INSTALLATION..........................4
REAR BUMPER REINFORCEMENT
REMOVAL.............................5
INSTALLATION..........................5
REAR FASCIA - SCUFF PAD
REMOVAL.............................5
INSTALLATION..........................5FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 6
SPECIFICATIONS - FRAME DIMENSIONS -
FOLD-IN-FLOOR SEATS ONLY...........11
SPECIFICATIONS - TORQUE............14
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER......................14
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR........14
REMOVAL.............................15
INSTALLATION.........................16
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................17
INSTALLATION.........................17
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five push pin fasteners attaching
bottom of fascia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD -
REMOVAL).(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1) and (Fig. 2).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.
(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle (Fig. 1)
and (Fig. 2).
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
RSFRAME & BUMPERS13-1

INSTALLATION
NOTE: If cradle crossmember requires replacement.
Refer to Group 2, Suspension, to transfer suspen-
sion components and Group 19, Steering, to trans-
fer steering components.
(1) Support crossmember on suitable lifting device
(Fig. 19).
(2) Position crossmember to vehicle.
(3) Loosely install bolts attaching cradle cross-
member to front frame rails.(4) Place upper half of bushing on top of cross-
member aligned to receive square tube protruding
upward from lower bushing half.
(5) Align crossmember to previously made marks
on frame rails.
(6) Tighten bolts attaching cradle crossmember to
frame rails.
(7) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 17) and tighten to
68 N´m (50 ft. lbs.) torque.
(8) Install the rear mount heat shield (Fig. 16).
(9) Connect lower ball joints to steering knuckles
(Refer to 2 - SUSPENSION/FRONT/LOWER BALL
JOINT - INSTALLATION)
(10) Connect stabilizer bar links to ends of stabi-
lizer bar.
(11) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(12) Install high pressure hose to pump.
(13) Connect return hose to metal tube.
(14) Tighten hose clamp at the cradle crossmember
coupling.
(15) Remove pinch-off pliers.
(16) Position steering so front wheels are straight
ahead.
(17) Install steering column coupling to telescoping
steering gear shaft.
(18) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(19) Install steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
INSTALLATION)
Fig. 16 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
Fig. 17 REAR MOUNT
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THROUGH BOLT
4 - REAR MOUNT
Fig. 18 CRADLE CROSSMEMBER MOUNT
1 - CROSSMEMBER MOUNT
2 - BRAKE HOSE MOUNT
3 - STEERING TIE ROD
4 - FRONT CROSSMEMBER
5 - FRAME RAIL
13 - 16 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)