Chrysler laser 1990 Technical document

SAFETY NOTICE
CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE
APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE
TRADE ONLY. All test and repair procedures on components or assemblies in
non-automotive applications should be repaired in accordance with instructions
supplied by the manufacturer of the total product.
Proper service and repair is important to the safe, reliable, operation of all motor vehicles.
The service procedures recommended and described in this publication were developed
for professional servlTe personnel and are effective methods for performing vehicle
repair. Following
these procedures will help assure efficient economical vehicle
performance and service reliability. Some of these service procedures require the use of
special tools designed for specific procedures. These special tools should be used when
recommended throughout this publication.
Special attention should be exercised when working with spring or tension loaded
fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal
may cause personal injury. Always wear safety goggles whenever working on
vehicles or vehicle components.
7
It is important to note that this publication contains various Cautions and Warnings.
These should be carefully read in order to minimize the risk of personal injury, or the
possibility that, improper service methods may damage the vehicle or render it unsafe.
It is important to note that these Cautions and Warnings cover only the situations and
procedures Chrysler Motors has encountered and recommended. Chrysler Motors could
not possibly know, evaluate, and advise the service trade of all conceivable ways that
service may *be performed, or of the possible hazards of each. Consequently, Chrysler
Motors has not undertaken any such broad service review. Accordingly, anyone who
uses a service procedure, or tool, that is not recommended in this publication, must assure
oneself thoroughly that neither personal safety, nor vehicle safety, be jeopardized by
the service methods they select.
WE SrjPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION
THROUGH

TALON
BACKUP
TECHNICAL
INFORMATION
MANUAL
FOREWORD
This manual has been prepared as an introduction to
the specifications, features, construction and func-
tions of the newly developed TALON. Please read
this manual carefully as it will be of assistance for
service and sales activities
Please note that the service manuals are also
available and should be used in conjunction with this
manual.
All information, illustrations and product descrip-
tions contained in this manual are current as at the
time of publication. We, however, reserve the right
to make changes at any time without prior notice or
obligation.
This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE
WHOLE SECTIONS.
This BACKUP was sold to you under the fact that you do indeed OWN
a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original
manual was lost or destroyed.)
Please See README.N or for additional information
Thank you. [email protected]
Chrysler Motors reserves the right to make changes in design or to
make additions to or improvements in its products without
imposing
any obligations upon itself to install them on its products PreViOUSlV
manufactured.
a *-a- .I._. .-1-L,.*
_____ #Q ^_^__ l L.-
Orintul in U.S.A.
GROUP INDEX
ROSA. - -
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
Front Suspension
................................
Rear Axle
............................................
.
Brakes - Eir$rii
. . . . . . . . . . . . . . . . . . . . . . . . . . ..s...
Clutch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling
. . . . . . :. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical
. . . . . . . . . . . . . . . . . . . . . . . . . . . ..-..................
Engine
....................................................
Intake and Exhaust
............................
Fuel System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft and Universal
. . . . . . . .
m
l
Joint
Rear Suspension
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering
l
....................................
CD
Manual
Transaxle - Automatic
....................
m
Body
....................................................
m
Heaters and Air Conditioning
........
RI
A
Emission Control Systems
............

._._ -_- 1 -.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
M/T: Indicates the manual transaxle, or models equipped ‘with the manual transaxle.
A/T: Indicates the automatic transaxle, or models equipped with the automatic transaxle.
MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection.
DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine,
Turbo:
Indicates an engine with turbocharger, or a model equipped with such an engine.
Non-Turbo:
Indicates an engine without turbocharger, or a model equipped with such an engine.
2WD: Indicates the front wheel-drive vehicles.
4WD: Indicates the 4 wheel-drive vehicles.
HOW TO READ A CIRCUIT DIAGRAM
Circuit diagrams are prepared as follows using these
symbols:
NOTE
For specific details concerning the interpretation of
circuit diagrams, refer to the separately bound
The current flow at the i nition
key positions “ACC” ”N” and
8
“ST” is shown combined.
Be sure to trace the appropriate
circuit depending on the ignition
key position.
~
Service Manual.
These symbols show the input to
and output from (direction of
current flow to and from) an
electronic control unit.
o&ficates that current flows
Input
and
1 Indicates power 1
supply connection.
Connectors
A : Female connector
9.1 Male connector
\ I l-4’
Input Output output
This symbol indicates connector
for equipment (male connector
is..
used as an intermediate connec-
tor) viewed from in front of the
Arrowindicates direction of
Connector for equip-
ment with attached har-
ness Connector inserted

GENERAL
- --- -~- -------l
O-l
CONTENTS
GENERAL DATA AND SPECIFICATIONS . . . . . . . . 13
VEHICLE IDENTIFICATION .._..................._........_ 9
TECHNICAL FEATURES
2
Engine Model Stamping
.................................... 12
....................................
Vehicle Identification Code Chart Plate
........
9
4WD (Four-wheel Drive)
........................................ 7
Vehicle Identification Number List
................ 10
PJT Safety-lock System
........................................
7
Vehicle Identification Number Location
........
9
Basic Construction
............................................
4
Vehicle Information Code Plate
........................
1 1
Engine
......................................................
.
......... 5
12
Exterior
2
Vehicle Safety Certification Label
....................
................................................................
Interior
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..__...............................
3
Theft-alarm System (Option for 4WD
Vehicles)
. . . . . . . . . . . . . . . . . . . . . . . . . .._._........_.....................
8

o-2
GENERAL - Technical Features
TECHNICAL FEATURES
ROOCAAB
EXTERIOR
Low and wide profile for appearance sports car
impression.
OOA0190 2
7
OOA0189
I
1 No. t
Features
1
Flush surface and low front high rear styling for outstanding aerodynamic performance
2
Pop up headlights of optical horn type
3
Hood bulge indicating DOHC engine
4
Futuristic glass upper body
5
Removable tilt up sunroof (option for all models)
I
f
6
Smooth integrated body lines giving a lean appearance
7
Wide tires and wide tread to emphasize power and stability
I
1
a
Bumpers made integral with the body
i
9
Wall to wall tail lamps for sporty image
I
i
--

Y
GENERAL - Technical Features o-3
INTERIOR
/
OOAO162
\
No.
Features
1 Cock pit type instrument panel to give sporty image
2 Switches arranged around the driver seat for easy access and operation
3
Hi back seats with integral head rest for comfortable and firm holding
4Integrally molded door trims with round and smooth transition to the instrument panel
,
I
5
Sporty double seat with firm holding
i
!
6
Rear quarter trims with built in dynamic speakers
!
7
Easy to use large capacity console box
I

o-4
GENERAL - Technical Features
BASIC CONSTRUCTION
The 4WD vehicles are equipped with 2.OL DOHC
16-valve turbocharged engine and incorporate new
technologies such as full time 4WD of center
differential type with viscous coupling differential
limiting for excellent running stability and excellent
Steering
l Light weight and compact rack and pinion
type for high steering response
l Tilt steering mechanism to give optimum
driving position
\
driving across bad roads, and $-wheel independent
suspension for comfortable riding.
Adopted on 2WD vehicles are 2.OL DOHC 16-valve
engine, MacPherson strut type front suspension
and torsion axle typ.e 3-link rear suspension.
Rear suspension
l Self-aligning double wishbone type suspen-
sion for comfortable ride (4WD)
l Torsion axle type 3 link suspension for
outstanding driving stability (2WD)
l Negative chamber for outstanding steer-
ability during high speed driving
0 Anti-lift geometry for high stability during
braking
l Integral torsional bar type axle beam for
optimum roll stiffness (2WD)
\
Front propeller shaft (3-piece 4-joint type)
l Robro joint to absorb lengthwise and angular
change and prevent transmission of vibrations.
(4WD)
I
Front suspension
The front suspension of McPherson strut type
independent suspension system
l Under steer geometry for outstanding steering
stability
l Negative offset geometry for outstanding stabil-
ity at braking
0 Offset coil springs for comfortable ride
Brakes
l Cross piping dual type proportioning valve
that keeps balanced braking power even at
failure of the hydraulic system.
l Four wheel disc brake system for high
braking power.

GENERAL - Technical Features o-5
ENGINE
The engines are the transverse-mounted engine
especially for front-engine/front-wheeldrive or
front-engine/4-wheel drive models, the 2.OL DOHC
16-valve engine with high-performance, silent-
operation,
low-vibration, low-noise, low-fuel-
consumption features, an engine that fully displays
the most up-todate engine technology.
SPECIFICATIONS
Engine model Displacement
cc (cu.in.1
h$xo$put (SAE net)
Max. torque (SAE net)
ft.Ibs./rpm
4G63 Non-Turbo 1997 (122)
135/6000 125/5000
4663 Turbo 1997 (122) 195/6000
203/3000
FEATURES
High performance and low fuel consumption
l The rocker arm reduces the valve-actuation torque as well as fuel consumption.
l Air-intake efficiency improved through the adoption of the optimum air-intake system layout.
l Improved response and fuel consumption has been achieved by electronic control multipoint
fuel injection.
l Water-cooled turbocharger. <Turbo>
Quiet operation
l Noise and vibration have been decreased by the adoption of roller rocker arms.
l Noise generated by the valve mechanism has been decreased by the hydraulic auto lash adjusters.
l Vibrations have been decreased by the adoption of bearing caps with beams which increase the
rigidity of the crankshaft support points.
-
Serviceability
l Complete self-diagnosis functions.
l Enhanced reliability through the adoption of gold-plated connector terminals.
l Use of an auto tensioner achieves maintenance-free, automatic adjustment of timing belt
tension.
l Use of the auto lash adjusters achieves maintenance-free, automatic adjustment of valve clearance
.o The 2coil ignition system without a distributor supplies sufficient ignition energy even during
high speed operation.

O-6
GENERAL - Technical Features
Valve mechanism
l The roller rocker arms de-
crease losses.due to friction in
the valve system.
l The auto lash adjusters elimin-
ate the need to adjust the valve
clearance.
I
Combustion chamber
The combustion chamber is pro-
vided with a squish area for high
combustion efficiency.
t
J
Ignition system
The 2coil ignition system without
a distributor supplies sufficient
ignition energy even in the high
speed operation.
76-4 Crankshaft pu!ley
The oullev orovrded with a torsion-
al da’mper ieduces the transmis-
sion of vibrations.
EN0376
Auto tensioner
The auto tensioner eliminates the
need to adjust the timing belt
tension.
]I
crankshaft has five marn bearings

GENERAL -
Technical Features o-7
4WD (Four-wheel drive)
The full time 4WD system adopts viscous coupling
unit (VCU) as the differential limiting device for the
center differential of 4WD vehicle to achieve auto-
matic and ideal distribution of engine torque to the
front and rear wheels.
r_
Engine
00P0031
Viscous coupling
Viscous coupling (VCU) VP?
limited slip differential (OptIOn)
A/T
SAFETY-LOCK SYSTEM interlock device) has been adopted to improve
JT safety-lock system (shift lock device and key
safety*FN
Key interlock device
Ignition key cylinder
Shift lock device
Selector handle
AIT control cable
Shift lock cable
~ ^.
._...

O-8
GENERAL - Technical Features
THEFT-ALARM SYSTEM (OPTION for
4WD VEHICLES)
To make the vehicle theftproof, this system is so
designed that the headlights go on and off and the
horn is sounded intermittently for ‘about three
minutes when the locked door, hood or liftgate has
been forced open without using a key.
Furthermore, the starter circuit is interrupted so that
the engine may not be operated, making the vehicle
theftproof.
About 20 seconds after all doors are closed
and locked, the rear hatch is closed, and the
hood is closed---t SYSTEM ARMED
4uthorized
I Unauthorized
A door, rf!ar hatch or hood is broken
to open + ALARM ACTIVATED
Engine is disabled to start.
a-
t
Driver opens door with the key
I
1
SYSTEM DISARMED
0 1
Normal starting-1
I
or rear hatch with the
- ALARM DEACTIVATED
(SYSTEM DISARMED)
16Y3575
/

GENERAL - Vehicle Identification
019
VEHICLE IDENTIFICATION
RooDAiA
VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number (V.I.N.) is located on a plate
attached to the left top side of the instrument panel.
VEHICLE IDENTIFICATION CODE CHART PLATE
All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
1st 2nd
Digit Digit
---l--
Country
Make
/
3rd
Digit
I
4th
Digit
I
5th
Digit
1
I-
USA E-
Eagle
Vehicle
I
Others
I
Line
tvw
3-6-
S-
Passenger Manual Talon
car
seat belt IZWDI
C- T-
Automatic Talon
seat belt
(4WD)
\
6th
Digit
Price
class
\
7th
Digit
Sody
4- 4-
High Bdoor
6- Hatch-
Premrum back
6
Special
6th
Digit 9th Digit 10th
Digit 11th
Digit
12th to
17th
Digits
Engine *Check
digits
Model
year
Plant Serial
number
R- 1 L- E- 000001
2.0 liters 1990 DSM
/;gHE.in.)
:
year
99%99
MPI]
U-
2.0 liters 1
/;gHF.in.)
MPI-Turbo] :
9
X
NOTE
l “Check digit” means a single number or letter X used to verify the accuracy of transcriptron of vehicle identification number.

r -.--
O-10
GENERAL - Vehicle Identification
VEHICLE IDENTIFICATION NUMBER LIST
VEHICLES FOR FEDERAL
V.I.N. (except sequence number)
Brand
4E3CT44RClLE Eagle TalonQWD)
Engine displacement
2.0 liter (122 cu,in.)
[DOHC-MPI]
4E3CT54UClLE
4E3CT64UOLE Eagle Talon
(4WD)
2.0 liter (122 cu.in.)
[DOHC-MPI-Turbo]
Models Code
D22AMNHML4E
D22AMRHML4E
D22AMNPFL4E
D27AMNGFL4E
VEHICLES FOR CALIFORNIA (Can also be sold in Federal States.)
1 V.I.N. (except sequence number) ( Brand
1 Engine displacement
I
Models Code
4E3CT44tKILE
Eagle Talon (2WD)
2.0 liter (122 cu.in.)
[DOHC-MPI]
4E3CT54UOLE
4E3CT64UOLE Eagle Talon
(4WD)
2.0 liter (122 cu.in.1
[DOHC-MPI-Turbo]
D22AMNHMLSE
D22AMRHMLSE
D22AMNPFLSE
D27AMNGFLSE
VEHICLES FOR CANADA
1 V.I.N. (except sequence number) 1 Brand Engine displacement
Models Code
4E3BT44ROLE
4E3BT54UOLE
4E3BT64UOLE
Eagle Talon (4WD)
2.0 liter (122 cu.in.)
[DOHC-MPI] D22AMNHML5E
D22AMRHML5E
2.0 liter (122 cu.in.)
[DOHC-MPI-Turbo]

GENERAL
- Vehicle Identification
o-11
/lb------
I OOAO164
HODEL
ENGINE
TNANS
3
coLoK E
4
OOAO163
J
VEHlCLE INFORMATION CODE PLATE
Vehicle information code plate
the engine compartment. is riveted onto the bulkhead in
The plate shows model code. engine model, transaxle model,
and body color code.
1. MODEL
SF bll~~l~~~e,
2. ENGINE 4663
I Engine model
3. TRANSAXLE
F5!Vl33
(Transaxle model
4. COLOR,
TRIM OPT
H18
) Monotone exterior
color code
BODY COLOR CODE
Exterior code
Body color
H18
Light Gray (M)
Rll
Red
R16 Dark-Red
T13
Turquoise Blue (M)
T-81 Dark Blue (M)
w12
White
x13
Black

o-12
GENERAL - Vehicle Identification
VEHICLE SAFETY CERTI,FICATION LABEL
1. The vehicle safety certification label is attached to the face
of left door pillar.
2. This label indicates the month and year of manufacture,
Gross Vehicle Weight Rating (G.V.W.R.), Gross Axle Weight
Rating (G.A.W.R.) front, rear and Vehicle identification
Number (V.I.N.).
ENGINE MODEL STAMPING
1. The engine model number is stamped at the front side on
the top edge of the cylinder block as shown in the
following.
Engine model
4663
Engine displacement
2.0 liter (122 cu.in.)
[DOHC-MPI] or [DOHC-MPI-Turbo1
2. The engine serial number is stamped near the engine
model number, and the serial number cycles, as shown
below.
Engine serial number Number cycling
AA0201 toYY9999 -
AAo201--------hAA
LAB0001 --------+ AY9999
L BAOOOl-------+ YY9999

GENERAL - General Data and Specifications
o-13
GENERAL DATA AND SPECIFICATIONS
M...
OOAO159
Items
Vehicle dimensions
mm (in.)
Overall length
1 4,330 (170.5) 4,350 (171.3) 4,380 (172.4)
Overall width
2 1,690 (66.5) 1,700 (66.9) 1,700 (66.9)
Overall height
3 1,306 (51.4) 1,306 (51.4) 1,321 (52.0)
Wheel base 42,470 (97.2) 2,470 (97.2)
2,470 (97.2)
Tread Front
5 1,465 (57.7) 1,465 (57.7) 1,465 (57.7)
Rear
6 1,450 (57.1) ‘1,450 (57.1) 1,455 (57.3)
Overhang
Front
7 950 (37.4) 960 (37.8) 960 (37.8)
Rear 8
910 (35.8) 920 (36.2) 950 (37.4)
Minimum running ground
’
clearance
9 lsO(6.3)
160 (6.3) 158 (6.2)
Angle of approach
10 16.5”
13.8” 1’4.7”
Angle of departure 11 19”
17” 18.4” .
Vehicle’weight kg (Ibs.)
Curb weights
M/T
1,215 (2,679) 1.245.(2,745) 1,245 (2,745)
Al-r 1,240 (2,734)
-
Gross vehicle weight
rating 1,620 (3,571) 1,620 (3,571) 1,782 (3,929)
Gross axle weight rating Front 930
(2.050)
930 (2,050) 979 (2,158)
Rear
690 (1,521)
690(1,521) 803 (1,770)
Seating capacity 4
4 4
Engine
Model No.
4663 (2.OL)
4663 (2.OL)
4663 (2.OL)
Transaxle
Model No.
Manual transaxle F5M22 F5M33
W5M33
Automatic transaxle F4A22
-
-
Clutch
Type
Dry-single disc &
Dry-single disc &Dry-single disc &
diaphragm spnng diaphragm spring diaphragm spring

o-14
GENERAL - General Data and Specifications
tiems
Chassis
Tire
Front suspension
Type
Rear suspension
Type
Brake
Type Front
Rear
Steering
Gear type
Gear ratio
Fuel tank
Capacity liters (gals.)
P205/55HR16 or
205l55VR 16
Independent strut
3-Link
Torsion axle
Disc
Disc
Rack and pinion
m
60 (16)
P205/55VR 16 or
205155VR16
Independent strut
3-Link
Torsion axle
Disc
Disc
Rack and pinion
00
60 (16)
P205155VR16 or
205155VR16
Independent strut
Double wishbone
Disc
Disc
Rack and pinion
co
60 (16)
ENGINE SPECIFICATIONS
Items
Type
Number of cylinders
Bore mm (in.)
Stroke
mm (in.)
Piston displacement
Compression ratio
Firing order
cm3 (cu.in.)
4G63 (2.OL) Non-Turbo
1 4663 (2.OL) Turbo
In-line DOHC
~In-line DOHC
4
‘4
85.0 (3.35) 85.0 (3.35)
88.0 (3.46)
88.0 (3.46)
1,997 (122) 1,997 (122)
9.0 7.8
l-3-4-2 l-3-4-2
TRANSAXLE SPECIFICATIONS
Items
Type
Gear ratio
Transfer ratio
gear
Final drive ratio
gear
1st
2nd
3rd
4th
5th
Reverse
F5M22 F5M33
W5M33
F4A22
5-speed M/T
5-speed M/T &speed
ArF
4-speed AiT
3.363 3.038 3.083
2.846
1.947 1.833 1.684
1.581
1.285 1.217 1.115
1 .ooo
0.939 0.888 0.833 0.686
0.756
0.741
0.666
3.083 3.166
’ 3.166 2.176
-
1.090
3.941
3.437 3.866
3.562

it?
2-1
FRONT
SUSPENSION
CONTENTS
no2&--
ANTI-DIVE GEOMETRY
....................................
5
LOWER ARM ........................................................ 7
FRONT AXLE
........................................................
8 NEGATIVE-OFFSET GEOMETRY ....................
5
Drive Shaft ........................................................
8
9
OFFSET SPRING
................................................
6
Hub andKnuckle
................................................
GENERAL INFORMATlON
2STABILIZER
............................................................
7
................................
Construction Diagram ........................................ 2
Specifications .....................................................
3

2-2
FRONT SUSPENSION - General Information
GENERAL INFORMATION
The front suspension has a simple construction, the l Excellent braking stability, thanks to the
McPherson strut type independent suspension negative-offset geometry.
t
featuring light unsprung weight. l Greatly improved riding comfort, thanks to the
The front Suspension has the following features: offset arrangement of the coil springs.
l Excellent driving stability, thanks to the
“antidive” geometry.
. CONSTRUCTION DIAGRAM
<2WD>
<4WD>
Rubber insulator
/
lshing
Coil spring
,Strut assembly
I ,Rubber bushing
Stabili
Centermember Lowecarm
Rubber insulator
Stabilizer bar
No.1 Crokmember
- -
12AOO25
Lower arm