1991−1999 Ford Explorer DIY Maintaince & Repair Manual – PDF DOWNLOAD

Description

1991−1999 Ford Explorer DIY Maintaince & Repair Manual – PDF DOWNLOAD

FILE DETAILS:

1991−1999 Ford Explorer DIY Maintaince & Repair Manual – PDF DOWNLOAD

Language : English
Pages : 1119
Downloadable : Yes
File Type : PDF
Size: 57.4 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

1991−1999 Ford Explorer DIY Maintaince & Repair Manual – PDF DOWNLOAD

Introduction:
This Chilton’s Total Car Care manual is intended to help you learn more about the inner workings of your
Ranger, Explorer or Mountaineer while saving you money on its upkeep and operation.
The beginning of the book will likely be referred to the most, since that is where you will find information for
maintenance and tune−up. The other sections deal with the more complex systems of your vehicle. Systems
(from engine through brakes) are covered to the extent that the average do−it−yourselfer can attempt. This
book will not explain such things as rebuilding a differential because the expertise required and the special
tools necessary make this uneconomical. It will, however, give you detailed instructions to help you change
your own brake pads and shoes, replace spark plugs, and perform many more jobs that can save you money
and help avoid expensive problems.
A secondary purpose of this book is a reference for owners who want to understand their vehicle and/or their
mechanics better.
Where to Begin:
Before removing any bolts, read through the entire procedure. This will give you the overall view of what
tools and supplies will be required. So read ahead and plan ahead. Each operation should be approached
logically and all procedures thoroughly understood before attempting any work.
If repair of a component is not considered practical, we tell you how to remove the part and then how to install
the new or rebuilt replacement. In this way, you at least save labor costs.

TABLE OF CONTENTS:

1991−1999 Ford Explorer DIY Maintaince & Repair Manual – PDF DOWNLOAD

Table of Contents 2
HOW TO USE THIS BOOK 19
Introduction 19
Where to Begin 19
Avoiding Trouble 19
Maintenance or Repair? 19
Avoiding the Most Common Mistakes 20
TOOLS AND EQUIPMENT 21
Introduction 21
Special Tools 29
SERVICING YOUR VEHICLE SAFELY 30
Introduction 30
Do’s 31
Don’ts 32
FASTENERS, MEASUREMENTS AND CONVERSIONS 33
Bolts, Nuts and Other Threaded Retainers 33
Torque 34
TORQUE WRENCHES 35
TORQUE ANGLE METERS 36
Standard and Metric Measurements 37
SERIAL NUMBER IDENTIFICATION 38
Vehicle Identification Number (VIN) 38
Vehicle Data 40
Safety Compliance Certification Label 43
Emission Calibration Label 44
Engine 45
Transmission 45
Transfer Case 45
Front Drive Axle 45
Rear Axle 45
ROUTINE MAINTENANCE AND TUNE-UP 47
Introduction 47
Air Cleaner (Element) 54
REMOVAL & INSTALLATION 54
Fuel Filter 57
REMOVAL & INSTALLATION 57
PCV Valve 62
INSPECTION 62
REMOVAL & INSTALLATION 63
Evaporative Canister 63
SERVICING 64
Battery 64
PRECAUTIONS 64
GENERAL MAINTENANCE 65
BATTERY FLUID 65
CABLES 68
CHARGING 71
REPLACEMENT 71
Belts 71
INSPECTION 71
ADJUSTMENT 73
REMOVAL & INSTALLATION 77
Timing Belts 82
INSPECTION 82
CAMSHAFT TIMING INSPECTION 86
Hoses 86
INSPECTION 86
REMOVAL & INSTALLATION 88
CV-Boots 90
INSPECTION 90
Spark Plugs 91
SPARK PLUG HEAT RANGE 92
REMOVAL & INSTALLATION 94
INSPECTION & GAPPING 96
Spark Plug Wires 99
REMOVAL & INSTALLATION 99
TESTING 100
Distributor Cap and Rotor 102
REMOVAL & INSTALLATION 102
INSPECTION 103
Ignition Timing 104
GENERAL INFORMATION 104
INSPECTION & ADJUSTMENT 104
Valve Lash 106
Idle Speed and Mixture Adjustments 106
Air Conditioning System 107
SYSTEM SERVICE & REPAIR 107
PREVENTIVE MAINTENANCE 107
SYSTEM INSPECTION 108
Windshield Wipers 108
ELEMENT (REFILL) CARE & REPLACEMENT 109
Tires and Wheels 110
TIRE ROTATION 111
TIRE DESIGN 111
TIRE STORAGE 113
INFLATION & INSPECTION 113
FLUIDS AND LUBRICANTS 117
Fluid Disposal 117
Oil and Fuel Recommendations 117
ENGINE OIL 117
FUEL 119
OPERATION IN FOREIGN COUNTRIES 119
Engine 119
OIL LEVEL CHECK 119
OIL & FILTER CHANGE 121
Manual Transmission 127
FLUID RECOMMENDATION 127
LEVEL CHECK 127
DRAIN & REFILL 127
Automatic Transmission 128
FLUID RECOMMENDATION 128
LEVEL CHECK 128
DRAIN, PAN/FILTER SERVICE & REFILL 130
Transfer Case 137
FLUID RECOMMENDATION 137
LEVEL CHECK 137
DRAIN & REFILL 139
Front and Rear Drive Axle 139
FLUID RECOMMENDATION 139
LEVEL CHECK 140
DRAIN & REFILL 142
Cooling System 145
FLUID RECOMMENDATIONS 146
INSPECTION 146
DRAINING, FLUSHING & REFILLING 150
Brake Master Cylinder 154
FLUID RECOMMENDATIONS 154
LEVEL CHECK 154
Clutch Master Cylinder 156
FLUID RECOMMENDATIONS 156
LEVEL CHECK 156
Power Steering Pump Reservoir 156
FLUID RECOMMENDATIONS 156
LEVEL CHECK 157
Manual Steering Gear 158
Chassis Greasing 158
Body Lubrication 159
HOOD/DOOR LATCH & HINGES 159
LOCK CYLINDERS 159
DOOR WEATHERSTRIPPING 159
THROTTLE VALVE (TV) & KICKDOWN LINKAGE 159
Wheel Bearings 159
REPACKING 160
TOWING THE VEHICLE 164
General Recommendations 164
Trailer Weight 164
Hitch (Tongue) Weight 164
Oil Cooler 165
TRANSMISSION 165
Handling a Trailer 165
Towing the Vehicle 165
JUMP STARTING A DEAD BATTERY 167
Introduction 167
Jump Starting Precautions 167
Jump Starting Procedure 168
JACKING 170
SPECIFICATION CHARTS 174
DISTRIBUTOR IGNITION SYSTEM 180
General Information 180
SYSTEM OPERATION 181
Diagnosis and Testing 182
SERVICE PRECAUTIONS 182
PRELIMINARY CHECKS 182
TEST PROCEDURES 182
Ignition Coil 188
TESTING 188
REMOVAL & INSTALLATION 191
Ignition Control Module (ICM) 191
REMOVAL & INSTALLATION 191
Distributor 193
REMOVAL & INSTALLATION 193
Camshaft Position (CMP) Sensor 195
DISTRIBUTORLESS IGNITION SYSTEM 196
General Information 196
SYSTEM OPERATION 196
Diagnosis and Testing 198
SERVICE PRECAUTIONS 198
PRELIMINARY CHECKS 198
GENERAL SYSTEM TEST 198
Ignition Coil Pack(s) 210
TESTING 210
REMOVAL & INSTALLATION 212
Ignition Control Module (ICM) 218
REMOVAL & INSTALLATION 218
Camshaft Position (CMP) and Crankshaft Position (CKP) Sensors 220
FIRING ORDERS 221
CHARGING SYSTEM 226
General Information 226
Alternator Precautions 227
Alternator 228
TESTING 228
REMOVAL & INSTALLATION 229
Voltage Regulator 232
REMOVAL & INSTALLATION 232
STARTING SYSTEM 236
General Information 236
Starter 238
TESTING 238
REMOVAL & INSTALLATION 239
RELAY REPLACEMENT 241
SENDING UNITS 245
Introduction 245
Coolant Temperature Sender 245
TESTING 245
REMOVAL & INSTALLATION 247
Oil Pressure Sender and Switch 249
TESTING 249
REMOVAL & INSTALLATION 251
Low Oil Level Sensor 253
TESTING 253
REMOVAL & INSTALLATION 254
SPECIFICATION CHARTS 256
ENGINE MECHANICAL 258
Engine 258
REMOVAL & INSTALLATION 258
Valve Rocker Arm Cover 265
REMOVAL & INSTALLATION 265
Rocker Arms 276
REMOVAL & INSTALLATION 276
Rocker Arm Shaft Assembly 278
REMOVAL & INSTALLATION 278
DISASSEMBLY & REASSEMBLY 281
Thermostat 281
REMOVAL & INSTALLATION 281
Intake Manifold 287
REMOVAL & INSTALLATION 287
Exhaust Manifold 312
REMOVAL & INSTALLATION 312
Radiator 321
REMOVAL & INSTALLATION 321
Engine Fan 325
REMOVAL & INSTALLATION 325
Water Pump 330
REMOVAL & INSTALLATION 331
Cylinder Head 341
REMOVAL & INSTALLATION 341
Oil Pan 363
REMOVAL & INSTALLATION 363
Oil Pump 371
REMOVAL & INSTALLATION 372
Crankshaft Damper 377
REMOVAL & INSTALLATION 377
Timing Belt and Cover 379
TROUBLESHOOTING 379
REMOVAL & INSTALLATION 379
Timing Chain Cover & Oil Seal 382
REMOVAL & INSTALLATION 382
Timing Chain and Gears 394
REMOVAL & INSTALLATION 394
TIMING CHAIN DEFLECTION 414
Camshaft and Auxiliary Shaft Sprockets and Seals 415
REMOVAL & INSTALLATION 415
Camshafts, Bearings and Lifters 415
REMOVAL & INSTALLATION 415
INSPECTION 428
BEARING REMOVAL & INSTALLATION 431
Auxiliary Shaft 434
REMOVAL & INSTALLATION 434
Rear Main Oil Seal 436
REMOVAL & INSTALLATION 436
Flywheel and Ring Gear 438
REMOVAL & INSTALLATION 438
EXHAUST SYSTEM 443
REPLACEMENT 446
ENGINE RECONDITIONING 449
Determining Engine Condition 449
COMPRESSION TEST 449
OIL PRESSURE TEST 450
Buy or Rebuild? 451
Engine Overhaul Tips 451
TOOLS 452
OVERHAUL TIPS 452
CLEANING 453
REPAIRING DAMAGED THREADS 455
Engine Preparation 457
Cylinder Head 458
DISASSEMBLY 459
INSPECTION 470
REFINISHING & REPAIRING 474
ASSEMBLY 477
Engine Block 477
GENERAL INFORMATION 478
DISASSEMBLY 478
INSPECTION 481
REFINISHING 484
ASSEMBLY 486
Engine Start-up and Break-in 492
STARTING THE ENGINE 492
BREAKING IT IN 493
KEEP IT MAINTAINED 493
SPECIFICATION CHARTS 494
EMISSION CONTROLS 515
Positive Crankcase Ventilation (PCV) System 515
OPERATION 515
TESTING 515
REMOVAL & INSTALLATION 516
Evaporative Emission Control System 519
OPERATION 519
COMPONENT TESTING 520
REMOVAL & INSTALLATION 527
Exhaust Gas Recirculation (EGR) System 528
OPERATION 528
COMPONENT TESTING 529
REMOVAL & INSTALLATION 533
ELECTRONIC ENGINE CONTROLS 537
Electronic Engine Control (EEC) 537
Powertrain Control Module (PCM) 537
OPERATION 537
REMOVAL & INSTALLATION 538
Heated Oxygen Sensors (HO2S) 541
OPERATION 541
TESTING 542
REMOVAL & INSTALLATION 543
Idle Air Control (IAC) Valve 544
OPERATION 544
TESTING 544
REMOVAL & INSTALLATION 545
Engine Coolant Temperature (ECT) Sensor 546
OPERATION 546
TESTING 547
REMOVAL & INSTALLATION 548
Intake Air Temperature (IAT) Sensor 549
OPERATION 549
TESTING 549
REMOVAL & INSTALLATION 549
Mass Air Flow (MAF) Sensor 550
OPERATION 550
TESTING 551
REMOVAL & INSTALLATION 552
Throttle Position (TP) Sensor 554
OPERATION 554
TESTING 555
REMOVAL & INSTALLATION 556
Camshaft Position (CMP) Sensor 557
OPERATION 557
TESTING 559
REMOVAL & INSTALLATION 560
Crankshaft Position (CKP) Sensor 565
OPERATION 565
TESTING 565
REMOVAL & INSTALLATION 566
Vehicle Speed Sensor(VSS) 569
OPERATION 570
TESTING 570
REMOVAL & INSTALLATION 570
COMPONENT LOCATIONS 571
TROUBLE CODES 584
General Description 584
FAILURE MODE EFFECTS MANAGEMENT (FMEM) 585
HARDWARE LIMITED OPERATION STRATEGY (HLOS) 585
MALFUNCTION INDICATOR LAMP (MIL) 585
Diagnostic Connector 585
Reading Codes 586
EEC-V EQUIPPED ENGINES 587
EEC-IV EQUIPPED ENGINES 587
Clearing Codes 589
CONTINUOUS MEMORY CODES 589
KEEP ALIVE MEMORY 589
Diagnostic Trouble Code Charts 589
VACUUM DIAGRAMS 600
SPECIFICATION CHARTS 601
BASIC FUEL SYSTEM DIAGNOSIS 602
FUEL LINES AND FITTINGS 603
General Information 603
Hairpin Clip Fitting 603
REMOVAL & INSTALLATION 603
Duckbill Clip Fitting 605
REMOVAL & INSTALLATION 605
REMOVAL & INSTALLATION 607
SEQUENTIAL FUEL INJECTION (SFI) SYSTEM 609
General Information 609
FUEL SYSTEM SERVICE PRECAUTIONS 610
Relieving Fuel System Pressure 610
Inertia Switch 611
GENERAL INFORMATION 611
RESETTING THE SWITCH 611
Fuel Pump 613
REMOVAL & INSTALLATION 613
TESTING 617
Throttle Body Assembly 620
REMOVAL & INSTALLATION 620
Fuel Supply Manifold and Injectors 625
REMOVAL & INSTALLATION 626
TESTING 632
Fuel Pressure Regulator 633
REMOVAL & INSTALLATION 633
Pressure Relief Valve 640
REMOVAL & INSTALLATION 640
FUEL TANK 641
Tank Assembly 641
REMOVAL & INSTALLATION 641
Sending Unit 647
REMOVAL & INSTALLATION 647
UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS 648
Basic Electrical Theory 648
HOW DOES ELECTRICITY WORK: THE WATER ANALOGY 648
OHM’S LAW 649
Electrical Components 650
POWER SOURCE 650
GROUND 650
PROTECTIVE DEVICES 650
SWITCHES & RELAYS 652
LOAD 653
WIRING & HARNESSES 653
CONNECTORS 654
Test Equipment 655
JUMPER WIRES 655
TEST LIGHTS 656
MULTIMETERS 657
Troubleshooting Electrical Systems 658
Testing 658
OPEN CIRCUITS 658
SHORT CIRCUITS 659
VOLTAGE 659
VOLTAGE DROP 660
RESISTANCE 660
Wire and Connector Repair 662
BATTERY CABLES 663
AIR BAG (SUPPLEMENTAL RESTRAINT) SYSTEM 664
SERVICE PRECAUTIONS 665
DISARMING THE SYSTEM 665
ARMING THE SYSTEM 665
HEATING AND AIR CONDITIONING 666
Blower Motor 666
REMOVAL & INSTALLATION 666
Blower Motor Resistor 669
REMOVAL & INSTALLATION 669
Heater Core 669
REMOVAL & INSTALLATION 669
Control Head 674
REMOVAL & INSTALLATION 675
Control Cables 678
ADJUSTMENT 678
REMOVAL & INSTALLATION 678
Air Conditioning Components 680
REMOVAL & INSTALLATION 680
CRUISE CONTROL 682
Vacuum Controlled Systems 682
Electronic Systems 682
ENTERTAINMENT SYSTEMS 684
Radio Receiver/Tape Player 684
REMOVAL & INSTALLATION 684
Speakers 686
REMOVAL & INSTALLATION 686
WINDSHIELD WIPERS 690
Wiper Arm And Blade 690
REMOVAL & INSTALLATION 690
Windshield Wiper Motor 692
REMOVAL & INSTALLATION 692
Windshield Washer Motor 698
REMOVAL & INSTALLATION 698
INSTRUMENTS AND SWITCHES 701
Instrument Cluster 701
REMOVAL & INSTALLATION 701
Fuel, Oil Pressure, Voltage and Coolant Temperature Gauges 705
REMOVAL & INSTALLATION 705
Rear Wiper Switch 707
REMOVAL & INSTALLATION 707
Headlight Switch 707
REMOVAL & INSTALLATION 708
Back-up Light Switch 709
Manual Transmissions 709
LIGHTING 711
Headlights 711
REMOVAL & INSTALLATION 711
AIMING THE HEADLIGHTS 715
Signal and Marker Lights 717
REMOVAL & INSTALLATION 717
Fog/Driving Lights 728
REMOVAL & INSTALLATION 728
TRAILER WIRING 732
CIRCUIT PROTECTION 733
Fuses 733
REPLACEMENT 740
Fusible Links 742
Circuit Breakers 742
REPLACEMENT 742
Turn Signal and Hazard Flasher Locations 743
WIRING DIAGRAMS 744
MANUAL TRANSMISSION 745
Understanding the Manual Transmission 745
Identification 745
Adjustments 745
SHIFTER & LINKAGE ADJUSTMENTS 746
Shift Handle 746
REMOVAL & INSTALLATION 746
Neutral Sensing Switch 747
REMOVAL & INSTALLATION 748
Extension Housing Seal 749
REMOVAL & INSTALLATION 749
Transmission 750
REMOVAL & INSTALLATION 750
CLUTCH 753
Understanding the Clutch 753
Clutch Interlock Switch 754
REMOVAL & INSTALLATION 754
Master Cylinder and Reservoir 754
REMOVAL & INSTALLATION 755
Slave Cylinder 756
REMOVAL & INSTALLATION 756
BLEEDING THE SYSTEM 758
Driven Disc and Pressure Plate 758
REMOVAL & INSTALLATION 758
AUTOMATIC TRANSMISSION 764
Understanding the Automatic Transmission 764
Identification 764
Neutral Start Switch/Back-up Switch 764
REMOVAL & INSTALLATION 764
ADJUSTMENT 768
Vacuum Diaphragm 768
REMOVAL & INSTALLATION 768
Extension Housing Seal 769
REMOVAL & INSTALLATION 769
Transmission Assembly 771
REMOVAL & INSTALLATION 771
ADJUSTMENTS 777
KICKDOWN CABLE 780
TRANSFER CASE 782
Identification 782
Rear Output Shaft Seal 783
REMOVAL & INSTALLATION 783
Front Output Shaft Seal 784
REMOVAL & INSTALLATION 784
Transfer Case Assembly 786
REMOVAL & INSTALLATION 786
ADJUSTMENTS 788
DRIVELINE 790
General Description 790
Single Cardan Type Front Driveshaft 790
REMOVAL & INSTALLATION 790
DUST SLINGER/BOOT REPLACEMENT 792
Double Cardan Type Front and Rear Driveshaft 792
REMOVAL & INSTALLATION 792
DISASSEMBLY & ASSEMBLY 793
Single Cardan Type Rear Driveshaft 795
REMOVAL & INSTALLATION 795
DISASSEMBLY & ASSEMBLY 798
Constant Velocity (CV) Type Rear Driveshaft 799
REMOVAL & INSTALLATION 800
DISASSEMBLY & ASSEMBLY 800
Center Bearing 803
REMOVAL & INSTALLATION 803
FRONT DRIVE AXLE 805
General Information 805
Manual Locking Hubs 805
REMOVAL & INSTALLATION 805
Automatic Locking Hubs 807
REMOVAL & INSTALLATION 807
Vacuum Disconnect Axle Lock 809
REMOVAL & INSTALLATION 809
Spindles and Spindle Bearings 811
REMOVAL & INSTALLATION 811
Axle Shafts and Seals 812
REMOVAL & INSTALLATION 812
Axle Housing 818
REMOVAL & INSTALLATION 818
REAR AXLE 824
Determining Axle Ratio 824
Axle Shaft, Bearing and Seal 824
REMOVAL & INSTALLATION 824
Pinion Oil Seal 830
REMOVAL & INSTALLATION 830
Axle Housing 833
REMOVAL & INSTALLATION 833
WHEELS 836
Front Wheels 836
REMOVAL & INSTALLATION 836
INSPECTION 837
Front Wheel Lug Studs 837
REMOVAL & INSTALLATION 837
INSPECTION 839
Rear Wheel Lug Studs 839
REMOVAL & INSTALLATION 839
2-WHEEL DRIVE FRONT SUSPENSION 841
Introduction 841
Coil Springs 842
REMOVAL & INSTALLATION 842
Torsion Bars 844
REMOVAL & INSTALLATION 844
RIDE HEIGHT ADJUSTMENT 846
Shock Absorbers 847
REMOVAL & INSTALLATION 847
TESTING 850
Ball Joints 851
INSPECTION 851
REMOVAL & INSTALLATION 852
Knuckle and Spindle 854
REMOVAL & INSTALLATION 854
Radius Arm 857
REMOVAL & INSTALLATION 857
Stabilizer Bar 859
REMOVAL & INSTALLATION 859
I-Beam Axle 862
REMOVAL & INSTALLATION 862
Upper Control Arm 863
REMOVAL & INSTALLATION 863
Lower Control Arm 865
REMOVAL & INSTALLATION 865
Front Wheel Bearings 867
REMOVAL & INSTALLATION 867
ADJUSTMENT 872
Wheel Alignment 873
CASTER 873
CAMBER 874
TOE 874
4-WHEEL DRIVE FRONT SUSPENSION 876
Introduction 876
Coil Springs 878
REMOVAL & INSTALLATION 878
Torsion Bars 879
REMOVAL & INSTALLATION 879
RIDE HEIGHT ADJUSTMENT 881
Shock Absorbers 882
REMOVAL & INSTALLATION 882
TESTING 888
Ball Joints 888
INSPECTION 888
REMOVAL & INSTALLATION 889
Steering Knuckle 890
REMOVAL & INSTALLATION 890
Radius Arm 892
REMOVAL & INSTALLATION 892
Stabilizer Bar 893
REMOVAL & INSTALLATION 893
I-Beam Axle 895
Upper Control Arm 895
REMOVAL & INSTALLATION 895
Lower Control Arm 897
REMOVAL & INSTALLATION 897
Front Wheel Bearings 899
REMOVAL & INSTALLATION 899
ADJUSTMENT 910
Wheel Alignment 912
REAR SUSPENSION 913
Introduction 913
Leaf Springs 914
REMOVAL & INSTALLATION 914
Shock Absorbers 916
REMOVAL & INSTALLATION 916
TESTING 920
Stabilizer Bar 921
REMOVAL & INSTALLATION 921
STEERING 923
Steering Wheel 923
REMOVAL & INSTALLATION 923
Combination Switch 929
REMOVAL & INSTALLATION 929
Ignition Switch 930
REMOVAL & INSTALLATION 930
Ignition Lock Cylinder Assembly 931
REMOVAL & INSTALLATION 931
Steering Column 932
REMOVAL & INSTALLATION 932
Steering Linkage 934
REMOVAL & INSTALLATION 935
Manual Steering Gear 940
ADJUSTMENTS 941
REMOVAL & INSTALLATION 942
Power Steering Gear 943
ADJUSTMENTS 943
REMOVAL & INSTALLATION 943
Power Rack and Pinion Steering Gear 945
REMOVAL & INSTALLATION 945
Power SteeringPump 947
REMOVAL & INSTALLATION 947
BLEEDING 950
QUICK-CONNECT PRESSURE LINE 950
SPECIFICATION CHARTS 952
BRAKE OPERATING SYSTEM 953
Basic Operating Principles 953
DISC BRAKES 954
DRUM BRAKES 955
Brake Light Switch 955
REMOVAL & INSTALLATION 955
Master Cylinder 956
REMOVAL & INSTALLATION 956
Power Booster 960
REMOVAL & INSTALLATION 960
Brake Hoses and Lines 965
REMOVAL & INSTALLATION 965
Bleeding The Brakes 967
FRONT DISC BRAKES 970
Introduction 970
Brake Pads 971
INSPECTION 971
REMOVAL & INSTALLATION 971
Calipers 986
REMOVAL & INSTALLATION 987
OVERHAUL 989
Brake Rotor (Disc) 993
REMOVAL & INSTALLATION 993
INSPECTION 993
REAR DRUM BRAKES 995
Introduction 995
Brake Drums 997
REMOVAL & INSTALLATION 997
INSPECTION 998
Brake Shoes 999
REMOVAL & INSTALLATION 999
ADJUSTMENTS 1009
Wheel Cylinders 1012
REMOVAL & INSTALLATION 1012
OVERHAUL 1013
REAR DISC BRAKES 1019
General Information 1019
Brake Pads 1019
REMOVAL & INSTALLATION 1019
INSPECTION 1021
Brake Caliper 1021
REMOVAL & INSTALLATION 1021
OVERHAUL 1022
Brake Disc 1022
REMOVAL & INSTALLATION 1022
INSPECTION 1022
REAR ANTI-LOCK BRAKE SYSTEM (RABS) 1023
Component Location 1023
System Self-Test 1024
Computer (RABS) Module 1025
REMOVAL & INSTALLATION 1025
RABS Valve 1025
REMOVAL & INSTALLATION 1025
RABS Sensor 1025
TESTING 1026
REMOVAL & INSTALLATION 1026
Exciter Ring 1027
PARKING BRAKE 1028
Cable 1028
ADJUSTMENT 1028
REMOVAL & INSTALLATION 1032
Brake Shoes 1038
REMOVAL & INSTALLATION 1038
ADJUSTMENT 1039
4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) 1041
Introduction 1041
System Self-Test 1041
Hydraulic Control Unit (HCU) 1042
PUMP TESTING 1042
REMOVAL & INSTALLATION 1043
Electronic Control Unit 1043
REMOVAL & INSTALLATION 1043
Front Wheel Speed Sensor 1044
TESTING 1044
REMOVAL & INSTALLATION 1044
Rear Speed Sensor 1044
TESTING 1044
REMOVAL & INSTALLATION 1044
Front Speed Sensor Ring 1045
REMOVAL & INSTALLATION 1046
Rear Speed Sensor Ring 1046
REMOVAL & INSTALLATION 1046
SPECIFICATION CHARTS 1047
EXTERIOR 1048
Doors 1048
REMOVAL & INSTALLATION 1048
ADJUSTMENT 1051
Hood 1052
REMOVAL & INSTALLATION 1052
ALIGNMENT 1054
Liftgate 1054
REMOVAL & INSTALLATION 1054
ALIGNMENT 1058
Tailgate 1060
REMOVAL & INSTALLATION 1060
Front and Rear Bumpers 1062
REMOVAL & INSTALLATION 1062
Grille 1065
REMOVAL & INSTALLATION 1066
Outside Mirrors 1067
REMOVAL & INSTALLATION 1067
Antenna 1069
REMOVAL & INSTALLATION 1069
Fenders 1071
REMOVAL & INSTALLATION 1071
Pickup Truck Bed 1073
REMOVAL & INSTALLATION 1073
Chassis and Cab Mount Bushings 1074
REMOVAL & INSTALLATION 1074
Spare Tire Carrier 1078
REMOVAL & INSTALLATION 1078
INTERIOR 1080
Door Panels 1080
REMOVAL & INSTALLATION 1080
Interior Trim Panels 1086
REMOVAL & INSTALLATION 1086
Instrument Panel 1091
REMOVAL & INSTALLATION 1091
Center Console 1094
REMOVAL & INSTALLATION 1094
Headliner 1096
REMOVAL & INSTALLATION 1096
Door Locks 1098
REMOVAL & INSTALLATION 1098
Door Glass and Regulator 1100
REMOVAL & INSTALLATION 1101
Electric Window Motor 1105
REMOVAL & INSTALLATION 1105
Windshield and Fixed Glass 1106
REMOVAL & INSTALLATION 1106
WINDSHIELD CHIP REPAIR 1107
Inside Rear View Mirror 1108
REMOVAL & INSTALLATION 1108
Seats 1108
REMOVAL & INSTALLATION 1109
Seat Belt Systems 1112
REMOVAL & INSTALLATION 1112
SPECIFICATION CHARTS 1118

Customer Support: [email protected]

https://vimeo.com/768055038

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V