1992 CHRYSLER ELECTRONIC SERVICE MANUAL – PDF DOWNLOAD
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 service 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.
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 DaimlerChrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation 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, DaimlerChrysler Corporation 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.
TABLE OF CONTENTS:
1992 CHRYSLER ELECTRONIC SERVICE MANUAL – PDF DOWNLOAD
WELCOME............................................................................................................................................ 1
INSTR.............................................................................................................................................. 2
IBC................................................................................................................................................ 13
IFC................................................................................................................................................ 14
92AS_0............................................................................................................................................. 15
LUBRICATION AND MAINTENANCE.................................................................................................................... 15
GENERAL INFORMATION........................................................................................................................ 15
INTRODUCTION........................................................................................................................... 15
PARTS AND LUBRICANT RECOMMENDATIONS.................................................................................................... 15
SEVERE SERVICE......................................................................................................................... 15
FUEL USAGE............................................................................................................................. 15
CLASSIFICATION OF LUBRICANTS........................................................................................................... 15
ENGINE OIL......................................................................................................................... 15
GEAR LUBRICANTS.................................................................................................................... 15
LUBRICANTS AND GREASES............................................................................................................. 16
PARTS REQUIRING NO LUBRICATION......................................................................................................... 16
JUMP STARTING PROCEDURE................................................................................................................ 16
TO JUMP START A DISABLED VEHICLE:.................................................................................................. 16
NLGI SYMBOL........................................................................................................................ 16
LUBRICATION AND MAINTENANCE SCHEDULES.............................................................................................. 17
GENERAL MAINTENANCE SCHEDULES SEVERE SERVICE SCHEDULES............................................................................. 18
HOISTING RECOMMENDATIONS............................................................................................................... 19
FLUID CAPACITIES................................................................................................................... 19
TO HOIST OR JACK VEHICLE SEE FIG. 2................................................................................................ 20
TOWING RECOMMENDATIONS................................................................................................................. 20
RECOMMENDED TOWING EQUIPMENT....................................................................................................... 20
GROUND CLEARANCE................................................................................................................... 20
LOCKED VEHICLE TOWING.............................................................................................................. 20
FLAT TOWING WITH TOW BAR........................................................................................................... 20
TOWING— FRONT WHEEL LIFT........................................................................................................... 21
TOWING— REAR WHEEL LIFT............................................................................................................ 21
ENGINE..................................................................................................................................... 22
FREQUENCY OF ENGINE OIL AND FILTER CHANGES............................................................................................. 22
ENGINE OIL......................................................................................................................... 22
OIL FILTER......................................................................................................................... 22
ENGINE OIL............................................................................................................................. 22
BREAK- IN PERIOD................................................................................................................... 22
SELECTING ENGINE OIL............................................................................................................... 22
ENGINE OIL ADDITIVES............................................................................................................... 23
CRANKCASE OIL LEVEL INSPECTION..................................................................................................... 23
ENGINE OIL CHANGE.................................................................................................................. 23
RECOMMENDED VISCOSITY GRADES....................................................................................................... 23
ENGINE OIL FILTER...................................................................................................................... 24
SELECTING OIL FILTER............................................................................................................... 24
OIL FILTER REMOVAL:................................................................................................................ 24
OIL FILTER INSTALLATION:........................................................................................................... 24
ENGINE COOLING SYSTEM.................................................................................................................. 24
WARNINGS AND PRECAUTIONS........................................................................................................... 24
COOLING SYSTEM INSPECTION.......................................................................................................... 24
SELECTING ANTIFREEZE............................................................................................................... 25
RADIATOR CAP....................................................................................................................... 25
COOLING SYSTEM SERVICE............................................................................................................. 25
ENGINE AIR CLEANER..................................................................................................................... 25
AIR CLEANER SERVICE................................................................................................................ 25
CRANKCASE VENTILATION SYSTEM........................................................................................................... 26
PCV SYSTEM TEST.................................................................................................................... 26
FUEL RECOMMENDATIONS................................................................................................................... 27
SELECTING GASOLINE................................................................................................................. 27
FUEL FILTER............................................................................................................................ 28
IGNITION CABLES, DISTRIBUTOR CAP, AND ROTOR............................................................................................ 28
SPARK PLUGS............................................................................................................................ 28
DRIVE BELTS............................................................................................................................ 28
EMISSION CONTROL SYSTEM................................................................................................................ 28
BATTERY................................................................................................................................ 28
RUBBER AND PLASTIC COMPONENT INSPECTION................................................................................................ 28
EXHAUST SYSTEM ISOLATOR AND HANGER................................................................................................. 28
DRIVETRAIN................................................................................................................................. 29
CLUTCH AND GEARSHIFT LINKAGE........................................................................................................... 29
MANUAL TRANSAXLE....................................................................................................................... 29
SELECTING MANUAL TRANSAXLE OIL..................................................................................................... 29
AUTOMATIC TRANSAXLE SHIFT MECHANISM.................................................................................................... 29
AUTOMATIC TRANSAXLE.................................................................................................................... 29
SELECTING AUTOMATIC TRANSAXLE FLUID................................................................................................ 30
POWER TRANSFER UNIT.................................................................................................................... 30
SELECTING LUBRICANT................................................................................................................ 30
OVERRUNNING CLUTCH..................................................................................................................... 30
SELECTING LUBRICANT................................................................................................................ 31
DRIVE LINE MODULE...................................................................................................................... 31
SELECTING LUBRICANT................................................................................................................ 31
DRIVE SHAFT CV AND TRIPOD JOINT BOOTS.................................................................................................. 31
FRONT WHEEL BEARINGS (REAR WHEEL BEAR-INGS ON ALL WHEEL DRIVE MODELS).................................................................. 31
TIRES.................................................................................................................................. 32
TIRE ROTATION...................................................................................................................... 32
CHASSIS AND BODY........................................................................................................................... 33
STEERING LINKAGE....................................................................................................................... 33
INSPECTION......................................................................................................................... 33
TIE ROD END LUBRICATION............................................................................................................ 33
LOWER BALL JOINTS...................................................................................................................... 33
INSPECTION......................................................................................................................... 33
BALL JOINT LUBRICATION............................................................................................................. 33
POWER STEERING......................................................................................................................... 33
POWER STEERING FLUID INSPECTION.................................................................................................... 34
REAR WHEEL BEARINGS (FRONT WHEEL DRIVE ONLY)........................................................................................... 35
INSPECTION......................................................................................................................... 35
REAR WHEEL BEARING LUBRICATION..................................................................................................... 35
BRAKES................................................................................................................................. 35
BRAKE PAD AND LINING INSPECTION.................................................................................................... 35
BRAKE HOSE INSPECTION.............................................................................................................. 35
BRAKE LINE INSPECTION.............................................................................................................. 36
BRAKE RESERVOIR LEVEL INSPECTION................................................................................................... 36
HEADLAMPS.............................................................................................................................. 36
DRIVER SUPPLEMENTAL AIRBAG SYSTEM...................................................................................................... 36
BODY LUBRICATION....................................................................................................................... 36
92AS_2............................................................................................................................................. 39
FRONT SUSPENSION AND DRIVE SHAFTS.............................................................................................................. 39
GENERAL INFORMATION........................................................................................................................ 39
FRONT SUSPENSION........................................................................................................................... 40
FRONT SUSPENSION MAJOR COMPONENTS (Fig. 1, 2 and 3).................................................................................... 40
STRUT SUPPORT...................................................................................................................... 40
STEERING KNUCKLE................................................................................................................... 40
LOWER CONTROL ARM.................................................................................................................. 40
DRIVESHAFTS........................................................................................................................ 40
SUSPENSION/ STEERING/ DRIVE DIAGNOSIS/ FRONT WHEEL DRIVE........................................................................... 43
FRONT SUSPENSION SERVICE PROCEDURES........................................................................................................ 44
WHEEL ALIGNMENT........................................................................................................................ 44
PRE- ALIGNMENT..................................................................................................................... 44
CAMBER ADJUSTMENT.................................................................................................................. 44
TOE ADJUSTMENT..................................................................................................................... 46
STRUT DAMPER ASSEMBLY.................................................................................................................. 46
REMOVAL............................................................................................................................ 46
SHOCK ABSORBER INSPECT............................................................................................................. 46
INSTALLATION....................................................................................................................... 46
DISASSEMBLY (STRUT DAMPER)......................................................................................................... 47
ASSEMBLE (STRUT DAMPER)............................................................................................................ 47
SUSPENSION COIL SPRINGS................................................................................................................ 48
SPRING RETAINER UPPER.............................................................................................................. 48
SPRING SEAT LOWER.................................................................................................................. 48
SHOCK ABSORBERS (Strut Damper)......................................................................................................... 48
INSPECTION......................................................................................................................... 48
LOWER CONTROL ARM...................................................................................................................... 48
REMOVAL (ASSEMBLY)................................................................................................................. 48
INSTALLATION (ASSEMBLY)............................................................................................................ 49
LOWER CONTROL ARM PIVOT BUSHINGS....................................................................................................... 49
LARGE BUSHING...................................................................................................................... 49
SMALL BUSHING...................................................................................................................... 50
SMALL BUSHING...................................................................................................................... 50
LARGE BUSHING...................................................................................................................... 51
BALL JOINTS............................................................................................................................ 51
INSPECTION BALL JOINT WEAR......................................................................................................... 51
BALL JOINT REMOVAL................................................................................................................. 52
BALL JOINT INSTALLATION............................................................................................................ 52
BALL JOINT SEAL INSTALLATION....................................................................................................... 52
SWAY BAR............................................................................................................................... 53
REMOVAL............................................................................................................................ 53
INSPECTION......................................................................................................................... 53
INSTALLATION....................................................................................................................... 53
KNUCKLE (FRONT SUSPENSION)............................................................................................................. 54
REMOVAL............................................................................................................................ 54
INSTALL............................................................................................................................ 56
HUB AND BEARING ASSEMBLY............................................................................................................... 58
REMOVAL............................................................................................................................ 59
INSTALLATION....................................................................................................................... 61
DRIVESHAFTS................................................................................................................................ 64
GENERAL INFORMATION.................................................................................................................... 64
DRIVESHAFT IDENTIFICATION.............................................................................................................. 64
DRIVESHAFT SERVICE PROCEDURES.......................................................................................................... 64
HUB NUT AND HUB ASSEMBLY REMOVAL................................................................................................... 65
DRIVESHAFT ASSEMBLIES.............................................................................................................. 66
HUB NUT ASSEMBLIES INSTALL......................................................................................................... 68
DRIVESHAFT RECONDITIONING.............................................................................................................. 69
INNER C/ V JOINT....................................................................................................................... 69
DISASSEMBLE........................................................................................................................ 69
TRIPOD ASSEMBLY REMOVAL FROM INTERCONNECTING SHAFT................................................................................. 70
INSPECT TRIPOD AND HOUSING......................................................................................................... 72
ASSEMBLE C/ V JOINT................................................................................................................ 72
INNER C/ V JOINT HOUSING INSTALLATION.............................................................................................. 73
OUTER C/ V JOINT....................................................................................................................... 73
DISASSEMBLE........................................................................................................................ 73
WEAR SLEEVE........................................................................................................................ 74
INSPECT............................................................................................................................ 75
ASSEMBLE........................................................................................................................... 76
C/ V JOINT BOOTS....................................................................................................................... 78
HANDLING AND CLEANING.............................................................................................................. 78
B00TS INSPECT...................................................................................................................... 78
BOOTS INSTALL...................................................................................................................... 78
LEFT INNER, LEFT AND RIGHT OUTER C/ V JOINT WITH PLASTIC BOOTS..................................................................... 81
RIGHT INNER C/ V JOINT WITH RUBBER BOOT............................................................................................ 81
S. S. G INNER C/ V JOINT LARGE CLAMP (MANUAL TRANS ONLY)........................................................................... 82
DAMPER WEIGHTS......................................................................................................................... 83
DRIVESHAFT POSITIONING SPECIFICATIONS.................................................................................................. 83
SPECIFICATIONS............................................................................................................................. 84
DRIVESHAFT DIMENSIONS INSTALLED TORQUE SPECIFICATIONS.................................................................................. 84
ALIGNMENT SPECIFICATIONS AT CURB HEIGHT............................................................................................ 85
92AS_3............................................................................................................................................. 87
REAR SUSPENSION AND DRIVELINE.................................................................................................................. 87
TWO WHEEL DRIVE REAR SUSPENSION............................................................................................................ 87
GENERAL INFORMATION.................................................................................................................... 87
REAR SPRINGS........................................................................................................................... 87
REMOVAL............................................................................................................................ 87
INSTALLATION....................................................................................................................... 87
REAR SHOCK ABSORBERS................................................................................................................... 88
REMOVAL AND INSTALLATION........................................................................................................... 88
REAR WHEEL ALIGNMENT— FRONT WHEEL DRIVE VAN/ WAGONS ONLY............................................................................... 88
INSTALLATION OF REAR ALIGNMENT SHIMS............................................................................................... 88
REAR SWAY BAR.......................................................................................................................... 90
REMOVAL............................................................................................................................ 90
INSPECTION......................................................................................................................... 91
ALL WHEEL DRIVE REAR SUSPENSION............................................................................................................ 91
GENERAL INFORMATION.................................................................................................................... 91
REAR WHEEL BEARINGS.................................................................................................................... 91
REMOVAL............................................................................................................................ 91
INSTALLATION....................................................................................................................... 92
REAR SPRINGS........................................................................................................................... 93
REMOVAL............................................................................................................................ 93
INSTALLATION....................................................................................................................... 93
JOUNCE BUMPER.......................................................................................................................... 94
REAR SHOCK ABSORBERS................................................................................................................... 94
REMOVAL AND INSTALLATION........................................................................................................... 94
REAR DRIVE LINE MODULE ASSEMBLY (ALL WHEEL DRIVE).......................................................................................... 95
GENERAL INFORMATION.................................................................................................................... 95
REAR DRIVE LINE NOISE DIAGNOSIS........................................................................................................ 95
REAR CARRIER ASSEMBLY NOISE........................................................................................................ 95
TIRE NOISE......................................................................................................................... 96
GEAR NOISE (DRIVE PINION AND RING GEAR)............................................................................................ 96
BEARING NOISE (DRIVE PINION AND DIFFER-ENTIAL)..................................................................................... 96
ENGINE AND TRANSMISSION NOISE...................................................................................................... 96
FLUID LEAK DIAGNOSIS................................................................................................................... 96
REAR DRIVE LINE MODULE ASSEMBLY SERVICE PROCEDURES......................................................................................... 97
REAR DRIVE LINE MODULE ASSEMBLY........................................................................................................ 97
REMOVAL AND INSTALLATION........................................................................................................... 97
REAR CARRIER UNIT...................................................................................................................... 98
REMOVAL AND INSTALLATION........................................................................................................... 98
REAR CARRIER OUTPUT SHAFT SEALS........................................................................................................ 99
REMOVAL............................................................................................................................ 99
INSTALLATION....................................................................................................................... 100
FRONT OVERRUNNING CLUTCH SEAL.......................................................................................................... 101
REMOVAL............................................................................................................................ 101
INSTALLATION....................................................................................................................... 103
DRIVE PINION SEAL AND/ OR REAR OVERRUN-NING CLUTCH SEAL................................................................................ 103
REAR CARRIER COMPONENT IDENTIFICATION.............................................................................................. 104
REMOVAL............................................................................................................................ 105
INSTALLATION....................................................................................................................... 107
DRIVE PINION BEARING SHIM SELECTION.................................................................................................... 108
REAR DRIVELINE MODULE DIFFERENTIAL SIDE GEARS.......................................................................................... 108
CASE COVER SERVICE..................................................................................................................... 109
DIFFERENTIAL CARRIER END COVER (RE- SEAL).......................................................................................... 109
OVERRUNNING CLUTCH COVER (RESEAL).................................................................................................. 110
OVERRUNNING CLUTCH CASE TO REAR CARRIER CASE (RESEAL).............................................................................. 110
TORQUE TUBE AND OVERRUNNING CLUTCH COMPONENTS...................................................................................... 111
TORQUE TUBE............................................................................................................................ 112
REMOVAL AND INSTALLATION........................................................................................................... 112
FRONT BEARING...................................................................................................................... 112
REAR BEARING....................................................................................................................... 113
OVERRUNNING CLUTCH..................................................................................................................... 114
VACUUM MOTOR....................................................................................................................... 114
REMOVAL............................................................................................................................ 115
INSTALLATION....................................................................................................................... 117
OVERRUNNING CLUTCH CASE............................................................................................................ 118
PROPELLER SHAFT SERVICE................................................................................................................ 119
REMOVAL AND INSTALLATION........................................................................................................... 119
HALF SHAFT SERVICE..................................................................................................................... 120
REMOVAL AND INSTALLATION........................................................................................................... 120
REAR HALF SHAFT JOINT/ BOOT REPLACEMENT............................................................................................ 121
REAR DRIVE LINE MODULE VACUUM ACTUATION DIAGNOSIS.......................................................................................... 123
REAR WHEELS NOT OVERRUNNING............................................................................................................ 123
NO ALL WHEEL DRIVE, IN FORWARD; PROPELLER SHAFT TURNING NO ALL WHEEL DRIVE FORWARD OR REVERSE.......................................... 124
XNO ALL WHEEL DRIVE, REVERSE ONLY; PROPELLER SHAFT TURNING......................................................................... 125
NO ALL WHEEL DRIVE, REVERSE ONLY; PROPELLER SHAFT TURNING (CONT.).................................................................. 126
VACUUM ACTUATION SCHEMATIC (SOLENOIDS ENERGIZED) VACUUM ACTUATION SCHEMATIC (SOLENOIDS DE- ENERGIZED).............................. 127
SPECIFICATIONS............................................................................................................................. 128
FASTENER TORQUE SPECIFICATIONS ........................................................................................................ 128
REAR WHEEL BEARING TORQUE SPECIFICATIONS .............................................................................................. 128
REAR CARRIER ASSEMBLY TORQUE SPECIFICATIONS............................................................................................ 128
OVERRUNNING CLUTCH AND TORQUE TUBE ASSEMBLY TORQUE SPECIFICATIONS BOLT APPLICATIONS AND TORQUE SPECIFICATIONS.......................... 129
BOLT APPLICATIONS AND TORQUE SPECIFICATIONS............................................................................................ 129
92AS_5............................................................................................................................................. 131
BRAKES......................................................................................................................................... 131
GENERAL INFORMATION........................................................................................................................ 131
SERVICE ADJUSTMENTS........................................................................................................................ 133
ADJUSTING REAR SERVICE BRAKES.......................................................................................................... 133
FRONT WHEEL DRIVE.................................................................................................................. 133
ALL WHEEL DRIVE.................................................................................................................... 133
MASTER CYLINDER FLUID LEVEL............................................................................................................ 134
NON- ABS BRAKES.................................................................................................................... 134
ABS BRAKES......................................................................................................................... 135
BLEEDING BRAKE SYSTEM.................................................................................................................. 135
PRESSURE BLEEDING.................................................................................................................. 135
BLEEDING WITHOUT A PRESSURE BLEEDER................................................................................................ 136
TEST FOR FLUID CONTAMINATION........................................................................................................... 137
WHEEL STUD NUT TIGHTENING.............................................................................................................. 137
BRAKE HOSE AND TUBING.................................................................................................................. 137
INSPECTION OF BRAKE HOSE AND TUBING................................................................................................ 137
INSTALLATION OF BRAKE HOSE......................................................................................................... 137
TYPES OF TUBING FLARES............................................................................................................. 137
REPAIR AND INSTALLATION OF BRAKE TUB- ING.......................................................................................... 138
TO REPAIR OR FLARE TUBING.......................................................................................................... 138
DOUBLE INVERTED TUBING FLARES...................................................................................................... 138
ISO TUBING FLARES.................................................................................................................. 139
STOP LAMP SWITCH ADJUSTMENT............................................................................................................ 139
TESTING APPLICATION ADJUSTER OPERATION................................................................................................. 140
BRAKE DIAGNOSIS............................................................................................................................ 145
BASIC DIAGNOSIS GUIDE.................................................................................................................. 145
BRAKE SYSTEM DIAGNOSTICS............................................................................................................... 146
BRAKE SYSTEM DIAGNOSTICS........................................................................................................... 147
BRAKE SYSTEM DIAGNOSTICS........................................................................................................... 148
BRAKE SYSTEM DIAGNOSTICS........................................................................................................... 149
DRUM BRAKES................................................................................................................................ 150
GENERAL INFORMATION.................................................................................................................... 150
SERVICE PROCEDURES..................................................................................................................... 150
BRAKE DRUM REMOVAL................................................................................................................. 150
BRAKE SHOE REMOVAL................................................................................................................. 150
CLEANING AND INSPECTION............................................................................................................ 152
BRAKE SHOE INSTALLATION............................................................................................................ 152
DRUM REFACING RECOMMENDATIONS.......................................................................................................... 153
BRAKE DRUM INSTALLATION................................................................................................................ 154
FRONT WHEEL DRIVE.................................................................................................................. 154
ALL WHEEL DRIVE.................................................................................................................... 154
BRAKE SUPPORT PLATE.................................................................................................................... 154
FRONT WHEEL DRIVE.................................................................................................................. 154
ALL WHEEL DRIVE.................................................................................................................... 154
FRONT WHEEL DRIVE.................................................................................................................. 155
ALL WHEEL DRIVE.................................................................................................................... 155
WHEEL CYLINDERS............................................................................................................................ 156
GENERAL INFORMATION.................................................................................................................... 156
SERVICE PROCEDURES..................................................................................................................... 156
REMOVING WHEEL CYLINDERS FROM BRAKE SUPPORT PLATES................................................................................. 156
DISASSEMBLING WHEEL CYLINDERS...................................................................................................... 156
ASSEMBLING WHEEL CYLINDERS......................................................................................................... 157
INSTALLING WHEEL CYLINDERS............................................................................................................. 157
HYDRAULIC SYSTEM CONTROL VALVES............................................................................................................ 158
GENERAL INFORMATION.................................................................................................................... 158
PRESSURE DIFFERENTIAL WARNING LIGHT SWITCH......................................................................................... 158
HEIGHT SENSING DUAL PROPORTIONING UNIT OPERATION................................................................................... 158
ABS BRAKE PROPORTIONING VALVE OPERATION................................................................................................ 159
PROPORTIONING VALVE APPLICATIONS................................................................................................... 160
SERVICE PROCEDURES......................................................................................................................... 161
BRAKE WARNING SYSTEM................................................................................................................... 161
CHECKING THE BRAKE WARNING SWITCH UNIT............................................................................................. 161
HEIGHT SENSING PROPORTIONING VALVE..................................................................................................... 161
TESTING THE HEIGHT SENSING VALVE UNIT.............................................................................................. 161
INSTALLATION AND ADJUSTMENT (FIG. 4)............................................................................................... 161
TESTING ABS PROPORTIONING VALVES....................................................................................................... 162
PROPORTIONING VALVE PRESSURES ABS- BRAKES.......................................................................................... 162
DISC BRAKES................................................................................................................................ 163
GENERAL INFORMATION.................................................................................................................... 163
SHOE AND LINING WEAR............................................................................................................... 163
SERVICE PRECAUTIONS.................................................................................................................... 165
KELSEY HAYES DOUBLE PIN FAMILY CALIPER..................................................................................................... 165
SERVICE PROCEDURES..................................................................................................................... 165
BRAKE SHOE REMOVAL................................................................................................................. 165
BRAKE SHOE INSTALLATION................................................................................................................ 167
CLEANING AND INSPECTION............................................................................................................ 168
DISASSEMBLING CALIPER.................................................................................................................. 168
CLEANING AND INSPECTION................................................................................................................ 169
ASSEMBLING CALIPER..................................................................................................................... 170
BRAKE DISC (ROTOR)......................................................................................................................... 172
GENERAL INFORMATION.................................................................................................................... 172
INSPECTION DIAGNOSIS................................................................................................................... 172
SERVICE PROCEDURES..................................................................................................................... 173
CHECKING BRAKING DISC FOR RUNOUT AND THICKNESS..................................................................................... 173
BRAKING DISC REMOVAL................................................................................................................... 174
INSTALLING BRAKING DISC................................................................................................................ 174
REFINISHING BRAKING DISC............................................................................................................... 174
REFACING BRAKING DISC.............................................................................................................. 174
RESURFACING BRAKING DISC........................................................................................................... 175
BRAKING DISC (ROTOR) REFINISHING LIMITS............................................................................................ 175
PARKING BRAKES............................................................................................................................. 176
GENERAL INFORMATION.................................................................................................................... 176
SERVICE PROCEDURES..................................................................................................................... 178
ADJUSTING PARKING BRAKE............................................................................................................ 178
PARKING BRAKE PEDAL ASSEMBLY........................................................................................................... 178
REMOVE............................................................................................................................. 178
INSTALL............................................................................................................................ 178
FRONT PARKING BRAKE CABLE.............................................................................................................. 178
REMOVE............................................................................................................................. 178
INSTALL............................................................................................................................ 179
REAR PARKING BRAKE CABLE............................................................................................................... 179
REMOVE............................................................................................................................. 179
INSTALL............................................................................................................................ 179
MASTER CYLINDER............................................................................................................................ 179
GENERAL INFORMATION.................................................................................................................... 179
RESERVOIR REPLACEMENT.................................................................................................................. 180
SERVICE PROCEDURES..................................................................................................................... 180
MASTER CYLINDER.................................................................................................................... 180
POWER BRAKES............................................................................................................................... 181
GENERAL INFORMATION.................................................................................................................... 181
SERVICE PROCEDURES..................................................................................................................... 182
POWER BRAKE BOOSTER ASSEMBLY....................................................................................................... 182
WHEEL BEARINGS............................................................................................................................. 184
FRONT WHEEL BEARINGS................................................................................................................... 184
REAR WHEEL BEARINGS (FRONT WHEEL DRIVE)................................................................................................ 184
NORMAL SERVICE..................................................................................................................... 184
INSPECTION......................................................................................................................... 184
REMOVAL AND INSTALLATION........................................................................................................... 184
ANTI- LOCK BRAKE SYSTEM (BENDIX ANTI- LOCK 10 AS BODY FWD/ AWD)............................................................................ 186
GENERAL INFORMATION.................................................................................................................... 186
ANTI- LOCK BRAKE SYSTEM DEFINITIONS.................................................................................................... 186
MAJOR ABS COMPONENTS................................................................................................................... 187
HYDRAULIC ASSEMBLY................................................................................................................. 187
WHEEL SPEED SENSORS................................................................................................................ 187
CONTROLLER- ANTI- LOCK BRAKE (CAB)................................................................................................. 187
PUMP/ MOTOR ASSEMBLY............................................................................................................... 188
ANTI- LOCK OPERATION AND PERFORMANCE................................................................................................... 188
NORMAL BRAKING SYSTEM FUNCTION..................................................................................................... 188
PEDAL FEEL......................................................................................................................... 188
ANTI- LOCK OPERATION............................................................................................................... 188
TIRE NOISE & MARKS................................................................................................................. 188
ABS EQUIPPED VEHICLE PERFORMANCE....................................................................................................... 188
ABS SYSTEM SELF- DIAGNOSTICS........................................................................................................... 189
WARNING SYSTEMS OPERATION.............................................................................................................. 189
RED BRAKE WARNING LAMP............................................................................................................. 189
ANTI- LOCK WARNING LAMP............................................................................................................ 189
NORMAL OPERATION OF WARNING LAMPS.................................................................................................. 189
ANTI- LOCK BRAKE SYSTEM COMPONENTS..................................................................................................... 190
HYDRAULIC ASSEMBLY................................................................................................................. 190
HYDRAULIC ASSEMBLY BRAKE FLUID RES-ERVOIR.......................................................................................... 190
BOOSTER/ MASTER CYLINDER........................................................................................................... 190
HYDRAULIC BLADDER ACCUMULATOR...................................................................................................... 191
DUAL FUNCTION PRESSURE SWITCH...................................................................................................... 191
PRESSURE TRANSDUCERS............................................................................................................... 192
DIFFERENTIAL PRESSURE SWITCH....................................................................................................... 192
PROPORTIONING VALVES............................................................................................................... 192
FILTERS- SERVICEABILITY............................................................................................................ 192
FLUID LEVEL SWITCH................................................................................................................. 192
DUAL FUNCTION PRESSURE SWITCH WIRING DIAGRAM....................................................................................... 192
PUMP/ MOTOR ASSEMBLY............................................................................................................... 193
WHEEL SPEED SENSORS................................................................................................................ 193
PRESSURE SWITCH AND PRESSURE TRANSDUCER WIRING..................................................................................... 193
CONTROLLER ANTI- LOCK BRAKE (CAB)...................................................................................................... 195
CONTROLLER ANTI- LOCK BRAKE (INPUTS)............................................................................................... 195
CONTROLLER ANTI- LOCK BRAKE (OUTPUTS).............................................................................................. 195
ABS SYSTEM DIAGNOSTIC CONNECTOR........................................................................................................ 195
ABS SYSTEM WIRING SCHEMATIC........................................................................................................ 196
ANTI- LOCK SYSTEM RELAYS AND WARNING LAMPS............................................................................................. 197
PUMP/ MOTOR RELAY.................................................................................................................. 197
SYSTEM RELAY....................................................................................................................... 197
ANTI- LOCK WARNING LAMP RELAY...................................................................................................... 197
ANTI- LOCK WARNING LAMP OFF........................................................................................................ 197
ANTI- LOCK WARNING LAMP ON......................................................................................................... 197
ANTI- LOCK SYSTEM RELAY WIRING SCHEMATIC........................................................................................... 198
ABS HYDRAULIC CIRCUITS AND VALVE OPERA-TION............................................................................................ 199
NORMAL BRAKING..................................................................................................................... 199
ABS BRAKING- BUILD PRESSURE........................................................................................................ 199
ABS BRAKING- HOLD PRESSURE......................................................................................................... 200
ABS BRAKING- DECAY PRESSURE........................................................................................................ 200
ABS BRAKING SYSTEM DIAGNOSIS........................................................................................................... 201
GENERAL INFORMATION................................................................................................................ 201
DEFINITIONS........................................................................................................................ 202
ABS CONTROLLER ANTI- LOCK BRAKE (CAB) SERVICE PRECAUTIONS.............................................................................. 202
ABS SYSTEM GENERAL SERVICE PRECAUTIONS................................................................................................. 202
TEST DRIVING ABS COMPLAINT VEHICLES................................................................................................ 202
DE- PRESSURIZING HYDRAULIC ACCUMULATOR............................................................................................. 203
WHEEL SPEED SENSOR CABLES.......................................................................................................... 203
MECHANICAL DIAGNOSTICS AND SERVICE PROCEDURES.......................................................................................... 203
SPECIAL SERVICE TOOLS.............................................................................................................. 203
INTERMITTENT FAULTS................................................................................................................ 204
ABS SYSTEM DIAGNOSTIC FEATURES......................................................................................................... 205
SYSTEM SELF DIAGNOSIS.............................................................................................................. 205
CONTROLLER ANTI- LOCK BRAKE (CAB).................................................................................................. 205
START- UP CYCLE.................................................................................................................... 205
DRIVE- OFF CYCLE................................................................................................................... 205
LATCHING VERSUS NON- LATCHING FAULTS............................................................................................... 205
BENDIX ABS SYSTEMS DIAGNOSTICS..................................................................................................... 205
ON CAR HYDRAULIC ABS COMPONENT SERVICE................................................................................................. 205
GENERAL SERVICE PRECAUTIONS............................................................................................................ 205
DE- PRESSURIZING HYDRAULIC ACCUMULATOR............................................................................................. 206
CHECKING BRAKE FLUID LEVEL......................................................................................................... 206
BLEEDING BRAKE SYSTEM.............................................................................................................. 206
PUMP/ MOTOR SERVICE (FIG. 4)....................................................................................................... 208
BRAKE FLUID PRESSURE AND RETURN HOSES (FIG. 6)..................................................................................... 209
INSTALL............................................................................................................................ 209
HYDRAULIC ASSEMBLY................................................................................................................. 210
BRAKE FLUID RESERVOIR.............................................................................................................. 211
HYDRAULIC BLADDER ACCUMULATOR...................................................................................................... 213
PROPORTIONING VALVES (FIG. 17)..................................................................................................... 214
ON CAR ELECTRONIC ABS COMPONENT SERVICE................................................................................................ 215
CONTROLLER ANTI- LOCK BRAKE (FIG. 1)............................................................................................... 215
SYSTEM RELAY, ANTI- LOCK WARNING LAMP RELAY AND PUMP/ MOTOR RELAYS (FIG. 2)........................................................ 215
DUAL FUNCTION PRESSURE SWITCH...................................................................................................... 216
WHEEL SPEED SENSORS................................................................................................................ 216
REAR WHEEL SPEED SENSOR............................................................................................................ 218
SPECIFICATIONS............................................................................................................................. 220
BRAKE SYSTEM COMPONENTS BRAKE ACTUATION SYSTEM......................................................................................... 220
TIGHTENING REFERENCE............................................................................................................... 221
92AS_6............................................................................................................................................. 223
MANUAL TRANSAXLE CLUTCH........................................................................................................................ 223
CONTENTS................................................................................................................................... 223
GENERAL INFORMATION.................................................................................................................... 223
CLUTCH CHATTER COMPLAINTS.............................................................................................................. 223
EXCESSIVE CLUTCH SPIN TIME/ CLASH INTO REVERSE COMPLAINTS.............................................................................. 223
CLUTCH CABLE MECHANISM................................................................................................................. 223
SERVICE DIAGNOSIS— CLUTCH SLIPS.................................................................................................... 224
SERVICE DIAGNOSIS— IMPROPER CLUTCH RELEASE......................................................................................... 225
SERVICE DIAGNOSIS— CLUTCH NOISE.................................................................................................... 226
CLUTCH CABLE REPLACEMENT............................................................................................................... 227
SERVICE DIAGNOSIS— CLUTCH GRAB/ CHATTER............................................................................................ 227
CLUTCH/ STARTER INTERLOCK SWITCH....................................................................................................... 229
DIAGNOSIS.......................................................................................................................... 229
REMOVAL............................................................................................................................ 229
INSTALLATION....................................................................................................................... 229
ADJUSTMENT PROCEDURE............................................................................................................... 229
CLUTCH DISC REPLACEMENT................................................................................................................ 230
REMOVAL............................................................................................................................ 230
INSPECTION......................................................................................................................... 230
INSTALLATION....................................................................................................................... 231
RELEASE BEARING AND FORK............................................................................................................... 231
REMOVAL AND INSTALLATION........................................................................................................... 231
CLEANING PRECAUTIONS................................................................................................................... 231
92AS_7............................................................................................................................................. 233
COOLING SYSTEM................................................................................................................................. 233
GENERAL INFORMATION........................................................................................................................ 233
COOLING SYSTEM......................................................................................................................... 233
3.0L WATER PIPES................................................................................................................... 234
COOLING SYSTEM DIAGNOSIS........................................................................................................... 236
COOLING SYSTEM DIAGNOSIS........................................................................................................... 237
COOLING SYSTEM DIAGNOSIS........................................................................................................... 238
COOLING SYSTEM DIAGNOSIS........................................................................................................... 239
COOLING SYSTEM DIAGNOSIS........................................................................................................... 240
COOLING SYSTEM DIAGNOSIS........................................................................................................... 241
SERVICE PROCEDURES......................................................................................................................... 242
WATER PUMPS............................................................................................................................ 242
WATER PUMP 2.5L ENGINE............................................................................................................. 242
WATER PUMP 3.0L ENGINE............................................................................................................. 243
WATER PUMP 3.3L ENGINE............................................................................................................. 243
ENGINE THERMOSTAT...................................................................................................................... 244
DESCRIPTION AND OPERATION.......................................................................................................... 244
OPERATION AND TESTING.............................................................................................................. 244
REMOVAL............................................................................................................................ 245
INSTALLATION— 2.5L ENGINE.......................................................................................................... 245
INSTALLATION— 3.0L ENGINE.......................................................................................................... 245
INSTALLATION— 3.3L................................................................................................................. 245
COOLANT................................................................................................................................ 246
PERFORMANCE........................................................................................................................ 246
SELECTION AND ADDITIVES............................................................................................................ 246
SERVICE............................................................................................................................ 246
ROUTINE LEVEL CHECK................................................................................................................ 246
ADDING ADDITIONAL COOLANT.............................................................................................................. 246
SERVICE COOLANT LEVEL.............................................................................................................. 246
LOW COOLANT LEVEL AERATION......................................................................................................... 246
DEAERATION......................................................................................................................... 246
COOLING SYSTEM DRAIN, CLEAN FLUSH AND REFILL........................................................................................... 247
DRAINING COOLING SYSTEM............................................................................................................ 247
CLEANING........................................................................................................................... 247
REVERSE FLUSHING................................................................................................................... 247
CHEMICAL CLEANING.................................................................................................................. 247
REFILLING.......................................................................................................................... 248
TESTING SYSTEM FOR LEAKS............................................................................................................... 248
COOLANT RECOVERY SYSTEM (CRS).......................................................................................................... 248
RADIATOR PRESSURE CAP.................................................................................................................. 249
RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK............................................................................. 249
PRESSURE TESTING RADIATOR CAP.......................................................................................................... 249
INSPECTION......................................................................................................................... 249
RADIATORS.............................................................................................................................. 250
RADIATOR DRAINCOCK SERVICE......................................................................................................... 250
RADIATOR COOLANT FLOW CHECK........................................................................................................ 251
RADIATOR HOSES......................................................................................................................... 251
FANS................................................................................................................................... 251
FAN SERVICE............................................................................................................................ 251
REMOVAL............................................................................................................................ 251
INSTALLATION....................................................................................................................... 251
RADIATOR FAN CONTROL............................................................................................................... 252
TEMPERATURE GAUGE INDICATION....................................................................................................... 252
ELECTRIC FAN MOTOR..................................................................................................................... 252
ELECTRIC FAN MOTOR TEST................................................................................................................ 253
TEST PROCEDURE..................................................................................................................... 253
FAN SHROUD............................................................................................................................. 253
AUTOMATIC TRANSMISSION OIL COOLERS..................................................................................................... 253
ACCESSORY DRIVE BELTS...................................................................................................................... 255
GENERAL INFORMATION.................................................................................................................... 255
PROPER BELT TENSION................................................................................................................ 255
BELT TENSION GAUGE METHOD.......................................................................................................... 255
TORQUE EQUIVALENT METHOD........................................................................................................... 255
2.5L ENGINE BELTS REMOVE/ INSTALL-ADJUST............................................................................................... 255
AIR CONDITIONING COMPRESSOR........................................................................................................ 255
ACCESSORY DRIVE BELTS DIAGNOSIS.................................................................................................... 255
POWER STEERING PUMP— S TYPE........................................................................................................ 256
ALTERNATOR BELT.................................................................................................................... 256
3.0L ENGINE BELTS REMOVE/ INSTALL- ADJUST.............................................................................................. 256
AIR CONDITIONING BELT.............................................................................................................. 256
ALTERNATOR/ POWER STEERING PUMP BELT............................................................................................... 257
3.3L ENGINE ACCESSORY DRIVE BELT REMOVE/ INSTALL....................................................................................... 257
ALTERNATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT............................................. 257
BELT TENSION CHART................................................................................................................. 258
ENGINE BLOCK HEATER........................................................................................................................ 259
DESCRIPTION AND OPERATION.............................................................................................................. 259
REMOVAL............................................................................................................................ 259
INSTALLATION....................................................................................................................... 259
SPECIFICATIONS............................................................................................................................. 261
TORQUE ................................................................................................................................ 261
COOLING SYSTEM CAPACITY................................................................................................................ 261
92AS_8A............................................................................................................................................ 263
BATTERY/ STARTING/ CHARGING SYSTEMS DIAGNOSTICS................................................................................................ 0
BATTERY TEST PROCEDURES ON- VEHICLE........................................................................................................ 264
GENERAL INFORMATION.................................................................................................................... 264
TEST INDICATOR......................................................................................................................... 265
STATE OF CHARGE TESTS.................................................................................................................. 265
USING TEST INDICATOR............................................................................................................... 265
CAUSES OF BATTERY DISCHARGING.......................................................................................................... 265
ABNORMAL BATTERY DISCHARGING....................................................................................................... 266
BATTERY OPEN CIRCUIT VOLTAGE TEST...................................................................................................... 266
BATTERY LOAD TEST...................................................................................................................... 266
BATTERY CHARGING....................................................................................................................... 268
CHARGING TIME REQUIRED............................................................................................................. 268
CHARGING COMPLETELY DISCHARGED BATTERY............................................................................................. 269
IGNITION OFF DRAW (IOD).................................................................................................................... 269
GENERAL INFORMATION.................................................................................................................... 269
IGNITION OFF DRAW (IOD) TESTS...................................................................................................... 270
STARTER TEST PROCEDURES ON VEHICLE......................................................................................................... 271
GENERAL INFORMATION.................................................................................................................... 271
DIAGNOSTIC PREPARATION................................................................................................................. 271
STARTER FEED CIRCUIT TESTS............................................................................................................. 271
STARTER FEED CIRCUIT RESISTANCE TEST................................................................................................... 273
STARTER CONTROL CIRCUIT TESTS.......................................................................................................... 274
STARTER SOLENOID TEST.............................................................................................................. 275
STARTER RELAY TEST................................................................................................................. 275
NEUTRAL STARTING AND BACK- UP SWITCH............................................................................................... 275
IGNITION SWITCH TEST............................................................................................................... 275
BENCH TESTING STARTER SOLENOID..................................................................................................... 275
ALTERNATOR TEST PROCEDURES ON VEHICLE...................................................................................................... 277
OUTPUT WIRE RESISTANCE TEST............................................................................................................ 277
PREPARATION........................................................................................................................ 277
TEST............................................................................................................................... 278
RESULTS............................................................................................................................ 279
CURRENT OUTPUT TEST.................................................................................................................... 279
PREPARATION........................................................................................................................ 279
TEST............................................................................................................................... 280
RESULTS............................................................................................................................ 280
FAULT CODES— ON BOARD DIAGNOSTICS.......................................................................................................... 280
GENERAL DESCRIPTION/ INFORMATION....................................................................................................... 280
EXAMPLES:.......................................................................................................................... 280
DIAGNOSTIC TESTING USING FAULT CODES................................................................................................... 281
DRB II DIAGNOSTIC TESTER............................................................................................................... 284
TESTING FAULT CODES................................................................................................................ 284
SPECIFICATIONS............................................................................................................................. 285
SPECIFICATIONS STARTER/ BATTERY ...................................................................................................... 285
SPECIFICATIONS ALTERNATOR AMPERAGE/ IDENTIFICATION NUMBERS............................................................................ 285
TORQUE SPECIFICATIONS ................................................................................................................. 286
SPECIFICATIONS ALTERNATOR OUTPUT VOLTAGE.............................................................................................. 286
92AS_8B............................................................................................................................................ 287
BATTERY/ STARTER/ ALTERNATOR SERVICE........................................................................................................... 287
BATTERY.................................................................................................................................... 287
GENERAL INFORMATION.................................................................................................................... 287
BATTERY VISUAL INSPECTION AND SERVICE.................................................................................................. 287
STARTER.................................................................................................................................... 289
GENERAL INFORMATION.................................................................................................................... 289
STARTING SYSTEM........................................................................................................................ 289
BOSCH STARTERS..................................................................................................................... 289
NIPPONDENSO STARTERS............................................................................................................... 289
SUPPLY CIRCUIT AND CONTROL CIRCUIT..................................................................................................... 289
STARTER MOTOR REPLACEMENT.............................................................................................................. 289
BOSCH STARTER 2.5L ENGINE.......................................................................................................... 289
BOSCH OR NIPPONDENSO STARTER— 3.0L OR 3.3L ENGINE.................................................................................. 290
STARTER COMPONENT REPLACEMENT.......................................................................................................... 291
NIPPONDENSO STARTER GEAR AND CLUTCH................................................................................................ 291
BOSCH STARTER SOLENOID REPLACEMENT................................................................................................. 292
BOSCH STARTER GEAR AND CLUTCH REPLACEMENT.......................................................................................... 293
NEUTRAL STARTING AND BACK- UP SWITCH................................................................................................... 293
ALTERNATOR SERVICE PROCEDURES.............................................................................................................. 294
GENERAL INFORMATION.................................................................................................................... 294
ALTERNATOR REPLACEMENT— 2.5L ENGINE.................................................................................................... 294
ALTERNATOR REPLACEMENT— 3.0L ENGINE.................................................................................................... 295
ALTERNATOR REPLACEMENT— 3.3L ENGINE.................................................................................................... 296
SPECIFICATIONS............................................................................................................................. 296
STARTER/ BATTERY....................................................................................................................... 296
ALTERNATOR AMPERAGE/ IDENTIFICATION NUMBERS ....................................................................................... 297
TORQUE SPECIFICATIONS ALTERNATOR/ STARTER......................................................................................... 297
92AS_8C............................................................................................................................................ 299
OVERHEAD CONSOLE............................................................................................................................... 299
CONTENTS................................................................................................................................... 299
MAP/ READING LAMPS..................................................................................................................... 299
LAMP HOUSING REPLACEMENT........................................................................................................... 299
LENS/ LAMP REPLACEMENT............................................................................................................. 299
LAMP TEST.......................................................................................................................... 299
REAR VENT WINDOWS SWITCHES............................................................................................................. 299
SWITCH VOLTAGE TEST................................................................................................................ 299
SWITCH MODULE TEST................................................................................................................. 300
SWITCH REMOVAL..................................................................................................................... 300
COMPASS MINI- TRIP COMPUTER (CMTC)..................................................................................................... 300
THERMOMETER AND COMPASS............................................................................................................ 300
VARIANCE PROCEDURE................................................................................................................. 301
TRAVELER MESSAGES.................................................................................................................. 301
DEMAGNETIZING PROCEDURE............................................................................................................ 301
SELF- DIAGNOSTIC TEST.............................................................................................................. 302
OVERHEAD CONSOLE REPLACEMENT........................................................................................................... 302
COMPASS MODULE REPLACEMENT............................................................................................................. 302
FRONT HEADER READING LAMP.............................................................................................................. 302
FRONT HEADER READING LAMP REPLACEMENT/ LAMP REPLACEMENT................................................................................ 302
92AS_8D............................................................................................................................................ 305
IGNITION SYSTEMS............................................................................................................................... 305
2.5L AND 3.0L IGNITION SYSTEMS— SYSTEM OPERATION........................................................................................... 305
GENERAL INFORMATION.................................................................................................................... 305
DISTRIBUTOR CAP........................................................................................................................ 305
ROTOR— 2.5L AND 3.0L ENGINES........................................................................................................... 306
SPARK PLUG CABLES...................................................................................................................... 306
SPARK PLUGS............................................................................................................................ 307
SPARK PLUG CONDITION............................................................................................................... 307
CABLE RESISTANCE CHART............................................................................................................. 307
SPARK PLUG SERVICE................................................................................................................. 310
ENGINE CONTROLLER...................................................................................................................... 310
HALL EFFECT PICK- UP— 2.5L ENGINES..................................................................................................... 310
DISTRIBUTOR PICK- UP— 3.0L ENGINE...................................................................................................... 311
COOLANT TEMPERATURE SENSOR............................................................................................................. 311
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 311
AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY.......................................................................................... 312
IGNITION COIL.......................................................................................................................... 313
2.5L AND 3.0L IGNITION SYSTEMS— DIAGNOSTIC PROCEDURES...................................................................................... 314
GENERAL INFORMATION.................................................................................................................... 314
SPARK PLUGS............................................................................................................................ 314
IGNITION COIL.......................................................................................................................... 314
TESTING FOR SPARK AT COIL.............................................................................................................. 314
COIL RESISTANCE.................................................................................................................... 314
FAILURE TO START TEST— 2.5L TBI AND 3.0L ENGINES....................................................................................... 315
POOR PERFORMANCE TEST.................................................................................................................. 316
COOLANT TEMPERATURE SENSOR TEST........................................................................................................ 316
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST........................................................................................... 316
2.5L AND 3.0L IGNITION SYSTEMS— SERVICE PROCEDURES......................................................................................... 317
ENGINE CONTROLLER...................................................................................................................... 317
REMOVAL............................................................................................................................ 317
INSTALLATION....................................................................................................................... 317
COOLANT TEMPERATURE SENSOR............................................................................................................. 317
REMOVAL............................................................................................................................ 317
INSTALLATION....................................................................................................................... 317
IGNITION COIL— 2.5L TBI ENGINES........................................................................................................ 318
REMOVAL............................................................................................................................ 318
INSTALLATION....................................................................................................................... 318
IGNITION COIL— 3.0L ENGINES............................................................................................................ 318
REMOVAL............................................................................................................................ 318
INSTALLATION....................................................................................................................... 318
SPARK PLUG SERVICE..................................................................................................................... 318
SPARK PLUG REMOVAL................................................................................................................. 318
SPARK PLUG GAP ADJUSTMENT.......................................................................................................... 319
IDLE RPM TEST— 2.5L AND 3.0L ENGINES................................................................................................... 319
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE— 2.5L ENGINE........................................................................ 319
IDLE SPECIFICATIONS................................................................................................................ 319
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE— 3.0L ENGINE........................................................................ 320
IDLE SPECIFICATIONS— 3.0L ENGINE................................................................................................... 320
IGNITION TIMING PROCEDURE— 2.5L TBI AND 3.0L ENGINES................................................................................... 321
DISTRIBUTOR— 2.5L ENGINE............................................................................................................... 322
REMOVAL............................................................................................................................ 322
INSTALLATION....................................................................................................................... 322
DISTRIBUTOR PICK- UP— 2.5L ENGINE...................................................................................................... 323
REMOVAL............................................................................................................................ 323
INSTALLATION....................................................................................................................... 323
DISTRIBUTOR SERVICE— 3.0L ENGINE....................................................................................................... 323
REMOVAL............................................................................................................................ 323
INSTALLATION....................................................................................................................... 324
DISASSEMBLY........................................................................................................................ 324
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SERVICE— 2.5L TBI AND 3.0L ENGINES............................................................. 328
3.3L IGNITION SYSTEM— SYSTEM OPERATION..................................................................................................... 329
GENERAL INFORMATION.................................................................................................................... 329
FIRING ORDER....................................................................................................................... 329
ENGINE CONTROLLER...................................................................................................................... 329
SPARK PLUG CABLES...................................................................................................................... 330
SPARK PLUGS............................................................................................................................ 330
SPARK PLUG CONDITION............................................................................................................... 331
CAMSHAFT SENSOR........................................................................................................................ 332
CRANKSHAFT TIMING SENSOR............................................................................................................... 333
IGNITION COIL.......................................................................................................................... 334
COOLANT TEMPERATURE SENSOR ENGINE CONTROLLER INPUT.................................................................................... 334
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 335
AUTO SHUTDOWN (ASD) RELAY ENGINE CONTROLLER OUTPUT.................................................................................... 335
3.3L IGNITION SYSTEM— DIAGNOSTIC PROCEDURES................................................................................................ 336
TESTING FOR SPARK AT COIL.............................................................................................................. 336
CHECK COIL TEST— 3.3L ENGINE........................................................................................................... 336
FAILURE TO START TEST.................................................................................................................. 337
COOLANT TEMPERATURE SENSOR TEST........................................................................................................ 337
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST........................................................................................... 338
CRANKSHAFT SENSOR AND CAMSHAFT SENSOR TESTS............................................................................................ 338
3.3L IGNITION SYSTEMS— SERVICE PROCEDURES.................................................................................................. 339
ENGINE CONTROLLER...................................................................................................................... 339
REMOVAL............................................................................................................................ 339
INSTALLATION....................................................................................................................... 339
COOLANT TEMPERATURE SENSOR............................................................................................................. 339
REMOVAL............................................................................................................................ 339
INSTALLATION....................................................................................................................... 340
SPARK PLUG CABLE SERVICE............................................................................................................... 340
SPARK PLUG SERVICE..................................................................................................................... 340
SPARK PLUG REMOVAL................................................................................................................. 340
SPARK PLUG GAP ADJUSTMENT.......................................................................................................... 340
IDLE RPM TEST.......................................................................................................................... 340
CABLE RESISTANCE CHART............................................................................................................. 340
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE..................................................................................... 341
IDLE SPECIFICATIONS................................................................................................................ 341
IGNITION TIMING PROCEDURE.............................................................................................................. 342
CRANKSHAFT TIMING SENSOR............................................................................................................... 342
REMOVAL............................................................................................................................ 342
INSTALLATION....................................................................................................................... 342
CAMSHAFT SENSOR........................................................................................................................ 342
REMOVAL............................................................................................................................ 342
INSTALLATION....................................................................................................................... 342
IGNITION COIL.......................................................................................................................... 343
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 343
IGNITION SWITCH............................................................................................................................ 344
IGNITION SWITCH AND KEY CYLINDER SERVICE............................................................................................... 344
REMOVAL............................................................................................................................ 344
IGNITION SWITCH DESIGNATIONS....................................................................................................... 344
INSTALLATION....................................................................................................................... 345
SPECIFICATIONS............................................................................................................................. 346
GENERAL INFORMATION.................................................................................................................... 346
SPARK PLUG WIRE ROUTING 2.5L ENGINES ............................................................................................. 346
SPARK PLUG WIRE ROUTING 3.0L ENGINE .............................................................................................. 346
SPARK PLUG WIRE ROUTING -3.3L ENGINES............................................................................................. 346
3.3L ENGINE DIRECT IGNITION SYSTEM................................................................................................. 346
DISTRIBUTORS ...................................................................................................................... 347
IGNITION COILS .................................................................................................................... 347
SPARK PLUGS ....................................................................................................................... 347
TORQUE............................................................................................................................. 347
92AS_8E............................................................................................................................................ 349
INSTRUMENT PANEL AND GAUGES.................................................................................................................... 349
CONTENTS................................................................................................................................... 349
GENERAL INFORMATION.................................................................................................................... 349
INSTRUMENT CLUSTERS................................................................................................................ 349
MAGNETIC GAUGES.................................................................................................................... 349
ELECTRONIC DIGITAL CLOCK........................................................................................................... 349
MAINTENANCE REQUIRED REMINDER...................................................................................................... 350
SEAT BELT WARNING SYSTEM........................................................................................................... 350
SEAT BELT WARNING LAMP............................................................................................................. 350
CLUSTER AND GAUGE SERVICE.............................................................................................................. 350
MECHANICAL CLUSTER SERVICE......................................................................................................... 350
ELECTRONIC CLUSTER SERVICE......................................................................................................... 350
SELF DIAGNOSTIC SYSTEM............................................................................................................. 350
CONDITION: MECHANICAL CLUSTER IS NOT FUNCTIONAL WITH ENGINE RUNNING................................................................ 350
WARNING INDICATOR MODULE REPLACE-MENT OR LAMP REPLACEMENT.......................................................................... 350
INSTRUMENT PANEL CLUSTER BEZEL RE-PLACEMENT........................................................................................ 350
INSTRUMENT PANEL CLUSTER LENS RE-PLACEMENT......................................................................................... 353
INSTRUMENT PANEL CLUSTER REPLACE-MENT.............................................................................................. 353
CLUSTER PRINTED CIRCUIT BOARD RE-PLACEMENT......................................................................................... 354
CLUSTER LAMPS BULB REPLACEMENT MECHANIAL CLUSTER ONLY.............................................................................. 355
GAUGES................................................................................................................................. 355
FUEL GAUGE REPLACEMENT............................................................................................................. 355
VOLTMETER REPLACEMENT.............................................................................................................. 355
TEMPERATURE GAUGE REPLACEMENT...................................................................................................... 356
OIL PRESSURE GAUGE REPLACEMENT..................................................................................................... 356
TACHOMETER REPLACEMENT............................................................................................................. 356
SPEEDOMETER ASSEMBLY REPLACEMENT................................................................................................... 356
ODOMETER ASSEMBLY REPLACEMENT...................................................................................................... 356
DISTANCE SENSOR REPLACEMENT........................................................................................................ 357
DISTANCE SENSOR TEST............................................................................................................... 357
SENDING UNIT TEST.................................................................................................................. 357
FUEL TANK SENDING UNIT TEST........................................................................................................ 357
CONDITION.......................................................................................................................... 357
WARNING LAMP SYSTEM TESTS.............................................................................................................. 358
BRAKE SYSTEM WARNING LAMP TEST..................................................................................................... 358
TEMPERATURE WARNING LAMP TEST...................................................................................................... 358
LOW OIL PRESSURE WARNING LAMP TEST................................................................................................. 358
COMBINATION OIL SENDING UNIT TESTS................................................................................................. 358
SWITCH AND PANEL COMPONENT SERVICE..................................................................................................... 360
HEADLAMP SWITCH.................................................................................................................... 360
SWITCH TEST........................................................................................................................ 360
SWITCH/ LAMP REPLACEMENT........................................................................................................... 360
REAR WIPER/ WASHER CONTROL POD SWITCH REPLACEMENT...................................................................................... 360
ACCESSORY SWITCH CARRIER............................................................................................................... 360
ACCESSORY SWITCH CARRIER TEST.......................................................................................................... 362
ACCESSORY SWITCH CARRIER REPLACEMENT................................................................................................... 362
A/ C AND HEATER CONTROL/ BLOWER SWITCH REPLACEMENT................................................................................. 362
A/ C AND HEATER CONTROL LAMP REPLACEMENT........................................................................................... 362
REAR A/ C- HEATER SWITCH REPLACEMENT............................................................................................... 363
CIGAR LIGHTER REPLACEMENT.......................................................................................................... 363
FORWARD CONSOLE REMOVAL............................................................................................................ 363
CENTER STORAGE MODULE REMOVAL...................................................................................................... 364
ASH RECEIVER ASSEMBLY.............................................................................................................. 364
BODY CONTROLLER REPLACEMENT........................................................................................................ 364
LOWER RIGHT INSTRUMENT PANEL REPLACEMENT............................................................................................... 364
INSTRUMENT PANEL REPLACEMENT........................................................................................................... 365
DOOR COURTESY LAMP/ REFLECTOR REPLACEMENT.......................................................................................... 366
DOOR COURTESY LAMP BULB REPLACEMENT................................................................................................ 366
DOME LAMP.......................................................................................................................... 366
LIFTGATE LAMP BULBS REPLACEMENT.................................................................................................... 366
GLOVEBOX LIGHT SWITCH REPLACEMENT.................................................................................................. 366
PRNDL REPLACEMENT.................................................................................................................. 366
92AS_8F............................................................................................................................................ 369
AUDIO SYSTEM................................................................................................................................... 369
CONTENTS................................................................................................................................... 369
RADIOS................................................................................................................................. 369
INTERFERENCE ELIMINATION........................................................................................................... 369
TEST............................................................................................................................... 369
REPLACEMENT........................................................................................................................ 369
MANUAL ANTENNAS........................................................................................................................ 369
TESTING............................................................................................................................ 369
REMOVAL............................................................................................................................ 369
INSTALLATION....................................................................................................................... 370
BENCH TEST FOR ANTENNA MALFUNCTION................................................................................................. 370
SPEAKERS............................................................................................................................... 370
FRONT SPEAKER REPLACEMENT.......................................................................................................... 370
FRONT DOOR SPEAKERS REPLACEMENT.................................................................................................... 370
REAR SPEAKERS REPLACEMENT.......................................................................................................... 372
RELAY/ CHOKE— INFINITY SPEAKERS........................................................................................................ 372
92AS_8G............................................................................................................................................ 375
HORNS.......................................................................................................................................... 375
CONTENTS................................................................................................................................... 375
GENERAL INFORMATION.................................................................................................................... 375
HORNS WILL NOT SOUND................................................................................................................... 375
HORNS SOUND CONTINUOUSLY............................................................................................................... 376
DIAGNOSIS TESTING...................................................................................................................... 376
HORN SWITCH REPLACEMENT................................................................................................................ 376
92AS_8H............................................................................................................................................ 379
SPEED CONTROL SYSTEM........................................................................................................................... 379
CONTENTS................................................................................................................................... 379
GENERAL INFORMATION.................................................................................................................... 379
DIAGNOSIS PROCEDURES................................................................................................................... 380
ROAD TEST.............................................................................................................................. 380
INOPERATIVE SYSTEM..................................................................................................................... 380
CHECKING FOR FAULT CODE................................................................................................................ 380
SYSTEM DIAGNOSIS................................................................................................................... 381
SYSTEM DIAGNOSIS— CONTINUED........................................................................................................ 382
ELECTRICAL TEST:....................................................................................................................... 383
SERVO ELECTRICAL TESTS................................................................................................................. 383
ENGINE CONTROLLER ELECTRICAL TEST...................................................................................................... 384
SPEED CONTROL SWITCH TEST.............................................................................................................. 385
STOP LAMP SPEED CONTROL SWITCH TEST.................................................................................................... 385
VACUUM SUPPLY TEST..................................................................................................................... 385
SERVO VACUUM TEST...................................................................................................................... 386
SERVO UNIT............................................................................................................................. 386
REMOVAL............................................................................................................................ 386
INSTALLATION....................................................................................................................... 386
SPEED CONTROL SWITCH................................................................................................................... 386
REMOVAL............................................................................................................................ 386
INSTALLATION....................................................................................................................... 386
92AS_8J............................................................................................................................................ 387
TURN SIGNALS AND HAZARD WARNING FLASHER........................................................................................................ 387
CONTENTS................................................................................................................................... 387
GENERAL INFORMATION.................................................................................................................... 387
HAZARD WARNING SWITCH.................................................................................................................. 387
CHIME FUNCTION......................................................................................................................... 387
MULTI- FUNCTION SWITCH................................................................................................................. 387
SWITCH TEST........................................................................................................................ 387
REMOVAL............................................................................................................................ 387
INSTALLATION....................................................................................................................... 387
ELECTRONIC COMBINATION FLASHER......................................................................................................... 387
FLASHER SYSTEM DIAGNOSIS............................................................................................................... 389
92AS_8K............................................................................................................................................ 391
WINDSHIELD WIPER AND WASHER SYSTEMS............................................................................................................ 391
WINDSHIELD WIPER BLADE AND ARM............................................................................................................. 391
GENERAL INFORMATION.................................................................................................................... 391
WIPER BLADES........................................................................................................................... 391
WIPER BLADE ELEMENT CHANGE REPLACEMENT................................................................................................. 391
WIPER ARM REPLACEMENT.................................................................................................................. 391
WIPER ARM ADJUSTMENT................................................................................................................... 393
WINDSHIELD WIPER MOTOR AND LINKAGE......................................................................................................... 394
MOTOR TESTS............................................................................................................................ 394
CONDITION: MOTOR WILL NOT RUN IN ANY SWITCH POSITION............................................................................... 394
CONDITION: MOTOR RUNS SLOWLY AT ALL SPEEDS......................................................................................... 394
CONDITION: MOTOR WILL RUN AT HIGH SPEED, BUT NOT AT LOW SPEED OR................................................................... 394
CONDITION: MOTOR KEEP RUNNING WITH SWITCH IN OFF POSITION.......................................................................... 396
CONDITION: MOTOR WILL STOP, WHEN SWITCH IS SET IN OFF POSITION. WIPERS DO NOT CONTINUE RUNNING TO PARK POSI-TION................... 396
WIPER MOTOR REPLACEMENT................................................................................................................ 397
INTERMITTENT WINDSHIELD WIPER MOTOR AND SWITCH............................................................................................. 397
INTERMITTENT WIPER MOTOR TEST.......................................................................................................... 397
CONDITION: EXCESSIVE DELAY OF MORE THAN 30 SECONDS OR INADEQUATE VARIA-TION IN DELAY............................................... 397
CONDITION: IN DELAY MODE WIPERS RUN CONTINUALLY WHEN WASH IS OPERATED BUT DO NOT PROVIDE AN EXTRA WIPE WHEN THE WASH CONTROL....... 397
INTERMITTENT WINDSHIELD WIPER SWITCH................................................................................................... 398
INTERMITTENT FUNCTION TESTS............................................................................................................ 398
CONDITION: EXCESSIVE DELAY, MORE THAN 30 SECONDS OR INADEQUATE VARIATION IN DELAY.................................................. 398
CONDITION: IN DELAY MODE WIPERS RUN CONTINUALLY WHEN WASH IS OPERATED BUT DO NOT PROVIDE AN EXTRA WIPE WHEN THE WASH CONTROL....... 398
CONDITION: WIPERS START ERRATICALLY DURING DELAY MODE.............................................................................. 398
WINDSHIELD WASHERS......................................................................................................................... 399
GENERAL INFORMATION.................................................................................................................... 399
WASHER RESERVOIR REMOVAL............................................................................................................... 399
WASHER RESERVOIR PUMP REPLACEMENT...................................................................................................... 399
WASHER NOZZLE.......................................................................................................................... 400
REAR WINDOW WIPER/ WASHER SYSTEM........................................................................................................... 400
REAR ARM ADJUSTMENT.................................................................................................................... 400
REAR WINDOW INTERMITTENT WIPE MODULE LOCATION.......................................................................................... 400
MODULE TEST............................................................................................................................ 401
REAR WIPER/ WASHER CONTROL POD SWITCH.................................................................................................. 401
REAR WIPER/ WASHER CONTROL POD SWITCH REPLACEMENT...................................................................................... 401
LIFTGATE WIPER MOTOR TEST.............................................................................................................. 401
LIFTGATE MOTOR REPLACEMENT............................................................................................................. 402
LIFTGATE WASHER RESERVOIR REMOVAL...................................................................................................... 402
LIFTGATE WASHER RESERVOIR PUMP REPLACE-MENT............................................................................................ 403
WASHER NOZZLE.......................................................................................................................... 403
92AS_8L............................................................................................................................................ 405
LAMPS.......................................................................................................................................... 405
GENERAL INFORMATION........................................................................................................................ 405
DIAGNOSTIC PROCEDURES.................................................................................................................. 405
HEADLAMP DIAGNOSIS................................................................................................................. 405
EXTERIOR LAMPS, SWITCHES AND SYSTEMS....................................................................................................... 406
HEADLAMP SWITCH........................................................................................................................ 406
HEADLAMP DIMMER SWITCH................................................................................................................. 406
HEADLAMP ALIGNMENT..................................................................................................................... 406
HEADLAMP ALIGNMENT PREPARATION......................................................................................................... 406
HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN............................................................................................. 406
ALIGNMENT SCREEN PREPARATION (FIG. 1).............................................................................................. 406
HEADLAMP ADJUSTMENT (FIG. 2 OR 3).................................................................................................. 406
FOG LAMP ALIGNMENT (FIG. 4)........................................................................................................ 406
AERO HEADLAMP BULB..................................................................................................................... 407
REMOVAL (FIG. 5)................................................................................................................... 407
INSTALLATION....................................................................................................................... 407
AERO HEADLAMP LENS/ HOUSING............................................................................................................ 408
REMOVAL............................................................................................................................ 408
INSTALLATION....................................................................................................................... 408
PARK/ TURN SIGNAL AND SIDE MARKER LAMP— AERO HEADLAMPS................................................................................. 409
LAMP OR BULB REMOVAL............................................................................................................... 409
LAMP OR BULB INSTALLATION.......................................................................................................... 409
PARK/ TURN SIGNAL AND SIDE MARKER LAMP................................................................................................. 410
LAMP OR BULB REMOVAL............................................................................................................... 410
LAMP OR BULB INSTALLATION.......................................................................................................... 410
FOG LAMP............................................................................................................................... 410
BULB REMOVAL....................................................................................................................... 410
BULB INSTALLATION.................................................................................................................. 410
TAIL LAMP.............................................................................................................................. 410
BULB REPLACEMENT (FIG. 16)......................................................................................................... 410
REMOVAL (FIG. 16).................................................................................................................. 410
INSTALLATION....................................................................................................................... 411
LICENSE PLATE LAMP/ BULB............................................................................................................... 411
REMOVAL (FIG. 17).................................................................................................................. 411
INSTALLATION....................................................................................................................... 411
CENTER HIGH- MOUNTED STOP LAMP (CHMSL)................................................................................................. 411
BULB OR LAMP REMOVAL (FIG. 18)..................................................................................................... 411
BULB OR LAMP INSTALLATION.......................................................................................................... 411
DAYTIME RUNNING LAMPS— CANADA ONLY..................................................................................................... 412
DIAGNOSTICS........................................................................................................................ 412
RELAY REMOVAL (FIG. 19)............................................................................................................ 412
RELAY INSTALLATION................................................................................................................. 412
HEADLAMP TIME DELAY SYSTEM............................................................................................................. 412
DIAGNOSTICS........................................................................................................................ 412
ILLUMINATED ENTRY SYSTEM................................................................................................................... 413
GENERAL INFORMATION.................................................................................................................... 413
DIAGNOSTIC PROCEDURES.................................................................................................................. 413
BODY CONTROLLER........................................................................................................................ 413
BODY CONTROLLER REMOVAL (FIG. 21).................................................................................................. 413
ILLUMINATED ENTRY SWITCH............................................................................................................... 413
REMOVAL (FIG. 20).................................................................................................................. 413
INSTALLATION....................................................................................................................... 413
INSTRUMENT PANEL LAMPS AND SWITCHES.................................................................................................... 413
ILLUMINATED ENTRY DIAGNOSIS........................................................................................................ 414
BULB APPLICATION TABLE..................................................................................................................... 415
GENERAL INFORMATION.................................................................................................................... 415
EXTERIOR LAMPS......................................................................................................................... 415
INTERIOR LAMPS......................................................................................................................... 415
DIMMER CONTROLLED LAMPS............................................................................................................ 415
INDICATOR LAMPS.................................................................................................................... 415
NON- DIMMING LAMPS................................................................................................................. 415
92AS_8M............................................................................................................................................ 417
RESTRAINT SYSTEMS.............................................................................................................................. 417
CONTENTS................................................................................................................................... 417
AIR BAG SERVICE AND TEST PROCEDURES.................................................................................................... 417
GENERAL INFORMATION.................................................................................................................... 417
AIR BAG MODULE..................................................................................................................... 417
FRONT IMPACT SENSORS............................................................................................................... 417
CLOCKSPRING........................................................................................................................ 418
DIAGNOSTIC MODULE.................................................................................................................. 418
STORAGE............................................................................................................................ 418
HANDLING LIVE MODULE............................................................................................................... 418
DEPLOYED MODULE.................................................................................................................... 418
CLEANUP PROCEDURE.................................................................................................................. 418
SERVICE OF DEPLOYED AIR BAG MODULE................................................................................................. 419
AIR BAG SYSTEM CHECK................................................................................................................... 419
AIR BAG MODULE......................................................................................................................... 419
REMOVAL............................................................................................................................ 419
INSTALLATION....................................................................................................................... 419
LEFT FRONT IMPACT SENSOR............................................................................................................... 420
REMOVAL............................................................................................................................ 420
INSTALLATION....................................................................................................................... 420
RIGHT FRONT IMPACT SENSOR.............................................................................................................. 420
REMOVAL............................................................................................................................ 420
INSTALLATION....................................................................................................................... 420
AIR BAG SYSTEM DIAGNOSTIC MODULE (ASDM)................................................................................................ 421
REMOVAL............................................................................................................................ 421
INSTALLATION....................................................................................................................... 421
CLOCKSPRING............................................................................................................................ 421
REMOVAL............................................................................................................................ 421
INSTALLATION....................................................................................................................... 422
CLOCKSPRING CENTERING PROCEDURE........................................................................................................ 422
STEERING WHEEL......................................................................................................................... 423
REMOVAL............................................................................................................................ 423
INSTALLATION....................................................................................................................... 423
STEERING COLUMN SWITCHES............................................................................................................... 423
REMOVAL............................................................................................................................ 423
INSTALLATION....................................................................................................................... 423
92AS_8N............................................................................................................................................ 425
REAR WINDOW DEFOGGER........................................................................................................................... 425
CONTENTS................................................................................................................................... 425
GENERAL INFORMATION.................................................................................................................... 425
ACCESSORY SWITCH CARRIER............................................................................................................... 425
SYSTEM TEST............................................................................................................................ 425
REAR WINDOW GRID LINES TEST............................................................................................................ 426
ACCESSORY SWITCH CARRIER TEST.......................................................................................................... 426
REPAIR GRID LINES, TERMINALS AND PIGTAILS.............................................................................................. 427
92AS_8P............................................................................................................................................ 429
POWER LOCKS.................................................................................................................................... 429
CONTENTS................................................................................................................................... 429
GENERAL INFORMATION.................................................................................................................... 429
DOOR LOCK INHIBIT...................................................................................................................... 429
POWER DOOR LOCKS....................................................................................................................... 429
DOOR LOCK SYSTEM TEST.................................................................................................................. 429
SWITCH VOLTAGE TEST.................................................................................................................... 429
CIRCUIT BREAKER TEST................................................................................................................... 430
SWITCH TEST............................................................................................................................ 430
CIRCUIT TEST SLIDING DOOR.............................................................................................................. 430
ELECTRIC MOTOR TEST.................................................................................................................... 430
LIFT GATE OPERATION.................................................................................................................... 431
TEST............................................................................................................................... 431
ADJUSTMENT......................................................................................................................... 431
DOOR LATCH WITH INTEGRAL LOCK— FRONT DOOR.............................................................................................. 431
REMOVAL............................................................................................................................ 431
INSTALLATION....................................................................................................................... 431
LOCK MOTOR REPLACEMENT SLIDING DOOR.................................................................................................... 431
REMOVAL............................................................................................................................ 431
INSTALLATION....................................................................................................................... 431
LOCK MOTOR REPLACEMENT LIFTGATE DOOR................................................................................................... 431
REMOVAL............................................................................................................................ 431
INSTALLATION....................................................................................................................... 432
92AS_8R............................................................................................................................................ 433
POWER SEATS.................................................................................................................................... 433
CONTENTS................................................................................................................................... 433
GENERAL INFORMATION.................................................................................................................... 433
TEST PROCEDURES........................................................................................................................ 433
CIRCUIT BREAKER TEST................................................................................................................... 433
HARNESS VOLTAGE TEST................................................................................................................... 433
MOTOR TESTS............................................................................................................................ 433
SWITCH TEST............................................................................................................................ 434
SEAT ASSEMBLY.......................................................................................................................... 434
REMOVAL............................................................................................................................ 434
INSTALLATION....................................................................................................................... 434
MOTOR CABLE AND HOUSING................................................................................................................ 434
REMOVAL............................................................................................................................ 434
INSTALLATION....................................................................................................................... 434
HORIZONTAL AND VERTICAL TRANSMISSIONS.................................................................................................. 435
ADJUSTER............................................................................................................................... 435
REMOVAL............................................................................................................................ 435
INSTALLATION....................................................................................................................... 435
MOTOR.................................................................................................................................. 435
REMOVAL............................................................................................................................ 435
INSTALLATION....................................................................................................................... 435
92AS_8S............................................................................................................................................ 437
POWER WINDOWS.................................................................................................................................. 437
CONTENTS................................................................................................................................... 437
GENERAL INFORMATION.................................................................................................................... 437
SWITCH VOLTAGE TEST.................................................................................................................... 437
SWITCH CONTINUITY TEST................................................................................................................. 437
WINDOW MOTOR TEST...................................................................................................................... 438
POWER WINDOW CABLE HOUSING/ MOTOR RE-PLACEMENT......................................................................................... 438
MOTOR REPLACEMENT...................................................................................................................... 438
REMOVAL............................................................................................................................ 438
INSTALLATION....................................................................................................................... 438
POWER VENT WINDOWS..................................................................................................................... 439
VENT WINDOW SWITCH TEST................................................................................................................ 439
VENT WINDOW MOTOR TEST................................................................................................................. 439
VENT CABLE AND CRANK MECHANISM......................................................................................................... 440
REMOVAL............................................................................................................................ 440
INSTALLATION....................................................................................................................... 440
VENT WINDOW MOTOR REPLACEMENT.......................................................................................................... 441
REMOVAL............................................................................................................................ 441
INSTALLATION....................................................................................................................... 441
92AS_8T............................................................................................................................................ 443
POWER MIRRORS.................................................................................................................................. 443
CONTENTS................................................................................................................................... 443
GENERAL INFORMATION.................................................................................................................... 443
MIRROR MOTOR TEST...................................................................................................................... 443
MIRROR SWITCH TEST..................................................................................................................... 443
HEATED MIRROR.......................................................................................................................... 443
TEST PROCEDURES.................................................................................................................... 444
MIRROR SWITCH REPLACEMENT.............................................................................................................. 444
MIRROR ASSEMBLY REPLACEMENT............................................................................................................ 444
92AS_8U............................................................................................................................................ 445
CHIME WARNING/ REMINDER SYSTEM................................................................................................................. 445
FASTEN SEAT BELTS.......................................................................................................................... 445
TURN SIGNAL WARNING........................................................................................................................ 445
EXTERIOR LAMPS LEFT ON................................................................................................................. 445
KEY LEFT IN IGNITION................................................................................................................... 445
FASTEN SEAT BELTS.......................................................................................................................... 445
TURN SIGNAL WARNING........................................................................................................................ 445
EXTERIOR LAMPS LEFT ON..................................................................................................................... 445
KEY LEFT IN IGNITION....................................................................................................................... 445
CHIME SYSTEM DIAGNOSIS..................................................................................................................... 445
CONDITION: NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVERS SEAT BELT IS UNBUCKLED................................................ 445
CONDITION: NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON.................................................................. 445
CONDITION: FASTEN SEAT BELT LAMP OR TONE CONTINUE FOR MORE THAN 10 SEC-ONDS AFTER SEAT BELTS ARE FASTENED AND DRIVERS DOOR I........... 445
CONDITION: NO TONE WHEN HEADLAMPS ARE ON AND DRIVERS DOOR IS OPEN...................................................................... 445
CONDITION: NO TONE WHEN KEY IS LEFT IN IGNITION AND DRIVERS DOOR IS OPEN............................................................... 446
CONDITION: CHIMES CONTINUE WHEN HEADLAMPS ARE TURNED OFF AND/ OR KEY IS REMOVED FROM IGNITION.......................................... 446
HEADLAMP SWITCH REPLACEMENT................................................................................................................ 446
SEAT BELT BUCKLE REPLACEMENT............................................................................................................... 446
KEY- IN SWITCH............................................................................................................................. 446
92as_8w............................................................................................................................................ 447
WIRING DIAGRAMS................................................................................................................................ 447
GENERAL INFORMATION........................................................................................................................ 447
DISTRIBUTOR SECONDARY WIRING........................................................................................................... 447
WIRING DIAGRAM SHEETS AND INDEXES...................................................................................................... 447
WIRE CODE IDENTIFICATION............................................................................................................... 448
MAIN CIRCUIT IDENTIFICATION............................................................................................................ 448
LOCATING A SYSTEM...................................................................................................................... 448
COMPONENT IDENTIFICATION............................................................................................................... 449
SPLICE LOCATIONS....................................................................................................................... 449
CONNECTORS............................................................................................................................. 450
TROUBLESHOOTING WIRING PROBLEMS........................................................................................................ 450
FUSIBLE LINKS.......................................................................................................................... 450
HARNESS REPAIR......................................................................................................................... 450
FUSIBLE LINK REPLACEMENT........................................................................................................... 450
WIRING REPAIR...................................................................................................................... 451
CONNECTOR REPLACEMENT.............................................................................................................. 451
CONNECTOR AND TERMINAL ASSEMBLY REPLACEMENT........................................................................................ 451
TERMINAL REPLACEMENT............................................................................................................... 452
SYMBOLS, FUSES AND ABBREVIATIONS....................................................................................................... 452
COMPONENT IDENTIFICATION................................................................................................................... 457
SPLICE LOCATION............................................................................................................................ 479
WIRING DIAGRAMS AS- BODY H- K.............................................................................................................. 493
ALPHABETICAL INDEX..................................................................................................................... 493
92AS_9............................................................................................................................................. 683
ENGINE......................................................................................................................................... 683
STANDARD SERVICE PROCEDURES................................................................................................................ 683
FORM- IN- PLACE GASKETS................................................................................................................ 683
MOPAR SILICONE RUBBER ADHESIVE SEAL-ANT............................................................................................ 683
MOPAR GASKET MAKER................................................................................................................. 683
GASKET DISASSEMBLY................................................................................................................. 683
SURFACE PREPARATION................................................................................................................ 683
FORM- IN- PLACE GASKET APPLICATION................................................................................................. 683
CRANKSHAFT SPROCKET BOLT ACCESS PLUG................................................................................................... 684
ENGINE PERFORMANCE..................................................................................................................... 684
HONING CYLINDER BORES.................................................................................................................. 684
MEASURING MAIN BEARING CLEARANCE AND CONNECTING ROD BEARING CLEARANCE.................................................................. 685
PLASTIGAGE METHOD.................................................................................................................. 685
CONNECTING ROD BEARING CLEARANCE................................................................................................... 686
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS................................................................................................. 686
REPAIR OF DAMAGED OR WORN THREADS...................................................................................................... 686
HYDROSTATIC LOCKED ENGINE.............................................................................................................. 687
ENGINE DIAGNOSIS— PERFORMANCE...................................................................................................... 688
ENGINE DIAGNOSIS— MECHANICAL....................................................................................................... 689
2.5L ENGINE................................................................................................................................ 690
GENERAL INFORMATION.................................................................................................................... 690
ENGINE IDENTIFICATION NUMBER OR CODE............................................................................................... 690
SPECIFICATIONS..................................................................................................................... 690
ENGINE MOUNTS.......................................................................................................................... 691
REMOVAL AND INSTALLATION RIGHT SIDE MOUNT.......................................................................................... 691
FRONT MOUNT........................................................................................................................ 692
LEFT SIDE MOUNT.................................................................................................................... 692
ENGINE MOUNT RUBBER INSULATORS..................................................................................................... 692
ENGINE MOUNT INSULATOR ADJUSTMENT.................................................................................................. 692
ENGINE ASSEMBLY........................................................................................................................ 693
REMOVAL............................................................................................................................ 693
INSTALLATION....................................................................................................................... 694
SOLID MOUNT COMPRESSOR BRACKET SERVICE................................................................................................. 695
ACCESSORIES REMOVAL................................................................................................................ 695
SOLID MOUNT BRACKET— REMOVAL (FIG. 7).............................................................................................. 695
SOLID MOUNT BRACKET— INSTALLATION.................................................................................................. 695
TIMING SYSTEM AND SEALS SERVICE........................................................................................................ 696
TIMING BELT SERVICE................................................................................................................ 696
SERVICING FRONT OIL SEALS— REPLACEMENT............................................................................................. 697
CAMSHAFT, CRANKSHAFT AND INTERMEDIATE SHAFTS TIMING PROCEDURE.......................................................................... 699
CYLINDER HEAD AND VALVE ASSEMBLY SERVICE............................................................................................... 700
CYLINDER HEAD COVER AND CURTAIN.................................................................................................... 701
REMOVAL............................................................................................................................ 701
CLEANING........................................................................................................................... 701
CURTAIN INSTALLATION............................................................................................................... 701
COVER SEALING AND INSTALLATION..................................................................................................... 701
CYLINDER HEAD COMPONENTS— IN- VEHICLE SERVICE.......................................................................................... 701
CAMSHAFT SERVICE................................................................................................................... 702
REMOVAL............................................................................................................................ 702
INSPECTION......................................................................................................................... 702
CAMSHAFT END PLAY.................................................................................................................. 703
INSTALLATION....................................................................................................................... 703
LASH ADJUSTER (TAPPET) NOISE....................................................................................................... 703
VALVE COMPONENTS REPLACE— CYLINDER HEAD NOT REMOVED ROCKER ARM AND HYDRAULIC LASH AD-JUSTER REMOVAL................................ 703
INSTALLATION....................................................................................................................... 703
VALVE SPRINGS AND VALVE STEM SEALS REMOVAL......................................................................................... 704
INSTALLATION....................................................................................................................... 704
CYLINDER HEAD.......................................................................................................................... 704
REMOVAL............................................................................................................................ 704
INSPECT HEAD AND CAMSHAFT BEARING JOURNALS......................................................................................... 704
CLEANING........................................................................................................................... 705
INSTALLATION....................................................................................................................... 705
VALVE SERVICE— CYLINDER HEAD REMOVED................................................................................................... 705
VALVES AND VALVE SPRINGS REMOVAL................................................................................................... 705
VALVE INSPECTION................................................................................................................... 705
VALVE GUIDES....................................................................................................................... 705
TESTING VALVE SPRINGS.............................................................................................................. 706
REFACING VALVES AND VALVE SEATS.................................................................................................... 707
CLEANING........................................................................................................................... 707
VALVE GEAR REASSEMBLY AFTER VALVE SERVICE.......................................................................................... 707
CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE............................................................................. 709
PISTON AND CONNECTING ROD— REMOVAL................................................................................................. 709
CYLINDER BLOCK CLEANING AND INSPEC- TION........................................................................................... 710
CYLINDER BORE INSPECTION........................................................................................................... 710
SIZING PISTONS..................................................................................................................... 710
PISTON RING— REMOVAL............................................................................................................... 711
FITTING RINGS...................................................................................................................... 711
PISTON RINGS— INSTALLATION......................................................................................................... 711
PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION.................................................................................... 712
CONNECTING RODS.................................................................................................................... 713
ENGINE CORE PLUGS...................................................................................................................... 713
REMOVAL............................................................................................................................ 713
INSTALLATION....................................................................................................................... 714
CRANKSHAFT, INTERMEDIATE AND BALANCE SHAFT ASSEMBLIES SERVICE.......................................................................... 715
CRANKSHAFT OIL SEALS SERVICE........................................................................................................... 716
REAR CRANKSHAFT SEAL RETAINER AND OIL SEAL......................................................................................... 716
FRONT CRANKSHAFT SEAL RETAINER..................................................................................................... 716
CRANKSHAFT SERVICE..................................................................................................................... 717
CRANKSHAFT MAIN BEARINGS........................................................................................................... 717
CRANKSHAFT MAIN JOURNALS........................................................................................................... 717
MAIN BEARING SERVICE— CRANKSHAFT NOT REMOVED....................................................................................... 717
CHECKING CRANKSHAFT END PLAY....................................................................................................... 717
OPTIONAL CRANKSHAFT END PLAY CHECK................................................................................................. 717
CRANKSHAFT BEARING CLEARANCE....................................................................................................... 718
BALANCE SHAFTS......................................................................................................................... 719
REMOVAL............................................................................................................................ 719
BALANCE SHAFTS CARRIER ASSEMBLY.................................................................................................... 720
CHAIN TENSIONING................................................................................................................... 721
INTERMEDIATE SHAFT SERVICE............................................................................................................. 721
REMOVAL............................................................................................................................ 721
INSTALLATION....................................................................................................................... 722
INTERMEDIATE SHAFT BUSHING SERVICE................................................................................................. 722
ENGINE LUBRICATION SYSTEM.............................................................................................................. 723
OIL PAN............................................................................................................................ 725
PRESSURE LUBRICATION............................................................................................................... 725
MAIN/ ROD BEARINGS................................................................................................................. 725
ACCESSORY SHAFT.................................................................................................................... 725
BALANCE SHAFTS..................................................................................................................... 725
CAMSHAFT/ HYDRAULIC LIFTERS........................................................................................................ 725
SPLASH LUBRICATION................................................................................................................. 725
OIL PAN................................................................................................................................ 725
REMOVAL............................................................................................................................ 725
OIL PAN RAIL TO BLOCK SEALING...................................................................................................... 725
INSTALLATION....................................................................................................................... 725
OIL PUMP SERVICE....................................................................................................................... 725
OIL PICKUP......................................................................................................................... 725
REMOVAL............................................................................................................................ 726
INSTALLATION....................................................................................................................... 726
INSPECTION......................................................................................................................... 726
CHECKING ENGINE OIL PRESSURE........................................................................................................... 728
OIL FILTER............................................................................................................................. 728
ANTI- DRAIN BACK VALVE............................................................................................................. 728
FILTER............................................................................................................................. 728
ENGINE SPECIFICATIONS.................................................................................................................. 729
ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 730
TORQUE............................................................................................................................. 731
3.0L ENGINE................................................................................................................................ 732
GENERAL INFORMATION.................................................................................................................... 732
ENGINE IDENTIFICATION NUMBER OR CODE............................................................................................... 732
3.0L ENGINE........................................................................................................................ 732
SPECIFICATIONS..................................................................................................................... 733
ENGINE MOUNTS.......................................................................................................................... 734
REMOVAL AND INSTALLATION RIGHT SIDE MOUNT.......................................................................................... 734
FRONT MOUNT........................................................................................................................ 734
LEFT SIDE MOUNT.................................................................................................................... 735
ENGINE MOUNT RUBBER INSULATORS..................................................................................................... 735
ENGINE MOUNT INSULATOR ADJUSTMENT.................................................................................................. 735
ENGINE ASSEMBLY........................................................................................................................ 735
REMOVAL............................................................................................................................ 735
INSTALLATION....................................................................................................................... 736
ACCESSORY DRIVE BELT SERVICE........................................................................................................... 736
REMOVAL............................................................................................................................ 736
ENGINE MOUNT BRACKET REMOVAL....................................................................................................... 737
TIMING BELT INSPECTION— IN VEHICLE..................................................................................................... 737
TIMING BELT SERVICE.................................................................................................................... 738
REMOVAL............................................................................................................................ 738
CAMSHAFT SPROCKETS REMOVAL......................................................................................................... 738
INSTALLATION....................................................................................................................... 738
TIMING BELT TENSIONER.............................................................................................................. 738
INSTALLATION— TIMING BELT.......................................................................................................... 740
CYLINDER HEAD AND CAMSHAFT SERVICE..................................................................................................... 741
CYLINDER HEAD COVER REMOVAL........................................................................................................ 741
INSTALLATION....................................................................................................................... 741
AUTO LASH ADJUSTER..................................................................................................................... 741
FUNCTION CHECK..................................................................................................................... 741
CAMSHAFT SERVICE....................................................................................................................... 742
SEE AUTO LASH ADJUSTER FUNCTION CHECK BEFORE DISASSEMBLY REMOVAL................................................................... 742
CAMSHAFT INSPECTION................................................................................................................ 742
CAMSHAFT INSTALL................................................................................................................... 742
ROCKER ARMS........................................................................................................................ 742
ROCKER ARM SHAFTS.................................................................................................................. 742
REASSEMBLE......................................................................................................................... 743
ASSEMBLE ROCKER ASSEMBLY........................................................................................................... 743
INSTALL ROCKER ARM SHAFT ASSEMBLY.................................................................................................. 743
CAMSHAFT OIL SEAL — ENGINE OUT OF VE- HICLE........................................................................................ 743
CAMSHAFT END SEAL (PLUG) — ENGINE IN VEHICLE....................................................................................... 743
CAMSHAFT END SEAL (PLUG) — ENGINE OUT OF VEHICLE................................................................................... 744
REMOVAL............................................................................................................................ 744
INSPECTION......................................................................................................................... 745
INSTALLATION....................................................................................................................... 745
VALVE SERVICE.......................................................................................................................... 746
VALVE AND VALVE SPRINGS............................................................................................................ 746
VALVES............................................................................................................................. 746
VALVE SEAT INSPECTION.............................................................................................................. 746
PISTON AND CONNECTING ROD ASSEMBLY SER-VICE............................................................................................ 748
CYLINDER BORE INSPECTION........................................................................................................... 748
FITTING PISTONS.................................................................................................................... 748
FITTING PISTON RINGS............................................................................................................... 748
PISTON RINGS— INSTALLATION......................................................................................................... 749
CONNECTING ROD CLEARANCE........................................................................................................... 750
CONNECTING ROD SIDE CLEARANCE...................................................................................................... 751
CRANKSHAFT AND CYLINDER BLOCK, ASSEMBLY SERVICE........................................................................................ 752
CRANKSHAFT SERVICE................................................................................................................. 752
CRANKSHAFT— REMOVAL................................................................................................................ 752
INSPECTION......................................................................................................................... 752
CRANKSHAFT OIL CLEARANCE MECHANICAL MEASUREMENT.................................................................................... 752
PLASTIGAGE MEASUREMENT............................................................................................................. 753
CRANKSHAFT BEARINGS INSTALLATION................................................................................................... 753
CHECKING CRANKSHAFT END PLAY....................................................................................................... 754
CRANKSHAFT OIL SEALS SERVICE REAR CRANKSHAFT SEAL RETAINER......................................................................... 754
FRONT CRANKSHAFT OIL PUMP AND OIL SEAL............................................................................................. 755
CYLINDER BLOCK......................................................................................................................... 755
BORING CYLINDER.................................................................................................................... 756
ENGINE LUBRICATION SYSTEM.............................................................................................................. 757
OIL PAN................................................................................................................................ 758
OIL PAN SEALING AND INSTALLATION................................................................................................... 758
OIL PUMP SERVICE....................................................................................................................... 758
REMOVAL............................................................................................................................ 758
INSPECTION OIL PUMP................................................................................................................ 758
OIL RELIEF PLUNGER................................................................................................................. 759
INSTALLATION....................................................................................................................... 759
CHECKING ENGINE OIL PRESSURE........................................................................................................... 759
OIL FILTER AND BRACKET................................................................................................................. 760
BRACKET INSPECTION................................................................................................................. 760
OIL FILTER......................................................................................................................... 760
ENGINE SPECIFICATIONS.................................................................................................................. 761
ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 762
TORQUE............................................................................................................................. 763
3.3L ENGINE................................................................................................................................ 764
GENERAL INFORMATION.................................................................................................................... 764
ENGINE IDENTIFICATION NUMBER OR CODE............................................................................................... 764
SPECIFICATIONS..................................................................................................................... 764
ENGINE MOUNTS.......................................................................................................................... 765
REMOVAL AND INSTALLATION RIGHT SIDE MOUNT.......................................................................................... 765
FRONT MOUNT........................................................................................................................ 767
LEFT SIDE MOUNT.................................................................................................................... 767
ENGINE MOUNT RUBBER INSULATORS..................................................................................................... 767
ENGINE MOUNT INSULATOR ADJUSTMENT.................................................................................................. 767
ENGINE ASSEMBLY........................................................................................................................ 767
REMOVAL............................................................................................................................ 767
INSTALLATION....................................................................................................................... 768
ROCKER ARMS AND SHAFT ASSEMBLY......................................................................................................... 768
REMOVAL............................................................................................................................ 768
INSTALLATION....................................................................................................................... 768
CYLINDER HEADS......................................................................................................................... 768
REMOVAL............................................................................................................................ 769
INSPECTION......................................................................................................................... 769
INSTALLATION....................................................................................................................... 769
INTAKE MANIFOLD SEALING................................................................................................................ 770
VALVE SERVICE.......................................................................................................................... 771
VALVES AND VALVE SPRINGS........................................................................................................... 771
REMOVAL............................................................................................................................ 771
VALVE INSPECTION................................................................................................................... 771
VALVE GUIDES....................................................................................................................... 772
REFACING VALVES AND VALVE SEATS.................................................................................................... 772
VALVES............................................................................................................................. 772
VALVE SEATS........................................................................................................................ 772
TESTING VALVE SPRINGS.............................................................................................................. 773
VALVE INSTALLATION................................................................................................................. 773
REPLACE VALVE STEM SEALS OR VALVE SPRINGS, CYLINDER HEAD NOT REMOVED............................................................... 774
HYDRAULIC TAPPETS...................................................................................................................... 774
PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS................................................................................. 774
OIL LEVEL TOO HIGH................................................................................................................. 774
OIL LEVEL TOO LOW.................................................................................................................. 774
TAPPET NOISE DIAGNOSIS............................................................................................................. 774
TAPPET REMOVAL..................................................................................................................... 775
DISASSEMBLY (FIG. 27).............................................................................................................. 775
CLEANING AND ASSEMBLY.............................................................................................................. 775
INSTALLATION....................................................................................................................... 775
VALVE TIMING........................................................................................................................... 775
TIMING CHAIN COVER, OIL SEAL AND CHAIN................................................................................................. 776
COVER.............................................................................................................................. 776
MEASURING TIMING CHAIN FOR STRETCH................................................................................................. 776
TIMING CHAIN COVER EXTERNAL OIL SEAL............................................................................................... 778
CAMSHAFT............................................................................................................................... 778
REMOVAL— ENGINE REMOVED FROM VE-HICLE.............................................................................................. 778
INSTALLATION....................................................................................................................... 778
CAMSHAFT BEARINGS— ENGINE REMOVED FROM VEHICLE......................................................................................... 779
REMOVAL............................................................................................................................ 779
INSTALLATION....................................................................................................................... 779
ENGINE CORE OIL AND CAM PLUGS.......................................................................................................... 780
REMOVAL............................................................................................................................ 780
INSTALLATION....................................................................................................................... 780
CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE............................................................................. 781
CYLINDER BLOCK PISTON— REMOVAL..................................................................................................... 781
CLEANING AND INSPECTION............................................................................................................ 781
CYLINDER BORE INSPECTION........................................................................................................... 781
FINISHED PISTONS................................................................................................................... 782
FITTING PISTONS.................................................................................................................... 782
PISTON PINS........................................................................................................................ 782
FITTING RINGS...................................................................................................................... 782
PISTON RINGS— INSTALLATION......................................................................................................... 782
INSTALLING PISTON AND CONNECTING ROD AS-SEMBLY......................................................................................... 784
CONNECTING RODS........................................................................................................................ 785
INSTALLATION OF CONNECTING ROD BEAR-INGS........................................................................................... 785
CRANKSHAFT SERVICE..................................................................................................................... 785
CRANKSHAFT MAIN BEARINGS........................................................................................................... 785
CRANKSHAFT MAIN JOURNALS........................................................................................................... 785
CHECKING CRANKSHAFT END PLAY....................................................................................................... 786
CRANKSHAFT END PLAY CHECK— OPTIONAL................................................................................................ 786
CRANKSHAFT OIL CLEARANCE........................................................................................................... 787
PLASTIGAGE (OIL CLEARANCE) MEASURE-MENT............................................................................................ 787
CRANKSHAFT OIL SEALS SERVICE........................................................................................................... 788
REMOVAL............................................................................................................................ 788
INSTALLATION....................................................................................................................... 788
REAR CRANKSHAFT SEAL RETAINER...................................................................................................... 788
ENGINE LUBRICATION SYSTEM.............................................................................................................. 789
OIL PAN SERVICE........................................................................................................................ 789
REMOVAL............................................................................................................................ 789
CLEANING AND INSPECTION............................................................................................................ 789
INSTALLATION....................................................................................................................... 789
OIL PUMP SERVICE....................................................................................................................... 790
DISASSEMBLY........................................................................................................................ 790
INSPECTION AND REPAIR.............................................................................................................. 790
OIL PUMP ASSEMBLY AND INSTALLATION................................................................................................. 791
CHECKING ENGINE OIL PRESSURE........................................................................................................... 792
OIL FILTER............................................................................................................................. 792
ENGINE SPECIFICATIONS.................................................................................................................. 793
ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 794
ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 795
ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 796
TORQUE............................................................................................................................. 797
92AS_11............................................................................................................................................ 799
EXHAUST SYSTEM AND INTAKE MANIFOLD............................................................................................................. 799
GENERAL INFORMATION........................................................................................................................ 799
EXHAUST SYSTEMS........................................................................................................................ 799
CATALYTIC CONVERTERS............................................................................................................... 799
SPECIAL EXHAUST BALL- JOINT COUPLING............................................................................................... 800
EXHAUST GAS RECIRCULATION (EGR).................................................................................................... 800
HEAT SHIELDS....................................................................................................................... 800
EXHAUST SYSTEM DIAGNOSIS........................................................................................................... 801
SERVICE PROCEDURES......................................................................................................................... 802
EXHAUST PIPES, MUFFLERS AND TAILPIPES.................................................................................................. 802
REMOVAL............................................................................................................................ 802
INSTALLATION....................................................................................................................... 802
INTAKE AND EXHAUST MANIFOLDS— TBI ENGINE............................................................................................... 802
INTAKE MANIFOLDS:.................................................................................................................. 802
EXHAUST MANIFOLDS:................................................................................................................. 802
THROTTLE BODY AIR HEATER........................................................................................................... 802
INTAKE AND EXHAUST MANIFOLDS SERVICE TBI ENGINE....................................................................................... 803
FUEL SYSTEM PRESSURE RELEASE PROCEDURE............................................................................................. 803
REMOVAL............................................................................................................................ 803
CLEANING AND INSPECTION............................................................................................................ 804
INSTALLATION....................................................................................................................... 804
INTAKE AND EXHAUST MANIFOLDS— 3.0L ENGINE.............................................................................................. 804
INTAKE PLENUM/ MANIFOLD............................................................................................................ 804
FUEL SYSTEM PRESSURE RELEASE PROCEDURE............................................................................................. 804
INSPECTION......................................................................................................................... 805
INSTALLATION....................................................................................................................... 806
EXHAUST MANIFOLDS.................................................................................................................. 809
INTAKE/ EXHAUST MANIFOLD 3.3L ENGINE................................................................................................... 810
REMOVAL............................................................................................................................ 810
FUEL SYSTEM PRESSURE RELEASE PROCEDURE............................................................................................. 810
INSPECTION......................................................................................................................... 812
EXHAUST MANIFOLDS.................................................................................................................. 814
TORQUE SPECIFICATION....................................................................................................................... 815
92AS_13............................................................................................................................................ 817
FRAME AND BUMPERS.............................................................................................................................. 817
CONTENTS................................................................................................................................... 817
GENERAL INFORMATIONA................................................................................................................... 817
LOW LINE FRONT BUMPER.................................................................................................................. 817
REMOVAL (FIG. 1)................................................................................................................... 817
INSTALLATION....................................................................................................................... 817
HIGH LINE FRONT BUMPER AND FASCIA...................................................................................................... 818
REMOVAL (FIG. 2)................................................................................................................... 818
INSTALLATION....................................................................................................................... 818
OVERHAUL (FIG. 3).................................................................................................................. 818
HIGH LINE FRONT BUMPER ASSEMBLY.................................................................................................... 818
FRONT BUMPER SUPPORT BRACKET........................................................................................................... 818
REMOVAL............................................................................................................................ 818
INSTALLATION....................................................................................................................... 818
REAR BUMPER............................................................................................................................ 819
REMOVAL (FIG. 4)................................................................................................................... 819
INSTALLATION....................................................................................................................... 819
HIGH LINE REAR BUMPER AND FASCIA....................................................................................................... 819
REMOVAL (FIG. 5)................................................................................................................... 819
INSTALLATION....................................................................................................................... 819
FRONT WHEEL DRIVE VAN/ WAGON CROSSMEM-BER.............................................................................................. 819
REMOVAL (FIG. 6)................................................................................................................... 819
INSTALLATION....................................................................................................................... 820
ALL WHEEL DRIVE VAN/ WAGON CROSSMEMBER................................................................................................. 820
REMOVAL (FIG. 7)................................................................................................................... 820
INSTALLATION....................................................................................................................... 820
FRAME DIMENSIONS....................................................................................................................... 820
VEHICLE PREPARATION................................................................................................................ 820
92AS_14............................................................................................................................................ 825
FUEL SYSTEM.................................................................................................................................... 825
GENERAL INFORMATION........................................................................................................................ 825
FUEL REQUIREMENTS...................................................................................................................... 825
GASOLINE/ OXYGENATE BLENDS......................................................................................................... 825
FUEL DELIVERY SYSTEM....................................................................................................................... 827
GENERAL INFORMATION.................................................................................................................... 827
FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 827
FUEL HOSES, CLAMPS, AND QUICK CONNECT FITTINGS......................................................................................... 827
HOSES AND CLAMPS................................................................................................................... 827
QUICK CONNECT FITTINGS............................................................................................................. 827
TUBE/ FITTING DISASSEMBLY.......................................................................................................... 828
TUBE/ FITTING ASSEMBLY............................................................................................................. 828
TUBE/ FITTING SERVICE.............................................................................................................. 828
FUEL PUMP/ LEVEL UNIT ASSEMBLY......................................................................................................... 829
FUEL PUMP PRESSURE TEST— 2.5L and 3.0L EN-GINES........................................................................................ 829
FUEL SYSTEM PRESSURE— WITHOUT VACUUM APPLIED TO PRESSURE REGULATOR................................................................. 829
FUEL PUMP PRESSURE TEST— 3.3L ENGINE................................................................................................... 830
FUEL PUMP/ LEVEL SENDING UNIT ASSEMBLY REMOVAL— FRONT WHEEL DRIVE...................................................................... 832
FUEL PUMP INLET STRAINER REMOVAL— FRONT WHEEL DRIVE................................................................................ 832
FUEL PUMP INLET STRAINER INSTALLATION— FRONT WHEEL DRIVE........................................................................... 832
FUEL LEVEL SENDING UNIT DIAGNOSIS.................................................................................................. 832
FUEL LEVEL SENDING UNIT REMOVAL— FRONT WHEEL DRIVE................................................................................. 832
FUEL LEVEL SENDING UNIT INSTALLATION— FRONT WHEEL DRIVE............................................................................ 832
FUEL PUMP/ LEVEL UNIT ASSEMBLY INSTALLATION— FRONT WHEEL DRIVE......................................................................... 833
FUEL PUMP MODULE REMOVAL— ALL WHEEL DRIVE.............................................................................................. 833
FUEL PUMP INLET STRAINER REMOVAL— ALL WHEEL DRIVE.................................................................................. 833
FUEL PUMP INLET STRAINER INSTALLATION— ALL WHEEL DRIVE............................................................................. 833
FUEL LEVEL SENDING UNIT DIAGNOSIS.................................................................................................. 833
FUEL LEVEL SENDING UNIT REMOVAL— ALL WHEEL DRIVE................................................................................... 834
FUEL LEVEL SENDING UNIT INSTALLATION— ALL WHEEL DRIVE.............................................................................. 834
FUEL PUMP MODULE INSTALLATION— ALL WHEEL DRIVE......................................................................................... 834
FUEL FILTER— FRONT WHEEL DRIVE......................................................................................................... 834
REMOVAL............................................................................................................................ 834
INSTALLATION....................................................................................................................... 835
FUEL FILTER— ALL WHEEL DRIVE........................................................................................................... 835
REMOVAL............................................................................................................................ 835
INSTALLATION....................................................................................................................... 835
CHASSIS FUEL TUBES..................................................................................................................... 835
FUEL TANK.................................................................................................................................. 837
GENERAL INFORMATION.................................................................................................................... 837
NO- LEAD FUEL TANK FILLER TUBE......................................................................................................... 837
PRESSURE- VACUUM FILLER CAP— FRONT WHEEL DRIVE......................................................................................... 837
FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 837
FUEL TANK CAPACITIES............................................................................................................... 837
FUEL TANK— FRONT WHEEL DRIVE........................................................................................................... 838
DRAINING FUEL TANK................................................................................................................. 838
FUEL TANK REMOVAL— FRONT WHEEL DRIVE............................................................................................... 838
FUEL TANK INSTALLATION— FRONT WHEEL DRIVE.......................................................................................... 840
FUEL TANK— ALL WHEEL DRIVE............................................................................................................. 840
DRAINING FUEL TANK— ALL WHEEL DRIVE................................................................................................ 840
FUEL TANK REMOVAL— ALL WHEEL DRIVE................................................................................................. 840
FUEL TANK INSTALLATION— ALL WHEEL DRIVE............................................................................................ 841
FUEL PUMP/ LEVEL UNIT— FRONT WHEEL DRIVE............................................................................................... 842
FUEL PUMP MODULE— ALL WHEEL DRIVE...................................................................................................... 842
FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVE— FRONT WHEEL DRIVE........................................................................... 842
REMOVAL............................................................................................................................ 842
INSTALLATION....................................................................................................................... 842
FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVE— ALL WHEEL DRIVE............................................................................. 843
REMOVAL............................................................................................................................ 843
INSTALLATION....................................................................................................................... 843
ACCELERATOR PEDAL AND THROTTLE CABLE....................................................................................................... 844
ACCELERATOR PEDAL SERVICE.............................................................................................................. 844
REMOVAL............................................................................................................................ 844
INSTALLATION....................................................................................................................... 844
THROTTLE CABLE SERVICE................................................................................................................. 844
REMOVAL............................................................................................................................ 844
INSTALLATION....................................................................................................................... 844
2.5L SINGLE POINT FUEL INJECTION— SYSTEM OPERATION......................................................................................... 846
GENERAL INFORMATION.................................................................................................................... 846
SYSTEM DIAGNOSIS................................................................................................................... 846
CCD BUS................................................................................................................................ 846
ENGINE CONTROLLER...................................................................................................................... 846
AIR CONDITIONING SWITCH SENSE— ENGINE CONTROLLER INPUT................................................................................. 848
BATTERY VOLTAGE— ENGINE CONTROLLER INPUT............................................................................................... 848
BRAKE SWITCH— ENGINE CONTROLLER INPUT.................................................................................................. 848
COOLANT TEMPERATURE SENSOR— ENGINE CON-TROLLER INPUT................................................................................... 848
DISTRIBUTOR (HALL EFFECT) PICK- UP— ENGINE CONTROLLER INPUT............................................................................ 848
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— ENGINE CONTROLLER INPUT....................................................................... 849
OXYGEN SENSOR (O2 SENSOR)— ENGINE CON-TROLLER INPUT.................................................................................... 849
SPEED CONTROL— ENGINE CONTROLLER INPUT................................................................................................. 850
TRANSMISSION PARK/ NEUTRAL SWITCH— ENGINE CONTROLLER INPUT............................................................................. 850
THROTTLE POSITION SENSOR (TPS)— ENGINE CONTROLLER INPUT................................................................................ 850
VEHICLE DISTANCE (SPEED) SENSOR— ENGINE CONTROLLER INPUT............................................................................... 850
AIR CONDITIONING (A/ C) CLUTCH RELAY— ENGINE CONTROLLER OUTPUT......................................................................... 850
ALTERNATOR FIELD— ENGINE CONTROLLER OUT-PUT............................................................................................ 851
AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY— ENGINE CONTROLLER OUTPUT................................................................ 851
AUTOMATIC IDLE SPEED (AIS) MOTOR— ENGINE CONTROLLER OUTPUT............................................................................. 851
CANISTER PURGE SOLENOID— ENGINE CONTROLLER OUTPUT...................................................................................... 852
CHECK ENGINE LAMP— ENGINE CONTROLLER OUTPUT............................................................................................ 852
DIAGNOSTIC CONNECTOR— ENGINE CONTROLLER OUTPUT......................................................................................... 852
EMISSION MAINTENANCE REMINDER (EMR) LAMP— ENGINE CONTROLLER OUTPUT..................................................................... 852
FUEL INJECTOR— ENGINE CONTROLLER OUTPUT................................................................................................ 853
IGNITION COIL— ENGINE CONTROLLER OUTPUT................................................................................................ 853
PART THROTTLE UNLOCK SOLENOID— ENGINE CONTROLLER OUTPUT................................................................................ 853
RADIATOR FAN RELAY— ENGINE CONTROLLER OUTPUT........................................................................................... 853
SPEED CONTROL SOLENOIDS— ENGINE CONTROL-LER OUTPUT..................................................................................... 853
TACHOMETER— ENGINE CONTROLLER OUTPUT................................................................................................... 853
MODES OF OPERATION..................................................................................................................... 854
FUEL PRESSURE REGULATOR................................................................................................................ 855
THROTTLE BODY.......................................................................................................................... 856
2.5L SINGLE POINT FUEL INJECTION— GENERAL DIAGNOSIS........................................................................................ 858
GENERAL INFORMATION.................................................................................................................... 858
VISUAL INSPECTION...................................................................................................................... 858
ON BOARD DIAGNOSTICS................................................................................................................... 862
MONITORED CIRCUITS................................................................................................................. 863
NON- MONITORED CIRCUITS............................................................................................................ 863
HIGH AND LOW LIMITS................................................................................................................ 864
FAULT CODE DESCRIPTION................................................................................................................. 864
SYSTEMS TEST........................................................................................................................... 864
OBTAINING FAULT CODES.............................................................................................................. 864
STATE DISPLAY TEST MODE................................................................................................................ 864
STATE DISPLAY INPUTS AND OUTPUTS................................................................................................... 864
STATE DISPLAY SENSORS.............................................................................................................. 864
FAULT CODE DESCRIPTION............................................................................................................. 865
CIRCUIT ACTUATION TEST MODE............................................................................................................ 866
OBTAINING CIRCUIT ACTUATION TEST................................................................................................... 866
FAULT CODE DESCRIPTION (CON’T)..................................................................................................... 866
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE......................................................................................... 867
IGNITION TIMING PROCEDURE.......................................................................................................... 867
60- WAY ENGINE CONTROLLER WIRING CONNEC-TOR............................................................................................ 867
IDLE SPECIFICATIONS................................................................................................................ 867
2.5L SINGLE POINT FUEL INJECTION— SERVICE PROCEDURES....................................................................................... 869
FUEL LINES AND HOSES................................................................................................................... 869
FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 869
THROTTLE BODY.......................................................................................................................... 869
REMOVAL............................................................................................................................ 869
INSTALLATION....................................................................................................................... 871
FUEL FITTING........................................................................................................................... 871
REMOVAL............................................................................................................................ 871
INSTALLATION....................................................................................................................... 871
FUEL PRESSURE REGULATOR................................................................................................................ 872
REMOVAL............................................................................................................................ 872
INSTALLATION....................................................................................................................... 872
FUEL INJECTOR.......................................................................................................................... 872
REMOVAL............................................................................................................................ 872
INSTALLATION....................................................................................................................... 873
THROTTLE POSITION SENSOR............................................................................................................... 873
REMOVAL............................................................................................................................ 873
INSTALLATION....................................................................................................................... 874
AUTOMATIC IDLE SPEED (AIS) MOTOR....................................................................................................... 874
REMOVAL............................................................................................................................ 874
INSTALLATION....................................................................................................................... 874
MANIFOLD ABSOLUTE PRESSURE SENSOR...................................................................................................... 874
REMOVAL............................................................................................................................ 874
CANISTER PURGE SOLENOID................................................................................................................ 874
ENGINE CONTROLLER...................................................................................................................... 874
OXYGEN SENSOR (O2 SENSOR).............................................................................................................. 875
3.0L MULTI- POINT FUEL INJECTION— SYSTEM OPERATION......................................................................................... 876
GENERAL INFORMATION.................................................................................................................... 876
SYSTEM DIAGNOSIS................................................................................................................... 876
CCD BUS................................................................................................................................ 876
ENGINE CONTROLLER...................................................................................................................... 877
AIR CONDITIONING SWITCH SENSE— ENGINE CONTROLLER INPUT................................................................................. 878
BATTERY VOLTAGE— ENGINE CONTROLLER INPUT............................................................................................... 878
BRAKE SWITCH— ENGINE CONTROLLER INPUT.................................................................................................. 878
COOLANT TEMPERATURE SENSOR— ENGINE CON-TROLLER INPUT................................................................................... 878
DISTRIBUTOR PICK- UP— ENGINE CONTROLLER INPUT.......................................................................................... 878
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— ENGINE CONTROLLER INPUT....................................................................... 879
OXYGEN SENSOR (O2 SENSOR)— ENGINE CON-TROLLER INPUT.................................................................................... 880
SPEED CONTROL— ENGINE CONTROLLER INPUT................................................................................................. 880
TRANSMISSION PARK/ NEUTRAL SWITCH— ENGINE CONTROLLER INPUT............................................................................. 880
THROTTLE POSITION SENSOR (TPS)— ENGINE CONTROLLER INPUT................................................................................ 880
VEHICLE DISTANCE (SPEED) SENSOR— ENGINE CONTROLLER INPUT............................................................................... 881
AIR CONDITIONING (A/ C) CLUTCH RELAY— ENGINE CONTROLLER OUTPUT......................................................................... 881
ALTERNATOR FIELD— ENGINE CONTROLLER OUT-PUT............................................................................................ 881
AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY— ENGINE CONTROLLER OUTPUT................................................................ 881
AUTOMATIC IDLE SPEED (AIS) MOTOR— ENGINE CONTROLLER OUTPUT............................................................................. 882
14 - 58 FUEL SYSTEM.................................................................................................................... 882
CHECK ENGINE LAMP— ENGINE CONTROLLER OUTPUT............................................................................................ 883
DIAGNOSTIC CONNECTOR— ENGINE CONTROLLER OUTPUT......................................................................................... 883
ELECTRONIC AUTOMATIC TRANSMISSION CONTROLLER— ENGINE CONTROLLER OUTPUT................................................................. 883
EMISSION MAINTENANCE REMINDER (EMR) LAMP— ENGINE CONTROLLER OUTPUT..................................................................... 883
FUEL INJECTORS— ENGINE CONTROLLER OUTPUT............................................................................................... 883
IGNITION COIL— ENGINE CONTROLLER OUTPUT................................................................................................ 884
PART THROTTLE UNLOCK SOLENOID— ENGINE CONTROLLER OUTPUT................................................................................ 884
RADIATOR FAN RELAY— ENGINE CONTROLLER OUTPUT........................................................................................... 884
SPEED CONTROL SOLENOIDS— ENGINE CONTROL-LER OUTPUT..................................................................................... 884
TACHOMETER— ENGINE CONTROLLER OUTPUT................................................................................................... 884
MODES OF OPERATION..................................................................................................................... 884
THROTTLE BODY.......................................................................................................................... 886
FUEL SUPPLY CIRCUIT.................................................................................................................... 886
FUEL PRESSURE REGULATOR................................................................................................................ 886
3.0L MULTI- POINT FUEL INJECTION— GENERAL DIAGNOSIS........................................................................................ 888
FUEL SYSTEM DIAGRAM.................................................................................................................... 888
VISUAL INSPECTION...................................................................................................................... 888
ON BOARD DIAGNOSTICS................................................................................................................... 891
MONITORED CIRCUITS................................................................................................................. 892
NON- MONITORED CIRCUITS............................................................................................................ 892
HIGH AND LOW LIMITS................................................................................................................ 893
FAULT CODE DESCRIPTION................................................................................................................. 893
SYSTEM TESTS........................................................................................................................... 893
OBTAINING FAULT CODES.............................................................................................................. 893
FAULT CODE DESCRIPTION............................................................................................................. 894
STATE DISPLAY TEST MODE................................................................................................................ 895
STATE DISPLAY INPUTS AND OUTPUTS................................................................................................... 895
FAULT CODE DESCRIPTION (CON’T)..................................................................................................... 895
STATE DISPLAY SENSORS.............................................................................................................. 896
CIRCUIT ACTUATION TEST MODE............................................................................................................ 896
OBTAINING CIRCUIT ACTUATION TEST................................................................................................... 896
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE......................................................................................... 896
IGNITION TIMING PROCEDURE.......................................................................................................... 897
60- WAY ENGINE CONTROLLER WIRING CONNEC-TOR............................................................................................ 897
IDLE SPECIFICATIONS................................................................................................................ 897
3.0L MULTI- POINT FUEL INJECTION— SERVICE PROCEDURES....................................................................................... 899
THROTTLE BODY SERVICE.................................................................................................................. 899
THROTTLE BODY.......................................................................................................................... 899
FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 900
THROTTLE POSITION SENSOR............................................................................................................... 900
REMOVAL............................................................................................................................ 900
INSTALLATION....................................................................................................................... 900
AUTOMATIC IDLE SPEED (AIS) MOTOR....................................................................................................... 900
REMOVAL............................................................................................................................ 900
INSTALLATION....................................................................................................................... 900
FUEL INJECTOR RAIL ASSEMBLY............................................................................................................ 901
REMOVAL............................................................................................................................ 901
FUEL INJECTOR RAIL ASSEMBLY............................................................................................................ 902
INSTALLATION....................................................................................................................... 902
FUEL PRESSURE REGULATOR SERVICE........................................................................................................ 902
REMOVAL............................................................................................................................ 902
INSTALLATION....................................................................................................................... 903
FUEL INJECTORS......................................................................................................................... 903
REMOVAL............................................................................................................................ 903
INSTALLATION....................................................................................................................... 903
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 904
CANISTER PURGE SOLENOID SERVICE........................................................................................................ 904
ENGINE CONTROLLER...................................................................................................................... 904
HEATED OXYGEN SENSOR (O2 SENSOR)....................................................................................................... 904
3.3L MULTI- POINT FUEL INJECTION— SYSTEM OPERATION......................................................................................... 905
GENERAL INFORMATION.................................................................................................................... 905
SYSTEM DIAGNOSIS................................................................................................................... 906
CCD BUS................................................................................................................................ 906
ENGINE CONTROLLER...................................................................................................................... 906
AIR CONDITIONING SWITCH SENSE— ENGINE CONTROLLER INPUT................................................................................. 907
BATTERY VOLTAGE— ENGINE CONTROLLER INPUT............................................................................................... 907
BRAKE SWITCH— ENGINE CONTROLLER INPUT.................................................................................................. 907
CAMSHAFT SENSOR— ENGINE CONTROLLER IN-PUT.............................................................................................. 908
COOLANT TEMPERATURE SENSOR— ENGINE CON-TROLLER INPUT................................................................................... 908
CRANKSHAFT SENSOR— ENGINE CONTROLLER INPUT............................................................................................. 908
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— ENGINE CONTROLLER INPUT....................................................................... 909
OXYGEN SENSOR (O2 SENSOR)— ENGINE CON-TROLLER INPUT.................................................................................... 910
SPEED CONTROL— ENGINE CONTROLLER INPUT................................................................................................. 910
TRANSMISSION PARK/ NEUTRAL SWITCH— ENGINE CONTROLLER INPUT............................................................................. 910
THROTTLE POSITION SENSOR (TPS)— ENGINE CONTROLLER INPUT................................................................................ 910
VEHICLE DISTANCE (SPEED) SENSOR— ENGINE CONTROLLER INPUT............................................................................... 911
AIR CONDITIONING (A/ C) CLUTCH RELAY— ENGINE CONTROLLER OUTPUT......................................................................... 911
ALTERNATOR FIELD— ENGINE CONTROLLER OUT-PUT............................................................................................ 911
AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY— ENGINE CONTROLLER OUTPUT................................................................ 912
AUTOMATIC IDLE SPEED (AIS) MOTOR— ENGINE CONTROLLER OUTPUT............................................................................. 912
CANISTER PURGE SOLENOID— ENGINE CONTROL-LER OUTPUT..................................................................................... 912
CHECK ENGINE LAMP— ENGINE CONTROLLER OUTPUT............................................................................................ 913
DIAGNOSTIC CONNECTOR— ENGINE CONTROLLER OUTPUT......................................................................................... 913
ELECTRONIC AUTOMATIC TRANSAXLE CONTROLLER— ENGINE CONTROLLER OUTPUT.................................................................... 913
EMISSION MAINTENANCE REMINDER (EMR) LAMP— ENGINE CONTROLLER OUTPUT..................................................................... 913
FUEL INJECTORS— ENGINE CONTROLLER OUTPUT............................................................................................... 913
IGNITION COIL— ENGINE CONTROLLER OUTPUT................................................................................................ 914
RADIATOR FAN RELAY— ENGINE CONTROLLER OUTPUT........................................................................................... 914
SPEED CONTROL SOLENOIDS— ENGINE CONTROL-LER OUTPUT..................................................................................... 914
TACHOMETER— ENGINE CONTROLLER OUTPUT................................................................................................... 914
MODES OF OPERATION..................................................................................................................... 914
THROTTLE BODY.......................................................................................................................... 916
FUEL SUPPLY CIRCUIT.................................................................................................................... 916
FUEL INJECTORS AND FUEL RAIL ASSEMBLY.................................................................................................. 916
FUEL PRESSURE REGULATOR................................................................................................................ 917
3.3L MULTI- POINT FUEL INJECTION— GENERAL DIAGNOSIS........................................................................................ 917
FUEL SYSTEM DIAGRAM.................................................................................................................... 917
VISUAL INSPECTION...................................................................................................................... 917
ON BOARD DIAGNOSTICS................................................................................................................... 921
MONITORED CIRCUITS................................................................................................................. 922
NON- MONITORED CIRCUITS............................................................................................................ 922
HIGH AND LOW LIMITS................................................................................................................ 923
FAULT CODE DESCRIPTION................................................................................................................. 923
SYSTEM TESTS........................................................................................................................... 923
OBTAINING FAULT CODES.............................................................................................................. 923
STATE DISPLAY TEST MODE................................................................................................................ 923
STATE DISPLAY INPUTS AND OUTPUTS................................................................................................... 923
FAULT CODE DESCRIPTION............................................................................................................. 924
FAULT CODE DESCRIPTION (CON’T)..................................................................................................... 925
STATE DISPLAY SENSORS.............................................................................................................. 926
CIRCUIT ACTUATION TEST MODE............................................................................................................ 926
OBTAINING CIRCUIT ACTUATION TEST................................................................................................... 926
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE......................................................................................... 926
60- WAY ENGINE CONTROLLER WIRING CONNECTOR............................................................................................. 927
IDLE SPECIFICATIONS................................................................................................................ 927
3.3L MULTI- POINT FUEL INJECTION— SERVICE PROCEDURES....................................................................................... 929
THROTTLE BODY REMOVAL.................................................................................................................. 929
THROTTLE BODY.......................................................................................................................... 929
FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 930
THROTTLE POSITION SENSOR............................................................................................................... 930
REMOVAL............................................................................................................................ 930
INSTALLATION....................................................................................................................... 930
AUTOMATIC IDLE SPEED (AIS) MOTOR....................................................................................................... 930
REMOVAL............................................................................................................................ 930
INSTALLATION....................................................................................................................... 930
FUEL INJECTOR RAIL ASSEMBLY............................................................................................................ 930
REMOVAL............................................................................................................................ 930
INSTALLATION....................................................................................................................... 932
FUEL PRESSURE REGULATOR................................................................................................................ 933
REMOVAL............................................................................................................................ 933
INSTALLATION....................................................................................................................... 934
FUEL INJECTOR.......................................................................................................................... 934
REMOVAL............................................................................................................................ 934
INSTALLATION....................................................................................................................... 934
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 934
CANISTER PURGE SOLENOID SERVICE........................................................................................................ 935
ENGINE CONTROLLER SERVICE.............................................................................................................. 935
CRANKSHAFT TIMING SENSOR............................................................................................................... 935
REMOVAL............................................................................................................................ 935
INSTALLATION....................................................................................................................... 935
CAMSHAFT SENSOR SERVICE................................................................................................................ 936
REMOVAL............................................................................................................................ 936
INSTALLATION....................................................................................................................... 936
HEATED OXYGEN SENSOR (O2 SENSOR) SERVICE............................................................................................... 936
SPECIFICATIONS............................................................................................................................. 937
TEMPERATURE SENSOR SPECIFICATIONS...................................................................................................... 937
TORQUE................................................................................................................................. 938
92AS_19............................................................................................................................................ 939
STEERING....................................................................................................................................... 939
GENERAL INFORMATION........................................................................................................................ 939
POWER STEERING PUMPS....................................................................................................................... 940
GENERAL INFORMATION.................................................................................................................... 940
STEERING COMPONENTS SERVICE DIAGNOSIS.................................................................................................. 941
POWER STEERING SERVICE DIAGNOSIS................................................................................................... 941
POWER STEERING SERVICE DIAGNOSIS................................................................................................... 942
POWER STEERING SERVICE DIAGNOSIS................................................................................................... 943
POWER STEERING SERVICE DIAGNOSIS................................................................................................... 944
POWER STEERING SERVICE DIAGNOSIS................................................................................................... 945
POWER STEERING SERVICE DIAGNOSIS................................................................................................... 946
POWER STEERING PUMP SERVICE............................................................................................................ 947
PUMP LEAKAGE DIAGNOSIS............................................................................................................. 947
CHECKING POWER STEERING FLUID LEVEL.................................................................................................... 948
POWER STEERING PUMP PRESSURE TEST...................................................................................................... 948
POWER STEERING HOSES................................................................................................................... 948
REMOVAL............................................................................................................................ 949
INSTALLATION....................................................................................................................... 949
POWER STEERING PUMP REMOVAL............................................................................................................ 950
2.5 LITER.......................................................................................................................... 950
3.0 LITER.......................................................................................................................... 951
3.3 LITER F. W. D. & A. W. D....................................................................................................... 953
POWER STEERING PUMP PULLEY............................................................................................................. 956
REMOVAL............................................................................................................................ 956
INSTALLATION....................................................................................................................... 956
POWER STEERING PUMP FLUID RESERVOIR.................................................................................................... 957
REMOVE............................................................................................................................. 957
INSTALL............................................................................................................................ 957
POWER STEERING PUMP— INITIAL OPERATION................................................................................................. 957
POWER STEERING GEAR........................................................................................................................ 958
GENERAL INFORMATION.................................................................................................................... 958
STEERING GEAR SERVICE (FRONT WHEEL DRIVE).............................................................................................. 959
REMOVAL............................................................................................................................ 959
INSTALLATION....................................................................................................................... 960
STEERING GEAR ALL WHEEL DRIVE...................................................................................................... 960
STEERING GEAR SERVICE (ALL WHEEL DRIVE)................................................................................................ 961
REMOVAL............................................................................................................................ 961
INSTALLATION....................................................................................................................... 964
OUTER TIE ROD.......................................................................................................................... 964
REMOVAL............................................................................................................................ 964
INSTALLATION....................................................................................................................... 964
STEERING GEAR BOOT SEAL................................................................................................................ 965
REMOVAL............................................................................................................................ 965
INSTALLATION....................................................................................................................... 965
ACUSTAR STANDARD AND TILT STEERING COLUMN.................................................................................................. 966
GENERAL INFORMATION.................................................................................................................... 966
STEERING COLUMN SERVICE PROCEDURES..................................................................................................... 966
STEERING COLUMN REMOVAL............................................................................................................ 968
STEERING COLUMN INSTALLATION....................................................................................................... 970
STEERING COLUMN COMPONENT SERVICE...................................................................................................... 971
GEAR SHIFT LEVER................................................................................................................... 971
IGNITION SWITCH SERVICE................................................................................................................ 972
TEST AND REPAIR.................................................................................................................... 972
SPECIFICATIONS AND TIGHTENING REFERENCE.................................................................................................... 973
TORQUE SPECIFICATIONS.................................................................................................................. 973
92AS_21............................................................................................................................................ 975
TRANSAXLE...................................................................................................................................... 975
A- 523 MANUAL TRANSAXLE.................................................................................................................... 975
GENERAL INFORMATION.................................................................................................................... 975
IDENTIFICATION......................................................................................................................... 975
GEARSHIFT LINKAGE ADJUSTMENT (CABLE OPER-ATED)......................................................................................... 976
IN- CAR TRANSAXLE DISASSEMBLE/ ASSEMBLE................................................................................................ 978
TRANSAXLE REMOVAL AND INSTALLATION..................................................................................................... 978
OUT OF CAR TRANSAXLE— DISASSEMBLE AND ASSEMBLE......................................................................................... 979
DIFFERENTIAL....................................................................................................................... 979
GEAR SET........................................................................................................................... 981
CLUTCH RELEASE BEARING INPUT SHAFT OIL SEAL........................................................................................ 988
REVERSE SHIFT LEVER................................................................................................................ 989
SUBASSEMBLY- RECONDITION............................................................................................................... 989
TRANSAXLE CASE..................................................................................................................... 989
INTERMEDIATE SHAFT ASSEMBLY........................................................................................................ 990
1- 2 SYNCHRONIZER (DUAL- CONE)..................................................................................................... 991
SYNCHRONIZERS...................................................................................................................... 993
GEARSHIFT HOUSING.................................................................................................................. 995
DIFFERENTIAL BEARING RETAINER...................................................................................................... 998
EXTENSION HOUSING.................................................................................................................. 999
INPUT SHAFT........................................................................................................................1000
A- 523 DIFFERENTIAL................................................................................................................1001
BEARING ADJUSTMENT PROCEDURE...........................................................................................................1003
GENERAL RULES ON SERVICING BEARINGS................................................................................................1003
INPUT SHAFT BEARING END PLAY ADJUSTMENT............................................................................................1003
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT................................................................................................1004
INPUT SHAFT SHIM CHART.............................................................................................................1004
DIFFERENTIAL BEARING SHIM CHART....................................................................................................1005
THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE................................................................................................1006
GENERAL INFORMATION....................................................................................................................1006
LOCKUP TORQUE CONVERTER............................................................................................................1007
HYDRAULIC CONTROL SYSTEM...........................................................................................................1007
PRESSURE SUPPLY SYSTEM.............................................................................................................1007
PRESSURE REGULATING VALVES.........................................................................................................1007
FLOW CONTROL VALVES................................................................................................................1007
CLUTCHES, BAND SERVOS, AND ACCUMULATOR.............................................................................................1007
GEARSHIFT AND PARKING LOCK CONTROLS................................................................................................1007
TORQUEFLITE DIAGNOSIS AND TESTS........................................................................................................1007
FLUID LEVEL AND CONDITION..............................................................................................................1010
DIAGNOSIS GUIDE— ABNORMAL NOISE....................................................................................................1010
SELECTION OF LUBRICANT.................................................................................................................1011
SPECIAL ADDITIVES......................................................................................................................1011
FLUID AND FILTER CHANGE................................................................................................................1011
FLUID DRAIN AND REFILL.................................................................................................................1011
LOCKUP SOLENOID WIRING CONNECTOR.......................................................................................................1011
ROAD TEST..............................................................................................................................1011
HYDRAULIC PRESSURE TESTS...............................................................................................................1012
TEST ONE (SELECTOR IN ‘‘ 1’’)......................................................................................................1012
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER.............................................................................1012
TEST TWO (SELECTOR IN ‘‘ 2’’)......................................................................................................1013
TEST THREE (SELECTOR IN ‘‘ D’’)....................................................................................................1013
TEST FOUR (SELECTOR IN REVERSE)....................................................................................................1013
TEST RESULT INDICATIONS............................................................................................................1014
GOVERNOR PRESSURE..................................................................................................................1014
THROTTLE PRESSURE..................................................................................................................1014
CLUTCH AND SERVO AIR PRESSURE TESTS....................................................................................................1014
FRONT CLUTCH.......................................................................................................................1014
REAR CLUTCH........................................................................................................................1014
KICKDOWN SERVO (FRONT).............................................................................................................1014
LOW AND REVERSE SERVO (REAR).......................................................................................................1014
FLUID LEAKAGE- TRANSAXLE TORQUE CON-VERTER HOUSING AREA................................................................................1014
LEAKAGE TEST PROBE.................................................................................................................1015
TORQUE CONVERTER LEAKAGE...........................................................................................................1016
AIR PRESSURE TEST OF TRANSAXLE.....................................................................................................1016
GEARSHIFT LINKAGE ADJUSTMENT...........................................................................................................1017
THROTTLE PRESSURE LINKAGE ADJUSTMENT...................................................................................................1017
CABLE ADJUSTMENT PROCEDURE (4- CYL.)...............................................................................................1017
ROD ADJUSTMENT PROCEDURE (6- CYL.).................................................................................................1017
BAND ADJUSTMENT........................................................................................................................1018
KICKDOWN BAND (FRONT)..............................................................................................................1018
LOW/ REVERSE BAND (REAR)...........................................................................................................1018
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS.................................................................................................1018
LINE PRESSURE......................................................................................................................1018
THROTTLE PRESSURE..................................................................................................................1018
DISTANCE SENSOR PINION GEAR............................................................................................................1018
REMOVAL AND INSTALLATION...........................................................................................................1018
NEUTRAL STARTING AND BACK- UP LAMP SWITCH..............................................................................................1018
REPLACEMENT AND TEST...............................................................................................................1018
GOVERNOR...............................................................................................................................1019
ALUMINUM THREAD REPAIR.................................................................................................................1019
OIL COOLERS AND TUBES REVERSE FLUSHING.................................................................................................1019
OIL COOLER FLOW CHECK..................................................................................................................1019
TRANSAXLE AND TORQUE CONVERTER REMOVAL.................................................................................................1020
TRANSAXLE DISASSEMBLY (SUBASSEMBLY REMOVAL)............................................................................................1022
TRANSAXLE ASSEMBLY (SUBASSEMBLY INSTALLATION)..........................................................................................1028
VALVE BODY RECONDITION.................................................................................................................1028
CLEANING AND INSPECTION............................................................................................................1028
PUMP OIL SEAL- REPLACEMENT.............................................................................................................1032
OIL PUMP- RECONDITION FRONT CLUTCH- RECONDITION........................................................................................1033
INSPECTION.........................................................................................................................1033
DISASSEMBLE/ ASSEMBLE MEASURING PLATE CLEARANCE....................................................................................1034
REAR CLUTCH- RECONDITION...............................................................................................................1035
INSPECTION.........................................................................................................................1035
DISASSEMBLE/ ASSEMBLE..............................................................................................................1035
MEASURING PLATE CLEARANCE..........................................................................................................1036
FRONT PLANETARY & ANNULUS GEAR- RECONDITION............................................................................................1036
LOW/ REVERSE (REAR) SERVO- RECONDITION.................................................................................................1037
ACCUMULATOR- RECONDITION...............................................................................................................1038
KICKDOWN SERVO (CONTROLLED LOAD) -RECONDITION..........................................................................................1038
TRANSFER SHAFT REPAIR..................................................................................................................1039
DETERMINING SHIM THICKNESS.........................................................................................................1043
PARKING PAWL...........................................................................................................................1043
OUTPUT SHAFT REPAIR....................................................................................................................1044
DETERMINING SHIM THICKNESS.........................................................................................................1046
DIFFERENTIAL REPAIR....................................................................................................................1047
DETERMINING SHIM THICKNESS.........................................................................................................1051
BEARING ADJUSTMENT PROCEDURES..........................................................................................................1053
GENERAL RULES ON SERVICING BEARINGS................................................................................................1053
OUTPUT SHAFT BEARING...............................................................................................................1053
DIFFERENTIAL BEARING...............................................................................................................1053
OUTPUT SHAFT BEARING SHIM CHART....................................................................................................1053
TRANSFER SHAFT BEARING.............................................................................................................1054
DIFFERENTIAL BEARING SHIM CHART....................................................................................................1054
TRANSFER BEARING SHIM CHART BEARING SHIM CHART.....................................................................................1055
4- SPEED ELECTRONIC AUTOMATIC TRANSAXLE....................................................................................................1056
GENERAL INFORMATION....................................................................................................................1056
TRANSAXLE IDENTIFICATION...........................................................................................................1056
OPERATION..........................................................................................................................1056
CLUTCH AND GEAR....................................................................................................................1058
HYDRAULICS.........................................................................................................................1058
SOLENOIDS..........................................................................................................................1058
SENSORS............................................................................................................................1058
ELECTRONICS........................................................................................................................1058
ADAPTIVE CONTROLS..................................................................................................................1058
ON- BOARD DIAGNOSTICS..............................................................................................................1059
GENERAL DIAGNOSIS......................................................................................................................1059
DIAGNOSIS GUIDE- VEHICLE WILL NOT MOVE.............................................................................................1059
FAULT CODE CHART ‘‘ A’’............................................................................................................1060
DIAGNOSIS CHART ‘‘ B’’.............................................................................................................1061
DIAGNOSIS GUIDE- ABNORMAL NOISE DIAGNOSIS GUIDE- FLUID LEAKS.......................................................................1062
FLUID LEVEL AND CONDITION..............................................................................................................1063
SELECTION OF LUBRICANT.................................................................................................................1063
SPECIAL ADDITIVES......................................................................................................................1063
FLUID AND FILTER CHANGE................................................................................................................1063
FLUID DRAIN AND REFILL.................................................................................................................1063
ROAD TEST..............................................................................................................................1064
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER.............................................................................1064
HYDRAULIC PRESSURE TESTS...............................................................................................................1065
TEST ONE (SELECTOR IN ‘‘ L’’ 1ST GEAR).............................................................................................1065
TEST TWO (SELECTOR IN ‘‘ 3’’ 2ND GEAR).............................................................................................1065
TEST THREE (OVERDRIVE CLUTCH CHECK)................................................................................................1065
TEST FOUR (SELECTOR IN ‘‘ CIRCLE D’’ OVER-DRIVE GEAR)..............................................................................1065
TEST FIVE (SELECTOR IN ‘‘ CIRCLE D’’ OVER-DRIVE LOCKUP)............................................................................1065
TEST SIX (SELECTOR IN REVERSE).....................................................................................................1065
TEST RESULT INDICATIONS............................................................................................................1066
CLUTCH AIR PRESSURE TESTS..............................................................................................................1066
OVERDRIVE CLUTCH...................................................................................................................1066
REVERSE CLUTCH.....................................................................................................................1066
PRESSURE CHECK SPECIFICATIONS......................................................................................................1066
2/ 4 CLUTCH........................................................................................................................1067
LOW/ REVERSE CLUTCH................................................................................................................1067
UNDERDRIVE CLUTCH..................................................................................................................1067
FLUID LEAKAGE- TRANSAXLE TORQUE CON-VERTER HOUSING AREA................................................................................1067
TORQUE CONVERTER LEAKAGE...........................................................................................................1067
LEAKAGE TEST PROBE.................................................................................................................1067
AIR PRESSURE TEST OF TRANSAXLE.....................................................................................................1068
GEARSHIFT LINKAGE ADJUSTMENT...........................................................................................................1068
DISTANCE SENSOR GEAR...................................................................................................................1069
REMOVAL AND INSTALL................................................................................................................1069
ALUMINUM THREAD REPAIR.................................................................................................................1069
OIL COOLERS AND TUBES REVERSE FLUSHING.................................................................................................1069
OIL COOLER FLOW CHECK..................................................................................................................1069
TRANSAXLE REMOVAL AND INSTALLATION.....................................................................................................1070
SOLENOID ASSEMBLY- REPLACE.............................................................................................................1072
PRNDL SWITCH...........................................................................................................................1073
NEUTRAL SAFETY SWITCH..................................................................................................................1073
SPEED SENSOR- INPUT....................................................................................................................1073
SPEED SENSOR- OUTPUT...................................................................................................................1073
TRANSAXLE- RECONDITION.................................................................................................................1074
DETERMINING No. 4 THRUST PLATE THICKNESS (Input Shaft End Play)........................................................................1089
LOW/ REVERSE REACTION PLATE CHART..................................................................................................1089
INPUT CLUTCHES- RECONDITION............................................................................................................1090
DISASSEMBLY........................................................................................................................1090
NO. 4 THRUST PLATE CHART...........................................................................................................1090
ASSEMBLY...........................................................................................................................1095
UNDERDRIVE REACTION PLATE CHART....................................................................................................1099
REVERSE CLUTCH SNAP RING CHART.....................................................................................................1101
VALVE BODY- RECONDITION................................................................................................................1102
OIL PUMP SEAL- REPLACE DIFFERENTIAL REPAIR.............................................................................................1106
DETERMINING SHIM THICKNESS.........................................................................................................1110
BEARING ADJUSTMENT PROCEDURES..........................................................................................................1111
GENERAL RULES ON SERVICING BEARINGS................................................................................................1111
OUTPUT GEAR BEARING................................................................................................................1111
DIFFERENTIAL BEARING...............................................................................................................1112
OUTPUT GEAR BEARING SHIM CHART DIFFERENTIAL BEARING SHIM CHART.....................................................................1112
TRANSFER SHAFT BEARING.............................................................................................................1113
TRANSFER BEARING SHIM CHART........................................................................................................1113
BEARING SHIM CHART.................................................................................................................1114
ALL WHEEL DRIVE POWER TRANSFER UNIT (P. T. U.).............................................................................................1115
GENERAL INFORMATION....................................................................................................................1115
SEAL IDENTIFICATION....................................................................................................................1115
FLUID LEAK DIAGNOSIS...................................................................................................................1115
POWER TRANSFER UNIT (P. T. U.).........................................................................................................1116
REMOVAL AND INSTALLATION...........................................................................................................1116
POWER TRANSFER UNIT END COVER— RESEAL..................................................................................................1119
POWER TRANSFER UNIT INPUT SHAFT SEAL...................................................................................................1120
REMOVAL............................................................................................................................1120
INSTALLATION.......................................................................................................................1120
TRANSAXLE DIFFERENTIAL CARRIER SEAL....................................................................................................1121
REMOVAL............................................................................................................................1121
INSTALLATION.......................................................................................................................1121
POWER TRANSFER UNIT REAR COVER O- RING.................................................................................................1122
REMOVAL............................................................................................................................1122
POWER TRANSFER UNIT OUTPUT SEAL........................................................................................................1122
REMOVAL............................................................................................................................1122
INSTALLATION.......................................................................................................................1123
OUTPUT FLANGE SHIM SELECTION...........................................................................................................1124
POWER TRANSFER UNIT INPUT SHAFT COVER SEAL.............................................................................................1124
REMOVAL............................................................................................................................1124
INSTALLATION.......................................................................................................................1124
POWER TRANSFER UNIT HALF SHAFT INNER SEAL..............................................................................................1126
REMOVAL............................................................................................................................1126
INSTALLATION.......................................................................................................................1126
POWER TRANSFER UNIT INPUT SHAFT END SEAL...............................................................................................1127
REMOVAL............................................................................................................................1127
INSTALLATION.......................................................................................................................1128
POWER TRANSFER UNIT OUTER HALF SHAFT SEAL..............................................................................................1129
REMOVAL............................................................................................................................1129
INSTALLATION.......................................................................................................................1129
POWER TRANSFER UNIT END COVER BALL BEAR-ING............................................................................................1129
REMOVAL............................................................................................................................1129
INSTALLATION.......................................................................................................................1130
4- SPEED ELECTRONIC TRANSAXLE ON- BOARD DIAGNOSTICS........................................................................................1131
GENERAL INFORMATION....................................................................................................................1131
ON- BOARD DIAGNOSTICS INFORMATION......................................................................................................1131
CCD BUS................................................................................................................................1131
SYSTEM FAULT MESSAGES/ CODES...........................................................................................................1131
HARD FAULTS........................................................................................................................1131
SOFT FAULTS........................................................................................................................1131
LIMP- IN MODE..........................................................................................................................1131
DRBII (DIAGNOSTIC READ- OUT BOX).......................................................................................................1132
FAULT CODE CHARTS......................................................................................................................1132
FAULT CODE 11......................................................................................................................1132
FAULT CODE 12 FAULT CODE 13........................................................................................................1133
FAULT CODE 14 FAULT CODE 15........................................................................................................1134
FAULT CODE 16 FAULT CODE 17........................................................................................................1135
FAULT CODE 18 FAULT CODE 19........................................................................................................1136
FAULT CODE 20......................................................................................................................1137
FAULT CODE 21- 27..................................................................................................................1138
FAULT CODE 28......................................................................................................................1139
FAULT CODE 29 FAULT CODE 31- 32....................................................................................................1140
FAULT CODE 36 FAULT CODE 37........................................................................................................1141
FAULT CODE 38......................................................................................................................1142
FAULT CODE 41- 44..................................................................................................................1143
FAULT CODE 45 FAULT CODE 46........................................................................................................1144
FAULT CODE 47......................................................................................................................1145
FAULT CODE 50- 58..................................................................................................................1146
FAULT CODE 60- 63..................................................................................................................1147
4 SPEED ELECTRONIC TRANSAXLE WIRING DIAGRAM........................................................................................1148
ON BOARD DIAGNOSTICS GLOSSARY......................................................................................................1149
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................................................................................1150
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1151
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1152
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1153
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1154
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1155
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1156
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1157
4- SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC..................................................................................1158
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATICS..........................................................................................1158
4- SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC......................................................................................1159
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1160
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1161
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1162
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1163
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1164
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1165
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1166
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1167
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1168
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1169
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1170
3- SPEED AUTOMATIC TRANSAXLE...........................................................................................................1171
4- SPEED ELECTRONIC AUTOMATIC TRANSAXLE................................................................................................1172
SPECIFICATIONS.............................................................................................................................1173
THREE SPEED TRANSAXLE TIGHTENING REFERENCE.............................................................................................1173
4 SPEED ELECTRONIC TRANSAXLE TIGHTENING REFERENCE .....................................................................................1174
CONVERSION CHART...................................................................................................................1175
POWER TRANSFER UNIT TIGHTENING REFERENCE...............................................................................................1174
92AS_22............................................................................................................................................1177
WHEELS TIRES...................................................................................................................................1177
TIRE SERVICE PROCEDURES....................................................................................................................1177
GENERAL INFORMATION....................................................................................................................1177
RADIAL- PLY TIRES......................................................................................................................1177
SPARE TIRE (COMPACT)...............................................................................................................1177
TIRE CHAINS........................................................................................................................1177
CLEANING OF TIRES......................................................................................................................1177
PRESSURE GAUGES........................................................................................................................1178
TIRE INFLATION PRESSURES...............................................................................................................1178
TIRE PRESSURE FOR HIGH SPEED OPERATION............................................................................................1178
REPLACEMENT TIRES......................................................................................................................1178
ROTATION...............................................................................................................................1179
TREAD WEAR INDICATORS..................................................................................................................1179
REPAIRING LEAKS........................................................................................................................1179
TIRE NOISE OR VIBRATION................................................................................................................1179
TIRE WEAR PATTERNS.....................................................................................................................1179
LEAD CORRECTION CHART..............................................................................................................1181
WHEEL SERVICE PROCEDURES...................................................................................................................1182
GENERAL INFORMATION....................................................................................................................1182
WHEEL INSTALLATION.....................................................................................................................1182
WHEEL REPLACEMENT......................................................................................................................1182
TIRE AND WHEEL BALANCE.................................................................................................................1182
TIRE AND WHEEL RUN OUT.................................................................................................................1183
METHOD 1 (RELOCATE WHEEL ON HUB)...................................................................................................1183
METHOD 2 (RELOCATE TIRE ON WHEEL)..................................................................................................1183
SPECIFICATIONS.............................................................................................................................1184
TORQUE.................................................................................................................................1184
92AS_23............................................................................................................................................1185
BODY...........................................................................................................................................1185
GENERAL SERVICE INFORMATION................................................................................................................1185
VEHICLE IDENTIFICATION.................................................................................................................1185
SAFETY PRECAUTIONS AND WARNINGS........................................................................................................1185
BODY DIAGNOSTIC PROCEDURES.................................................................................................................1186
WATER LEAKS............................................................................................................................1186
VISUAL INSPECTION BEFORE WATER LEAK TESTS..........................................................................................1186
WATER LEAK TESTS...................................................................................................................1186
WATER LEAK DETECTION...............................................................................................................1186
MIRROR INSPECTION METHOD...........................................................................................................1186
BRIGHT LIGHT LEAK TEST METHOD......................................................................................................1186
PRESSURIZED LEAK TEST METHOD.......................................................................................................1186
WIND NOISE.............................................................................................................................1187
VISUAL INSPECTION BEFORE TESTS.....................................................................................................1187
ROAD TESTING WIND NOISE............................................................................................................1187
PAINT......................................................................................................................................1188
INTRODUCTION...........................................................................................................................1188
BASE COAT/ CLEAR COAT FINISH...........................................................................................................1188
WET SANDING, BUFFING AND POLISHING.....................................................................................................1188
PAINTED SURFACE TOUCH- UP..............................................................................................................1188
TOUCH- UP PROCEDURE................................................................................................................1188
PAINT AND TRIM CODE DESCRIPTIONS...................................................................................................1188
WINDSHIELD.................................................................................................................................1189
SAFETY PRECAUTIONS AND WARNINGS........................................................................................................1189
WINDSHIELD REPLACEMENT.................................................................................................................1189
REMOVAL............................................................................................................................1189
INSTALLATION.......................................................................................................................1189
SEAT COMPONENT SERVICE.....................................................................................................................1191
GENERAL INFORMATION....................................................................................................................1191
HEAD RESTRAINT.........................................................................................................................1191
REMOVAL (FIG. 1)...................................................................................................................1191
INSTALLATION (FIG. 2)..............................................................................................................1191
ARMREST................................................................................................................................1191
REMOVAL (FIG. 3)...................................................................................................................1191
INSTALLATION.......................................................................................................................1192
BUCKET SEAT BACK.......................................................................................................................1192
REMOVAL (FIG. 4 AND 5).............................................................................................................1192
INSTALLATION.......................................................................................................................1192
RECLINER HANDLE........................................................................................................................1192
REMOVAL (FIG. 6)...................................................................................................................1192
RECLINER HANDLE INSTALLATION.......................................................................................................1193
SEAT BACK RECLINER.....................................................................................................................1193
REMOVAL (FIG. 7)...................................................................................................................1193
INSTALLATION.......................................................................................................................1193
LUMBAR SUPPORT HANDLE..................................................................................................................1193
REMOVAL (FIG. 8)...................................................................................................................1193
LUMBAR SUPPORT HANDLE INSTALLATION.................................................................................................1193
SEAT BACK ASSIST STRAP.................................................................................................................1193
REMOVAL (FIG. 9)...................................................................................................................1193
INSTALLATION.......................................................................................................................1193
SEAT BACK FRAME........................................................................................................................1193
REMOVAL (FIG. 10 AND 11)...........................................................................................................1193
SEAT BACK FRAME INSTALLATION (FIG. 12, 13 AND 14)..................................................................................1194
BUCKET SEAT RISER TRIM COVER...........................................................................................................1195
REMOVAL (FIG. 15)..................................................................................................................1195
INSTALLATION.......................................................................................................................1195
BUCKET SEAT RISER......................................................................................................................1195
REMOVAL (FIG. 16)..................................................................................................................1195
INSTALLATION.......................................................................................................................1195
BUCKET SEAT CUSHION SIDE COVER.........................................................................................................1195
REMOVAL (FIG. 17)..................................................................................................................1195
INSTALLATION.......................................................................................................................1195
BUCKET SEAT CUSHION FRAME..............................................................................................................1195
REMOVAL (FIG. 18)..................................................................................................................1195
INSTALLATION.......................................................................................................................1195
BUCKET SEAT CUSHION PAD................................................................................................................1195
REMOVAL (FIG. 19)..................................................................................................................1195
BUCKET SEAT CUSHION PAD INSTALLATION (FIG. 20).....................................................................................1196
SECOND REAR SEAT BACK PANEL............................................................................................................1196
REMOVAL (FIG. 21)..................................................................................................................1196
INSTALLATION.......................................................................................................................1196
SECOND REAR SEAT BACK HINGE COVER......................................................................................................1196
REMOVAL (FIG. 22)..................................................................................................................1196
INSTALLATION.......................................................................................................................1196
SECOND REAR SEAT BACK..................................................................................................................1196
REMOVAL (FIG. 23)..................................................................................................................1196
SECOND REAR SEAT BACK INSTALLATION.................................................................................................1197
SECOND REAR SEAT BACK HINGE............................................................................................................1197
REMOVAL (FIG. 24)..................................................................................................................1197
INSTALLATION.......................................................................................................................1197
SECOND REAR SEAT TRACK.................................................................................................................1197
REMOVAL (FIG. 25)..................................................................................................................1197
INSTALLATION.......................................................................................................................1197
SECOND REAR SEAT RISER.................................................................................................................1197
REMOVAL (FIG. 26)..................................................................................................................1197
INSTALLATION.......................................................................................................................1197
SECOND REAR SEAT CUSHION PAD...........................................................................................................1198
REMOVAL............................................................................................................................1198
INSTALLATION.......................................................................................................................1198
SECOND REAR SEAT BACK PAD..............................................................................................................1198
REMOVAL............................................................................................................................1198
INSTALLATION.......................................................................................................................1198
CHILD RESTRAINT SEAT...................................................................................................................1198
CHILD SEAT MODULE......................................................................................................................1198
REMOVAL............................................................................................................................1198
INSTALLATION.......................................................................................................................1198
CHILD SEAT MODULE HEAD RESTRAINT.......................................................................................................1199
REMOVAL (FIG. 29)..................................................................................................................1199
INSTALLATION.......................................................................................................................1199
CHILD SEAT MODULE HEAD RESTRAINT COVER AND PAD.........................................................................................1199
REMOVAL............................................................................................................................1199
INSTALLATION.......................................................................................................................1199
CHILD SEAT MODULE CUSHION COVER AND PAD................................................................................................1199
REMOVAL............................................................................................................................1199
INSTALLATION.......................................................................................................................1199
CHILD SEAT BACK COVER AND PADS.........................................................................................................1200
REMOVAL............................................................................................................................1200
INSTALLATION.......................................................................................................................1200
CHILD SEAT CUSHION COVER AND PAD.......................................................................................................1200
REMOVAL............................................................................................................................1200
CHILD SEAT CUSHION COVER AND PAD INSTALLATION......................................................................................1201
CONVERTA- BED SEATS....................................................................................................................1201
CONVERTA- BED SEAT RISER...............................................................................................................1201
REMOVAL (FIG. 35)..................................................................................................................1201
INSTALLATION.......................................................................................................................1201
CONVERTA- BED FORWARD RAIL AND PIVOT...................................................................................................1201
REMOVAL (FIG. 36)..................................................................................................................1201
INSTALLATION.......................................................................................................................1201
CONVERTA- BED SEAT HINGE COVERS........................................................................................................1201
REMOVAL............................................................................................................................1201
INSTALLATION.......................................................................................................................1201
CONVERTA- BED LATCH HANDLE AND LINK BAR................................................................................................1202
REMOVAL............................................................................................................................1202
INSTALLATION.......................................................................................................................1202
CONVERTA- BED SEAT BACK HINGE..........................................................................................................1202
REMOVAL............................................................................................................................1202
INSTALLATION.......................................................................................................................1202
CONVERTA- BED SEAT BACK FRAME..........................................................................................................1202
REMOVAL............................................................................................................................1202
CONVERTA- BED SEAT BACK FRAME INSTALLATION.........................................................................................1203
CONVERTA- BED SEAT CUSHION FRAME.......................................................................................................1203
REMOVAL............................................................................................................................1203
INSTALLATION.......................................................................................................................1203
BODY COMPONENT SERVICE.....................................................................................................................1204
GRILLE.................................................................................................................................1204
REMOVAL (FIG. 1 OR 2)..............................................................................................................1204
INSTALLATION.......................................................................................................................1204
HOOD ORNAMENT..........................................................................................................................1204
REMOVAL (FIG. 3)...................................................................................................................1204
INSTALLATION.......................................................................................................................1204
HOOD AND HINGES........................................................................................................................1205
HOOD REMOVAL (FIG. 4)..............................................................................................................1205
HOOD INSTALLATION..................................................................................................................1205
HOOD HINGE REMOVAL (FIG. 4)........................................................................................................1205
HOOD HINGE INSTALLATION............................................................................................................1205
HOOD SAFETY CATCH......................................................................................................................1205
REMOVAL (FIG. 5)...................................................................................................................1205
INSTALLATION.......................................................................................................................1205
HOOD LATCH.............................................................................................................................1205
REMOVAL (FIG. 6)...................................................................................................................1205
HOOD LATCH INSTALLATION............................................................................................................1206
HOOD RELEASE CABLE.....................................................................................................................1206
REMOVAL (FIG. 7)...................................................................................................................1206
INSTALLATION.......................................................................................................................1206
SIGHT SHIELD...........................................................................................................................1206
REMOVAL (FIG. 8)...................................................................................................................1206
INSTALLATION.......................................................................................................................1206
COWL COVER.............................................................................................................................1206
REMOVAL (FIG. 9)...................................................................................................................1206
COWL COVER INSTALLATION............................................................................................................1207
FRONT END SPLASH SHIELDS...............................................................................................................1207
FRONT WHEELHOUSE SPLASH SHIELD RE-MOVAL (FIG. 10)..................................................................................1207
FRONT WHEELHOUSE SPLASH SHIELD IN-STALLATION.......................................................................................1207
ENGINE DRIVE BELT SPLASH SHIELD RE-MOVAL (FIG. 10).................................................................................1207
ENGINE DRIVE BELT SPLASH SHIELD INSTAL-LATION......................................................................................1207
REAR ENGINE COMPARTMENT SPLASH SHIELD..................................................................................................1207
REAR ENGINE COMPARTMENT SPLASH SHIELD REMOVAL (FIG. 10)............................................................................1207
REAR ENGINE COMPARTMENT SPLASH SHIELD INSTALLATION.................................................................................1207
TRANSAXLE SPLASH SHIELD................................................................................................................1207
REMOVAL (FIG. 11)..................................................................................................................1207
INSTALLATION.......................................................................................................................1207
FRONT FENDER...........................................................................................................................1207
REMOVAL (FIG. 12)..................................................................................................................1207
FRONT FENDER INSTALLATION..........................................................................................................1208
FRONT DOOR TRIM PANEL..................................................................................................................1208
REMOVAL (FIG. 13)..................................................................................................................1208
FRONT DOOR TRIM PANEL INSTALLATION.................................................................................................1208
FRONT DOOR AND HINGE...................................................................................................................1208
FRONT DOOR REMOVAL (FIG. 14).......................................................................................................1208
FRONT DOOR INSTALLATION............................................................................................................1209
FRONT DOOR HINGE REMOVAL (FIG. 14).................................................................................................1209
FRONT DOOR HINGE INSTALLATION......................................................................................................1209
OUTSIDE FRONT DOOR LATCH RELEASE HANDLE................................................................................................1209
REMOVAL (FIG. 15)..................................................................................................................1209
INSTALLATION.......................................................................................................................1209
FRONT DOOR LATCH.......................................................................................................................1209
REMOVAL (FIG. 16)..................................................................................................................1209
INSTALLATION.......................................................................................................................1209
FRONT DOOR SIDE VIEW MIRROR............................................................................................................1210
REMOVAL (FIG. 17)..................................................................................................................1210
INSTALLATION.......................................................................................................................1210
FRONT DOOR GLASS.......................................................................................................................1210
REMOVAL (FIG. 18)..................................................................................................................1210
INSTALLATION.......................................................................................................................1210
FRONT DOOR BELT MOLDING AND WEATHERSTRIP— VAN..........................................................................................1210
REMOVAL (FIG. 19)..................................................................................................................1210
INSTALLATION.......................................................................................................................1210
FRONT DOOR FRAME REAR MOLDING— VAN.....................................................................................................1210
REMOVAL (FIG. 19)..................................................................................................................1210
INSTALLATION.......................................................................................................................1210
FRONT DOOR BELT MOLDING AND WEATHERSTRIP— WAGON........................................................................................1211
REMOVAL (FIG. 20)..................................................................................................................1211
INSTALLATION.......................................................................................................................1211
FRONT DOOR GLASS CHANNEL AND RUN WEATH-ERSTRIP.........................................................................................1211
REMOVAL (FIG. 21)..................................................................................................................1211
INSTALLATION.......................................................................................................................1211
FRONT DOOR GLASS LOWER CHANNEL.........................................................................................................1211
REMOVAL (FIG. 22)..................................................................................................................1211
INSTALLATION.......................................................................................................................1211
FRONT DOOR WINDOW REGULATOR— MANUAL....................................................................................................1211
REMOVAL (FIG. 22)..................................................................................................................1211
MANUAL WINDOW REGULATOR INSTALLA-TION..............................................................................................1212
FRONT DOOR WINDOW REGULATOR— POWER.....................................................................................................1212
REMOVAL (FIG. 22)..................................................................................................................1212
INSTALLATION.......................................................................................................................1212
SLIDING DOOR TRIM PANEL................................................................................................................1212
REMOVAL (FIG. 23)..................................................................................................................1212
INSTALLATION.......................................................................................................................1212
SLIDING DOOR FRAME UPPER MOLDING.......................................................................................................1212
REMOVAL (FIG. 23)..................................................................................................................1212
INSTALLATION.......................................................................................................................1212
SLIDING DOOR PULL HANDLE...............................................................................................................1212
REMOVAL (FIG. 23)..................................................................................................................1212
INSTALLATION.......................................................................................................................1212
SLIDING DOOR...........................................................................................................................1212
REMOVAL............................................................................................................................1212
SLIDING DOOR INSTALLATION..........................................................................................................1213
SLIDING DOOR CENTER HINGE TRACK COVER..................................................................................................1213
REMOVAL (FIG. 24)..................................................................................................................1213
INSTALLATION.......................................................................................................................1213
SLIDING DOOR CENTER HINGE..............................................................................................................1213
REMOVAL (FIG. 25)..................................................................................................................1213
INSTALLATION.......................................................................................................................1213
SLIDING DOOR UPPER HINGE...............................................................................................................1213
REMOVAL (FIG. 26)..................................................................................................................1213
SLIDING DOOR UPPER HINGE INSTALLATION..............................................................................................1214
SLIDING DOOR LOWER HINGE...............................................................................................................1214
REMOVAL (FIG. 27)..................................................................................................................1214
INSTALLATION.......................................................................................................................1214
SLIDING DOOR INSIDE LATCH/ LOCK CONTROL................................................................................................1214
REMOVAL (FIG. 28)..................................................................................................................1214
INSTALLATION.......................................................................................................................1214
SLIDING DOOR LATCH/ LOCK LINKAGE.......................................................................................................1214
REMOVAL (FIG. 29)..................................................................................................................1214
SLIDING DOOR LATCH/ LOCK LINKAGE IN-STALLATION.....................................................................................1215
SLIDING DOOR POWER LOCK ACTUATOR.......................................................................................................1215
REMOVAL (FIG. 29)..................................................................................................................1215
INSTALLATION.......................................................................................................................1215
SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE..............................................................................................1215
REMOVAL (FIG. 30)..................................................................................................................1215
INSTALLATION.......................................................................................................................1215
SLIDING DOOR REAR LATCH................................................................................................................1215
REMOVAL (FIG. 31)..................................................................................................................1215
INSTALLATION.......................................................................................................................1215
VENT WINDOW............................................................................................................................1216
REMOVAL (FIG. 32)..................................................................................................................1216
INSTALLATION.......................................................................................................................1216
VENT WINDOW WEATHERSTRIP...............................................................................................................1216
REMOVAL (FIG. 33)..................................................................................................................1216
INSTALLATION.......................................................................................................................1216
DOOR OPENING WEATHERSTRIPS.............................................................................................................1216
REMOVAL............................................................................................................................1216
INSTALLATION.......................................................................................................................1216
STICK- ON BODY SIDE MOLDING............................................................................................................1216
REMOVAL AND INSTALLATION...........................................................................................................1216
EXTERIOR MOLDINGS (FIG. 34)............................................................................................................1217
UPPER MOLDINGS.....................................................................................................................1217
LOWER MOLDINGS.....................................................................................................................1217
WHEEL LIP MOLDINGS.................................................................................................................1217
SILL MOLDINGS......................................................................................................................1217
BODY SIDE APPLIQUE (FIG. 35)...........................................................................................................1217
DOOR APPLIQUE......................................................................................................................1217
FRONT SILL APPLIQUE................................................................................................................1217
RIGHT REAR SILL APPLIQUE...........................................................................................................1217
LEFT QUARTER APPLIQUE..............................................................................................................1218
WOOD GRAIN OVERLAY.....................................................................................................................1219
REMOVAL............................................................................................................................1219
INSTALLATION.......................................................................................................................1219
RIGHT SIDE GRAB HANDLE.................................................................................................................1219
REMOVAL (FIG. 36)..................................................................................................................1219
INSTALLATION.......................................................................................................................1219
COWL TRIM AND SCUFF PLATES.............................................................................................................1219
REMOVAL (FIG. 37)..................................................................................................................1219
COWL TRIM AND SCUFF PLATE INSTALLA-TION............................................................................................1220
SLIDING DOOR SCUFF PLATE REMOVAL (FIG. 37).........................................................................................1220
SLIDING DOOR SCUFF PLATE INSTALLATION..............................................................................................1220
A- PILLAR AND ROOF RAIL MOLDINGS.......................................................................................................1220
REMOVAL (FIG. 37)..................................................................................................................1220
INSTALLATION.......................................................................................................................1220
RIGHT B- PILLAR TRIM COVER.............................................................................................................1220
REMOVAL (FIG. 37)..................................................................................................................1220
INSTALLATION.......................................................................................................................1220
UPPER TRACK COVER......................................................................................................................1220
REMOVAL (FIG. 37)..................................................................................................................1220
INSTALLATION.......................................................................................................................1220
RIGHT QUARTER TRIM PANEL...............................................................................................................1221
REMOVAL (FIG. 37)..................................................................................................................1221
INSTALLATION.......................................................................................................................1221
LEFT QUARTER TRIM PANEL................................................................................................................1221
REMOVAL (FIG. 38)..................................................................................................................1221
INSTALLATION.......................................................................................................................1221
LEFT QUARTER TRIM PANEL— WITH REAR A/ C................................................................................................1222
REMOVAL (FIG. 39)..................................................................................................................1222
INSTALLATION.......................................................................................................................1222
FRONT SEAT BELTS.......................................................................................................................1222
OUTBOARD SHOULDER HARNESS/ LAP BELT REMOVAL (FIG. 40 OR 41)........................................................................1222
OUTBOARD SHOULDER HARNESS/ LAP BELT INSTALLATION...................................................................................1222
INBOARD BUCKLE REMOVAL (FIG. 42)...................................................................................................1222
INBOARD BUCKLE INSTALLATION........................................................................................................1222
REAR SEAT BELTS........................................................................................................................1223
OUTBOARD SHOULDER HARNESS/ LAP BELT REMOVAL (FIG. 43 OR 44)........................................................................1223
OUTBOARD SHOULDER HARNESS/ LAP BELT INSTALLATION...................................................................................1223
SEATS..................................................................................................................................1223
FRONT SEAT REMOVAL (FIG. 45).......................................................................................................1223
FRONT SEAT INSTALLATION............................................................................................................1223
FRONT CENTER CONSOLE...................................................................................................................1224
REMOVAL (FIG. 46)..................................................................................................................1224
INSTALLATION.......................................................................................................................1224
FLOOR CARPET...........................................................................................................................1224
REMOVAL (FIG. 47)..................................................................................................................1224
INSTALLATION.......................................................................................................................1224
OVERHEAD CONSOLE.......................................................................................................................1224
REMOVAL (FIG. 48)..................................................................................................................1224
OVERHEAD CONSOLE INSTALLATION......................................................................................................1225
HEAD LINING............................................................................................................................1225
REMOVAL (FIG. 49)..................................................................................................................1225
INSTALLATION.......................................................................................................................1225
LIFTGATE...............................................................................................................................1225
REMOVAL (FIG. 50)..................................................................................................................1225
INSTALLATION.......................................................................................................................1225
LIFTGATE TRIM PANEL....................................................................................................................1225
REMOVAL (FIG. 51)..................................................................................................................1225
INSTALLATION.......................................................................................................................1225
LIFTGATE LATCH.........................................................................................................................1226
REMOVAL (FIG. 52)..................................................................................................................1226
INSTALLATION.......................................................................................................................1226
ROOF TOP LUGGAGE RACK..................................................................................................................1226
REMOVAL (FIG. 53)..................................................................................................................1226
INSTALLATION.......................................................................................................................1226
FUEL FILL DOOR RELEASE CABLE...........................................................................................................1226
REMOVAL (FIG. 54)..................................................................................................................1226
FUEL FILL DOOR CABLE INSTALLATION..................................................................................................1227
REAR WINDOW GLASS......................................................................................................................1227
92AS_24............................................................................................................................................1229
HEATING AND AIR CONDITIONING...................................................................................................................1229
GENERAL INFORMATION........................................................................................................................1229
A/ C SYSTEM IDENTIFICATION.............................................................................................................1229
DESCRIPTION AND OPERATION..............................................................................................................1229
SYSTEM AIRFLOW.........................................................................................................................1229
SIDE WINDOW DEMISTERS..................................................................................................................1230
ENGINE COOLING SYSTEM REQUIREMENTS.....................................................................................................1230
SAFETY PRECAUTIONS AND WARNINGS........................................................................................................1230
COOLING SYSTEM PRECAUTIONS.............................................................................................................1231
HANDLING TUBING AND FITTINGS...........................................................................................................1231
VARIABLE COMPRESSOR AND COMPONENTS DIAGNOSTIC PROCEDURES...................................................................................1232
GENERAL INFORMATION....................................................................................................................1232
COMPRESSOR IDENTIFICATION..............................................................................................................1232
VARIABLE DISPLACEMENT COMPRESSOR DIAG-NOSIS............................................................................................1232
COMPRESSOR NOISE.......................................................................................................................1232
COMPRESSOR CLUTCH INOPERATIVE..........................................................................................................1232
VARIABLE DISPLACEMENT COMPRESSOR DIAGNOSIS.........................................................................................1233
REFRIGERANT SYSTEM DIAGNOSIS— VARIABLE DISPLACEMENT COMPRESSOR.....................................................................1234
COMPRESSOR NOISE AND COMPRESSOR CLUTCH DIAGNOSIS...................................................................................1235
CLUTCH COIL TESTS......................................................................................................................1236
DIFFERENTIAL PRESSURE CUT- OUT SWITCH DI-AGNOSIS.......................................................................................1236
DPCO SWITCH TEST...................................................................................................................1236
AMBIENT SWITCH DIAGNOSIS...............................................................................................................1236
AMBIENT SWITCH TEST................................................................................................................1236
CONDENSER FAN CONTROL SWITCH DIAGNOSIS.................................................................................................1236
FAN CONTROL SWITCH TEST............................................................................................................1236
COMPRESSOR CLUTCH DIAGNOSIS— VARIABLE DISPLACEMENT COMPRESSOR— MODEL 6C17..........................................................1237
HIGH PRESSURE CUT- OUT SWITCH DIAGNOSIS................................................................................................1238
HPCO SWITCH TESTS..................................................................................................................1238
BLACK EXPANSION VALVE TEST.............................................................................................................1239
HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS.............................................................................................1239
HPR VALVE LOCATION.................................................................................................................1239
FIXED DISPLACEMENT COMPRESSOR AND COMPONENTS DIAGNOSTIC PROCE-DURES........................................................................1241
GENERAL INFORMATION COMPRESSOR IDENTIFICATION COMPRESSOR NOISE.........................................................................1241
COMPRESSOR CLUTCH INOPERATIVE..........................................................................................................1241
CLUTCH COIL TESTS......................................................................................................................1241
LOW- PRESSURE CUT- OFF SWITCH DIAGNOSIS................................................................................................1241
COMPRESSOR NOISE AND COMPRESSOR CLUTCH DIAGNOSIS...................................................................................1242
LPCO SWITCH TEST...................................................................................................................1243
ELECTRONIC CYCLING CLUTCH SWITCH.......................................................................................................1243
TEST PROCEDURE.....................................................................................................................1243
FIXED DISPLACEMENT COMPRESSOR REFRIGER-ANT SYSTEM......................................................................................1243
SILVER EXPANSION VALVE TESTS...........................................................................................................1243
REFRIGERANT SYSTEM DIAGNOSIS.......................................................................................................1244
HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS.............................................................................................1245
HPR VALVE LOCATION.................................................................................................................1245
VACUUM CONTROL SYSTEM DIAGNOSIS............................................................................................................1246
GENERAL INFORMATION....................................................................................................................1246
VACUUM TESTING THE ONE- WAY CHECK VALVE................................................................................................1246
VACUUM TESTING THE HEATER- A/ C CONTROLS...............................................................................................1246
LOCATING VACUUM LEAKS..................................................................................................................1246
HEATER AND A/ C PERFORMANCE TESTS..........................................................................................................1247
VACUUM CIRCUITS— HEATER OR HEATER A/ C CONTROL.........................................................................................1247
HEATER OUTPUT TEST.....................................................................................................................1248
PRE- DIAGNOSTIC PREPARATIONS.......................................................................................................1248
MAXIMUM HEATER OUTPUT: TEST AND AC-TION............................................................................................1248
A/ C PERFORMANCE TEST..................................................................................................................1248
PERFORMANCE TEST PROCEDURE.........................................................................................................1248
TEMPERATURE REFERENCE CHART........................................................................................................1248
A/ C PERFORMANCE TEMPERATURES......................................................................................................1249
REFRIGERANT SERVICE PROCEDURES.............................................................................................................1250
SIGHT GLASS REFRIGERANT LEVEL INSPECTION...............................................................................................1250
R- 12 REFRIGERANT EQUIPMENT............................................................................................................1250
REFRIGERANT RECYCLING..................................................................................................................1251
MANIFOLD GAUGE SET CONNECTIONS.........................................................................................................1251
GENERAL INFORMATION................................................................................................................1251
TESTING FOR REFRIGERANT LEAKS..........................................................................................................1252
EMPTY REFRIGERANT SYSTEM LEAK TEST.................................................................................................1252
LOW REFRIGERANT LEVEL LEAK TEST....................................................................................................1252
ADDING PARTIAL REFRIGERANT CHARGE......................................................................................................1252
DISCHARGING REFRIGERANT SYSTEM.........................................................................................................1253
EVACUATING REFRIGERANT SYSTEM..........................................................................................................1253
CHARGING REFRIGERANT SYSTEM— EMPTY SYS-TEM.............................................................................................1254
REFRIGERANT CAPACITIES:............................................................................................................1254
OIL LEVEL..............................................................................................................................1254
REFRIGERANT OIL LEVEL CHECK........................................................................................................1254
VERIFY REFRIGERANT OIL LEVEL.......................................................................................................1254
REFRIGERANT OIL CAPACITIES.........................................................................................................1254
VARIABLE DISPLACEMENT COMPRESSOR SERVICE PROCEDURES........................................................................................1255
COMPRESSOR REMOVAL AND INSTALLATION....................................................................................................1255
COMPRESSOR CLUTCH/ COIL ASSEMBLY.......................................................................................................1255
REMOVAL AND INSTALLATION...........................................................................................................1255
COMPRESSOR FRONT SHAFT SEAL............................................................................................................1256
REMOVAL............................................................................................................................1256
INSTALLATION.......................................................................................................................1258
COMPRESSOR HIGH PRESSURE CUT- OUT SWITCH...............................................................................................1258
REMOVAL AND INSTALLATION...........................................................................................................1258
COMPRESSOR HIGH PRESSURE RELIEF VALVE..................................................................................................1259
REMOVAL AND INSTALLATION...........................................................................................................1259
COMPRESSOR MAIN OR SUB CONTROL VALVES..................................................................................................1259
REMOVAL AND INSTALLATION...........................................................................................................1259
FIXED DISPLACEMENT COMPRESSOR SERVICE PROCEDURES...........................................................................................1260
COMPRESSOR REMOVAL AND INSTALLATION....................................................................................................1260
COMPRESSOR CLUTCH/ COIL— MODEL 10PA17..................................................................................................1260
REMOVAL............................................................................................................................1260
INSTALLATION.......................................................................................................................1261
CLUTCH BREAK- IN...................................................................................................................1262
COMPRESSOR FRONT SHAFT SEAL— MODEL 10PA17..............................................................................................1262
REMOVAL............................................................................................................................1262
INSTALLATION.......................................................................................................................1263
COMPRESSOR HIGH- PRESSURE RELIEF VALVE.................................................................................................1264
REMOVAL AND INSTALLATION...........................................................................................................1264
COMPONENT DIAGNOSIS........................................................................................................................1266
CONDENSATE WATER DRAINAGE..............................................................................................................1266
BLOWER MOTOR VIBRATION AND/ OR NOISE DI-AGNOSIS........................................................................................1266
BLOWER MOTOR ELECTRICAL DIAGNOSIS......................................................................................................1266
BLOWER MOTOR NOISE/ VIBRATION DIAGNOSIS............................................................................................1267
BLOWER MOTOR ELECTRICAL SYSTEM DIAGNOSIS...........................................................................................1268
COMPONENT SERVICE PROCEDURES...............................................................................................................1269
TEMPERATURE CONTROL CABLE..............................................................................................................1269
REMOVAL AND INSTALLATION...........................................................................................................1269
BLOWER RESISTOR BLOCK..................................................................................................................1269
REMOVAL AND INSTALLATION...........................................................................................................1269
VACUUM ACTUATOR— FRESH/ RECIRC DOOR....................................................................................................1270
REMOVAL AND INSTALLATION...........................................................................................................1270
VACUUM ACTUATORS— MODE DOORS...........................................................................................................1270
REMOVAL............................................................................................................................1270
INSTALLATION.......................................................................................................................1270
AIR DISTRIBUTION DUCT..................................................................................................................1270
REMOVAL AND INSTALLATION...........................................................................................................1270
DEFROSTER DUCTS/ DEMISTER DUCTS AND HOSES..............................................................................................1271
REMOVAL AND INSTALLATION...........................................................................................................1271
HEATER HOSES...........................................................................................................................1271
REMOVAL AND INSTALLATION...........................................................................................................1271
WATER CONTROL VALVE....................................................................................................................1272
REMOVAL AND INSTALLATION...........................................................................................................1272
AMBIENT SWITCH.........................................................................................................................1272
REMOVAL AND INSTALLATION...........................................................................................................1272
ELECTRONIC CYCLING CLUTCH SWITCH (ECCS)................................................................................................1272
REMOVAL AND INSTALLATION...........................................................................................................1272
CONDENSER FAN CONTROL SWITCH— VARIABLE DISPLACEMENT COMPRESSOR SYSTEM..................................................................1272
REMOVAL AND INSTALLATION...........................................................................................................1273
LOW OR DIFFERENTIAL PRESSURE CUT- OFF SWITCH...........................................................................................1273
REMOVAL AND INSTALLATION...........................................................................................................1273
EXPANSION VALVE........................................................................................................................1273
REMOVAL............................................................................................................................1273
INSTALLATION.......................................................................................................................1273
FILTER- DRIER ASSEMBLY.................................................................................................................1274
REMOVAL AND INSTALLATION...........................................................................................................1274
CONDENSER ASSEMBLY.....................................................................................................................1274
REMOVAL AND INSTALLATION...........................................................................................................1274
BLOWER MOTOR AND WHEEL ASSEMBLY........................................................................................................1274
REMOVAL AND INSTALLATION...........................................................................................................1274
BLOWER MOTOR WHEEL.....................................................................................................................1275
REMOVAL AND INSTALLATION...........................................................................................................1275
HEATER CORE............................................................................................................................1275
REMOVAL AND INSTALLATION...........................................................................................................1275
EVAPORATOR COIL........................................................................................................................1275
REMOVAL AND INSTALLATION...........................................................................................................1275
HEATER- A/ C UNIT HOUSING..............................................................................................................1275
REMOVAL AND INSTALLATION...........................................................................................................1275
HEATER A/ C UNIT RECONDITION...........................................................................................................1275
DISASSEMBLY........................................................................................................................1275
ASSEMBLY...........................................................................................................................1276
CONDENSATE DRAIN TUBE..................................................................................................................1277
REMOVAL AND INSTALLATION...........................................................................................................1277
AUXILIARY REAR HEATING OR HEATING- AIR/ CONDITIONING.......................................................................................1278
GENERAL INFORMATION....................................................................................................................1278
DIAGNOSTIC PROCEDURES..................................................................................................................1278
REAR HEATER A/ C CONTROL...............................................................................................................1278
REMOVE AND INSTALL.................................................................................................................1278
REAR HEATER A/ C CONTROL ILLUMINATION BULB.............................................................................................1278
REMOVE AND INSTALL.................................................................................................................1278
REAR HEATER A/ C AIR OUTLETS...........................................................................................................1278
REMOVAL AND INSTALL................................................................................................................1278
REAR BLOWER RESISTOR BLOCK.............................................................................................................1279
REMOVE AND INSTALL.................................................................................................................1279
REAR HEATER A/ C BLOWER MOTOR..........................................................................................................1279
REMOVE AND INSTALL.................................................................................................................1279
REAR HEATER- A/ C UNIT.................................................................................................................1279
REMOVE AND INSTALL.................................................................................................................1279
AIR DISTRIBUTION DUCT..................................................................................................................1279
REMOVE AND INSTALL.................................................................................................................1279
HEATER CORE............................................................................................................................1279
REMOVE AND INSTALL.................................................................................................................1279
EVAPORATOR AND EXPANSION VALVE.........................................................................................................1279
REMOVE.............................................................................................................................1279
INSTALL............................................................................................................................1280
AUXILIARY UNDER BODY HEATER PLUMBING...................................................................................................1280
REMOVAL AND INSTALLATION...........................................................................................................1280
AUXILIARY UNDER BODY REFRIGERANT PLUMBING..............................................................................................1280
REMOVAL............................................................................................................................1280
INSTALL............................................................................................................................1280
92AS_25............................................................................................................................................1283
EMISSION CONTROL SYSTEMS.......................................................................................................................1283
CONTENTS...................................................................................................................................1283
GENERAL INFORMATION....................................................................................................................1283
EMISSION MAINTENANCE REMINDER (EMR) SYSTEM.............................................................................................1283
RESETTING EMR LAMP.................................................................................................................1283
EVAPORATIVE EMISSION CONTROLS..............................................................................................................1284
VEHICLE EMISSION CONTROL INFORMATION LABEL.............................................................................................1284
FEDERAL EMISSION CONTROL INFORMATION LABEL— TYPICAL................................................................................1284
VACUUM SCHEMATICS......................................................................................................................1285
CALIFORNIA VEHICLE CONTROL INFORMATION LABEL— TYPICAL CANADA VEHICLE EMISSION CONTROL INFORMATION LABEL— TYPICAL...................1285
ENGINE VACUUM SCHEMATIC— 2.5L ENGINE ENGINE VACUUM SCHEMATIC— 3.0L ENGINE..........................................................1286
EVAPORATION CONTROL SYSTEM.............................................................................................................1287
PRESSURE RELIEF/ ROLLOVER VALVE....................................................................................................1287
EVAPORATIVE CANISTER...............................................................................................................1287
CANISTER PURGE SOLENOID................................................................................................................1287
ENGINE VACUUM SCHEMATIC— 3.3L ENGINE...............................................................................................1287
PRESSURE- VACUUM FILLER CAP........................................................................................................1288
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEMS.......................................................................................1288
PCV VALVE TEST.....................................................................................................................1288
CRANKCASE VENT FILTER..............................................................................................................1289
EXHAUST EMISSION CONTROLS..................................................................................................................1290
HEATED INLET AIR SYSTEM................................................................................................................1290
HEATED INLET AIR SYSTEM SERVICE....................................................................................................1290
HEATED AIR TEMPERATURE SENSOR SER- VICE............................................................................................1291
HEATED OXYGEN SENSOR (O2 SENSOR).......................................................................................................1291
REMOVAL............................................................................................................................1292
EXHAUST GAS RECIRCULATION (EGR) SYSTEM.................................................................................................1292
EGR SYSTEM ON- BOARD DIAGNOSTICS (CALIFORNIA VEHICLES).............................................................................1293
EXHAUST GAS RECIRCULATION (EGR) SYS-TEM TEST.......................................................................................1293
EGR DIAGNOSIS CHART................................................................................................................1294
EGR GAS FLOW TEST..................................................................................................................1295
EGR SYSTEM SERVICE.....................................................................................................................1295
EGR VALVE REMOVAL..................................................................................................................1295
INSTALLATION.......................................................................................................................1295
EGR TUBE REMOVAL...................................................................................................................1295
INSTALLATION.......................................................................................................................1295
92AS_FR............................................................................................................................................1297
92AS_IN............................................................................................................................................1301
INTRODUCTION...................................................................................................................................1301
CONTENTS...................................................................................................................................1301
VEHICLE FAMILY IDENTIFICATION..........................................................................................................1301
VEHICLE IDENTIFICATION NUMBER..........................................................................................................1301
VEHICLE SAFETY CERTIFICATION LABEL.....................................................................................................1301
VEHICLE IDENTIFICATION NUMBER DECODING CHART.......................................................................................1302
BODY CODE PLATE LOCATION AND DECODING INFORMATION......................................................................................1303
BODY CODE PLATE LINE 3.............................................................................................................1303
BODY CODE PLATE LINE 2.............................................................................................................1303
BODY CODE PLATE LINE 1.............................................................................................................1303
BODY CODE PLATE....................................................................................................................1303
IF TWO BODY CODE PLATES ARE REQUIRED...............................................................................................1304
TORQUE REFERENCES......................................................................................................................1304
STANDARD BODY DIMENSIONS...........................................................................................................1304
METRIC THREAD AND GRADE IDENTIFICATION.................................................................................................1305
INTERNATIONAL SYMBOLS..................................................................................................................1305
METRIC SYSTEM..........................................................................................................................1306
CONVERSION TABLES..................................................................................................................1307
CONVERSION TABLES..................................................................................................................1308
92AS_IX............................................................................................................................................1309
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