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1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements

Original price was: $36.95.Current price is: $21.95.

Chrysler Corporation service manual and supplement set for the 1993 Jeep Grand Cherokee and Grand Wagoneer ZJ, covering 2WD and 4WD wagons with 4.0L six-cylinder and 5.2L V-8 engines, diagnosis, overhaul, wiring, and scheduled maintenance.

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Description

1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements

This 1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements is the Chrysler Corporation service manual and supplement compilation prepared for professional technicians working on ZJ-platform Grand Cherokee and Grand Wagoneer wagons. Vehicle designation ZJ identifies the line throughout charts, captions, and procedures. Coverage includes 2WD and 4WD four-door wagons. VIN decoding in the introduction identifies Grand Cherokee 4×2 and 4×4, plus series codes for Laredo, Sport, Limited, and Grand Wagoneer. Engines called out in the identification charts and Group 9 are the 4.0 liter (242 CID) inline six with multi-point fuel injection and 8.8:1 compression, and the 5.2 liter (318 CID) overhead-valve V-8.

The publication is organized by numbered groups. Each group opens with a contents list, then general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly. A torque chart appears at the end of each group. Groups marked with the suffix -S are supplements to the original service manual publication and are bound with the base book, including the 21-S transmission and transfer case supplement that adds 42RE automatic transmission coverage. The foreword states the book is written for daily repair work and does not teach theory of operation. Tightening torques are given as midpoint values for clean, dry OEM fasteners.

File Details

  • Manual type: Service manual and supplement
  • Brand / models: Jeep Grand Cherokee and Grand Wagoneer, vehicle code ZJ
  • Language: English
  • Page count: 1468
  • File format: PDF
  • Document marking: Copyright 1992 Chrysler Corporation 10M0792
  • Title page: 1993 Jeep Grand Cherokee Grand Wagoneer Service Manual and Supplement

What the ZJ Book Identifies

Introduction material explains how to read the vehicle. The Vehicle Safety Certification Label is on the left B-pillar and lists month and year of manufacture, GVWR, front and rear GAWR, VIN, vehicle type, rear-wheel type, bar code, and MDH of final assembly. The VIN plate sits on the top left of the instrument panel and is also stamped on the body code plate, equipment identification plate, certification label, and frame rail. A metal body code plate is riveted to the top left of the radiator reinforcement and can carry up to seven rows of sales, paint, trim, engine, and model data.

Exterior dimensions printed for the wagon are a 2691 mm (105.9 in.) wheelbase, 1473 mm (58.0 in.) front and rear track, 4488 mm (176.7 in.) overall length, 1758 mm (69.2 in.) overall width, and 1635 mm (64.4 in.) height. Interior figures include front/rear head room 991/994 mm, leg room 1044/945 mm, shoulder room 1480/1463 mm, and hip room 1445/1252 mm. Weight tables list ZJ 4WD GVWR 5300 lb and ZJ 2WD GVWR 4950 lb with P205/75R15 tires on 15 x 7 rims, 750 lb maximum passenger weight, 400 lb maximum cargo, 2500 lb front GAWR, and 2905 lb rear GAWR. Trailer towing tables for the 4.0 six with 3.55 axle and automatic transmission with auxiliary cooler give 5000 lb maximum trailer weight, 750 lb tongue weight, 9550 lb GCWR on 4WD, and 9200 lb GCWR on 2WD, with notes calling for a 500-ampere battery, maximum engine cooling, heavy-duty shocks, front stabilizer bar, heavy-duty variable-load flasher, and trailer-light harness.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements” are as follows:

welcome.pdfp. 1
ibc.pdfp. 1468
ifc.pdfp. 12
TABULADORp. 13
IN INTRODUCTIONp. 4
INTRODUCTIONp. 4
DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTSp. 4
VEHICLE DESIGNATIONp. 4
VEHICLE SAFETY CERTIFICATION LABELp. 4
VEHICLE IDENTIFICATION NUMBER (VIN) PLAGEp. 4
BODY CODE PLATEp. 4
VEHICLE IDENTIFICATION NUMBER (VIN) DECODINGp. 5
ENGINE AND TRANSMISSION/TRANSFER CASE IDENTIFICATIONp. 5
MAJOR COMPONENT IDENTIFICATIONp. 5
BODY CODE DECODINGp. 5
VEHICLE DIMENSIONp. 6
VEHICLE DEMINSIONSp. 6
VEHICLE WEIGHTSp. 6
TRAILER TOWING SPECIFICATIONSp. 7
TRAILER TOWING SPECIFICATIONSp. 7
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLSp. 7
INTERNATIONAL CONTROL AND DISPLAY SYMBOLSp. 7
MEASUREMENT AND TORQUE SPECIFICATIONSp. 8
SPECIFICATION NOTATIONSp. 8
METRIC AND ENGLISH/SAE CONVERSIONp. 8
TORQUE SPECIFICATIONSp. 8
TORQUE CHARTSp. 8
CONVERSION FORMULAS AND EQUIVALENT VALUESp. 8
STANDARD TORQUE SPECIFICATIONSp. 8
BOLT THREAD AND GRADE/CLASS IDENTIFICATIONp. 9
THREAD NOTATION-SAE AND METRICp. 9
METRIC CONVERSIONp. 9
METRIC CONVERSIONp. 10
0 LUBRICATION AND MAINTENANCEp. 14
LUBRICATION AND MAINTENANCEp. 14
GENERAL INFORMATIONp. 14
INTRODUCTIONp. 14
SEVERE DRIVING CONDITIONSp. 14
ROUTINE MAINTENANCEp. 15
FUEL REQUIREMENTSp. 15
GASOLINE ENGINESp. 15
CLASSIFICATION OF LUBRICANTSp. 15
ENGINE OIL (FIG. 2)p. 15
GEAR LUBRICANTSp. 16
CHASSIS COMPONENT AND WHEEL BEARING LUBRICANTSp. 16
LUBRICATION AND REPLACEMENT PARTS REC-OMMENDATIONp. 16
COMPONENTS REQUIRING NO LUBRICATIONp. 16
SCHEDULED MAINTENANCE ZJ VEHICLES (EXCEPT CALIFORNIA)p. 17
SCHEDULED MAINTENANCE ZJ VEHICLES (CALIFORNIA)p. 18
GENERAL MAINTENANCE SERVICES FOR PROPER VEHICLE PERFORMANCEp. 19
GENERAL MAINTENANCE 4.0L ENGINESp. 19
GENERAL MAINTENANCE 5.2L ENGINESp. 19
STARTING ASSISTANCE (JUMP STARTING)p. 20
BOOSTER BATTERYp. 20
FLUID CAPACITIESp. 20
PORTABLE STARTING UNITp. 21
VEHICLE LIFTING RECOMMENDATIONSp. 21
FLOOR JACKp. 21
HOISTp. 22
4WD VEHICLESp. 22
VEHICLE TOWING RECOMMENDATIONSp. 22
GROUND CLEARANCEp. 22
SAFETY PRECAUTIONSp. 22
REAR- END RAISED TOWINGp. 23
FRONT- END RAISED TOWINGp. 23
LOCKED VEHICLE TOWINGp. 23
ENGINE MAINTENANCEp. 24
ENGINE BREAK- INp. 24
ENGINE OILp. 24
SPECIFICATIONSp. 24
OIL LEVEL INDICATOR (DIPSTICK)p. 24
ACCEPTABLE OIL LEVELp. 24
ENGINE OIL CHANGE AND FILTER REPLACEMENTp. 25
ENGINE OIL FILTERp. 25
OIL CHANGE AND FILTER REPLACEMENTp. 25
COOLING SYSTEMp. 25
INSPECTION SCHEDULEp. 26
COOLANT LEVELp. 26
COOLANT FREEZE PROTECTIONp. 26
SYSTEM INSPECTIONp. 26
DRAIN, FLUSH AND FILLp. 26
HOSES AND FITTINGSp. 26
ENGINE AIR CLEANER FILTER ELEMENTp. 26
MAINTENANCE SCHEDULEp. 26
SERVICE/ REPLACEMENTp. 26
EMR LAMP AND TIMER SERVICE INFORMATIONp. 26
CRANKCASE VENTILATION SYSTEMp. 26
SYSTEM OPERATIONp. 26
RECOMMENDED MAINTENANCEp. 27
FUEL SYSTEMp. 27
INSPECTIONp. 27
FUEL FILTERp. 27
GAS0LINE ENGINE FUEL REQUIREMENTSp. 27
VACUUM OPERATED, EMISSION CONTROL COM-PONENTSp. 27
EXHAUST GAS RECIRCULATION (EGR) SYSTEMp. 27
OXYGEN (O2 ) SENSORp. 28
IGNITION CABLES, DISTRIBUTOR CAP AND RO-TORp. 28
IGNITION TIMINGp. 28
SPARK PLUGSp. 28
BATTERYp. 28
RECOMMENDED MAINTENANCEp. 28
INSPECTION/ SERVICEp. 28
RUBBER/ PLASTIC COMPONENTSp. 28
INSPECTIONp. 28
ENGINE MOUNTSp. 28
SERPENTINE DRIVE BELTp. 28
INSPECTIONp. 29
EXHAUST SYSTEMp. 29
INSPECTIONp. 29
AIR- CONDITIONER COMPRESSORp. 29
LUBRICANT AND REFRIGERANTp. 29
DRIVETRAINp. 30
CLUTCH AND BRAKE PEDAL BUSHINGSp. 30
CLUTCH MASTER CYLINDERp. 30
HYDRAULIC FLUID LEVELp. 30
FLUID SPECIFICATIONp. 30
TRANSMISSIONSp. 30
SPECIAL ADDITIVESp. 30
GEAR SHIFTER BOOTSp. 30
SEVERE DRIVING CONDITIONSp. 30
MANUAL TRANSMISSIONSp. 30
AUTOMATIC TRANSMISSIONSp. 31
TRANSFER CASE (4WD VEHICLES)p. 31
INSPECTIONp. 31
FLUID LEVELp. 31
FLUID DRAIN AND REFILLp. 31
FLUID SPECIFICATIONp. 32
SHIFT MECHANISMp. 32
AXLESp. 32
INSPECTIONp. 32
LUBRICANT LEVELp. 32
DRAIN AND REFILLp. 32
LUBRICANT VISCOSITIES FOR ANTICIPATED TEMPERATURE RANGESp. 32
LUBRICANT SPECIFICATIONp. 33
FRONT AXLE PIVOT BEARINGS (4 W/ D)p. 33
DRIVE SHAFTSp. 33
SLIP- YOKE LUBRICATIONp. 33
U- JOINT/ CV- JOINT LUBRICATIONp. 33
LUBRICANT SPECIFICATIONp. 33
CHASSIS AND BODYp. 34
STEERING LINKAGEp. 34
INSPECTIONp. 34
LUBRICATION SCHEDULEp. 34
LUBRICATIONp. 34
FRONT SUSPENSION BALL JOINTSp. 34
INSPECTIONp. 34
LUBRICATION SCHEDULEp. 34
LUBRICATIONp. 34
POWER STEERING SYSTEMp. 34
FLUID LEVELp. 34
FLUID SPECIFICATIONp. 35
FRONT WHEEL BEARINGSp. 35
LOWER AND UPPER SUSPENSION ARM BUSH-INGSp. 35
INSPECTION SCHEDULEp. 35
INSPECTIONp. 35
POWER BRAKE SYSTEMp. 35
FLUID SPECIFICATIONp. 35
BRAKE FLUID LEVELp. 35
BRAKE SYSTEM INSPECTIONp. 36
BRAKE OPERATIONAL TESTp. 36
BODY COMPONENT MECHANISMSp. 36
LUBRICATION REQUIREMENTSp. 36
LUBRICANT SPECIFICATIONSp. 36
LUBRICATIONp. 36
TIRESp. 37
RECOMMENDED MAINTENANCEp. 37
INSPECTIONp. 37
ROTATIONp. 37
HEADLAMPSp. 37
AIM ADJUSTMENTp. 37
SPEEDOMETER CABLEp. 37
SERVICE INFORMATIONp. 37
BODY LUBRICANT SPECIFICATIONSp. 37
2 FRONT SUSPENSION AND AXLEp. 38
FRONT SUSPENSION AND AXLEp. 38
GENERAL INFORMATIONp. 38
FRONT SUSPENSIONp. 38
FRONT DRIVE AXLEp. 39
STANDARD DIFFERENTIAL OPERATIONp. 39
TUBE AXLE (2WD VEHICLES)p. 40
FRONT WHEEL ALIGNMENTp. 41
GENERAL INFORMATIONp. 41
PRE- ALIGNMENT INSPECTIONp. 41
ALIGNMENT MEASUREMENTS AND ADJUST-MENTSp. 42
CAMBERp. 42
SUSPENSION AND STEERING SYSTEM DIAGNOSISp. 43
CASTERp. 44
TOE POSITIONp. 44
ALIGNMENT SPECIFICATIONSp. 45
FRONT SUSPENSIONp. 46
SERVICE INFORMATIONp. 46
TRACK BARp. 46
REMOVALp. 46
INSTALLATIONp. 46
STABILIZER BARp. 46
REMOVALp. 46
INSTALLATIONp. 46
UPPER SUSPENSION ARMp. 47
REMOVALp. 47
INSTALLATIONp. 47
AXLE BUSHING REPLACEMENTp. 47
LOWER SUSPENSION ARMp. 48
REMOVALp. 48
INSTALLATIONp. 48
SPRING AND SHOCK DIAGNOSISp. 48
SHOCK ABSORBERp. 49
REMOVALp. 49
INSTALLATIONp. 49
COIL SPRINGp. 49
REMOVALp. 49
INSTALLATIONp. 49
AXLE NOISE/ VIBRATION DIAGNOSISp. 50
GENERAL INFORMATIONp. 50
GEAR AND BEARING NOISEp. 50
GEAR NOISEp. 50
BEARING NOISEp. 50
LOW SPEED KNOCKp. 51
VIBRATIONp. 51
DRIVELINE SNAPp. 51
SERVICE DIAGNOSISp. 52
SERVICE DIAGNOSIS (CONT’D)p. 53
MODEL 30 AXLE AND TUBE AXLE (2WD)p. 54
GENERAL INFORMATIONp. 54
LUBRICANT SPECIFICATIONSp. 54
DRIVE AXLE ASSEMBLY REPLACEMENTp. 54
REMOVALp. 54
INSTALLATIONp. 55
LUBRICANT CHANGEp. 55
PINION SHAFT SEAL REPLACEMENTp. 55
REMOVALp. 55
INSTALLATIONp. 56
HUB BEARING AND AXLE SHAFTp. 57
REMOVALp. 57
INSTALLATIONp. 57
AXLE SHAFT— CARDAN U- JOINTp. 57
DISASSEMBLYp. 57
CLEANING AND INSPECTIONp. 58
ASSEMBLYp. 58
AXLE SHAFT— CV- JOINTp. 58
HANDLING AND CLEANING PRECAUTIONSp. 58
INSPECTIONp. 58
DISASSEMBLYp. 59
INSPECTIONp. 60
ASSEMBLYp. 60
STEERING KNUCKLE AND BALL STUDSp. 62
KNUCKLE REMOVALp. 62
UPPER BALL STUD REPLACEMENTp. 62
LOWER BALL STUD REPLACEMENTp. 62
KNUCKLE INSTALLATIONp. 62
AXLE BUSHING REPLACEMENTp. 63
DIFFERENTIAL REMOVALp. 63
AXLE SHAFT OIL SEALSp. 64
DIFFERENTIAL DISASSEMBLYp. 64
PINION REMOVAL/ DISASSEMBLYp. 65
CLEANING/ INSPECTIONp. 66
DIFFERENTIAL ASSEMBLYp. 67
PINION GEAR DEPTH INFORMATIONp. 67
PINION GEAR DEPTH VARIANCEp. 69
DIFFERENTIAL AND PINION MEASUREMENT WITH GAUGE SET D- 115- 30p. 69
DIFFERENTIAL ZERO END PLAY MEASURE-MENTp. 69
PINION GEAR DEPTH MEASUREMENTp. 70
PINION GEAR ASSEMBLY/ INSTALLATIONp. 71
DIFFERENTIAL SHIM PACK MEASUREMENT AND ADJUSTMENTp. 72
DIFFERENTIAL INSTALLATIONp. 73
BACKLASH AND CONTACT PATTERN ANALYSISp. 74
FINAL ASSEMBLYp. 77
AXLE SPECIFICATIONSp. 77
MODEL 30 FRONT AXLEp. 77
TORQUE SPECIFICATIONSp. 78
FRONT SUSPENSION COMPONENTSp. 78
MODEL 30 AXLEp. 78
3 REAR SUSPENSION AND AXLESp. 80
REAR SUSPENSION AND AXLESp. 80
GENERAL INFORMATIONp. 80
REAR SUSPENSIONp. 80
REAR AXLEp. 80
STANDARD DIFFERENTIAL OPERATIONp. 81
REAR SUSPENSIONp. 82
SERVICE INFORMATIONp. 82
TRACK BARp. 82
REMOVALp. 82
INSTALLATIONp. 82
STABILIZER BARp. 82
REMOVALp. 82
INSTALLATIONp. 83
UPPER SUSPENSION ARMp. 83
REMOVALp. 83
INSTALLATIONp. 83
LOWER SUSPENSION ARMp. 83
REMOVALp. 83
INSTALLATIONp. 83
SPRING AND SHOCK DIAGNOSISp. 83
SHOCK ABSORBERp. 83
REMOVALp. 83
INSTALLATIONp. 83
COIL SPRINGp. 83
REMOVALp. 83
INSTALLATIONp. 84
AXLE NOISE/ VIBRATION DIAGNOSISp. 85
GENERAL INFORMATIONp. 85
GEAR AND BEARING NOISEp. 85
GEAR NOISEp. 85
BEARING NOISEp. 85
LOW SPEED KNOCKp. 86
VIBRATIONp. 86
DRIVELINE SNAPp. 86
REAR AXLE ALIGNMENTp. 86
MEASUREMENTp. 86
LIMITED SLIP DIFFERENTIALp. 86
SERVICE DIAGNOSISp. 87
SERVICE DIAGNOSIS (CONT’D)p. 88
MODEL 35 AXLEp. 89
GENERAL INFORMATIONp. 89
LUBRICANT SPECIFICATIONSp. 89
DRIVE AXLE ASSEMBLY REPLACEMENTp. 89
REMOVALp. 89
INSTALLATIONp. 89
LUBRICANT CHANGEp. 90
PINION SHAFT SEAL REPLACEMENTp. 90
REMOVALp. 90
INSTALLATIONp. 90
AXLE SHAFTp. 92
REMOVALp. 92
INSTALLATIONp. 92
AXLE SHAFT SEAL AND BEARINGp. 92
REMOVALp. 92
INSTALLATIONp. 92
DIFFERENTIAL REMOVALp. 92
DIFFERENTIAL DISASSEMBLYp. 93
PINION REMOVAL/ DISASSEMBLYp. 94
CLEANING/ INSPECTIONp. 95
DIFFERENTIAL ASSEMBLYp. 96
PINION GEAR DEPTH INFORMATIONp. 96
PINION GEAR ASSEMBLY/ INSTALLATIONp. 97
PINION GEAR DEPTH VARIANCEp. 97
DIFFERENTIAL SHIM PACK MEASUREMENT AND ADJUSTMENTp. 98
RING GEAR INSTALLATIONp. 100
DIFFERENTIAL INSTALLATIONp. 100
BACKLASH AND CONTACT PATTERN ANALYSISp. 101
FINAL ASSEMBLYp. 104
AXLE SPECIFICATIONSp. 105
MODEL 35 REAR AXLEp. 105
TRAC- LOK DIFFERENTIALp. 106
OPERATIONp. 106
NOISE DIAGNOSISp. 106
DIFFERENTIAL TESTp. 106
DIFFERENTIAL OVERHAULp. 106
DISASSEMBLYp. 106
CLEANING AND INSPECTIONp. 109
ASSEMBLYp. 109
TORQUE SPECIFICATIONSp. 111
REAR SUSPENSION COMPONENTSp. 111
REAR AXLE MODEL 35p. 111
5 BRAKESp. 112
BRAKESp. 112
GENERAL INFORMATIONp. 112
SERVICE BRAKE COMPONENTSp. 112
WHEEL BRAKE UNITSp. 112
VACUUM/ HYDRAULIC COMPONENTSp. 112
BRAKE WARNING LIGHTSp. 112
BRAKELINING MATERIALp. 112
ANTILOCK BRAKE SYSTEM (ABS)p. 112
BRAKE FLUID/ LUBRICANTS/ CLEANING SOLVENTSp. 113
BRAKE SAFETY PRECAUTIONSp. 113
ANTILOCK BRAKE SYSTEM DIAGNOSISp. 114
DIAGNOSIS PROCEDUREp. 114
REAR SPEED SENSOR AIR GAPp. 114
WHEEL/ TIRE SIZE AND INPUT SIGNALSp. 114
OPERATING SOUND LEVELSp. 114
VEHICLE RESPONSE IN ANTILOCK MODEp. 114
STEERING RESPONSEp. 114
LOSS OF SENSOR INPUTp. 114
ABS WARNING LIGHT DISPLAYp. 114
ABS LIGHT ILLUMINATES AT STARTUPp. 114
ABS LIGHT REMAINS ON AFTER STARTUPp. 115
ABS LIGHT ILLUMINATES DURING BRAKE STOPp. 115
BRAKE WARNING LIGHT OPERATIONp. 115
ANTILOCK CONTROL UNIT (ECU) DIAGNOSISp. 115
HYDRAULIC CONTROL UNIT (HCU) DIAGNOSISp. 115
ABS FAULT DIAGNOSIS CHARTp. 115
POTENTIAL ABS FAULT CONDITIONS AND CAUSESp. 115
SERVICE BRAKE COMPONENT DIAGNOSISp. 116
GENERAL INFORMATIONp. 116
DIAGNOSIS PROCEDURESp. 116
PRELIMINARY BRAKE CHECKp. 116
ROAD TESTINGp. 116
COMPONENT INSPECTIONp. 117
DIAGNOSING BRAKE PROBLEMSp. 117
BRAKE WARNING LIGHT OPERATIONp. 117
PEDAL FALLS AWAYp. 117
LOW PEDALp. 117
SPONGY PEDALp. 117
HARD PEDAL OR HIGH PEDAL EFFORTp. 117
BRAKE DRAGp. 117
BRAKE FADEp. 118
PEDAL PULSATIONp. 118
BRAKE PULLp. 118
REAR BRAKE GRABp. 118
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLESp. 118
BRAKE FLUID CONTAMINATIONp. 118
BRAKE NOISEp. 119
BRAKELINING CONTAMINATIONp. 119
WHEEL AND TIRE PROBLEMSp. 119
POWER BRAKE BOOSTER CHECK VALVE TESTp. 119
POWER BRAKE BOOSTER VACUUM TESTp. 120
BRAKE ADJUSTMENTS- FLUID LEVEL- BRAKE BLEEDINGp. 121
RECOMMENDED BRAKE FLUIDp. 121
CORRECT BRAKE FLUID LEVELp. 121
IMPORTANCE OF CLEAN BRAKE FLUIDp. 121
CHECKING BRAKE FLUID FOR CONTAMINATIONp. 121
BRAKE BLEEDINGp. 121
REAR DRUM BRAKESHOE ADJUSTMENTp. 122
ADJUSTMENT PROCEDUREp. 122
PARKING BRAKE CABLE ADJUSTMENTp. 123
ADJUSTMENT PROCEDUREp. 123
REAR WHEEL SPEED SENSOR AIR GAP ADJUST-MENTp. 123
BRAKELIGHT SWITCH ADJUSTMENTp. 123
BRAKELIGHT SWITCH ADJUSTMENT PROCE-DUREp. 124
WHEEL NUT TIGHTENINGp. 124
ANTILOCK BRAKE OPERATIONp. 125
SYSTEM DESCRIPTIONp. 125
HYDRAULIC CONTROL UNIT (HCU)p. 125
MASTER CYLINDERp. 126
POWER BRAKE BOOSTERp. 126
PEDAL TRAVEL SENSORp. 126
WHEEL SPEED SENSORSp. 126
ELECTRONIC CONTROL UNIT (ECU)p. 127
ACCELERATION SWITCHp. 127
SYSTEM RELAYSp. 127
IGNITION SWITCHp. 128
SYSTEM WARNING LIGHTSp. 128
COMBINATION VALVEp. 128
ANTILOCK SYSTEM OPERATIONp. 128
SYSTEM POWER- UP AND INITIALIZATIONp. 128
ABS OPERATION IN NORMAL BRAKING MODEp. 129
ABS OPERATION IN ANTILOCK BRAKING MODEp. 129
HCU SOLENOID VALVE OPERATIONp. 129
HCU PUMP AND PEDAL TRAVEL SENSOR OP- ERATIONp. 130
WHEEL SPEED SENSOR OPERATIONp. 131
ACCELERATION SWITCH OPERATIONp. 131
ECU OPERATIONp. 131
MASTER CYLINDER— HCU— COMBINATION VALVE— BRAKELINESp. 132
SERVICE INFORMATIONp. 132
MASTER CYLINDER RESERVOIR FLUID LEVELp. 132
MASTER CYLINDER REMOVALp. 132
MASTER CYLINDER INSTALLATIONp. 132
HCU REMOVALp. 133
HCU INSTALLATIONp. 134
COMBINATION VALVE REMOVALp. 134
COMBINATION VALVE INSTALLATIONp. 135
BRAKELINES AND HOSESp. 135
BRAKELINE CHARTSp. 135
POWER BRAKE BOOSTER SERVICEp. 137
BOOSTER SERVICE INFORMATIONp. 137
POWER BRAKE BOOSTER REMOVALp. 137
POWER BRAKE BOOSTER INSTALLATIONp. 137
ANTILOCK ELECTRONIC COMPONENT SERVICEp. 139
SERVICE INFORMATIONp. 139
PEDAL TRAVEL SENSOR SERVICEp. 139
PEDAL TRAVEL SENSOR REMOVALp. 139
PEDAL TRAVEL SENSOR REPLACEMENT INFOR-MATIONp. 139
PEDAL TRAVEL SENSOR INSTALLATIONp. 139
AXLE SHAFT TONE WHEEL SERVICEp. 140
FRONT WHEEL SENSOR REMOVALp. 140
FRONT WHEEL SENSOR INSTALLATIONp. 140
REAR WHEEL SENSOR REMOVALp. 141
REAR WHEEL SENSOR INSTALLATIONp. 141
ACCELERATION SENSOR REMOVALp. 142
ACCELERATION SENSOR INSTALLATIONp. 142
ELECTRONIC CONTROL UNIT (ECU) SERVICEp. 142
ECU REMOVAL AND INSTALLATIONp. 142
DISC BRAKE SERVICEp. 144
DISC BRAKESHOE REMOVALp. 144
DISC BRAKESHOE INSTALLATIONp. 145
DISC BRAKE CALIPER OVERHAULp. 146
CALIPER REMOVALp. 146
CALIPER DISASSEMBLYp. 146
CALIPER CLEANING AND INSPECTIONp. 147
CALIPER ASSEMBLYp. 148
CALIPER INSTALLATIONp. 148
DISC BRAKE ROTOR SERVICEp. 149
ROTOR REMOVALp. 149
ROTOR INSTALLATIONp. 149
CHECKING ROTOR THICKNESSp. 149
CHECKING ROTOR THICKNESS VARIATIONp. 149
CHECKING ROTOR LATERAL RUNOUTp. 149
ROTOR REFINISHINGp. 150
DRUM BRAKE SERVICEp. 152
DRUM BRAKESHOE REMOVAL (Fig. 1)p. 152
DRUM BRAKESHOE INSTALLATION (Fig. 1)p. 152
WHEEL CYLINDER REMOVALp. 153
WHEEL CYLINDER OVERHAUL (Fig. 3)p. 153
WHEEL CYLINDER INSTALLATIONp. 153
BRAKE DRUM REFINISHINGp. 153
PARKING BRAKE SERVICEp. 155
PARKING BRAKE LEVER REMOVAL— WITH FULL CONSOLEp. 155
PARKING BRAKE LEVER INSTALLATION— WITH FULL CONSOLEp. 155
PARKING BRAKE LEVER REMOVAL— WITH MINI CONSOLEp. 155
PARKING BRAKE LEVER INSTALLATION— WITH MINI CONSOLEp. 156
PARKING BRAKE FRONT CABLE REMOVALp. 156
PARKING BRAKE FRONT CABLE INSTALLATIONp. 157
PARKING BRAKE REAR CABLE REMOVALp. 157
PARKING BRAKE REAR CABLE INSTALLATIONp. 157
PARKING BRAKE FRONT CABLE ADJUSTMENTp. 158
BRAKE PEDAL AND SWITCH SERVICEp. 159
GENERAL INFORMATIONp. 159
BRAKE PEDAL SERVICEp. 159
BRAKE PEDAL REMOVAL (Fig. 1)p. 159
BRAKE PEDAL INSTALLATION (Fig. 1)p. 159
BRAKELIGHT SWITCH REMOVALp. 159
BRAKELIGHT SWITCH INSTALLATIONp. 159
BRAKELIGHT SWITCH ADJUSTMENTp. 160
SPECIFICATIONSp. 161
BRAKE TORQUE SPECIFICATIONSp. 161
6 CLUTCHp. 162
CLUTCHp. 162
CONTENTSp. 162
CLUTCH COMPONENTSp. 162
MECHANICAL COMPONENTSp. 162
HYDRAULIC LINKAGE COMPONENTSp. 162
CLUTCH LINKAGE FLUIDp. 162
CLUTCH COMPONENT LUBRICATIONp. 162
RECOMMENDED LUBRICANTSp. 162
CLUTCH DIAGNOSISp. 163
GENERAL DIAGNOSIS INFORMATIONp. 163
CLUTCH PROBLEM CAUSESp. 163
CONTAMINATIONp. 163
CLUTCH MISALIGNMENTp. 163
INSPECTION AND DIAGNOSIS CHARTSp. 164
CLUTCH SERVICEp. 170
CLUTCH COVER AND DISC REMOVALp. 170
CLUTCH COVER AND DISC INSTALLATIONp. 170
CLUTCH HOUSING REMOVALp. 170
CLUTCH HOUSING INSTALLATIONp. 171
RELEASE BEARING REPLACEMENTp. 171
PILOT BEARING REPLACEMENTp. 171
CLUTCH HYDRAULIC LINKAGE REMOVALp. 172
CLUTCH HYDRAULIC LINKAGE INSTALLATIONp. 172
CLUTCH PEDAL REMOVALp. 172
CLUTCH PEDAL INSTALLATIONp. 173
FLYWHEEL SERVICEp. 173
7 COOLING SYSTEMp. 176
COOLING SYSTEMp. 176
CONTENTSp. 176
GENERAL INFORMATIONp. 176
COOLING SYSTEMp. 176
COOLING SYSTEM COMPONENTSp. 176
SYSTEM COOLANT ROUTINGp. 176
DIAGNOSISp. 177
PRELIMINARY CHECKSp. 177
ENGINE COOLING SYSTEM OVERHEATINGp. 177
SYMPTOM AND ACTION— SEE PRELIMINARY CHECKS FIRSTp. 178
SYSTEM DIAGNOSISp. 179
SYSTEM DIAGNOSIS (CONT.)p. 180
SERVICE PROCEDURESp. 181
WATER PUMPS— GENERAL INFORMATIONp. 181
WATER PUMP TESTSp. 181
LOOSE IMPELLERp. 181
INSPECTING FOR INLET RESTRICTIONSp. 182
WATER PUMPS— REMOVAL/ INSTALLATIONp. 182
4.0L 6 CYLINDER ENGINEp. 182
5.2L V- 8 ENGINEp. 185
WATER PUMP BYPASS HOSE— 5.2L ENGINEp. 187
WITHOUT AIR CONDITIONING (A/ C)p. 188
WITH AIR CONDITIONING (A/ C)p. 188
THERMOSTATp. 190
DESCRIPTION AND OPERATIONp. 190
ON- BOARD DIAGNOSTICSp. 190
REMOVAL— 4.0L 6 CYLINDER ENGINEp. 190
INSTALLATION— 4.0L 6 CYLINDER ENGINEp. 191
REMOVAL— 5.2L V- 8 ENGINEp. 191
INSTALLATION— 5.2L V- 8 ENGINEp. 192
COOLANTp. 193
GENERAL INFORMATIONp. 193
COOLANT PERFORMANCEp. 193
COOLANT SELECTION- ADDITIVESp. 194
COOLANT SERVICEp. 194
COOLANT LEVEL CHECK- ROUTINEp. 194
ADDING ADDITIONAL COOLANT- ROUTINEp. 194
COOLANT LEVEL CHECK- SERVICEp. 194
LOW COOLANT LEVEL- AERATIONp. 194
DEAERATIONp. 194
DRAINING COOLING SYSTEMp. 194
REFILLING COOLING SYSTEMp. 195
COOLING SYSTEM CLEANING/ REVERSE FLUSHINGp. 195
CLEANINGp. 195
REVERSE FLUSHINGp. 195
REVERSE FLUSHING RADIATORp. 195
REVERSE FLUSHING ENGINEp. 196
CHEMICAL CLEANINGp. 196
TESTING COOLING SYSTEM FOR LEAKSp. 196
ULTRAVIOLET LIGHT METHODp. 196
PRESSURE TESTER METHODp. 196
INTERNAL LEAKAGE INSPECTIONp. 197
COMBUSTION LEAKAGE TEST (WITHOUT PRESSURE TESTER)p. 197
COOLANT RESERVE/ OVERFLOW SYSTEMp. 198
RADIATOR PRESSURE CAPp. 198
RADIATOR CAP- TO- FILLER NECK SEAL— PRESSURE RELIEF CHECKp. 198
PRESSURE TESTING RADIATOR CAPSp. 199
INSPECTIONp. 199
RADIATORp. 199
GENERAL INFORMATIONp. 199
RADIATOR COOLANT FLOW CHECKp. 199
REMOVALp. 199
INSTALLATIONp. 202
COOLING SYSTEM HOSESp. 202
COOLING SYSTEM FANp. 203
VISCOUS FAN DRIVE OPERATIONp. 203
VISCOUS FAN DRIVE TESTp. 204
VISCOUS FAN DRIVE REPLACEMENT 4.0L 6 CYLINDER ENGINEp. 204
5.2 L V- 8 ENGINEp. 205
FAN BLADE INSPECTIONp. 206
AUTOMATIC TRANSMISSION OIL COOLERSp. 206
REMOVALp. 206
INSTALLATIONp. 206
ENGINE ACCESSORY DRIVE BELTSp. 207
GENERAL INFORMATIONp. 207
BELT DIAGNOSISp. 207
SERPENTINE ACCESSORY DRIVE BELT DIAGNOSISp. 208
BELT TENSION— 4.0L ENGINEp. 209
BELT TENSION— 5.2L ENGINEp. 209
SERPENTINE ACCESSORY DRIVE BELT DIAGNOSIS— CONTINUEDp. 209
BELT TENSION SPECIFICATIONSp. 210
4.0L ENGINEp. 210
BELT SCHEMATICSp. 210
BELT SERVICEp. 210
REPLACEMENT/ ADJUSTMENT— 4.0L ENGINEp. 210
REPLACEMENT— 5.2L V- 8 ENGINEp. 211
AUTOMATIC BELT TENSIONER— 5.2L ENGINEp. 212
REMOVALp. 212
INSTALLATIONp. 212
ENGINE BLOCK HEATERp. 213
DESCRIPTION AND OPERATIONp. 213
REMOVALp. 213
INSTALLATIONp. 214
SPECIFICATIONSp. 215
GENERAL INFORMATIONp. 215
COOLING SYSTEM CAPACITIESp. 215
DRIVE BELT TENSIONp. 215
TORQUEp. 215
8 ELECTRICALp. 216
ELECTRICALp. 216
BATTERY/ STARTING/ CHARGING SYSTEMS DIAGNOSTICSp. 216
BATTERY TEST PROCEDURESp. 217
GENERAL INFORMATIONp. 217
BATTERY TESTING GENERAL INFORMATIONp. 218
TEST INDICATORp. 218
STATE OF CHARGE TEST USING TEST INDICATORp. 218
HYDROMETER TESTp. 219
CAUSES OF BATTERY DISCHARGINGp. 219
ABNORMAL BATTERY DISCHARGINGp. 219
BATTERY OPEN CIRCUIT VOLTAGE TESTp. 219
BATTERY LOAD TESTp. 220
BATTERY OPEN CIRCUIT VOLTAGEp. 220
BATTERY CHARGINGp. 221
CHARGING TIME REQUIREDp. 222
CHARGING COMPLETELY DISCHARGED BAT- TERYp. 222
BATTERY CHARGING TIME TABLEp. 222
CHARGE RATEp. 222
BATTERY DIAGNOSTICS CHARTp. 223
IGNITION OFF DRAW (IOD)p. 224
TEST PROCEDUREp. 224
ENGINE STARTER MOTOR TEST PROCEDURESp. 225
GENERAL INFORMATIONp. 225
STARTER SYSTEM DIAGNOSTIC INSPECTIONSp. 225
BATTERY INSPECTIONp. 225
WIRING INSPECTIONp. 225
SOLENOID, RELAY AND IGNITION/ START SWITCH INSPECTIONp. 225
COLD CRANKING TESTp. 225
STARTER FEED CIRCUIT TESTS – (VOLTAGE DROP METHOD)p. 225
STARTING SYSTEM DIAGNOSISp. 226
STARTER CONTROL CIRCUIT TESTSp. 228
SOLENOID TESTINGp. 228
STARTER RELAY OPERATION/ TESTINGp. 228
OPERATIONp. 228
ENGINE STARTER RELAY CONNECTIONSp. 228
TESTINGp. 229
IGNITION SWITCH TESTp. 229
PARK/ NEUTRAL POSITION SWITCHp. 229
GENERATOR TEST PROCEDURES ON VEHICLEp. 230
GENERAL INFORMATIONp. 230
OPERATIONAL CHECK WITH BATTERY INDICATOR (BASE CLUSTER ONLY)p. 230
OPERATIONAL CHECK WITH VOLTMETERp. 230
DIAGNOSTIC PROCEDURESp. 230
VISUAL INSPECTIONp. 230
OUTPUT WIRE RESISTANCE TESTp. 231
PREPARATIONp. 231
TESTp. 231
RESULTSp. 231
CURRENT OUTPUT TESTp. 231
PREPARATIONp. 231
TESTp. 231
RESULTSp. 232
USING ON- BOARD DIAGNOSTIC SYSTEMp. 232
OPERATION OF ON- BOARD DIAGNOSTIC (OBD) SYSTEMp. 232
DIAGNOSTIC TROUBLE CODESp. 232
HOW TO USE MALFUNCTION INDICATOR LAMP FOR DIAGNOSTIC TROUBLE CODESp. 233
CHARGING SYSTEM DIAGNOSTIC TROUBLE CODESp. 233
GENERATOR DIAGNOSTIC TROUBLE CODE (DTC)p. 235
SPECIFICATIONSp. 236
BATTERY CLASSIFICATIONS AND RATINGSp. 236
GENERATOR OUTPUT VOLTAGE SPECIFICATIONSp. 236
ENGINE STARTER MOTOR AND SOLENOID TESTING SPECIFICATIONSp. 236
ENGINE STARTER MOTOR COLD CRANKING SPECIFICATIONSp. 236
4.0L ENGINEp. 236
REDUCTION GEAR STARTERp. 236
5.2L ENGINEp. 236
TORQUE SPECIFICATIONSp. 236
TORQUE SPECIFICATIONSp. 236
8B BATTERY STARTER MOTOR GENERATOR SERVICEp. 238
BATTERY/ STARTER MOTOR/ GENERATOR SERVICEp. 238
BATTERY SERVICE PROCEDURESp. 238
GENERAL INFORMATIONp. 238
BATTERY MAINTENANCEp. 238
BATTERY REPLACEMENTp. 239
REMOVALp. 239
INSTALLATIONp. 239
ENGINE STARTER MOTOR SERVICE PROCEDURESp. 241
GENERAL INFORMATIONp. 241
STARTER RELAY REPLACEMENTp. 241
STARTER MOTOR GENERAL INFORMATION— 4.0Lp. 241
STARTER MOTOR REMOVAL/ INSTALLATION— 4.0Lp. 241
STARTER MOTOR GENERAL INFORMATION— 5.2Lp. 242
STARTER MOTOR REMOVAL/ INSTALLATION— 5.2Lp. 242
PARK/ NEUTRAL POSITION SWITCHp. 242
GENERATOR SERVICE PROCEDURESp. 243
GENERALp. 243
GENERATOR REMOVAL AND INSTALLATION— 4.0Lp. 243
GENERATOR REMOVAL AND INSTALLATION— 5.2L ENGINEp. 244
REMOVALp. 244
INSTALLATIONp. 244
SPECIFICATIONSp. 246
BATTERY CLASSIFICATIONS AND RATINGSp. 246
GENERATOR OUTPUT VOLTAGE SPECIFICATIONSp. 246
4.0L ENGINEp. 246
TORQUE SPECIFICATIONSp. 246
TORQUE SPECIFICATIONSp. 246
ENGINE STARTER MOTOR AND SOLENOID TESTING SPECIFICATIONSp. 246
ENGINE STARTER MOTOR COLD CRANKING SPECIFICATIONSp. 246
5.2L ENGINEp. 246
REDUCTION GEAR STARTERp. 246
8C OVERHEAD CONSOLEp. 248
OVERHEAD CONSOLEp. 248
CONTENTSp. 248
DESCRIPTIONp. 248
READING AND COURTESY LAMPSp. 248
TRIP COMPUTERp. 248
COMPASSp. 248
THERMOMETERp. 249
DIAGNOSTIC PROCEDURESp. 249
COMPASS REPAIR PROCEDURESp. 253
VARIATION ADJUSTMENT PROCEDUREp. 253
COMPASS CALIBRATION PROCEDUREp. 253
DEMAGNETIZING PROCEDUREp. 253
SELF- DIAGNOSTIC TESTp. 254
THERMOMETER SENSOR REPLACEMENTp. 255
CONSOLE REPAIR PROCEDURESp. 255
TRIP COMPUTER REPLACEMENTp. 255
PUSH BUTTON MODULE REPLACEMENTp. 255
LENS/ LAMP REPLACEMENTp. 256
KEYLESS ENTRY RECEIVERp. 256
8D IGNITION SYSTEMp. 258
IGNITION SYSTEMSp. 258
COMPONENT IDENTIFICATION/ SYSTEM OPERATIONp. 258
GENERAL INFORMATIONp. 258
IGNITION SYSTEMSp. 258
AUTOMATIC SHUT DOWN RELAY (ASD) RELAYp. 258
CAMSHAFT POSITION SENSORp. 259
CRANKSHAFT POSITION SENSORp. 259
SENSOR OPERATION— 4.0L ENGINEp. 260
SENSOR OPERATION— 5.2L ENGINEp. 260
DISTRIBUTORSp. 260
IGNITION COILp. 261
ENGINE COOLANT TEMPERATURE SENSORp. 262
INTAKE MANIFOLD CHARGE AIR TEMPERATURE SENSORp. 262
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORp. 263
POWERTRAIN CONTROL MODULE (PCM)p. 263
THROTTLE POSITION SENSORp. 264
DIAGNOSTICS/ SERVICE PROCEDURESp. 265
GENERAL INFORMATIONp. 265
AUTOMATIC SHUT DOWN (ASD) RELAYp. 265
CAMSHAFT POSITION SENSOR TESTp. 265
4.0L OR 5.2L ENGINEp. 265
CRANKSHAFT POSITION SENSOR TESTp. 266
DISTRIBUTOR CAPp. 266
INSPECTIONp. 266
DISTRIBUTOR ROTORp. 267
IGNITION COILp. 268
ENGINE COOLANT TEMPERATURE SENSOR TESTp. 268
IGNITION COIL RESISTANCEp. 269
IGNITION SECONDARY CIRCUIT DIAGNOSISp. 270
CHECKING FOR SPARKp. 270
FAILURE TO START TESTp. 270
SENSOR RESISTANCE (OHMS)p. 270
IGNITION TIMINGp. 271
INTAKE MANIFOLD CHARGE AIR TEMPERATURE SENSOR TESTp. 271
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TESTp. 272
SENSOR RESISTANCE (OHMS)p. 272
POWERTRAIN CONTROL MODULE (PCM)p. 273
SPARK PLUGSp. 273
CONDITIONp. 274
SPARK PLUG SECONDARY CABLESp. 275
TESTINGp. 276
SPARK PLUG CABLE RESISTANCEp. 276
THROTTLE POSITION SENSOR TESTp. 277
OXYGEN SENSOR TESTSp. 277
COMPONENT REMOVAL/ INSTALLATIONp. 278
GENERAL INFORMATIONp. 278
AUTOMATIC SHUT DOWN (ASD) RELAYp. 278
REMOVALp. 278
INSTALLATIONp. 278
CAMSHAFT POSITION SENSORp. 278
REMOVAL— 4.0L ENGINEp. 278
INSTALLATION— 4.0L ENGINEp. 279
REMOVAL— 5.2L ENGINEp. 279
INSTALLATION— 5.2L ENGINEp. 279
CRANKSHAFT POSITION SENSORp. 279
REMOVAL— 4.0L ENGINEp. 279
INSTALLATION— 4.0L ENGINEp. 280
REMOVAL— 5.2L ENGINEp. 280
INSTALLATION— 5.2L ENGINEp. 281
ENGINE COOLANT TEMPERATURE SENSORp. 281
REMOVAL— 4.0L ENGINEp. 281
INSTALLATION— 4.0L ENGINEp. 281
REMOVAL— 5.2L ENGINEp. 281
INSTALLATION— 5.2L ENGINEp. 282
DISTRIBUTORp. 282
REMOVAL— 4.0L ENGINEp. 282
INSTALLATION— 4.0L ENGINEp. 283
REMOVAL— 5.2L ENGINEp. 284
INSTALLATION— 5.2L ENGINEp. 284
IGNITION COILp. 285
REMOVAL— 4.0L ENGINEp. 285
INSTALLATION— 4.0L ENGINEp. 285
REMOVAL— 5.2L ENGINEp. 285
INSTALLATION— 5.2L ENGINEp. 286
INTAKE MANIFOLD CHARGE AIR TEMPERATURE SENSORp. 286
REMOVAL— 4.0L ENGINEp. 286
INSTALLATION— 4.0L ENGINEp. 286
REMOVAL— 5.2L ENGINEp. 286
INSTALLATION— 5.2L ENGINEp. 286
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORp. 286
REMOVAL— 4.0L ENGINEp. 286
INSTALLATION— 4.0L ENGINEp. 287
REMOVAL— 5.2L ENGINEp. 287
INSTALLATION— 5.2L ENGINEp. 287
OXYGEN (O2 ) SENSORp. 287
POWERTRAIN CONTROL MODULE (PCM)p. 287
REMOVALp. 287
INSTALLATIONp. 288
SPARK PLUGSp. 288
PLUG REMOVALp. 289
PLUG CLEANINGp. 289
PLUG GAP ADJUSTMENTp. 289
SPARK PLUG GAPp. 289
PLUG INSTALLATIONp. 289
SPARK PLUG SECONDARY CABLESp. 289
THROTTLE POSITION SENSOR (TPS)p. 290
REMOVAL— 4.0L ENGINEp. 290
INSTALLATION— 4.0L ENGINEp. 290
REMOVAL— 5.2L ENGINEp. 290
INSTALLATION— 5.2L ENGINEp. 290
IGNITION SWITCHp. 292
GENERAL INFORMATIONp. 292
IGNITION SWITCH AND KEY CYLINDER SERVICEp. 292
REMOVALp. 292
INSTALLATIONp. 293
IGNITION SWITCH CIRCUITSp. 294
SPECIFICATIONSp. 295
GENERAL INFORMATIONp. 295
SPARK PLUGSp. 295
SPARK PLUG CABLE RESISTANCEp. 295
IGNITION COIL RESISTANCEp. 295
ENGINE FIRING ORDER 4.0L ENGINEp. 296
ENGINE FIRING ORDER 5.2L ENGINEp. 296
TORQUEp. 296
8E INSTRUMENT PANELp. 298
INSTRUMENT PANEL AND GAUGESp. 298
INSTRUMENT CLUSTER GENERAL INFORMATIONp. 298
VOLTMETERp. 298
OIL PRESSURE GAUGEp. 298
COOLANT TEMPERATURE GAUGEp. 298
TACHOMETERp. 298
FUEL GAUGEp. 298
LOW FUEL WARNINGp. 298
UPSHIFT INDICATORp. 298
BRAKE INDICATORp. 299
MALFUNCTION INDICATOR (CHECK ENGINE LAMP)p. 299
SECURITY LAMPp. 299
CHECK ANTI- LOCK LAMPp. 299
AIR BAGp. 299
HAZARD FLASHER INDICATOR (CANADA)p. 299
MASTER LIGHTING INDICATOR (CANADA)p. 299
INSTRUMENT CLUSTER DIAGNOSISp. 300
SPEEDOMETER/ OIL PRESSURE GAUGE/ AIR BAG LAMPp. 300
SPEEDOMETERp. 300
OIL PRESSURE GAUGE INOPERATIVEp. 300
AIR BAG LAMPp. 300
UPSHIFT INDICATORp. 300
MALFUNCTION INDICATOR (CHECK ENGINE)p. 300
BRAKE INDICATORp. 300
CHECK ANTI- LOCK (ABS)p. 301
VOLTMETER/ TACHOMETER/ FUEL GAUGE/ LOW FUEL INOPERATIVEp. 301
VOLTMETERp. 301
TACHOMETER INOPERATIVEp. 301
FUEL GAUGEp. 301
LOW FUEL WARNING INOPERATIVEp. 301
COOLANT TEMPERATURE GAUGE INOPERATIVEp. 301
SECURITY INDICATORp. 301
SEAT BELT INDICATORp. 301
INSTRUMENT CLUSTER SERVICE PROCEDURESp. 302
INSTRUMENT CLUSTER REPLACEMENTp. 302
Zp. 302
GAUGE REPLACEMENT— INSTRUMENT CLUSTER REMOVEDp. 303
SPEEDOMETER REPLACEMENT— INSTRUMENT CLUSTER REMOVEDp. 303
TACHOMETER REPLACEMENT— INSTRUMENT CLUSTER REMOVEDp. 303
PRINTED CIRCUIT REPLACEMENT— INSTRUMENT CLUSTER REMOVEDp. 303
DISASSEMBLYp. 303
ASSEMBLYp. 303
INSTRUMENT CLUSTERp. 306
SPECIFICATIONSp. 307
INSTRUMENT CLUSTER GAUGESp. 307
VEHICLE INFORMATION CENTER (VIC)p. 308
GENERAL INFORMATIONp. 308
CLOCK/ CALENDAR DISPLAYp. 308
MONITORED SYSTEMSp. 308
SERVICE REMINDERSp. 308
FOUR WHEEL DRIVE DISPLAYp. 308
CONTROLSp. 308
CLOCK/ CALENDARp. 309
OPERATING SYSTEM MESSAGESp. 309
WARNING MESSAGESp. 309
LEVEL MESSAGESp. 309
SERVICE MESSAGESp. 309
4WD SYSTEM MODE DISPLAYSp. 310
VIC DIAGNOSTICSp. 310
VIC DIAGNOSTICS CHARTp. 311
SETUPp. 312
LANGUAGE SELECTp. 312
CLOCK DISPLAY SELECTp. 312
SERVICE INTERVALp. 312
VIC DIAGNOSTIC MESSAGESp. 312
CONNECTOR IDENTIFICATIONp. 312
VIC INITIAL SETUP CHARTp. 313
VIC SYSTEM SCHEMATICp. 314
SERVICE PROCEDURESp. 315
ENGINE OIL LEVEL SENSORp. 315
COOLANT LEVEL SENSOR WASHER FLUID LEVEL SENSORp. 316
GRAPHIC DISPLAY MODULEp. 316
WIRING SCHEMATIC— 249 TRANSFER CASEp. 316
WIRING SCHEMATIC 231 TRANSFER CASEp. 317
WIRING SCHEMATIC 242 TRANSFER CASEp. 317
DIAGNOSISp. 318
SERVICE PROCEDURESp. 318
INSTRUMENT PANEL SERVICE PROCEDURESp. 319
SWITCH POD REPLACEMENTp. 319
LEFT HAND PODp. 321
RIGHT HAND PODp. 321
8F AUDIO SYSTEMp. 322
AUDIO SYSTEMSp. 322
GENERAL INFORMATIONp. 322
DESCRIPTIONp. 322
INTERFERENCE ELIMINATIONp. 322
RADIO NOISE DIAGNOSISp. 322
TEST PROCEDURESp. 323
RADIO DIAGNOSISp. 323
RADIO SCHEMATICp. 324
SPEAKER DIAGNOSISp. 325
AM/ FM/ STEREO— STEREO CASSETTEp. 325
ANTENNA TESTINGp. 326
ANTENNA DIAGNOSISp. 326
CASSETTE TAPE PLAYER DIAGNOSIS COMPACT DISC PLAYER DIAGNOSISp. 327
TAPE PLAYER DIAGNOSISp. 327
COMPACT DISC PLAYER REPLACEMENTp. 328
COMPACT DISC PLAYER DIAGNOSISp. 328
SERVICE PROCEDURESp. 329
RADIO REPLACEMENTp. 329
DOOR MOUNTED SPEAKERSp. 329
INSTRUMENT PANEL MOUNTED TWEETERSp. 330
STANDARD RADIO ANTENNAp. 331
GENERAL INFORMATIONp. 331
REPLACEMENTp. 331
POWER RADIO ANTENNAp. 332
GENERAL INFORMATIONp. 332
DESCRIPTIONp. 332
REPLACEMENTp. 332
POWER ANTENNA RELAYp. 333
REPLACEMENTp. 333
DIAGNOSISp. 333
POWER ANTENNA RELAYp. 333
POWER ANTENNAp. 333
8G HORNSp. 334
HORNSp. 334
CONTENTSp. 334
GENERAL INFORMATIONp. 334
HORNS WILL NOT SOUNDp. 334
HORN RELAYp. 334
HORNp. 334
HORNS SOUND CONTINUOUSLYp. 335
HORN SWITCH REPLACEMENTp. 335
HORN REPLACEMENTp. 336
RELAY REPLACEMENTp. 336
8H SPEED CONTROLp. 338
VEHICLE SPEED CONTROL SYSTEMp. 338
CONTENTSp. 338
GENERAL INFORMATIONp. 338
TEST PROCEDURESp. 342
GENERAL INFORMATIONp. 342
ROAD TESTp. 342
INOPERATIVE SYSTEMp. 342
CHECKING FOR DIAGNOSTIC TROUBLE CODEp. 342
VEHICLE SPEED SENSOR TESTp. 342
VEHICLE SPEED CONTROL SYSTEM ELECTRICAL TESTSp. 342
ELECTRICAL TESTS AT SERVOp. 342
ELECTRICAL TESTS AT POWERTRAIN CONTROL MODULEp. 343
VEHICLE SPEED CONTROL SWITCH TESTp. 344
STOP LAMP SPEED CONTROL SWITCH TESTp. 344
SPEED CONTROL SWITCH CONTINUITY CHARTp. 344
VACUUM SUPPLY TESTp. 345
VEHICLE SPEED CONTROL SYSTEM SCHEMATICp. 345
SERVICE PROCEDURESp. 346
SERVO UNITp. 346
REMOVALp. 346
INSTALLATIONp. 346
SPEED CONTROL SWITCHp. 346
REMOVALp. 346
INSTALLATIONp. 346
SERVO CABLE REPLACEMENTp. 346
VACUUM RESERVOIRp. 347
REMOVALp. 347
INSTALLATIONp. 347
8J TURN SIGNALp. 348
TURN SIGNALS AND HAZARD WARNING FLASHERp. 348
GENERAL INFORMATIONp. 348
TURN SIGNAL AND HAZARD WARNING FLASHER LOCATIONp. 348
TURN SIGNALSp. 348
DESCRIPTIONp. 348
DIAGNOSIS— TURN SIGNAL INOPERATIVEp. 349
HAZARD WARNING SYSTEMp. 349
DESCRIPTIONp. 349
DIAGNOSIS— HAZARD FLASHER INOPERA-TIVEp. 349
MULTI- FUNCTION SWITCH TESTING PROCEDURESp. 350
MULTI- FUNCTION SWITCH SERVICE PROCEDURESp. 351
REMOVALp. 351
INSTALLATIONp. 351
8H WIPER AND WASHERp. 352
WINDSHIELD WIPER AND WASHER SYSTEMSp. 352
FRONT WIPERS/ WASHERSp. 352
GENERAL INFORMATIONp. 352
WIPERSp. 352
WASHERSp. 352
DIAGNOSING WINDSHIELD WIPERSp. 353
INTERMITTENT WIPER FUNCTION TESTING PRO-CEDURESp. 353
WINDSHIELD WIPER AND WASHER SYSTEMp. 353
CONDITIONp. 354
PROCEDUREp. 354
CONDITIONp. 354
PROCEDUREp. 354
CONDITIONp. 354
PROCEDUREp. 354
MULTIFUNCTION (INTERMITTENT WIPER) SWITCH TESTING PROCEDURESp. 355
INTERMITTENT WIPE SWITCH CONTINUITY CHART INTERMITTENT WIPER SYSTEM SCHEMATICp. 355
WIPER SWITCH REPLACEMENTp. 356
REMOVALp. 356
INSTALLATIONp. 356
WASHER PUMP REPLACEMENTp. 356
WIPER MOTOR REPLACEMENTp. 356
REMOVALp. 356
INSTALLATIONp. 357
REAR WINDOW WIPER/ WASHERp. 358
GENERAL INFORMATIONp. 358
DIAGNOSING REAR WIPERp. 358
DIAGNOSING REAR WASHERp. 358
REAR WIPER/ WASHER CIRCUITRYp. 359
REAR WIPER/ WASHER SWITCH TESTINGp. 359
WIPER BLADE REPLACEMENTp. 360
REAR WIPER MOTOR REPLACEMENTp. 360
REMOVALp. 360
INSTALLATIONp. 360
REAR WASHER NOZZLEp. 361
REAR WIPER SWITCH REPLACEMENTp. 361
REAR WASHER PUMP REPLACEMENTp. 362
8L LAMPp. 364
LAMPSp. 364
GENERAL INFORMATIONp. 364
DIAGNOSTIC PROCEDURESp. 364
LEFT HAND SWITCH PODp. 364
TURN SIGNAL/ DIMMER SWITCHp. 364
DIMMER SWITCH TESTp. 364
SERVICE PROCEDURESp. 366
HEADLAMP ALIGNMENTp. 366
HEADLAMP ALIGNMENT PREPARATIONp. 366
HEADLAMP/ FOG LAMP ADJUSTMENT USING ALIGNMENT SCREENp. 366
ALIGNMENT SCREEN PREPARATIONp. 366
HEADLAMP ADJUSTMENTp. 366
FOG LAMP ADJUSTMENTp. 366
AERO HEADLAMP REPLACEMENTp. 366
HEADLAMP BULB REMOVALp. 367
PARKING LAMP BULB/ LENS REPLACEMENTp. 367
TURN SIGNAL AND SIDE MARKER LAMPp. 367
FOG LAMPSp. 367
FOG LAMP BULB/ LENS REPLACEMENTp. 368
HEADLAMP SWITCHp. 369
TURN SIGNAL/ DIMMER SWITCHp. 369
FOG LAMP SWITCH REPLACEMENTp. 369
TAIL AND STOP LAMPSp. 369
BACKUP LAMPSp. 369
BACKUP LAMP SWITCHp. 369
TURN SIGNAL LAMPp. 369
REAR SIDE MARKER LAMPp. 370
LICENSE PLATE LAMPp. 370
REMOVALp. 370
INSTALLATIONp. 370
CENTER HIGH MOUNTED STOP LAMP (CHMSL)p. 370
UNDERHOOD LAMPp. 371
BULB REMOVALp. 371
BULB INSTALLATIONp. 371
HOUSING REMOVALp. 371
HOUSING INSTALLATIONp. 371
INTERIOR LAMPSp. 372
DOME/ COURTESY LAMP SERVICE INFORMATIONp. 372
DOME/ COURTESY LAMP TROUBLE DIAGNOSISp. 372
ALL LAMPS INOPERATIVEp. 372
ONE LAMP INOPERATIVEp. 372
LAMPS INOPERATIVE WITH ONE OR MORE DOORS OPENEDp. 372
LIGHTED VANITY MIRRORp. 372
SERVICE INFORMATIONp. 372
LIGHTED VANITY MIRROR TROUBLE DIAGNOSISp. 372
VANITY LAMPS INOPERATIVEp. 372
DOME/ READING LAMPp. 373
REMOVALp. 373
INSTALLATIONp. 373
DOME LAMP BULBp. 373
REMOVALp. 373
INSTALLATIONp. 373
CARGO LAMP/ BULBp. 373
REMOVALp. 373
INSTALLATIONp. 373
DOOR COURTESY LAMPp. 373
REMOVALp. 373
INSTALLATIONp. 374
UNDER PANEL LAMPp. 374
REMOVALp. 374
INSTALLATIONp. 374
OVERHEAD CONSOLEp. 374
ILLUMINATED ENTRY SYSTEM SERVICE INFORMATIONp. 374
ILLUMINATED ENTRY RELAYp. 374
EXTERIOR LAMP SYSTEMSp. 375
DAYTIME RUNNING LIGHT MODULEp. 375
AUTO HEADLAMPSp. 375
AUTO HEADLAMP SYSTEM DIAGNOSISp. 375
AUTO HEADLAMP MODULEp. 375
AUTO HEADLAMP SYSTEM CHECKp. 376
AUTO HEADLAMP SENSORp. 378
LAMP OUTAGE MODULEp. 379
REMOVALp. 379
BULB APPLICATIONp. 380
GENERAL INFORMATIONp. 380
EXTERIOR LAMPSp. 380
INTERIOR LAMPSp. 380
8M RESTRAINTp. 382
RESTRAINT SYSTEMSp. 382
AIR BAG SYSTEMp. 382
AIR BAG SYSTEM GENERAL INFORMATIONp. 382
FRONT IMPACT SENSORSp. 382
CLOCKSPRINGp. 383
DIAGNOSTIC MODULEp. 383
STORAGEp. 383
HANDLING UNDEPLOYED MODULEp. 383
DEPLOYED MODULEp. 383
CLEAN UP PROCEDUREp. 383
SERVICE OF DEPLOYED AIR BAGp. 384
AIR BAG SYSTEM CHECKp. 384
AIR BAG SYSTEM SCHEMATICp. 384
AIR BAG SYSTEM SERVICE PROCEDURESp. 385
AIR BAG MODULEp. 385
REMOVALp. 385
INSTALLATIONp. 385
IMPACT SENSORSp. 385
REMOVALp. 385
INSTALLATIONp. 386
AIR BAG SYSTEM DIAGNOSTIC MODULE (ASDM)p. 386
REMOVALp. 387
INSTALLATIONp. 388
CLOCKSPRINGp. 388
REMOVALp. 388
INSTALLATIONp. 388
CLOCKSPRING CENTERING PROCEDUREp. 389
STEERING WHEELp. 389
REMOVALp. 389
INSTALLATIONp. 389
8N REAR WINDOW DEFOGGERp. 392
REAR WINDOW DEFOGGERp. 392
GENERALp. 392
DIAGNOSISp. 393
REAR WINDOW DEFOGGER GRID TESTp. 393
SWITCH TESTINGp. 393
BATTERY, IGNITION & FUSESp. 393
DEFOGGER SWITCHp. 393
REAR DEFOGGER RELAYp. 393
DEFOGGER GRIDp. 394
REAR WINDOW DEFOGGER SYSTEM SCHEMATICp. 394
SERVICE PROCEDURESp. 395
REAR WINDOW DEFOGGER GRID REPAIRp. 395
REAR WINDOW DEFOGGER SWITCH REPLACEMENTp. 395
REAR DEFOGGER RELAYp. 398
8P POWER DOOR LOOKSp. 400
POWER DOOR LOCKSp. 400
POWER LOCKSp. 400
GENERALp. 400
DESCRIPTIONp. 400
DIAGNOSING POWER DOOR LOCKSp. 400
DOOR LOCKS DO NOT OPERATE USING DOOR LOCK SWITCHESp. 400
ACTUATOR MOTOR STALL TESTp. 401
SWITCH REPLACEMENT— FRONT DOORp. 401
SWITCH REPLACEMENT— REAR DOORp. 401
SOLENOID AND LATCH ASSEMBLY REPLACEMENTp. 402
LIFTGATE LOCK ACTUATOR REPLACEMENTp. 403
KEYLESS ENTRYp. 404
SYSTEM DESCRIPTIONp. 404
TRANSMITTERp. 404
RECEIVERp. 405
SYSTEM OPERATIONp. 405
TRANSMITTER PROGRAMMINGp. 405
DIAGNOSING POWER DOOR LOCKSp. 405
NO DOOR LOCKS OPERATE, USING TRANS-MITTERp. 405
POWER DOOR LOCKSp. 406
TRANSMITTER SERVICEp. 407
TRANSMITTER BATTERY REPLACEMENTp. 407
RECEIVER SERVICEp. 407
WITH OVERHEAD CONSOLEp. 407
WITHOUT OVERHEAD CONSOLEp. 408
DOOR LOCK/ UNLOCK RELAY REPLACEMENTp. 408
8Q VEHICLE THEFT SECURITYp. 410
VEHICLE THEFT SECURITY SYSTEMp. 410
CONTENTSp. 410
GENERAL INFORMATIONp. 410
SYSTEM SELF- TESTSp. 410
ON- BOARD DIAGNOSTIC SYSTEMp. 411
VEHICLE THEFT SECURITY SYSTEM DIAGNOSISp. 412
VEHICLE THEFT SECURITY SYSTEM DIAGNOSIS CONTINUEDp. 413
VEHICLE THEFT SECURITY SYSTEM DIAGNOSIS CONTINUEDp. 414
SECURITY SYSTEM MODULE REPLACEMENTp. 415
SECURITY ALARM MODULE RELAYp. 416
SECURITY SYSTEM HOOD SWITCH REPLACEMENTp. 416
SECURITY SYSTEM DOOR DISARM SWITCHp. 416
REMOVALp. 416
INSTALLATIONp. 417
SECURITY SYSTEM LIFTGATE DISARM SWITCHp. 418
SECURITY SYSTEM SCHEMATICp. 419
8R POWER SEATSp. 422
POWER SEATSp. 422
CONTENTSp. 422
GENERALp. 422
DIAGNOSISp. 422
SEAT MOTOR ASSEMBLYp. 422
NO SEAT MOTORS OPERATEp. 422
SWITCH TESTp. 423
DRIVER’S POWER SEAT PASSENGER’S POWER SEATp. 423
SEAT REMOVAL/ INSTALLATIONp. 424
REMOVALp. 424
INSTALLATIONp. 424
POWER SEAT MOTOR REPLACEMENTp. 424
8S POWER WINDOWSp. 426
POWER WINDOWSp. 426
DESCRIPTIONp. 426
DIAGNOSIS (Fig. 1)p. 426
NO WINDOWS OPERATEp. 426
ONE WINDOW OPERATESp. 426
WINDOW REGULATOR REPLACEMENTp. 426
FRONT DOOR REMOVALp. 426
INSTALLATIONp. 428
REAR DOOR REMOVALp. 428
INSTALLATIONp. 429
8T POWER MIRRORSp. 430
POWER MIRRORSp. 430
POWER SIDE MIRRORSp. 430
GENERAL INFORMATIONp. 430
HEATED MIRRORp. 430
MIRROR TEST PROCEDUREp. 430
MIRROR SWITCH TEST PROCEDUREp. 431
MIRROR SWITCH REPLACEMENTp. 431
MIRROR ASSEMBLY REPLACEMENTp. 434
AUTOMATIC DAY/ NIGHT REAR VIEW MIRRORp. 435
GENERALp. 435
SENSORSp. 435
SWITCHp. 435
REPLACEMENTp. 435
8U CHIME/BUZZERp. 436
CHIME/ BUZZER WARNING SYSTEMSp. 436
SEAT BELT WARNING SYSTEMp. 436
GENERAL INFORMATIONp. 436
OPERATIONp. 436
LIGHTS ONp. 436
SEAT BELT WARNINGp. 436
KEY IN IGNITIONp. 437
VEHILCE INFORMATION CENTERp. 437
DOOR LOCK INHIBITp. 437
DIAGNOSISp. 437
VOLTAGE TESTSp. 437
RESISTANCE TESTSp. 437
KEY- IN SWITCH REPLACEMENTp. 439
REMOVALp. 439
INSTALLATIONp. 439
8W WIRING DIAGRAMSp. 442
WIRING DIAGRAMSp. 442
GENERAL INFORMATIONp. 442
SECONDARY IGNITION WIRINGp. 442
WIRING DIAGRAM SHEETS AND INDEXESp. 442
WIRE CODE IDENTIFICATIONp. 443
CIRCUIT IDENTIFICATIONp. 443
LOCATING A SYSTEMp. 443
COMPONENT IDENTIFICATIONp. 443
SPLICE LOCATIONSp. 444
CONNECTORSp. 444
TROUBLESHOOTING WIRING PROBLEMSp. 444
HARNESS REPAIRp. 444
WIRING REPAIRp. 444
CONNECTOR REPLACEMENTp. 445
CONNECTOR AND TERMINAL ASSEMBLY RE- PLACEMENTp. 445
TERMINAL REPLACEMENTp. 446
SYMBOLS, FUSES, AND RELAYSp. 446
MODULES AND CONTROLLERSp. 446
COMPONENT IDENTIFICATIONp. 452
SPLICE LOCATIONSp. 467
WIRING DIAGRAMSp. 476
9 ENGINESp. 614
ENGINESp. 614
STANDARD SERVICE PROCEDURESp. 614
FORM- IN- PLACE GASKETSp. 614
MOPAR SILICONE RUBBER ADHESIVE SEAL-ANTp. 614
MOPAR GASKET MAKERp. 614
SURFACE PREPARATIONp. 614
GASKET APPLICATIONp. 614
ENGINE PERFORMANCEp. 615
HONING CYLINDER BORESp. 615
MEASURING WITH PLASTIGAGEp. 616
CRANKSHAFT MAIN BEARING CLEARANCEp. 616
CONNECTING ROD BEARING CLEARANCEp. 617
REPAIR DAMAGED OR WORN THREADSp. 617
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)— 4.0L ENGINEp. 617
HYDROSTATIC LOCKp. 617
ENGINE DIAGNOSISp. 618
SERVICE DIAGNOSISp. 618
INTAKE MANIFOLD LEAKAGE DIAGNOSISp. 618
METHOD 1p. 618
METHOD 2p. 618
CYLINDER COMPRESSION PRESSURE TESTp. 618
ENGINE CYLINDER HEAD GASKET FAILURE DIAGNOSISp. 618
CYLINDER- TO- CYLINDER LEAKAGE TESTp. 618
CYLINDER- TO- WATER JACKET LEAKAGE TESTp. 618
CYLINDER COMBUSTION PRESSURE LEAKAGE TESTp. 619
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST DIAGNOSISp. 619
SERVICE DIAGNOSIS— PERFORMANCEp. 620
SERVICE DIAGNOSIS— MECHANICALp. 621
4.0L ENGINE SERVICE PROCEDURESp. 622
GENERAL INFORMATIONp. 622
BUILD DATE CODEp. 622
OVERSIZE AND UNDERSIZE COMPONENT CODESp. 623
ENGINE MOUNTS— FRONTp. 623
REMOVALp. 623
INSTALLATIONp. 624
ENGINE MOUNT— REARp. 624
REMOVALp. 624
INSTALLATIONp. 624
ENGINE ASSEMBLYp. 624
REMOVALp. 624
INSTALLATIONp. 626
ENGINE CYLINDER HEAD COVERp. 627
REMOVALp. 627
CLEANINGp. 627
INSPECTIONp. 627
INSTALLATIONp. 627
ROCKER ARMSp. 628
REMOVALp. 628
CLEANINGp. 628
INSPECTIONp. 628
INSTALLATIONp. 628
ENGINE CYLINDER HEADp. 628
REMOVALp. 628
CLEANINGp. 629
INSPECTIONp. 629
INSTALLATIONp. 629
VALVE SPRINGS AND OIL SEALSp. 630
REMOVALp. 630
INSPECTIONp. 631
INSTALLATIONp. 631
VALVES AND VALVE SPRINGSp. 631
REMOVALp. 631
VALVE CLEANINGp. 631
INSPECTIONp. 631
VALVE REFACINGp. 632
VALVE SEAT REFACINGp. 632
VALVE STEM OIL SEAL REPLACEMENTp. 632
VALVE GUIDESp. 632
VALVE STEM- TO- GUIDE CLEARANCE MEA- SUREMENTp. 632
VALVE SPRING TENSION TESTp. 633
INSTALLATIONp. 633
HYDRAULIC TAPPETSp. 634
REMOVALp. 634
DISASSEMBLEp. 634
CLEANINGp. 634
INSPECTIONp. 634
ASSEMBLYp. 634
LEAK- DOWN TESTp. 634
INSTALLATIONp. 635
VALVE TIMINGp. 635
VIBRATION DAMPERp. 635
REMOVALp. 635
INSTALLATIONp. 636
TIMING CASE COVER OIL SEAL REPLACEMENTp. 636
TIMING CASE COVERp. 636
REMOVALp. 636
CLEANINGp. 637
INSTALLATIONp. 637
TIMING CHAIN AND SPROCKETSp. 637
REMOVALp. 637
INSTALLATIONp. 638
CAMSHAFTp. 638
REMOVALp. 638
INSPECTIONp. 639
INSTALLATIONp. 639
CAMSHAFT PIN REPLACEMENTp. 639
REMOVALp. 639
CAMSHAFT BEARINGSp. 640
INSTALLATIONp. 640
OIL PANp. 641
REMOVALp. 641
CLEANINGp. 641
INSTALLATIONp. 641
OIL PUMPp. 642
REMOVALp. 642
DISASSEMBLEp. 642
DISASSEMBLE (CONT.)p. 643
ASSEMBLYp. 644
INSTALLATIONp. 644
OIL PUMP PRESSUREp. 644
PISTONS AND CONNECTING RODSp. 644
REMOVALp. 644
INSPECTION— CONNECTING RODp. 644
PISTON FITTINGp. 646
PISTON PINp. 647
CONNECTING ROD BEARING FITTING CHARTp. 647
PISTON RING FITTINGp. 648
CLEANINGp. 650
INSTALLATIONp. 650
CRANKSHAFT MAIN BEARINGSp. 650
REMOVALp. 650
INSPECTIONp. 650
FITTING (CRANKSHAFT INSTALLED)p. 651
INSTALLATIONp. 652
MAIN BEARING FITTING CHARTp. 653
REAR MAIN OIL SEALSp. 654
REMOVALp. 654
INSTALLATIONp. 654
CYLINDER BLOCKp. 655
DISASSEMBLYp. 655
CLEANINGp. 655
INSPECTION— CYLINDER BOREp. 655
HONING— CYLINDER BOREp. 655
ASSEMBLYp. 655
SPECIFICATIONSp. 657
ENGINE SPECIFICATIONSp. 657
ENGINE SPECIFICATIONS (CONT.)p. 658
ENGINE SPECIFICATIONS (CONT.)p. 659
TORQUE SPECIFICATIONSp. 659
5.2L ENGINE SERVICE PROCEDURESp. 660
GENERAL INFORMATIONp. 660
ENGINE FRONT MOUNTSp. 660
REMOVALp. 660
INSTALLATIONp. 661
ENGINE REAR SUPPORTp. 661
REMOVALp. 661
INSTALLATIONp. 662
ENGINE ASSEMBLYp. 662
REMOVALp. 662
INSTALLATIONp. 662
CYLINDER HEAD COVERp. 663
REMOVALp. 663
CLEANINGp. 663
INSPECTIONp. 663
INSTALLATIONp. 663
ROCKER ARMSp. 663
REMOVALp. 663
INSTALLATIONp. 663
CYLINDER HEADSp. 663
REMOVALp. 663
CLEANINGp. 664
INSPECTIONp. 664
INSTALLATIONp. 664
VALVES / VALVE SPRINGSp. 665
REMOVALp. 666
VALVE CLEANINGp. 666
VALVE INSPECTIONp. 666
REFACING VALVES / VALVE SEATSp. 666
VALVE SPRING INSPECTIONp. 667
INSTALLATIONp. 667
VALVE STEM SHIELD / SPRING REPLACEMENTp. 668
HYDRAULIC TAPPETSp. 668
OIL LEVELp. 668
TAPPET NOISE DIAGNOSISp. 668
REMOVALp. 669
DISASSEMBLEp. 669
ASSEMBLEp. 669
INSTALLATIONp. 669
VALVE TIMINGp. 669
VIBRATION DAMPERp. 669
REMOVALp. 669
INSTALLATIONp. 670
TIMING CHAIN COVERp. 670
REMOVALp. 670
TIMING CHAIN STRETCHp. 670
CLEANINGp. 671
INSTALLATIONp. 671
FRONT CRANKSHAFT OIL SEAL REPLACEMENTp. 672
CAMSHAFTp. 672
REMOVALp. 672
REMOVAL— BEARINGp. 672
INSTALLATION— BEARINGp. 672
INSTALLATIONp. 673
DISTRIBUTORp. 674
REMOVALp. 674
REMOVAL— DRIVE SHAFT BUSHINGp. 674
INSTALLATION— DRIVE SHAFT BUSHINGp. 674
DISTRIBUTOR TIMINGp. 674
INSTALLATIONp. 674
OIL PANp. 674
REMOVALp. 674
CLEANINGp. 675
INSPECTIONp. 675
INSTALLATIONp. 675
OIL PUMPp. 675
REMOVALp. 675
DISASSEMBLEp. 675
INSPECTIONp. 676
ASSEMBLEp. 677
INSTALLATIONp. 677
PISTON / CONNECTING ROD ASSEMBLYp. 677
REMOVALp. 678
INSPECTIONp. 678
FITTING PISTONSp. 678
FITTING RINGSp. 678
CONNECTING ROD BEARINGSp. 679
INSTALLATIONp. 679
CRANKSHAFTp. 679
REMOVALp. 680
INSPECTION OF JOURNALSp. 680
INSTALLATIONp. 680
CRANKSHAFT MAIN BEARINGSp. 680
REMOVALp. 680
INSTALLATIONp. 680
CRANKSHAFT REAR OIL SEALSp. 681
UPPER SEAL REPLACEMENT (CRANKSHAFT REMOVED)p. 681
UPPER SEAL REPLACEMENT (CRANKSHAFT INSTALLED)p. 681
LOWER SEAL REPLACEMENTp. 682
CYLINDER BLOCKp. 682
DISASSEMBLEp. 682
CLEANINGp. 682
INSPECTIONp. 682
OIL LINE PLUGp. 682
ENGINE CORE, OIL AND CAMSHAFT PLUGSp. 682
ASSEMBLEp. 683
SPECIFICATIONS— 5.2L ENGINEp. 684
ENGINE SPECIFICATIONSp. 684
ENGINE SPECIFICATIONS (CONT.)p. 685
ENGINE SPECIFICATIONS (CONT.)p. 686
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGSp. 686
TORQUE SPECIFICATIONSp. 687
11 EXHAUST AND INTAKEp. 688
EXHAUST SYSTEM AND INTAKE MANIFOLDp. 688
EXHAUST SYSTEMp. 688
GENERAL INFORMATIONp. 688
CATALYTIC CONVERTERp. 689
HEAT SHIELDSp. 689
EXHAUST GAS RECIRCULATION (EGR)p. 689
EXHAUST SYSTEM DIAGNOSISp. 690
SERVICE PROCEDURESp. 691
EXHAUST PIPEp. 691
REMOVALp. 691
INSTALLATIONp. 691
CATALYTIC CONVERTERp. 692
REMOVALp. 692
INSTALLATIONp. 692
MUFFLER AND TAILPIPEp. 692
REMOVALp. 692
INSTALLATIONp. 693
EXHAUST MANIFOLD— 4.0L ENGINEp. 693
INTAKE MANIFOLD— 4.0L ENGINEp. 693
REMOVALp. 693
CLEANINGp. 693
INSTALLATIONp. 693
INTAKE MANIFOLD— 5.2L ENGINEp. 694
REMOVALp. 694
CLEANINGp. 694
INSPECTIONp. 694
INSTALLATIONp. 695
EXHAUST MANIFOLD— 5.2L ENGINEp. 696
REMOVALp. 696
CLEANINGp. 696
INSPECTIONp. 696
INSTALLATIONp. 697
TORQUE SPECIFICATIONSp. 697
13 FRAME AND BUMPERp. 698
FRAME AND BUMPERSp. 698
FRAMEp. 698
GENERAL INFORMATIONp. 698
COLLISION DAMAGEp. 698
DAMAGE DIAGNOSISp. 698
DAMAGE REPAIRp. 698
BUMPERSp. 701
FRONT BUMPER/ FASCIAp. 701
GENERAL INFORMATIONp. 701
REMOVALp. 701
FRONT TOW HOOKSp. 701
REMOVALp. 701
INSTALLATIONp. 701
REAR BUMPERp. 702
REMOVALp. 702
INSTALLATIONp. 702
REAR BUMPER FASCIAp. 702
REMOVALp. 702
REAR TOW HOOKp. 703
REMOVALp. 703
INSTALLATIONp. 703
14 FUEL SYSTEMp. 704
FUEL SYSTEMp. 704
GENERAL INFORMATIONp. 704
FUEL USAGE STATEMENTp. 704
GASOLINE/ OXYGENATE BLENDSp. 704
FUEL DELIVERY SYSTEMp. 706
FUEL PUMP MODULEp. 706
REMOVALp. 706
INSTALLATIONp. 706
FUEL PUMP CONTROLp. 707
FUEL PRESSURE RELEASE PROCEDUREp. 707
FUEL SYSTEM PRESSURE TESTp. 708
FUEL PUMP CAPACITY TESTp. 710
FUEL PRESSURE LEAK DOWN TESTp. 710
ENGINE OFFp. 710
MECHANICAL MALFUNCTIONSp. 711
FUEL FILTERp. 711
REMOVALp. 711
INSTALLATIONp. 712
FUEL TUBES/ LINES/ HOSES AND CLAMPSp. 712
QUICK- CONNECT FITTINGSp. 712
PLASTIC RING TYPE FITTINGp. 713
TAB TYPE FITTINGp. 713
FUEL TANKSp. 715
GENERAL INFORMATIONp. 715
NO- LEAD FUEL TANK FILLER TUBEp. 715
FUEL TANK FILLER TUBE CAPp. 715
HEAT SHIELDSp. 715
FUEL TANKp. 715
REMOVALp. 715
INSTALLATIONp. 716
FUEL PUMP— REMOVAL/ INSTALLATIONp. 717
FUEL GAUGE SENDING UNITp. 717
FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVEp. 717
REMOVALp. 717
INSTALLATIONp. 717
ACCELERATOR PEDAL AND THROTTLE CABLEp. 718
GENERAL INFORMATIONp. 718
ACCELERATOR PEDALp. 718
REMOVALp. 718
INSTALLATIONp. 718
THROTTLE CABLEp. 718
REMOVALp. 718
INSTALLATIONp. 719
MPI SYSTEM— 4.0L ENGINE— COMPONENT DESCRIPTION/ SYSTEM OPERATIONp. 720
GENERAL INFORMATIONp. 720
SYSTEM DIAGNOSISp. 721
POWERTRAIN CONTROL MODULE (PCM)p. 721
AIR CONDITIONING (A/ C) CONTROLS— PCM INPUTp. 722
AUTOMATIC SHUT DOWN (ASD) SENSE— PCM INPUTp. 722
BATTERY VOLTAGE— PCM INPUTp. 723
BRAKE SWITCH— PCM INPUTp. 723
CAMSHAFT POSITION SENSOR— PCM INPUTp. 723
CHARGE AIR TEMPERATURE SENSOR— PCM IN-PUTp. 723
CRANKSHAFT POSITION SENSOR— PCM INPUTp. 723
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUTp. 724
IGNITION CIRCUIT SENSE— PCM INPUTp. 724
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— PCM INPUTp. 724
OXYGEN (O2 ) SENSOR— PCM INPUTp. 724
OVERDRIVE/ OVERRIDE SWITCHp. 724
PARK/ NEUTRAL SWITCH— PCM INPUTp. 725
POWER GROUNDp. 725
SCI RECEIVE— PCM INPUTp. 725
SPEED CONTROL— PCM INPUTp. 725
SENSOR RETURN— PCM INPUTp. 725
THROTTLE POSITION SENSOR (TPS)— PCM INPUTp. 725
VEHICLE SPEED SENSOR— PCM INPUTp. 725
AIR CONDITIONING (A/ C) CLUTCH RELAY— PCM OUTPUTp. 726
IDLE AIR CONTROL (IAC) MOTOR— PCM OUTPUTp. 726
AUTO SHUT DOWN (ASD) RELAY— PCM OUTPUTp. 727
GENERATOR FIELD— PCM OUTPUTp. 727
GENERATOR LAMP— PCM OUTPUTp. 727
EMR LAMP— PCM OUTPUTp. 727
FUEL INJECTORS— PCM OUTPUTp. 727
MALFUNCTION INDICATOR LAMP— PCM OUTPUTp. 727
IGNITION COIL— PCM OUTPUTp. 727
SCI TRANSMIT— PCM OUTPUTp. 728
SHIFT INDICATOR— PCM OUTPUTp. 728
SPEED CONTROL— PCM OUTPUTp. 728
TACHOMETER— PCM OUTPUTp. 728
OPEN LOOP/ CLOSED LOOP MODES OF OPERA-TIONp. 728
MODESp. 728
IGNITION SWITCH (KEY- ON) MODEp. 728
ENGINE START- UP MODEp. 729
ENGINE WARM- UP MODEp. 729
IDLE MODEp. 729
CRUISE MODEp. 729
ACCELERATION MODEp. 730
DECELERATION MODEp. 730
WIDE OPEN THROTTLE MODEp. 730
IGNITION SWITCH OFF MODEp. 730
THROTTLE BODYp. 730
FUEL RAILp. 731
FUEL PRESSURE REGULATORp. 731
MPI SYSTEM— 4.0L ENGINE— GENERAL DIAGNOSISp. 732
GENERAL INFORMATIONp. 732
VISUAL INSPECTIONp. 732
POWERTRAIN CONTROL MODULE (PCM) 60- WAY CONNECTORp. 735
SYSTEM SCHEMATICSp. 735
CAMSHAFT POSITION SENSOR TESTp. 738
COOLANT TEMPERATURE SENSOR TESTp. 738
CHARGE AIR TEMPERATURE SENSOR TESTp. 738
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TESTp. 738
SENSOR RESISTANCE (OHMS)— COOLANT TEMPERATURE SENSOR/ MANIFOLD AIR TEMPERATUREp. 738
CRANKSHAFT POSITION SENSOR TESTp. 739
THROTTLE POSITION SENSOR (TPS) TESTp. 739
OXYGEN SENSOR (O2 ) HEATING ELEMENT TESTp. 739
IDLE AIR CONTROL MOTOR TESTp. 739
RELAYS— OPERATION/ TESTINGp. 741
OPERATIONp. 741
TESTINGp. 742
STARTER MOTOR RELAY TESTp. 742
INJECTOR TESTp. 742
FUEL SYSTEM PRESSURE TESTp. 742
ON- BOARD DIAGNOSTICS (OBD)p. 742
MONITORED CIRCUITSp. 742
NON- MONITORED CIRCUITSp. 742
INJECTOR DIAGNOSIS— VEHICLE RUNS ROUGH AND/ OR HAS A MISSp. 743
HIGH AND LOW LIMITSp. 744
ACCESSING DIAGNOSTIC TROUBLE CODESp. 744
ERASING TROUBLE CODESp. 745
DRB II SCAN TOOLp. 745
DIAGNOSTIC TROUBLE CODE (DTC)p. 745
DIAGNOSTIC TROUBLE CODE DESCRIPTIONp. 746
DIAGNOSTIC TROUBLE CODE DESCRIPTION— CONTINUEDp. 747
DIAGNOSTIC TROUBLE CODE DESCRIPTION— CONTINUEDp. 748
MPI SYSTEM— 4.0L ENGINE— COMPONENT REMOVAL/ INSTALLATIONp. 749
ACCELERATOR PEDAL AND THROTTLE CABLEp. 749
AIR CONDITIONING (A/ C) CLUTCH RELAYp. 749
AIR CLEANER HOUSINGp. 749
AIR FILTERp. 749
AUTOMATIC SHUT DOWN (ASD) RELAYp. 749
BRAKE SWITCHp. 749
CAMSHAFT POSITION SENSORp. 749
CHARGE AIR TEMPERATURE SENSORp. 749
REMOVALp. 749
INSTALLATIONp. 749
CRANKSHAFT POSITION SENSORp. 749
REMOVALp. 750
INSTALLATIONp. 750
ENGINE COOLANT TEMPERATURE SENSORp. 750
REMOVALp. 750
INSTALLATIONp. 750
FUEL FILTERp. 750
FUEL INJECTORp. 750
REMOVALp. 750
INSTALLATIONp. 750
FUEL PUMP MODULEp. 750
FUEL PUMP RELAYp. 751
FUEL RAIL ASSEMBLYp. 751
REMOVALp. 751
INSTALLATIONp. 751
FUEL SYSTEM PRESSURE RELEASE PROCEDUREp. 752
FUEL TANKSp. 752
FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVEp. 752
FUEL TUBES/ LINES/ HOSES AND CLAMPSp. 752
IDLE AIR CONTROL (IAC) MOTORp. 752
REMOVALp. 752
INSTALLATIONp. 752
IGNITION COILp. 752
INTAKE MANIFOLDp. 752
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORp. 752
REMOVALp. 752
INSTALLATIONp. 752
OXYGEN (O2 ) SENSORp. 752
REMOVALp. 752
INSTALLATIONp. 753
PARK NEUTRAL SWITCHp. 753
POWERTRAIN CONTROL MODULE (PCM)p. 753
REMOVALp. 753
INSTALLATIONp. 753
QUICK- CONNECT FITTINGSp. 754
THROTTLE BODYp. 754
REMOVALp. 754
INSTALLATIONp. 754
THROTTLE POSITION SENSOR (TPS)p. 754
REMOVALp. 754
INSTALLATIONp. 754
VEHICLE SPEED SENSORp. 755
REMOVALp. 755
INSTALLATIONp. 755
MPI SYSTEM— 5.2L ENGINE— COMPONENT DESCRIPTION/ SYSTEM OPERATIONp. 756
GENERAL INFORMATIONp. 756
SYSTEM DIAGNOSISp. 757
POWERTRAIN CONTROL MODULE (PCM)p. 757
AIR CONDITIONING (A/ C) CONTROLS— PCM INPUTp. 758
AUTOMATIC SHUT DOWN (ASD) SENSE— PCM INPUTp. 758
BATTERY VOLTAGE— PCM INPUTp. 759
BRAKE SWITCH— PCM INPUTp. 759
CAMSHAFT POSITION SENSOR— PCM INPUTp. 759
CHARGE AIR TEMPERATURE SENSOR— PCM IN-PUTp. 759
CRANKSHAFT POSITION SENSOR— PCM INPUTp. 759
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUTp. 759
IGNITION CIRCUIT SENSE— PCM INPUTp. 760
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— PCM INPUTp. 760
OXYGEN (O2 ) SENSOR— PCM INPUTp. 760
OVERDRIVE/ OVERRIDE SWITCHp. 761
PARK/ NEUTRAL SWITCH— PCM INPUTp. 761
POWER GROUNDp. 761
SCI RECEIVE— PCM INPUTp. 761
SPEED CONTROL— PCM INPUTp. 761
SENSOR RETURN— PCM INPUTp. 761
THROTTLE POSITION SENSOR (TPS)— PCM INPUTp. 761
VEHICLE SPEED SENSOR— PCM INPUTp. 761
AIR CONDITIONING (A/ C) CLUTCH RELAY— PCM OUTPUTp. 762
IDLE AIR CONTROL (IAC) MOTOR— PCM OUTPUTp. 762
AUTO SHUT DOWN (ASD) RELAY— PCM OUTPUTp. 763
GENERATOR FIELD— PCM OUTPUTp. 763
GENERATOR LAMP— PCM OUTPUTp. 763
ELECTRIC EXHAUST GAS RECIRCULATION TRANS-DUCER (EET) SOLENOID— PCM OUTPUTp. 763
EMR LAMP— PCM OUTPUTp. 763
EVAP CANISTER PURGE SOLENOID— PCM OUT-PUTp. 763
FUEL INJECTORS— PCM OUTPUTp. 763
MALFUNCTION INDICATOR LAMP— PCM OUTPUTp. 764
IGNITION COIL— PCM OUTPUTp. 764
SCI TRANSMIT— PCM OUTPUTp. 764
SHIFT INDICATOR— PCM OUTPUTp. 764
SPEED CONTROL— PCM OUTPUTp. 764
TACHOMETER— PCM OUTPUTp. 764
OPEN LOOP/ CLOSED LOOP MODES OF OPERA-TIONp. 764
MODESp. 765
IGNITION SWITCH (KEY- ON) MODEp. 765
ENGINE START- UP MODEp. 765
ENGINE WARM- UP MODEp. 765
IDLE MODEp. 766
CRUISE MODEp. 766
ACCELERATION MODEp. 766
DECELERATION MODEp. 766
WIDE OPEN THROTTLE MODEp. 767
IGNITION SWITCH OFF MODEp. 767
THROTTLE BODYp. 767
FUEL RAILp. 767
FUEL PRESSURE REGULATORp. 768
MPI SYSTEM— 5.2L ENGINE— GENERAL DIAGNOSISp. 769
VISUAL INSPECTIONp. 769
POWERTRAIN CONTROL MODULE (PCM) 60- WAY CONNECTORp. 772
SYSTEM SCHEMATICSp. 772
CAMSHAFT POSITION SENSOR TESTINGp. 775
COOLANT TEMPERATURE SENSOR TESTp. 775
CHARGE AIR TEMPERATURE SENSOR TESTp. 775
SENSOR RESISTANCE (OHMS)— COOLANT TEMPERATURE SENSOR/ CHARGE AIR TEMPERATURE SENSORp. 775
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TESTp. 776
CRANKSHAFT POSITION SENSOR TESTp. 776
THROTTLE POSITION SENSOR (TPS) TESTp. 777
OXYGEN (O2 ) SENSOR HEATING ELEMENT TESTp. 777
IDLE AIR CONTROL (IAC) MOTOR TESTp. 777
RELAYS— OPERATION/ TESTINGp. 779
OPERATIONp. 779
TESTINGp. 779
STARTER MOTOR RELAY TESTp. 779
FUEL INJECTOR TESTp. 781
FUEL PUMP PRESSURE TESTp. 781
ON- BOARD DIAGNOSTICS (OBD)p. 781
MONITORED CIRCUITSp. 781
NON- MONITORED CIRCUITSp. 781
INJECTOR DIAGNOSIS— VEHICLE RUNS ROUGH AND/ OR HAS A MISSp. 782
HIGH AND LOW LIMITSp. 783
ACCESSING DIAGNOSTIC TROUBLE CODESp. 783
ERASING TROUBLE CODESp. 784
DRB II SCAN TOOLp. 784
DIAGNOSTIC TROUBLE CODE (DTC)p. 784
DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONp. 785
DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTION— CONTINUEDp. 786
DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTION— CONTINUEDp. 787
MPI SYSTEM— 5.2L ENGINE— COMPONENT REMOVAL/ INSTALLATIONp. 788
ACCELERATOR PEDAL AND THROTTLE CABLEp. 788
AIR CONDITIONING (A/ C) CLUTCH RELAYp. 788
AIR CLEANER HOUSINGp. 788
AIR FILTERp. 788
AUTOMATIC SHUT DOWN (ASD) RELAYp. 788
BRAKE SWITCHp. 788
CAMSHAFT POSITION SENSORp. 788
CHARGE AIR TEMPERATURE SENSORp. 788
REMOVALp. 788
INSTALLATIONp. 788
CRANKSHAFT POSITION SENSORp. 788
ENGINE COOLANT TEMPERATURE SENSORp. 789
REMOVALp. 789
INSTALLATIONp. 789
EVAP CANISTER PURGE SOLENOIDp. 789
FUEL FILTERp. 789
FUEL INJECTOR( S)p. 789
REMOVALp. 789
INSTALLATIONp. 790
FUEL PRESSURE REGULATORp. 790
REMOVALp. 790
INSTALLATIONp. 790
FUEL PUMP MODULEp. 790
FUEL PUMP RELAYp. 790
FUEL RAILp. 790
REMOVALp. 791
INSTALLATIONp. 792
FUEL SYSTEM PRESSURE RELEASE PROCEDUREp. 792
FUEL TANKSp. 792
FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVEp. 792
FUEL TUBES/ LINES/ HOSES AND CLAMPSp. 792
IDLE AIR CONTROL (IAC) MOTORp. 793
REMOVALp. 793
INSTALLATIONp. 793
IGNITION COILp. 793
INTAKE MANIFOLDp. 793
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORp. 793
REMOVALp. 793
INSTALLATIONp. 794
OXYGEN (O2 ) SENSORp. 794
REMOVALp. 794
INSTALLATIONp. 794
PARK/ NEUTRAL SWITCHp. 794
POWERTRAIN CONTROL MODULE (PCM)p. 794
REMOVALp. 794
INSTALLATIONp. 794
QUICK- CONNECT FITTINGSp. 795
THROTTLE BODYp. 795
REMOVALp. 795
INSTALLATIONp. 795
THROTTLE POSITION SENSOR (TPS)p. 796
REMOVALp. 796
INSTALLATIONp. 796
VEHICLE SPEED SENSORp. 797
REMOVALp. 797
INSTALLATIONp. 797
SPECIFICATIONSp. 798
GENERAL INFORMATIONp. 798
FUEL TANK CAPACITIESp. 798
FUEL SYSTEMp. 798
TORQUEp. 798
16 PROPELLER SHAFTSp. 800
PROPELLER SHAFTSp. 800
GENERAL INFORMATIONp. 800
PROPELLER SHAFTSp. 800
UNIVERSAL JOINTSp. 800
LUBRICATIONp. 800
SERVICE DIAGNOSIS/ PROCEDURESp. 802
VIBRATIONp. 802
UNBALANCEp. 802
DRIVELINE VIBRATIONp. 802
RUNOUTp. 803
UNIVERSAL JOINT ANGLE MEASUREMENTp. 803
INFORMATIONp. 803
RUNOUT SPECIFICATIONSp. 803
INSPECTIONp. 804
MEASUREMENTp. 804
ADJUSTMENT WITH CAMSp. 805
PROPELLER SHAFT REPLACEMENTp. 806
PRECAUTIONSp. 806
FRONTp. 806
REMOVALp. 806
INSTALLATIONp. 806
REARp. 806
REMOVALp. 806
INSTALLATIONp. 806
UNIVERSAL JOINT REPLACEMENTp. 808
PRECAUTIONSp. 808
SINGLE CARDANp. 808
REMOVAL/ DISASSEMBLYp. 808
CLEANING AND INSPECTIONp. 808
ASSEMBLY/ INSTALLATIONp. 808
DOUBLE CARDAN (CV)p. 809
REMOVAL/ DISASSEMBLYp. 809
CLEANING AND INSPECTIONp. 810
ASSEMBLY/ INSTALLATIONp. 810
TORQUE SPECIFICATIONSp. 813
PROPELLER SHAFTS AND U- JOINTSp. 813
19 STEERINGp. 814
STEERINGp. 814
GENERAL INFORMATIONp. 814
STEERING SYSTEM COMPONENTSp. 814
POWER STEERING GEARp. 814
STEERING LINKAGEp. 815
POWER STEERING PUMPp. 815
STEERING COLUMNSp. 815
POWER STEERING SYSTEM DIAGNOSISp. 816
HISS NOISE COMPLAINTp. 816
POWER STEERING PUMP PRESSURE TESTp. 816
POWER STEERING SYSTEM DIAGNOSISp. 817
POWER STEERING SYSTEM DIAGNOSISp. 818
POWER STEERING SYSTEM DIAGNOSISp. 819
POWER STEERING SYSTEM DIAGNOSISp. 820
PUMP LEAKAGE DIAGNOSISp. 821
GEAR LEAKAGE DIAGNOSISp. 821
POWER STEERING PUMPp. 822
SERVICE INFORMATIONp. 822
PRESSURE AND RETURN HOSE REPLACEMENTp. 822
REMOVALp. 822
INSTALLATIONp. 822
PUMP REPLACEMENT— 4.0Lp. 822
REMOVALp. 822
INSTALLATIONp. 823
PUMP REPLACEMENT— 5.2L V/ 8p. 823
REMOVALp. 823
INSTALLATIONp. 824
DRIVE PULLEY REPLACEMENTp. 824
REMOVALp. 824
INSTALLATIONp. 824
RESERVOIR REPLACEMENTp. 824
REMOVALp. 824
INSTALLATIONp. 825
FLOW CONTROL VALVE FITTING O- RING SEALp. 825
REMOVALp. 825
INSTALLATIONp. 825
POWER STEERING PUMP INITIAL OPERATIONp. 825
STEERING LINKAGEp. 827
SERVICE INFORMATIONp. 827
TIE RODp. 827
REMOVALp. 827
INSTALLATIONp. 827
DRAG LINKp. 827
REMOVALp. 827
INSTALLATIONp. 827
STEERING DAMPENERp. 828
REMOVALp. 828
INSTALLATIONp. 828
PITMAN ARMp. 828
REMOVALp. 828
INSTALLATIONp. 828
RECIRCULATING BALL POWER STEERING GEARp. 830
SERVICE INFORMATIONp. 830
PITMAN SHAFT SEALS— IN CAR REPLACEMENTp. 832
REMOVALp. 832
INSTALLATIONp. 832
INTERMEDIATE (COUPLING) SHAFTp. 832
REMOVALp. 832
INSTALLATIONp. 833
STEERING GEAR REPLACEMENTp. 833
REMOVALp. 833
INSTALLATIONp. 833
STEERING GEAR ADJUSTMENTSp. 833
SERVICE INFORMATIONp. 833
WORM THRUST BEARING PRELOAD ADJUST-MENTp. 833
OVER- CENTER ADJUSTMENTp. 834
GEAR DISASSEMBLY INFORMATIONp. 835
PITMAN SHAFT AND SIDE COVER REPLACEMENTp. 837
REMOVEp. 837
DISASSEMBLEp. 837
ASSEMBLEp. 837
INSTALLp. 837
HOUSING END PLUGp. 837
REMOVEp. 837
DISASSEMBLEp. 837
ASSEMBLEp. 838
INSTALLp. 838
ADJUSTER PLUG ASSEMBLY REPLACEMENTp. 838
REMOVEp. 838
DISASSEMBLEp. 838
ASSEMBLEp. 839
INSTALLp. 839
VALVE REPLACEMENTp. 839
REMOVEp. 839
DISASSEMBLEp. 839
ASSEMBLEp. 840
INSTALLp. 841
RACK PISTON AND WORM SHAFT REPLACEMENTp. 841
REMOVEp. 841
DISASSEMBLEp. 841
CLEAN AND INSPECTIONp. 842
ASSEMBLEp. 842
INSTALLp. 843
PITMAN SHAFT SEALS AND BEARING REPLACE-MENTp. 843
REMOVEp. 843
DISASSEMBLEp. 843
ASSEMBLEp. 843
INSTALLp. 844
CHECK VALVE REPLACEMENTp. 844
REMOVEp. 844
DISASSEMBLEp. 844
ASSEMBLEp. 844
INSTALLp. 844
POWER STEERING GEAR SPECIFICATIONSp. 845
STEERING COLUMNp. 846
SERVICE INFORMATIONp. 846
STEERING WHEELp. 847
REMOVALp. 847
INSTALLATIONp. 847
CLOCKSPRINGp. 848
REMOVALp. 848
INSTALLATIONp. 848
CENTERING PROCEDUREp. 848
COLUMN ASSEMBLY REPLACEMENTp. 848
REMOVALp. 848
INSTALLATIONp. 849
COLUMN COMPONENT SERVICEp. 850
AUTOMATIC TRANSMISSION SHIFTER/ IGNITION INTERLOCK MECHANISMp. 851
INTERLOCK CABLE REPLACEMENTp. 851
REMOVALp. 851
INSTALLATION/ ADJUSTMENTp. 851
TEST/ INSPECTIONp. 852
TORQUE SPECIFICATIONSp. 853
STEERING GEARp. 853
STEERING LINKAGEp. 853
STEERING PUMPp. 853
STEERING COLUMNp. 853
21 TRANSMISSIONS AND TRANSFER CASESp. 854
TRANSMISSION AND TRANSFER CASEp. 854
AX 15 MANUAL TRANSMISSIONp. 854
GENERAL INFORMATIONp. 854
TRANSMISSION IDENTIFICATIONp. 854
TRANSMISSION SHIFT PATTERNp. 855
TRANSMISSION LUBRICANTp. 855
TRANSMISSION SWITCH AND PLUG LOCATIONSp. 855
TRANSMISSION GEAR RATIOSp. 855
TRANSMISSION DIAGNOSISp. 855
LOW LUBRICANT LEVELp. 855
HARD SHIFTINGp. 856
TRANSMISSION NOISEp. 856
TRANSMISSION REMOVALp. 856
TRANSMISSION INSTALLATIONp. 857
TRANSMISSION DISASSEMBLY AND OVERHAULp. 858
ADAPTER HOUSING REMOVALp. 858
GEAR CASE REMOVALp. 861
FIFTH GEAR AND SYNCHRO ASSEMBLY REMOVALp. 862
OUTPUT SHAFT AND CLUSTER GEAR RE-MOVALp. 867
OUTPUT SHAFT DISASSEMBLYp. 868
TRANSMISSION CLEANING AND INSPECTIONp. 870
GEAR AND SYNCHRO INSPECTIONp. 871
TRANSMISSION ASSEMBLY AND ADJUSTMENTp. 872
FRONT BEARING/ BEARING SEAL/ REVERSE SHAFT PIN INSTALLATIONp. 872
OUTPUT SHAFT ASSEMBLYp. 873
OUTPUT SHAFT AND CLUSTER GEAR INSTALLATIONp. 875
SHIFT RAIL AND FORK INSTALLATIONp. 876
FIFTH- REVERSE GEAR AND SHIFT COMPONENT INSTALLATIONp. 879
GEAR CASE AND ADAPTER INSTALLATIONp. 882
AW- 4 AUTOMATIC TRANSMISSION CONTENTSp. 887
GENERAL INFORMATIONp. 887
DESCRIPTIONp. 887
TRANSMISSION RANGES AND SHIFT LEVER POSI-TIONSp. 888
TRANSMISSION IDENTIFICATIONp. 888
COMPONENTS AND OPERATIONp. 888
ELECTRONIC CONTROLSp. 888
TRANSMISSION CONTROL MODULE (TCM)p. 888
TRANSMISSION VALVE BODY SOLENOIDSp. 888
SENSORSp. 888
TORQUE CONVERTERp. 889
FOURTH GEAR OVERDRIVE COMPONENTSp. 889
FIRST— THIRD— REVERSE GEAR COMPONENTSp. 890
GEARTRAIN OPERATION AND APPLICATION CHARTSp. 890
HYDRAULIC SYSTEMp. 891
OIL PUMPp. 891
TRANSMISSION VALVE BODY COMPONENTSp. 891
AW- 4 TRANSMISSION DIAGNOSISp. 898
GENERAL DIAGNOSIS INFORMATIONp. 898
Zp. 898
PRELIMINARY INSPECTION AND ADJUSTMENTp. 899
MANUAL SHIFTING TESTp. 899
HYDRAULIC PRESSURE TESTp. 899
PRESSURE TEST PROCEDUREp. 899
PRESSURE TEST ANALYSISp. 900
TORQUE CONVERTER STALL TESTp. 900
STALL SPEED TEST ANALYSISp. 900
TIME LAG TESTp. 900
TEST PROCEDUREp. 900
TIME LAG TEST ANALYSISp. 901
AW- 4 TRANSMISSION DIAGNOSISp. 902
AW- 4 TRANSMISSION DIAGNOSISp. 903
AW- 4 IN- VEHICLE SERVICEp. 904
CHECKING TRANSMISSION FLUID LEVEL AND CONDITIONp. 904
CHECKING FLUID LEVELp. 904
CHECKING FLUID CONDITIONp. 904
TRANSMISSION CONTROL MODULE (TCM) SER-VICEp. 904
TRANSMISSION CONTROL MODULE RE-PLACEMENTp. 904
PARK/ NEUTRAL POSITION SWITCHp. 905
SWITCH TESTINGp. 905
PARK/ NEUTRAL POSITION SWITCH REMOVALp. 905
PARK/ NEUTRAL POSITION SWITCH INSTAL-LATION AND ADJUSTMENTp. 905
VALVE BODY SOLENOID REPLACEMENTp. 906
SOLENOID REMOVALp. 906
SOLENOID INSTALLATIONp. 907
SOLENOID HARNESS ADAPTER SEAL REPLACEMENTp. 907
VALVE BODY REMOVALp. 908
VALVE BODY INSTALLATIONp. 908
MANUAL VALVE SHAFT SEAL REPLACEMENTp. 909
ACCUMULATOR PISTONS AND SPRINGSp. 910
ACCUMULATOR PISTON AND SPRING RE-MOVALp. 910
SECOND COAST BRAKE SERVOp. 912
SERVO OVERHAULp. 912
PARK ROD AND PAWL SERVICEp. 913
PARK ROD AND PAWL REMOVALp. 913
ADAPTER HOUSING SEAL REPLACEMENTp. 913
SPEED SENSORp. 914
SPEED SENSOR TESTINGp. 914
SPEED SENSOR REPLACEMENTp. 914
SPEED SENSOR ROTOR— SPEEDOMETER DRIVE GEARp. 914
ROTOR— DRIVE GEAR REMOVALp. 914
ROTOR AND DRIVE GEAR INSTALLATIONp. 915
THROTTLE POSITION SENSOR (TPS) SERVICEp. 915
TRANSMISSION THROTTLE CABLE REPLACEMENTp. 915
THROTTLE CABLE REMOVALp. 915
THROTTLE CABLE INSTALLATIONp. 916
TRANSMISSION THROTTLE CABLE ADJUSTMENTp. 917
SHIFT LEVER ASSEMBLY REMOVAL— WITH FULL CONSOLEp. 917
SHIFT LEVER ASSEMBLY INSTALLATION— WITH FULL CONSOLEp. 918
SHIFT LEVER ASSEMBLY REMOVAL— WITH MINI CONSOLEp. 918
SHIFT LEVER ASSEMBLY INSTALLATION— WITH MINI CONSOLEp. 918
SHIFT CABLE ADJUSTMENTp. 918
PARK INTERLOCK CABLE ADJUSTMENTp. 919
TRANSMISSION COOLER SERVICEp. 919
REVERSE FLUSHING MAIN AND AUXILIARY COOLERS AND COOLER LINESp. 920
FLOW TESTING TRANSMISSION MAIN COOLERp. 920
TRANSMISSION COOLER LINE FITTINGSp. 921
AW- 4 TRANSMISSION/ CONVERTER REMOVAL AND INSTALLATIONp. 922
TRANSMISSION AND TORQUE CONVERTER RE-MOVALp. 922
TORQUE CONVERTER STATOR OVERRUNNING CLUTCH INSPECTIONp. 922
OIL PUMP SEAL REPLACEMENTp. 922
TRANSMISSION AND TORQUE CONVERTER INSTALLATIONp. 923
AW- 4 TRANSMISSION OVERHAULp. 925
OVERHAUL SERVICE TOOLSp. 925
TRANSMISSION DISASSEMBLYp. 925
CLEANING AND INSPECTIONp. 937
MANUAL VALVE SHAFT OVERHAULp. 938
OIL PUMP OVERHAULp. 939
OVERDRIVE PLANETARY GEAR AND CLUTCH OVERHAULp. 941
GEAR AND CLUTCH DISASSEMBLYp. 941
OVERDRIVE SUPPORT OVERHAULp. 948
SUPPORT DISASSEMBLYp. 948
ASSEMBLING OVERDRIVE SUPPORTp. 950
DIRECT CLUTCH OVERHAULp. 951
CLUTCH DISASSEMBLYp. 951
DIRECT CLUTCH ASSEMBLYp. 953
FORWARD CLUTCH OVERHAULp. 955
FORWARD CLUTCH DISASSEMBLYp. 955
FORWARD CLUTCH ASSEMBLYp. 957
FRONT PLANETARY GEAR OVERHAULp. 959
FRONT PLANETARY DISASSEMBLYp. 959
FRONT PLANETARY ASSEMBLYp. 959
SUN GEAR AND NO. 1 ONE- WAY CLUTCH OVER-HAULp. 961
SUN GEAR AND CLUTCH DISASSEMBLYp. 961
SUN GEAR AND CLUTCH ASSEMBLYp. 962
SECOND BRAKE OVERHAULp. 963
BRAKE DISASSEMBLYp. 963
SECOND BRAKE ASSEMBLYp. 965
REAR PLANETARY, NO. 2 ONE- WAY CLUTCH AND OUTPUT SHAFT OVERHAULp. 966
PLANETARY/ BRAKE PACK/ OUTPUT SHAFT DISASSEMBLYp. 966
ASSEMBLING REAR PLANETARY, BRAKE PACK, CLUTCH AND SHAFTp. 968
FIRST- REVERSE BRAKE PISTON AND TRANSMIS-SION CASE OVERHAULp. 969
BRAKE DISASSEMBLY AND INSPECTIONp. 969
ASSEMBLING FIRST/ REVERSE BRAKE PIS-TONp. 970
TRANSMISSION VALVE BODY OVERHAULp. 972
REMOVING UPPER BODY FROM LOWER BODYp. 974
LOWER BODY DISASSEMBLYp. 974
LOWER BODY ASSEMBLYp. 977
UPPER BODY DISASSEMBLY AND INSPECTIONp. 978
UPPER BODY ASSEMBLYp. 980
INSTALLING UPPER BODY ON LOWER BODYp. 984
TRANSMISSION ASSEMBLY AND ADJUSTMENTp. 987
46RH AUTOMATIC TRANSMISSION CONTENTSp. 1004
GENERAL INFORMATIONp. 1004
TRANSMISSION DESCRIPTIONp. 1004
TORQUE CONVERTERp. 1004
GEAR RATIOSp. 1004
FOURTH GEAR OVERDRIVE COMPONENTSp. 1005
RECOMMENDED FLUIDp. 1007
TRANSMISSION IDENTIFICATIONp. 1007
FOURTH GEAR OVERDRIVE CONTROLSp. 1007
TRANSMISSION HYDRAULIC CONTROLSp. 1008
PRESSURE REGULATIONp. 1008
46RH TRANSMISSION DIAGNOSISp. 1010
GENERAL INFORMATIONp. 1010
PRELIMINARY DIAGNOSISp. 1010
VEHICLE IS DRIVEABLEp. 1010
VEHICLE IS DISABLEDp. 1010
CHECKING FLUID LEVEL AND CONDITIONp. 1010
EFFECTS OF INCORRECT FLUID LEVELp. 1011
OVERDRIVE ELECTRICAL CONTROLSp. 1011
TRANSMISSION THROTTLE CABLE AND SHIFT LINKAGEp. 1011
ROAD TESTINGp. 1011
ANALYZING THE ROAD TESTp. 1011
HYDRAULIC PRESSURE TESTp. 1012
PRESSURE TEST PORT LOCATIONSp. 1012
HYDRAULIC PRESSURE TEST PROCEDUREp. 1013
CONVERTER STALL TESTp. 1014
STALL TEST PROCEDUREp. 1014
STALL TEST ANALYSISp. 1015
STALL SPEED TOO HIGHp. 1015
STALL SPEED TOO LOWp. 1015
STALL SPEED NORMALp. 1015
CONVERTER NOISE DURING TESTp. 1015
AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATIONp. 1015
FRONT CLUTCH AIR TESTp. 1015
REAR CLUTCH AIR TESTp. 1015
FRONT SERVO AIR TESTp. 1015
REAR SERVO AIR TESTp. 1015
CONVERTER HOUSING FLUID LEAK DIAGNOSISp. 1015
LEAK DIAGNOSIS PROCEDUREp. 1016
TORQUE CONVERTER LEAK POINTSp. 1016
LEAK TESTING WITH AIR PRESSUREp. 1016
AIR PRESSURE LEAK TEST PROCEDUREp. 1017
CONVERTER HOUSING AREA LEAK CORREC-TIONp. 1017
DIAGNOSIS CHARTSp. 1018
TRANSMISSION DIAGNOSISp. 1019
TRANSMISSION DIAGNOSISp. 1020
TRANSMISSION DIAGNOSISp. 1021
TRANSMISSION DIAGNOSISp. 1022
TRANSMISSION DIAGNOSISp. 1023
TRANSMISSION DIAGNOSISp. 1024
TRANSMISSION DIAGNOSISp. 1025
TRANSMISSION DIAGNOSISp. 1026
TRANSMISSION DIAGNOSISp. 1027
OVERDRIVE DIAGNOSISp. 1028
OVERDRIVE DIAGNOSISp. 1029
OVERDRIVE DIAGNOSISp. 1030
OVERDRIVE DIAGNOSISp. 1031
OVERDRIVE DIAGNOSISp. 1032
TORQUE CONVERTER CLUTCH DIAGNOSISp. 1033
HYDRAULIC FLOW IN NEUTRALp. 1034
HYDRAULIC FLOW IN PARKp. 1035
HYDRAULIC FLOW IN REVERSEp. 1036
HYDRAULIC FLOW IN MANUAL LOW (1)p. 1037
HYDRAULIC FLOW IN MANUAL SECOND (2)p. 1038
HYDRAULIC FLOW IN DRIVE FIRST GEARp. 1039
HYDRAULIC FLOW IN DRIVE SECOND GEARp. 1040
HYDRAULIC FLOW IN DRIVE THIRD GEARp. 1041
HYDRAULIC FLOW IN DRIVE FOURTH GEAR (OVERDRIVE)p. 1042
IN- VEHICLE SERVICE— 46RHp. 1043
GOVERNOR AND PARK LOCK SERVICEp. 1043
OIL PUMP SEALp. 1043
RECOMMENDED FLUIDp. 1043
TRANSMISSION FLUID LEVEL CHECKp. 1043
FLUID LEVEL CHECK PROCEDUREp. 1043
FLUID AND FILTER CHANGEp. 1044
NORMAL CHANGE INTERVALp. 1044
SEVERE USAGE CHANGE INTERVALp. 1044
FLUID/ FILTER REPLACEMENT PROCEDUREp. 1044
GEARSHIFT LINKAGE ADJUSTMENTp. 1044
GEARSHIFT LINKAGE ADJUSTMENTp. 1044
TRANSMISSION THROTTLE CABLE ADJUSTMENTp. 1045
FRONT BAND ADJUSTMENTp. 1045
ADJUSTMENT PROCEDUREp. 1045
REAR BAND ADJUSTMENTp. 1046
SPEEDOMETER SERVICEp. 1046
ADAPTER AND PINION REMOVAL/ INSTALLATIONp. 1046
PARK/ NEUTRAL POSITION SWITCHp. 1047
SWITCH TESTp. 1048
PARK/ NEUTRAL POSITION SWITCH REPLACE- MENTp. 1048
VALVE BODY SERVICEp. 1048
GENERAL SERVICE INFORMATIONp. 1048
VALVE BODY REMOVALp. 1048
VALVE BODY INSTALLATIONp. 1048
SERVICING COOLER LINE QUICK DISCONNECT FITTINGSp. 1049
PROCEDURE FOR DISCONNECTING COOLER LINESp. 1050
PROCEDURE FOR RECONNECTING COOLER LINESp. 1050
TRANSMISSION COOLER TESTING AND FLUSHINGp. 1051
COOLER REVERSE FLUSHING PROCEDUREp. 1051
TESTING COOLER FLUID FLOWp. 1051
MAIN COOLER REPLACEMENTp. 1052
AUXILIARY COOLER REPLACEMENTp. 1052
ALUMINUM THREAD REPAIRp. 1052
46RH TRANSMISSION/ OVERDRIVE REMOVAL AND INSTALLATIONp. 1053
GENERAL INFORMATIONp. 1053
TRANSMISSION AND CONVERTER REMOVALp. 1053
OIL PUMP SEAL REPLACEMENTp. 1054
TORQUE CONVERTER AND DRIVE PLATE SERVICEp. 1054
TRANSMISSION AND CONVERTER INSTALLATIONp. 1055
OVERDRIVE UNIT REMOVALp. 1058
OVERDRIVE UNIT INSTALLATIONp. 1059
TRANSMISSION OVERHAUL— 46RHp. 1061
TRANSMISSION DISASSEMBLYp. 1061
OVERHAUL SERVICE INFORMATIONp. 1068
TRANSMISSION CASE CLEANING AND INSPECTIONp. 1069
OVERDRIVE PISTON AND RETAINER SERVICEp. 1069
OVERRUNNING CLUTCH OVERHAULp. 1069
OVERRUNNING CLUTCH CAM REPLACEMENTp. 1069
INSTALLING OVERRUNNING CLUTCH ASSEM-BLYp. 1070
ACCUMULATOR OVERHAULp. 1071
FRONT SERVO AND BAND OVERHAULp. 1072
FRONT SERVO PISTON OVERHAUL (FIG. 49)p. 1072
REAR SERVO AND BAND OVERHAULp. 1072
REAR SERVO PISTON OVERHAUL (FIG. 50)p. 1072
OIL PUMP AND REACTION SHAFT SUPPORT OVERHAULp. 1073
PUMP AND SUPPORT DISASSEMBLYp. 1073
INSPECTING PUMP AND SUPPORTp. 1074
OIL PUMP BUSHING REPLACEMENT (FIG. 57)p. 1074
REPLACING REACTION SHAFT SUPPORT BUSHING (FIG. 59)p. 1075
ASSEMBLING OIL PUMP AND REACTION SHAFT SUPPORTp. 1075
FRONT CLUTCH OVERHAULp. 1076
FRONT CLUTCH DISASSEMBLYp. 1076
FRONT CLUTCH INSPECTIONp. 1077
FRONT CLUTCH RETAINER BUSHING REPLACEMENT (FIG. 63)p. 1077
ASSEMBLING FRONT CLUTCHp. 1077
REAR CLUTCH OVERHAULp. 1078
REAR CLUTCH DISASSEMBLY (FIG. 66)p. 1078
REAR CLUTCH INSPECTIONp. 1078
INPUT SHAFT REPLACEMENTp. 1079
REAR CLUTCH ASSEMBLYp. 1079
PLANETARY GEARTRAIN OVERHAULp. 1080
PLANETARY GEARTRAIN DISASSEMBLYp. 1080
PLANETARY GEARTRAIN ASSEMBLY AND ADJUSTMENTp. 1081
VALVE BODY SERVICE AND ADJUSTMENTp. 1084
VALVE BODY MAIN COMPONENT DISASSEMBLYp. 1084
VALVE BODY UPPER HOUSING DISASSEMBLYp. 1089
VALVE BODY LOWER HOUSING DISASSEMBLY (FIG. 116)p. 1089
3- 4 ACCUMULATOR HOUSING DISASSEMBLY (FIG. 117)p. 1089
VALVE BODY CLEANING AND INSPECTIONp. 1090
VALVE BODY REASSEMBLYp. 1094
VALVE BODY CONTROL PRESSURE ADJUSTMENTSp. 1097
TRANSMISSION ASSEMBLYp. 1097
TRANSMISSION ASSEMBLY PROCEDUREp. 1098
OVERDRIVE UNIT OVERHAUL— 46RHp. 1106
OVERDRIVE UNIT DISASSEMBLYp. 1106
OVERDRIVE GEARTRAIN DISASSEMBLYp. 1108
OVERDRIVE COMPONENT CLEANING AND INSPECTIONp. 1112
OVERDRIVE GEARTRAIN ASSEMBLYp. 1115
OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENTp. 1120
NP231 TRANSFER CASEp. 1124
GENERAL INFORMATIONp. 1124
OPERATING RANGESp. 1124
SHIFT MECHANISMp. 1125
TRANSFER CASE IDENTIFICATIONp. 1125
TRANSFER CASE LUBRICANTp. 1125
SHIFT LINKAGE ADJUSTMENTp. 1125
TRANSFER CASE REMOVALp. 1125
TRANSFER CASE INSTALLATIONp. 1125
NP231 SERVICE DIAGNOSISp. 1126
TRANSFER CASE DISASSEMBLY AND OVERHAULp. 1128
TRANSFER CASE CLEANING AND INSPECTIONp. 1133
TRANSFER CASE ASSEMBLYp. 1134
NP231 TRANSFER CASEp. 1143
LEGEND FOR NP231 TRANSFER CASEp. 1144
NP242 TRANSFER CASEp. 1145
GENERAL INFORMATIONp. 1145
OPERATING RANGESp. 1145
SHIFT MECHANISMp. 1145
TRANSFER CASE IDENTIFICATIONp. 1145
TRANSFER CASE LUBRICANTp. 1145
TRANSFER CASE FILL LEVELp. 1146
SHIFT LINKAGE ADJUSTMENTp. 1146
TRANSFER CASE REMOVALp. 1146
TRANSFER CASE INSTALLATIONp. 1146
NP242 SERVICE DIAGNOSISp. 1147
TRANSFER CASE DISASSEMBLY AND OVERHAULp. 1149
CLEANING AND INSPECTIONp. 1158
TRANSFER CASE ASSEMBLYp. 1158
NP242 TRANSFER CASEp. 1170
LEGEND FOR NP242 TRANSFER CASEp. 1171
NP249 TRANSFER CASEp. 1172
GENERAL INFORMATIONp. 1172
SHIFT MECHANISMp. 1173
TRANSFER CASE IDENTIFICATIONp. 1173
RECOMMENDED LUBRICANTp. 1173
SHIFT LINKAGE ADJUSTMENTp. 1173
NP249 SERVICE DIAGNOSISp. 1173
TRANSFER CASE REMOVALp. 1175
TRANSFER CASE INSTALLATIONp. 1175
TRANSFER CASE DISASSEMBLY AND OVERHAULp. 1176
TRANSFER CASE DISASSEMBLYp. 1176
INPUT AND LOW RANGE GEAR DISASSEMBLYp. 1181
MAINSHAFT AND DIFFERENTIAL DISASSEMBLYp. 1181
DIFFERENTIAL DISASSEMBLYp. 1183
COMPONENT CLEANING AND INSPECTIONp. 1184
TRANSFER CASE BEARING AND SEAL RE- PLACEMENTp. 1186
TRANSFER CASE ASSEMBLY AND ADJUSTMENTp. 1188
PREPARING FRONT CASE FOR ASSEMBLYp. 1188
INPUT— LOW RANGE GEAR ASSEMBLY AND INSTALLATIONp. 1188
RANGE FORK/ CLUTCH SLEEVE ASSEMBLY AND INSTALLATIONp. 1189
DETENT INSTALLATIONp. 1189
MAINSHAFT— DIFFERENTIAL ASSEMBLY AND INSTALLATIONp. 1190
DRIVE CHAIN— OUTPUT SHAFT— SPROCKET INSTALLATIONp. 1191
VISCOUS COUPLING INSTALLATIONp. 1191
REAR CASE INSTALLATIONp. 1192
OIL PUMP— REAR BEARING— REAR RETAINER INSTALLATIONp. 1194
FRONT BEARING RETAINER, YOKE AND RANGE LEVER INSTALLATIONp. 1195
NP249 TRANSFER CASEp. 1196
LEGEND FOR NP249 TRANSFER CASEp. 1197
SPECIFICATIONSp. 1198
TORQUE SPECIFICATIONS— AX- 15p. 1198
SELECTIVE SNAP RING CHART— AX- 15p. 1199
GENERAL SPECIFICATIONS— AW- 4p. 1200
OIL PUMP WEAR LIMITS AW- 4p. 1201
CLUTCH DISC AND PLATE THICKNESS AW- 4p. 1201
BUSHING AND PISTON CLEARANCE— AW- 4p. 1202
RETAINER AND PISTON SPECIFICATIONS— AW- 4p. 1203
VALVE BODY CHECK BALL DIMENSIONS AW- 4p. 1204
CLUTCH/ BRAKE PACK REQUIREMENTS AW- 4p. 1204
ACCUMULATOR COMPONENT IDENTIFICATION— AW- 4p. 1205
VALVE AND SPRING IDENTIFICATION— AW- 4p. 1206
TORQUE SPECIFICATIONS AW- 4p. 1207
GENERAL SPECIFICATIONS 46RHp. 1207
PRESSURE TEST SPECIFICATIONS 46RHp. 1208
SPACER/ THRUST PLATE/ SNAP RING SPECIFICATIONS 46RHp. 1208
TORQUE SPECIFICATIONS 46RHp. 1209
TORQUE SPECIFICATIONS NP231/ NP242p. 1209
TORQUE SPECIFICATIONS NP249p. 1209
21 A AUTOMATIC TRANSMp. 1210
AUTOMATIC TRANSMISSION— 42REp. 1210
GENERAL INFORMATIONp. 1210
TRANSMISSION DESCRIPTIONp. 1210
TORQUE CONVERTERp. 1212
GEAR RATIOSp. 1212
RECOMMENDED FLUIDp. 1212
TRANSMISSION IDENTIFICATIONp. 1212
FRONT BAND ADJUSTMENTp. 1212
ELECTRONIC GOVERNOR COMPONENTSp. 1212
GOVERNOR PRESSURE CURVESp. 1214
TRANSMISSION SHIFTINGp. 1214
CONVERTER CLUTCH ENGAGEMENTp. 1214
OVERDRIVE OFF SWITCHp. 1214
QUICK FILL VALVEp. 1214
SERVICE MANUAL UPDATESp. 1215
NEW THROTTLE VALVE CABLEp. 1215
NEW THROTTLE VALVE CABLE ADJUSTMENT PROCEDUREp. 1215
TRANSMISSION SHIFT MECHANISMp. 1215
42RE TRANSMISSION DIAGNOSISp. 1216
DIAGNOSIS PROCEDURESp. 1216
PRELIMINARY DIAGNOSISp. 1216
VEHICLE IS DRIVEABLEp. 1216
VEHICLE IS DISABLEDp. 1216
CHECKING FLUID LEVEL AND CONDITIONp. 1216
EFFECTS OF INCORRECT FLUID LEVELp. 1217
OVERDRIVE ELECTRICAL CONTROLSp. 1217
DIAGNOSTIC TROUBLE FLASH CODESp. 1217
TRANSMISSION THROTTLE VALVE CABLE AND SHIFT CABLE ADJUSTMENTp. 1217
ROAD TESTINGp. 1218
ANALYZING THE ROAD TESTp. 1218
HYDRAULIC PRESSURE TESTp. 1219
PRESSURE TEST PORT LOCATIONSp. 1219
HYDRAULIC PRESSURE TEST PROCEDUREp. 1219
CONVERTER STALL TESTp. 1220
STALL TEST PROCEDUREp. 1221
STALL TEST ANALYSISp. 1221
STALL SPEED TOO HIGHp. 1221
STALL SPEED TOO LOWp. 1221
STALL SPEED NORMALp. 1221
CONVERTER NOISE DURING TESTp. 1221
AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATIONp. 1221
FRONT CLUTCH AIR TESTp. 1221
REAR CLUTCH AIR TESTp. 1222
FRONT SERVO AIR TESTp. 1222
REAR SERVO AIR TESTp. 1222
CONVERTER HOUSING FLUID LEAK DIAGNOSISp. 1222
LEAK DIAGNOSIS PROCEDUREp. 1222
TORQUE CONVERTER LEAK POINTSp. 1223
LEAK TESTING WITH AIR PRESSUREp. 1223
AIR PRESSURE LEAK TEST PROCEDUREp. 1224
CONVERTER HOUSING AREA LEAK CORREC-TIONp. 1224
DIAGNOSIS AND HYDRAULIC FLOW CHARTSp. 1225
TRANSMISSION CONTROL MODULE (TCM) SERVICEp. 1225
TRANSMISSION DIAGNOSISp. 1226
TRANSMISSION DIAGNOSISp. 1227
TRANSMISSION DIAGNOSISp. 1228
TRANSMISSION DIAGNOSISp. 1229
TRANSMISSION DIAGNOSISp. 1230
TRANSMISSION DIAGNOSISp. 1231
TRANSMISSION DIAGNOSISp. 1232
TRANSMISSION DIAGNOSISp. 1233
TRANSMISSION DIAGNOSISp. 1234
OVERDRIVE DIAGNOSISp. 1235
OVERDRIVE DIAGNOSISp. 1236
OVERDRIVE DIAGNOSISp. 1237
OVERDRIVE DIAGNOSISp. 1238
OVERDRIVE DIAGNOSISp. 1239
TORQUE CONVERTER CLUTCH DIAGNOSISp. 1240
HYDRAULIC FLOW IN PARKp. 1241
HYDRAULIC FLOW IN NEUTRALp. 1242
HYDRAULIC FLOW IN REVERSEp. 1243
HYDRAULIC FLOW IN DRIVE FIRST GEARp. 1244
HYDRAULIC FLOW IN DRIVE SECOND GEARp. 1245
HYDRAULIC FLOW IN DRIVE THIRD GEARp. 1246
HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED)p. 1247
HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH APPLIED)p. 1248
HYDRAULIC FLOW IN MANUAL LOW (1)p. 1249
HYDRAULIC FLOW IN MANUAL SECOND (2)p. 1250
HYDRAULIC FLOW DURING FULL THROTTLE 3- 2 DOWNSHIFTp. 1251
IN- VEHICLE SERVICE— 42REp. 1252
PARK LOCK SERVICEp. 1252
OIL PUMP SEALp. 1252
RECOMMENDED FLUIDp. 1252
TRANSMISSION FLUID LEVEL CHECKp. 1252
FLUID LEVEL CHECK PROCEDUREp. 1252
FLUID AND FILTER CHANGEp. 1252
NORMAL CHANGE INTERVALp. 1252
SEVERE USAGE CHANGE INTERVALp. 1253
FLUID/ FILTER REPLACEMENT PROCEDUREp. 1253
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENTp. 1253
CHECKING THROTTLE VALVE CABLE ADJUSTMENTp. 1253
THROTTLE VALVE CABLE ADJUSTMENT PROCEDUREp. 1253
GEARSHIFT CABLE ADJUSTMENTp. 1254
PARK INTERLOCK CABLE ADJUSTMENTp. 1254
FRONT BAND ADJUSTMENTp. 1255
ADJUSTMENT PROCEDUREp. 1255
REAR BAND ADJUSTMENTp. 1255
SPEEDOMETER SERVICEp. 1256
SPEEDOMETER ASSEMBLY REMOVALp. 1256
SPEEDOMETER INSTALLATION AND INDEXINGp. 1256
PARK/ NEUTRAL POSITION SWITCHp. 1257
SWITCH TESTp. 1257
PARK/ NEUTRAL POSITION SWITCH REPLACEMENTp. 1257
VALVE BODY SERVICEp. 1257
GENERAL SERVICE INFORMATIONp. 1257
VALVE BODY REMOVALp. 1258
VALVE BODY INSTALLATIONp. 1258
SERVICING TRANSMISSION COOLER LINE FITTINGSp. 1259
QUICK DISCONNECT FITTING SERVICEp. 1259
DISCONNECTING COOLER LINE (TYPE I FITTING)p. 1259
RECONNECTING COOLER LINES (TYPE I FITTING)p. 1260
DISCONNECTING COOLER LINES (TYPE II FITTING)p. 1261
RECONNECTING COOLER LINES (TYPE II FITTING)p. 1261
TRANSMISSION COOLER TESTING AND FLUSHINGp. 1262
COOLER REVERSE FLUSHING PROCEDUREp. 1262
TESTING COOLER FLUID FLOWp. 1262
MAIN COOLER REPLACEMENTp. 1263
AUXILIARY COOLER REPLACEMENTp. 1263
ALUMINUM THREAD REPAIRp. 1263
TRANSMISSION/ OVERDRIVE REMOVAL AND INSTALLATION— 42REp. 1264
GENERAL INFORMATIONp. 1264
TRANSMISSION REMOVAL (2- WHEEL DRIVE)p. 1264
TRANSMISSION REMOVAL (4- WHEEL DRIVE)p. 1264
OIL PUMP SEAL REPLACEMENTp. 1265
TORQUE CONVERTER AND DRIVE PLATE SERVICEp. 1266
TRANSMISSION INSTALLATION (2- WHEEL DRIVE)p. 1266
TRANSMISSION INSTALLATION— 4- WHEEL DRIVEp. 1268
OVERDRIVE UNIT REMOVAL (4- WHEEL DRIVE)p. 1269
OVERDRIVE UNIT INSTALLATION (4- WHEEL DRIVE)p. 1270
OVERDRIVE UNIT REMOVAL (2- WHEEL DRIVE)p. 1271
OVERDRIVE UNIT INSTALLATION (2- WHEEL DRIVE)p. 1272
TRANSMISSION OVERHAUL— 42REp. 1273
TRANSMISSION DISASSEMBLYp. 1273
OVERHAUL SERVICE INFORMATIONp. 1279
TRANSMISSION CASE CLEANING AND INSPEC-TIONp. 1280
OVERRUNNING CLUTCH, LOW- REVERSE DRUM AND OVERDRIVE PISTON RETAINER INSPECTION AND OVERHAULp. 1280
CLEANING AND INSPECTIONp. 1280
OVERRUNNING CLUTCH ASSEMBLYp. 1280
OIL PUMP AND REACTION SHAFT SUPPORT OVERHAULp. 1281
PUMP AND SUPPORT DISASSEMBLYp. 1281
OIL PUMP AND REACTION SHAFT SUPPORT CLEANING AND INSPECTIONp. 1282
REPLACING OIL PUMP BUSHINGp. 1282
REPLACING REACTION SHAFT SUPPORT BUSHINGp. 1283
ASSEMBLING OIL PUMP AND REACTION SHAFT SUPPORTp. 1283
FRONT CLUTCH OVERHAULp. 1285
FRONT CLUTCH DISASSEMBLYp. 1285
FRONT CLUTCH INSPECTIONp. 1285
FRONT CLUTCH ASSEMBLYp. 1286
REAR CLUTCH OVERHAULp. 1287
REAR CLUTCH DISASSEMBLYp. 1287
REAR CLUTCH INSPECTIONp. 1287
REAR CLUTCH ASSEMBLYp. 1287
PLANETARY GEAR TRAIN AND INTERMEDIATE SHAFT OVERHAULp. 1290
GEARTRAIN DISASSEMBLY (FIG. 69)p. 1290
PLANETARY GEARTRAIN INSPECTIONp. 1291
PLANETARY GEARTRAIN ASSEMBLYp. 1291
FRONT SERVO AND BAND OVERHAULp. 1294
FRONT SERVO DISASSEMBLY (FIG. 86)p. 1294
FRONT BAND AND SERVO INSPECTIONp. 1294
ASSEMBLING FRONT SERVO PISTONp. 1294
REAR SERVO AND BAND OVERHAULp. 1295
REAR SERVO PISTON DISASSEMBLYp. 1295
REAR SERVO INSPECTIONp. 1295
ASSEMBLING REAR SERVO PISTONp. 1295
VALVE BODY SERVICE AND ADJUSTMENTp. 1296
VALVE BODY MAIN COMPONENT DISASSEM-BLYp. 1296
VALVE BODY UPPER HOUSING DISASSEMBLYp. 1302
VALVE BODY LOWER HOUSING DISASSEM-BLY (FIG. 124)p. 1304
3- 4 ACCUMULATOR HOUSING DISASSEMBLY (FIG. 125)p. 1304
VALVE BODY CLEANING AND INSPECTIONp. 1305
VALVE BODY REASSEMBLYp. 1308
GOVERNOR BODY, SENSOR AND SOLENOID INSTALLATIONp. 1310
VALVE BODY CONTROL PRESSURE ADJUST- MENTSp. 1311
TRANSMISSION ASSEMBLY AND ADJUSTMENTp. 1311
TRANSMISSION ASSEMBLY PROCEDUREp. 1312
OVERDRIVE UNIT OVERHAUL- 42REp. 1321
OVERDRIVE UNIT DISASSEMBLYp. 1321
OVERDRIVE REMOVALp. 1321
OVERDRIVE PISTON REMOVALp. 1321
OVERDRIVE CLUTCH PACK REMOVALp. 1321
OVERDRIVE GEARTRAIN REMOVALp. 1323
DIRECT CLUTCH, HUB AND SPRING RE- MOVALp. 1324
GEARTRAIN DISASSEMBLYp. 1325
GEAR CASE AND PARK LOCK DISASSEMBLYp. 1326
OVERDRIVE COMPONENT CLEANING AND INSPEC-TIONp. 1327
OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENTp. 1329
GEARTRAIN AND DIRECT CLUTCH ASSEM-BLYp. 1329
GEAR CASE ASSEMBLY AND INSTALLATIONp. 1334
OVERDRIVE CLUTCH INSTALLATIONp. 1335
SHAFT END PLAY ADJUSTMENTp. 1336
SPECIFICATIONSp. 1338
42RE GENERAL SPECIFICATIONSp. 1338
42RE THRUST WASHER/ SPACER/ SNAP RING DIMENSIONSp. 1338
42RE PRESSURE SPECIFICATIONSp. 1338
42RE TORQUE SPECIFICATIONSp. 1339
22 WHEELS AND TIRESp. 1340
WHEELS AND TIRESp. 1340
TIRESp. 1340
GENERAL INFORMATIONp. 1340
IDENTIFICATIONp. 1340
RADIAL- PLY TIRESp. 1340
SPARE TIRE (TEMPORARY)p. 1340
TIRE CHAINSp. 1341
CLEANING OF TIRESp. 1341
PRESSURE GAUGESp. 1341
TIRE INFLATION PRESSURESp. 1341
REPLACEMENT TIRESp. 1341
ROTATIONp. 1342
TREAD WEAR INDICATORSp. 1342
REPAIRING LEAKSp. 1342
TIRE NOISE OR VIBRATIONp. 1343
TIRE WEAR PATTERNSp. 1343
LEAD CORRECTION CHARTp. 1344
WHEELSp. 1345
GENERAL INFORMATIONp. 1345
WHEEL INSTALLATIONp. 1345
WHEEL REPLACEMENTp. 1345
WHEEL ORNAMENTATIONp. 1345
TIRE AND WHEEL BALANCEp. 1345
MATCH MOUNTINGp. 1346
TIRE AND WHEEL RUNOUTp. 1347
METHOD 1 (RELOCATE WHEEL ON HUB)p. 1348
METHOD 2 (RELOCATE TIRE ON WHEEL)p. 1348
VEHICLE VIBRATIONp. 1349
VIBRATION TYPESp. 1349
ENGINE TORQUE SENSITIVE VIBRATIONp. 1349
VEHICLE SPEED SENSITIVE VIBRATIONp. 1349
ENGINE SPEED (RPM) SENSITIVE VIBRATIONp. 1349
VIBRATION DIAGNOSISp. 1349
VIBRATION DIAGNOSISp. 1350
SPECIFICATIONSp. 1351
WHEEL LUG NUTp. 1351
WHEEL DESCRIPTIONp. 1351
23 BODY COMPONENTSp. 1352
BODY COMPONENTSp. 1352
EXTERIOR COMPONENTSp. 1352
GRILLE AND GRILLE OPENING REINFORCEMENT (GOR)p. 1352
REMOVALp. 1352
INSTALLATIONp. 1354
RADIATOR SUPPORT CROSSMEMBERp. 1354
HOODp. 1354
REMOVALp. 1354
INSTALLATIONp. 1354
HOOD ADJUSTMENTp. 1355
HOOD HINGESp. 1355
REMOVALp. 1355
INSTALLATIONp. 1356
HOOD LATCHp. 1356
REMOVALp. 1356
INSTALLATIONp. 1356
HOOD LATCH STRIKERp. 1356
REMOVALp. 1356
INSTALLATIONp. 1356
LATCH RELEASE CABLEp. 1356
REMOVALp. 1356
INSTALLATIONp. 1356
SAFETY LATCH STRIKERp. 1356
REMOVALp. 1356
INSTALLATIONp. 1356
COWL GRILLE AND SCREENp. 1356
REMOVALp. 1356
INSTALLATIONp. 1357
BATTERY TRAYp. 1357
REMOVALp. 1357
INSTALLATIONp. 1357
FRONT FENDERp. 1358
REMOVALp. 1358
INSTALLATIONp. 1358
BODY SIDE CLADDINGp. 1358
REMOVAL/ FRONT DOORp. 1358
INSTALLATION/ FRONT DOORp. 1359
REMOVAL/ REAR DOORp. 1359
INSTALLATION/ REAR DOORp. 1359
REMOVAL/ FENDER- QUARTER PANELp. 1359
INSTALLATION/ FENDER- QUARTER PANELp. 1359
WOODGRAIN (VINYL CLAD METAL) MOLDINGp. 1359
REMOVAL/ INSTALLATIONp. 1359
WOODGRAIN OVERLAYp. 1359
REMOVALp. 1359
INSTALLATIONp. 1360
BODY STRIPES/ DECALSp. 1360
GENERAL INFORMATIONp. 1360
REMOVALp. 1360
INSTALLATIONp. 1361
QUARTER WINDOW APPLIQUE/ AIR EXHAUSTERp. 1361
REMOVALp. 1361
INSTALLATIONp. 1361
EXTERIOR NAMEPLATESp. 1361
SERVICE INFORMATIONp. 1361
REMOVAL/ INSTALLATIONp. 1362
EXTERNAL MIRRORSp. 1362
REMOVALp. 1362
INSTALLATIONp. 1362
LUGGAGE RACKp. 1362
REMOVALp. 1362
INSTALLATIONp. 1362
POWER SUNROOFp. 1363
GENERAL INFORMATIONp. 1363
LUBRICATIONp. 1363
DRAIN TUBESp. 1363
GLASS VERTICAL HEIGHT ADJUSTMENTp. 1363
GLASS VERTICAL ADJUSTMENTp. 1363
WIND DEFLECTORp. 1363
REMOVALp. 1363
INSTALLATIONp. 1363
WIND DEFLECTOR ADJUSTMENTp. 1364
GLASS PANELp. 1364
REMOVALp. 1364
INSTALLATIONp. 1364
ADJUSTMENT BRACKETp. 1364
REMOVAL AND INSTALLATIONp. 1364
DRAIN CHANNELp. 1364
REMOVAL AND INSTALLATIONp. 1364
DRIVE CABLE LOCATORSp. 1364
REMOVAL AND INSTALLATIONp. 1364
MOTOR AND DRIVE GEARSp. 1364
REMOVALp. 1364
INSTALLATIONp. 1365
DRIVE CABLESp. 1365
REMOVALp. 1365
INSTALLATIONp. 1365
SUNSHADEp. 1365
REMOVAL AND INSTALLATIONp. 1365
GUIDE ASSEMBLYp. 1365
REMOVALp. 1365
INSTALLATIONp. 1365
DOORSp. 1366
FRONT DOOR TRIM PANELp. 1366
REMOVALp. 1366
INSTALLATIONp. 1367
DOOR REMOVAL/ INSTALLATIONp. 1367
DOOR ALIGNMENT ADJUSTMENT— MINORp. 1368
DOOR ALIGNMENT— MINORp. 1368
FRONT DOOR WINDOW REGULATORp. 1369
REMOVALp. 1369
FRONT DOOR WINDOWp. 1369
REMOVALp. 1369
REAR DOOR WINDOW REGULATORp. 1369
REMOVALp. 1369
REAR DOOR WINDOWp. 1370
REMOVALp. 1370
INSTALLATIONp. 1370
DOOR KEY LOCK CYLINDERp. 1370
REMOVALp. 1370
DOOR LATCH ADJUSTMENTp. 1370
OUTSIDE DOOR HANDLEp. 1371
REMOVALp. 1371
DOOR LATCHp. 1371
REMOVALp. 1371
DOOR INSIDE LATCH RELEASE AND LOCK RODSp. 1372
REMOVALp. 1372
DOOR WINDOW EXTERIOR MOLDINGSp. 1372
REMOVALp. 1372
INSTALLATIONp. 1372
DOOR WINDOW GLASS AND DOOR OPENING SEALSp. 1372
WINDOW GLASS SEAL INSTALLATIONp. 1373
DOOR OPENING WEATHERSTRIP SEAL IN-STALLATIONp. 1373
LIFTGATEp. 1373
TRIM PANELp. 1373
LIFTGATEp. 1373
HINGEp. 1373
LIFTGATE LATCH/ LOCK COMPONENTSp. 1374
LIFTGATE ADJUSTMENTp. 1375
LIFTGATE OPENING WEATHERSTRIP SEALp. 1375
LICENSE PLATE LAMP HOUSINGp. 1375
FIXED WINDOW GLASSp. 1376
SAFETY PRECAUTIONS AND WARNINGSp. 1376
WINDSHIELD REPLACEMENTp. 1376
WINDSHIELD REMOVALp. 1376
WINDSHIELD INSTALLATIONp. 1377
FIXED GLASS WATER LEAK DETECTION AND RE-PAIRp. 1377
SERVICE INFORMATIONp. 1377
LEAK TESTp. 1378
SEALING LEAK AREASp. 1378
UNDERBODY COMPONENTSp. 1379
SERVICE INFORMATIONp. 1379
TRANSFER CASE SKID PLATEp. 1379
REMOVALp. 1379
INSTALLATIONp. 1379
TRAILER HITCHp. 1379
REMOVALp. 1379
INSTALLATIONp. 1379
INTERIOR COMPONENTSp. 1380
INSTRUMENT PANELp. 1380
REMOVALp. 1380
FRONT BUCKET SEATSp. 1381
REMOVALp. 1381
INSTALLATIONp. 1381
BUCKET SEAT CUSHION AND COVERp. 1381
REMOVALp. 1381
INSTALLATIONp. 1382
BUCKET SEATBACK COVER AND FRAMEp. 1382
REMOVALp. 1382
INSTALLATIONp. 1382
BUCKET SEAT PLATFORMp. 1382
REPLACEMENTp. 1382
REAR SEAT CUSHIONp. 1382
REMOVALp. 1382
INSTALLATIONp. 1382
REAR SEAT CUSHION COVERp. 1382
REMOVALp. 1382
INSTALLATIONp. 1382
REAR SEATBACKp. 1382
REMOVALp. 1382
INSTALLATIONp. 1383
REAR SEATBACK COVERp. 1383
REMOVALp. 1383
INSTALLATIONp. 1383
INTERIOR TRIM PANELS AND SCUFF PLATESp. 1383
SERVICE INFORMATIONp. 1383
LOWER B- PILLAR TRIM PANELp. 1383
REMOVALp. 1383
WINDSHIELD SIDE MOLDINGp. 1383
REMOVALp. 1383
QUARTER TRIM PANELSp. 1383
REMOVALp. 1383
B AND C- PILLAR TRIM COVERSp. 1386
REMOVALp. 1386
INSTALLATIONp. 1386
D- PILLAR TRIM COVERp. 1386
REMOVALp. 1386
INSTALLATIONp. 1386
OUTER SCUFF PLATESp. 1386
REMOVALp. 1386
ASSIST HANDLEp. 1387
REMOVALp. 1387
INSTALLATIONp. 1387
FRONT SHOULDER BELT/ BUCKLEp. 1387
REMOVALp. 1387
REAR SHOULDER/ LAP BELT/ BUCKLEp. 1387
REMOVALp. 1387
HEADLINERp. 1387
REMOVALp. 1387
INSTALLATIONp. 1389
SUNVISORSp. 1390
REMOVALp. 1390
MINI- FLOOR CONSOLEp. 1390
PARKING BRAKE HANDLE COVERp. 1390
SHIFTER COVERp. 1390
FULL FLOOR CONSOLEp. 1390
REMOVALp. 1390
CARPETS AND FLOOR MATSp. 1392
FRONT CARPET/ MATp. 1392
CARGO CARPET/ MATp. 1392
FUEL DOOR CABLEp. 1392
REMOVALp. 1392
REFINISHING PROCEDURESp. 1394
SERVICE INFORMATIONp. 1394
BASE COAT/ CLEAR COAT FINISHp. 1394
WET SANDING, BUFFING AND POLISHINGp. 1394
PAINTED SURFACE TOUCH- UPp. 1394
TOUCH- UP PROCEDUREp. 1394
PAINT CODE CHARTp. 1394
GENERAL INFORMATIONp. 1394
EXTERIOR COLORSp. 1394
INTERIOR COLORSp. 1394
24 HEATING AND A/Cp. 1396
HEATING AND AIR CONDITIONINGp. 1396
GENERAL INFORMATIONp. 1396
HEATER SYSTEMp. 1396
SIDE WINDOW DEMISTERSp. 1397
AIR CONDITIONING SYSTEMp. 1397
SYSTEM AIRFLOWp. 1397
REFRIGERANTp. 1397
REFRIGERANT SAFETY PRECAUTIONS AND WARNINGS FOR R134ap. 1398
COOLING SYSTEMp. 1398
REQUIREMENTSp. 1398
PRECAUTIONSp. 1398
HANDLING TUBING AND FITTINGSp. 1398
COMPONENT DESCRIPTIONp. 1399
COMPRESSORp. 1399
EVAPORATOR COREp. 1399
CONDENSERp. 1399
SPRING LOCK COUPLINGp. 1399
ACCUMULATORp. 1401
CLUTCH CYCLING PRESSURE SWITCHp. 1401
FIXED ORIFICE TUBEp. 1402
HIGH PRESSURE RELIEF VALVEp. 1402
HIGH PRESSURE CUT- OUT SWITCHp. 1402
SERVICE GAUGE PORT VALVESp. 1402
SYSTEM DIAGNOSTICSp. 1403
A/ C PERFORMANCE TESTp. 1403
REFRIGERANT SYSTEMp. 1403
VACUUM CONTROLp. 1403
VACUUM TESTING THE ONE- WAY CHECK VALVEp. 1404
VACUUM TESTING THE HEATER- A/ C CONTROLSp. 1404
LOCATING VACUUM LEAKSp. 1404
CONDENSATE WATER DRAINAGEp. 1404
BLOWER MOTOR VIBRATION AND/ OR NOISE DIAGNOSISp. 1404
A/ C PERFORMANCE (TEMPERATURE AND PRESSURE)p. 1404
REFRIGERANT SYSTEM DIAGNOSISp. 1405
BLOWER MOTOR ELECTRICAL DIAGNOSISp. 1406
COMPRESSOR NOISEp. 1406
COMPRESSOR CLUTCH INOPERATIVEp. 1406
CLUTCH COIL TESTSp. 1406
VACUUM CIRCUITSp. 1406
BLOWER MOTOR NOISE/ VIBRATION DIAGNOSISp. 1407
BLOWER MOTOR ELECTRICAL SYSTEM DIAGNOSISp. 1408
COMPRESSOR NOISE AND COMPRESSOR CLUTCH DIAGNOSISp. 1409
HIGH PRESSURE RELIEF VALVEp. 1410
HEATER OUTPUT TESTp. 1410
PRE- DIAGNOSTIC PREPARATIONSp. 1410
MAXIMUM HEATER OUTPUTp. 1410
TEMPERATURE CONTROLp. 1411
AUTOMATIC TEMPERATURE CONTROL DIAGNOSTICSp. 1411
DIAGNOSTICS TEST SELECTORp. 1411
ENTER DIAGNOSTICSp. 1411
TEMPERATURE REFERENCE CHARTp. 1411
FAULT CODE DIAGNOSTICSp. 1412
CLEARING FAULT CODESp. 1412
CURRENT FAULTSp. 1413
HISTORICAL FAULTSp. 1414
INPUT CIRCUIT TESTINGp. 1415
OUTPUT CIRCUIT TESTING / ACTUATOR TESTSp. 1415
CIRCUIT TESTINGp. 1416
CIRCUIT TESTING (CONT.)p. 1417
ELECTRICAL CIRCUITSp. 1418
HEATER SYSTEMp. 1418
MANUAL AIR CONDITIONING SYSTEMp. 1419
AUTOMATIC TEMPERATURE CONTROL SYSTEMp. 1420
BLEND AIR DOOR ACTUATOR DRIVE CIRCUITp. 1421
MODE DOOR ACTUATOR DRIVE CIRCUITp. 1421
AIR INLET/ RECIRC DOOR ACTUATOR DRIVE CIRCUITp. 1421
FRONT PANEL MODE CONTROLp. 1421
FRONT PANEL BLOWER/ FAN CONTROLp. 1422
AMBIENT TEMPERATURE SENSORp. 1422
SOLAR SENSORp. 1422
IN- VEHICLE TEMPERATURE SENSORp. 1422
CHRYSLER COLLISION DETECTION BUSp. 1423
CALIBRATION AND CPU DATAp. 1423
REFRIGERANT SERVICE PROCEDURESp. 1424
REFRIGERANT EQUIPMENTp. 1424
MANIFOLD GAUGE SET CONNECTIONSp. 1424
LOW PRESSURE GAUGE HOSEp. 1424
HIGH PRESSURE GAUGE HOSEp. 1424
EVACUATION / RECOVERY / RECYCLING / CHARGING LINE CONNECTIONp. 1425
REFRIGERANT LEAK TESTINGp. 1425
SYSTEM EMPTYp. 1425
LOW LEVELp. 1425
REFRIGERANT CHARGE CHECKp. 1425
PREFERRED METHOD:p. 1425
ALTERNATIVE METHOD:p. 1426
HIGH COMPRESSOR DISCHARGE PRESSUREp. 1427
REPLACE VISCOUS FAN DRIVEp. 1427
SYSTEM OVERCHARGEDp. 1427
RESTRICTION IN SYSTEMp. 1427
REPLACE COMPRESSORp. 1427
DISCHARGING REFRIGERANT SYSTEMp. 1427
EVACUATING REFRIGERANT SYSTEMp. 1428
LOW CHARGE DETERMINATION COMPRESSOR DISCHARGE PRESSUREp. 1428
CHARGING REFRIGERANT SYSTEM— SYSTEM EMPTYp. 1429
REFRIGERANT OIL LEVELp. 1429
COMPRESSOR DISCHARGE PRESSURE DIAGNOSISp. 1429
OIL LEVEL CHECKp. 1430
VERIFY REFRIGERANT OIL LEVELp. 1430
A/ C REFRIGERANT OIL CAPACITIESp. 1430
COMPRESSOR SERVICE PROCEDURESp. 1431
COMPRESSORp. 1431
REMOVALp. 1431
INSTALLATIONp. 1431
COMPRESSOR MANIFOLDp. 1431
REMOVALp. 1431
INSPECTIONp. 1431
INSTALLATIONp. 1431
COMPRESSOR CLUTCH / COIL ASSEMBLYp. 1431
REMOVALp. 1431
INSPECTIONp. 1432
INSTALLATIONp. 1432
CLUTCH BREAK- INp. 1433
COMPRESSOR HIGH- PRESSURE RELIEF VALVEp. 1433
REMOVALp. 1433
INSTALLATIONp. 1433
CLIMATE CONTROL SYSTEMp. 1434
CONTROL PANELp. 1434
REMOVALp. 1434
INSTALLATIONp. 1434
BLOWER MOTOR AND WHEELp. 1435
REMOVALp. 1435
INSPECTIONp. 1435
INSTALLATIONp. 1435
BLOWER MOTOR RESISTORp. 1435
REMOVALp. 1435
INSTALLATIONp. 1436
HEATER— A/ C UNITp. 1436
REMOVALp. 1436
INSTALLATIONp. 1437
HEATER COREp. 1437
REMOVALp. 1437
INSTALLATIONp. 1437
EVAPORATOR COREp. 1438
REMOVALp. 1438
INSTALLATIONp. 1438
RECIRCULATING AIR DOOR ACTUATORp. 1438
REMOVALp. 1438
INSTALLATIONp. 1438
RECIRCULATING AIR DOORp. 1438
REMOVALp. 1438
INSTALLATIONp. 1439
TEMPERATURE / BLEND AIR DOOR MOTORp. 1439
REMOVALp. 1439
INSTALLATIONp. 1439
TEMPERATURE / BLEND AIR DOORp. 1439
REMOVALp. 1439
INSTALLATIONp. 1439
HEAT / DEFROST DOOR ACTUATORp. 1440
HEAT / DEFROST – PANEL / DEFROST DOOR MOTORp. 1440
HEAT / DEFROST DOORp. 1440
INSTALLATIONp. 1441
PANEL / DEFROST DOOR ACTUATORp. 1441
REMOVALp. 1441
INSTALLATIONp. 1441
PANEL / DEFROST DOORp. 1441
REMOVALp. 1441
INSTALLATIONp. 1442
SOLAR SENSORp. 1442
REMOVALp. 1442
INSTALLATIONp. 1442
IN- VEHICLE TEMPERATURE SENSORp. 1442
REMOVALp. 1442
INSTALLATIONp. 1443
AMBIENT AIR TEMPERATURE SENSORp. 1443
REMOVALp. 1443
INSTALLATIONp. 1443
DEFROSTER DUCTp. 1443
REMOVALp. 1443
INSTALLATIONp. 1443
REAR FLOOR HEAT DUCTp. 1443
REMOVALp. 1443
INSTALLATIONp. 1444
CONDENSERp. 1444
REMOVALp. 1444
INSTALLATIONp. 1445
ACCUMULATORp. 1445
REMOVALp. 1445
INSTALLATIONp. 1445
LIQUID LINEp. 1445
REMOVALp. 1445
INSTALLATIONp. 1445
DISCHARGE LINEp. 1445
REMOVALp. 1445
INSTALLATIONp. 1445
HIGH PRESSURE CUT- OUT SWITCHp. 1446
REMOVALp. 1446
INSTALLATIONp. 1446
VACUUM RESERVOIRp. 1446
REMOVALp. 1446
INSTALLATIONp. 1446
TORQUE SPECIFICATIONSp. 1446
25 EMISSIONS AND CONTROL SYSTEMp. 1448
EMISSION CONTROL SYSTEMSp. 1448
GENERAL INFORMATIONp. 1448
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABELp. 1448
FEDERAL VECI LABEL— TYPICALp. 1448
VACUUM HOSE ROUTING SCHEMATICSp. 1449
CALIFORNIA VECI LABEL— TYPICAL CANADIAN VECI LABEL— TYPICALp. 1449
VACUUM ROUTING SCHEMATIC— 4.0L ENGINE VACUUM ROUTING SCHEMATIC— 5.2L ENGINE— TYPICALp. 1450
EVAPORATIVE EMISSION CONTROLSp. 1451
EVAP (EVAPORATION) CONTROL SYSTEMp. 1451
GENERAL INFORMATIONp. 1451
EVAP CANISTERp. 1451
CANISTER OPERATION— 4.0L ENGINEp. 1451
CANISTER OPERATION— 5.2L ENGINEp. 1452
EVAP CANISTER PURGE SOLENOID— 5.2L ENGINEp. 1452
FUEL TANK FILLER TUBE CAPp. 1452
CRANKCASE VENTILATION SYSTEM— 4.0L ENGINEp. 1452
POSITIVE CRANKCASE VENTILATION SYSTEMp. 1452
DESCRIPTION/ OPERATIONp. 1452
POSITIVE CRANKCASE VENTILATION (PCV) VALVEp. 1453
INSPECTION AND SERVICE PROCEDUREp. 1454
CRANKCASE BREATHER/ FILTER— 5.2L ENGINESp. 1455
PRESSURE RELIEF/ ROLLOVER VALVEp. 1455
EXHAUST EMISSION CONTROLSp. 1456
AIR CLEANERp. 1456
EXHAUST GAS RECIRCULATION SYSTEM— 5.2L ENGINEp. 1456
GENERAL INFORMATIONp. 1456
EGR OPERATION— 5.2L ENGINEp. 1456
EGR SYSTEM ON- BOARD DIAGNOSTICS (CALIFORNIA VEHICLES ONLY)p. 1457
EGR SYSTEM SERVICE— 5.2L ENGINEp. 1458
EGR GAS FLOW TEST— 5.2L ENGINEp. 1458
ELECTRIC EGR TRANSDUCER (EET)— 5.2L EN- GINEp. 1458
OXYGEN (O2 ) SENSORp. 1458
EGR DIAGNOSIS CHART— 5.2L ENGINEp. 1459
COMPONENT REMOVAL/ INSTALLATIONp. 1460
AIR CLEANER HOUSINGp. 1460
REMOVALp. 1460
INSTALLATIONp. 1460
AIR FILTERp. 1461
COOLANT TEMPERATURE SENSORp. 1461
EGR VALVE— 5.2L ENGINEp. 1461
REMOVALp. 1461
INSTALLATIONp. 1461
EGR TUBE— 5.2L ENGINEp. 1462
REMOVALp. 1462
INSTALLATIONp. 1462
ELECTRIC EGR TRANSDUCER (EET)— 5.2L ENGINEp. 1463
REMOVALp. 1463
INSTALLATIONp. 1463
EVAP CANISTERp. 1463
REMOVALp. 1463
INSTALLATIONp. 1463
EVAP CANISTER PURGE SOLENOIDp. 1463
REMOVAL— 5.2L ENGINEp. 1463
INSTALLATIONp. 1464
FUEL TANK FILLER TUBE CAPp. 1464
OXYGEN (O2 ) SENSORp. 1464
POWERTRAIN CONTROL MODULE (PCM)p. 1464
PRESSURE RELIEF/ ROLLOVER VALVEp. 1464
93zj_fr.pdfp. 2
INDEXp. 1465
INDEX SUPPLEMENTp. 1467

Chapters Covered

  • Introduction — designations, labels/plates/decals, VIN and body-code decoding, dimensions/weights, trailer towing specifications, measurement and torque specifications
  • Group 0 Lubrication and Maintenance — general information, engine maintenance, drivetrain, chassis and body; scheduled maintenance for ZJ vehicles except California and California schedules; fluid capacities; jump starting; vehicle lifting and towing
  • Group 2 Front Suspension and Axle — front wheel alignment, front suspension, axle noise/vibration diagnosis, Model 30 axle and tube axle (2WD), torque specifications
  • Group 3 Rear Suspension and Axles — rear suspension, axle noise/vibration diagnosis, Model 35 axle, Trac-Lok differential, torque specifications
  • Group 5 Brakes — antilock brake system diagnosis and operation, service brake diagnosis, adjustments/fluid/bleeding, master cylinder-HCU-combination valve-brakelines, power booster, antilock electronic components, disc and drum service, parking brake, pedal and switch service, specifications
  • Group 6 Clutch — clutch diagnosis and clutch service for the hydraulic linkage used with manual transmission
  • Group 7 Cooling System — diagnosis, service procedures, engine accessory drive belts, engine block heater, specifications
  • Group 8 Electrical — battery/starting/charging diagnostics (8A); battery/starter/generator service (8B); overhead console (8C); ignition systems (8D); instrument panel and gauges (8E); audio systems (8F); horns (8G); vehicle speed control (8H); turn signals and hazard flasher (8J); windshield wiper and washer (8K); lamps (8L); restraint systems (8M); rear window defogger (8N); power door locks (8P); vehicle theft security system (8Q); power seats (8R); power windows (8S); power mirrors (8T); chime warning/reminder (8U); wiring diagrams (8W)
  • Group 9 Engines — standard service procedures, engine diagnosis, 4.0L engine service procedures, 5.2L engine service procedures
  • Group 11 Exhaust System and Intake Manifold — exhaust and intake service for both engines
  • Group 13 Frame and Bumpers — bumper and frame-related service
  • Group 14 Fuel System — fuel delivery, fuel tanks, accelerator pedal and throttle cable, MPI system description/operation, diagnosis, and component R&I for 4.0L and 5.2L, specifications
  • Group 16 Propeller Shafts — shaft identification, vibration diagnosis, single and double Cardan joint service
  • Group 19 Steering — power steering diagnosis, pump, linkage, recirculating-ball gear, steering column, automatic transmission shifter/ignition interlock, torque specifications
  • Group 21 Transmissions and Transfer Cases — AX 15 manual transmission; AW-4 automatic transmission; 46RH automatic transmission; NP231, NP242, and NP249 transfer cases; specifications
  • Group 21-S Transmissions and Transfer Cases supplement — 42RE automatic transmission diagnosis, in-vehicle service, removal/installation, transmission and overdrive overhaul, specifications
  • Group 22 Wheels and Tires — tires, wheels, vehicle vibration, specifications
  • Group 23 Body Components — exterior components, power sunroof, doors, fixed glass, underbody, interior, paint code chart, refinishing
  • Group 24 Heating and Air Conditioning — system diagnostics, refrigerant service, compressor service, climate control, torque specifications
  • Group 25 Emission Control Systems — evaporative and exhaust emission controls, component removal/installation, VECI label information
  • Component and System Index, Index Supplement, Service Manual Comment Forms

Taken together, the groups give a working technician the identification data, inspection intervals, diagnostic trees, on-board diagnostic guidance, wiring sheets, exploded hardware views, and rebuild sequences needed to service a 1993 ZJ from scheduled oil and filter work through engine short-block procedures, axle rebuild, transmission overhaul, and body refinish codes. Electrical Group 8 is especially large: starting and charging tests sit next to ignition sensor locations, cluster lamp diagnosis, keyless-entry transmitter programming, air-bag module cautions, and a full 8W wiring-diagram section with component identification, splice maps, and system sheets.

Engines, Fuel, and Emissions

Group 9 treats the 4.0L six as an in-line, lightweight, overhead-valve engine and the 5.2L as a V-type single-cam overhead-valve engine. Shared standard procedures cover form-in-place gaskets (Mopar Silicone Rubber Adhesive Sealant versus Mopar Gasket Maker), cylinder-bore honing, Plastigage measurements, thread repair, and hydrostatic lock. Engine diagnosis charts walk no-start, stall, rough idle, and mechanical noise complaints back to oil level, ignition, fuel pressure, and internal wear. Separate service-procedure sections then cover cylinder head, valve train, front cover and oil pump, oil pan, camshaft, pistons, and in-vehicle engine R&I for each displacement, with cross-references to cooling, fuel, exhaust, and A/C groups so belts, manifolds, and refrigerant are handled in the right order.

Group 14 documents a tank-mounted electric pump, in-line filter, supply and return lines, rail, injectors, and pressure regulator, plus the pressure-relief/rollover valve and filler cap. MPI coverage is split by engine: component description and system operation, general diagnosis including on-board diagnostics and PCM connector information, then component removal and installation for sensors, relays, throttle body, idle air control, fuel rail, and injectors. Fuel-usage text requires unleaded gasoline with a minimum posted octane of 87 and discusses ethanol blends at 10 percent. Group 25 explains the VECI label in the engine compartment (engine family, evaporative family, schematic, certification application, timing and idle if adjustable, spark-plug gap) and services evaporative and exhaust devices including PCV, EGR, EVAP canister and purge solenoid, and oxygen-sensor cross-references.

Driveline, Brakes, and Chassis

Front suspension is a link/coil layout with a Model 30 drive axle on 4WD or a tube axle on 2WD, track bar, stabilizer bar, upper and lower arms, coil springs, dual-action shocks, and jounce bumpers. Hub/bearings are non-serviceable assemblies. Alignment procedures give caster, camber, and toe guidance and note that propeller-shaft angle has priority over caster. Rear suspension uses the same link/coil idea with a Model 35 hypoid axle, optional Trac-Lok, and ABS tone rings pressed on the axle shafts. Lubricant quantities printed in the axle groups include 50±1 fl oz for the non-disconnect front axle and 40±1 fl oz of synthetic gear lubricant with friction modifier for the rear.

IMAGES PREVIEW

1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements — PDF page 2 preview
1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements — PDF page 38 preview
1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements — PDF page 854 preview

Brakes combine front single-piston disc calipers and ventilated rotors with 254 x 44 mm (10.0 x 1.75 in.) rear drums, a 200 mm (7.8 in.) dual-diaphragm vacuum booster, dual-reservoir master cylinder, and combination proportioning valve. ABS is standard, with an ECU, wheel-speed sensors, tone rings, and hydraulic control unit. The book covers bleeding, lining service, parking-brake cable tension, and antilock electronic diagnosis. Clutch coverage applies to manual-transmission models: dry disc, diaphragm cover, hydraulic master and slave cylinders, and DOT 3 fluid only.

Cooling procedures differ by engine. The 4.0L uses a manually adjusted accessory belt; the 5.2L uses an automatic tensioner. Water-pump, thermostat, radiator, viscous fan drive, and optional block-heater service are written separately for each engine. Capacities listed in Group 0 are 6 qt engine oil with filter on the six-cylinder, 5 qt with filter on the V-8, 9.3 qt coolant on the six, and 14.9 qt coolant on the V-8. Fuel tank capacity is given as approximately 23 gallons (87.4 liters).

Transmission Group 21 and the 21-S supplement are a large share of the page count. The AX 15 five-speed manual lists ratios of 3.83, 2.33, 1.44, 1.00, 0.79 overdrive, and 4.22 reverse, with Mopar SAE 75W-90 GL-5 lubricant. Automatic units covered are AW-4, 46RH, and, in the supplement, 42RE with electronic governor pressure. Transfer cases are NP231 part-time, NP242, and NP249, with shift-linkage adjustment, overhaul legends, and ATF fill-to-plug-hole procedures. Steering is a recirculating-ball power gear (codes AL and MN at 12.7:1, MN with trailer-tow seals), belt-driven pump, linkage with adjustable sleeves, and column service that includes air-bag cautions and the automatic-transmission shifter/ignition interlock cable.

Electrical, Climate, and Body

Wiring diagrams occupy Group 8W with secondary-ignition layouts for both engines (4.0L firing order 1-5-3-6-2-4; 5.2L 1-8-4-3-6-5-7-2), harness-repair notes, splice locations, and indexed system sheets. Restraint Group 8M covers air-bag system checks and module handling. Climate Group 24 treats heater-only, manual A/C, and automatic temperature control from a common heater-A/C housing, with R-134a refrigerant warnings, evacuate/charge steps, compressor clutch service, and door-actuator replacement that often requires instrument-panel removal. Body Group 23 walks grille and GOR, hood, fenders, cladding, woodgrain overlay, sunroof, doors, glass, seats, consoles, trailer hitch, transfer-case skid plate, and paint-code use from the body code plate.

Maintenance Group 0 remains the everyday reference: API SG or SG/CD oil with SAE 10W-30 preferred, unleaded 87-octane fuel, California versus federal interval charts, severe-service definitions (short trips under 15 miles, dust, towing, idle, high speed, desert, cold, commercial use), and general services such as 4×4 steering-linkage lubrication every 7,500 miles or 6 months, automatic-transmission drain and refill every 30,000 miles normal or 12,000 miles severe, transfer-case drain and refill every 30,000 miles, and axle service on the same normal/severe split. Jump-starting, floor-jack lift points on the subframe rails, and towing cautions are included so the vehicle can be supported without loading an axle tube.

Use This Manual On the Vehicle

The 1993 Jeep Grand Cherokee Grand Wagoneer ZJ Service Manual and Supplements supports the jobs a ZJ owner or shop actually faces: reading VIN and body-code data, setting alignment and pinion angle, diagnosing ABS and PCM fault lamps, pressure-testing the fuel rail after a correct pressure-release procedure, replacing a Model 30 or Model 35 differential, overhauling an AX 15, AW-4, 46RH, or 42RE, rebuilding an NP231/242/249 transfer case, tracing a circuit on an 8W sheet, recovering R-134a, and following the printed torque and capacity figures instead of guessing. Correct procedures and midpoint torque values matter on this platform because the book repeatedly warns that wrong hardware, lubricated threads without the stated 10 percent reduction, or skipped pressure-release and air-bag steps can damage parts or create an unsafe assembly.

After payment the file is delivered as an instant PDF download. There is no printed-book shipping delay. Open it on a shop computer, tablet, or phone and print the group, wiring sheet, or torque chart you need for the job in front of you.

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